CONSTRUCTION PROVIDED WITH FAÇADE PANELS AND METHOD FOR PRODUCING SUCH A CONSTRUCTION

BACKGROUND OF THE INVENTION

The invention relates to constructions designed to form a building and to methods for producing such a construction.

STATE OF THE ART

Different structures to produce a construction such as a house or a building exist at the present time. In conventional manner, prefabricated hollow concrete blocks, or bricks, are used assembled with mortar as construction of the wall progresses. These walls do however have to be manufactured on site, and these methods are lengthy to implement.

Prefabricated concrete modules can be produced that are assembled to one another. The prefabricated modules then have to be transported from their place of manufacture to the erection site.

It is also known to produce constructions having a support frame lined by a metal or glass façade. This technical solution remains complex to implement and does not always present a good trade-off between production costs and the thermal insulation procured by the façade.

U.S. Pat. No. 5,239,798 discloses a façade structure mounted on a supporting structure. The façade structure has a steel support plate fixed to two consecutive slabs of the supporting structure. A plurality of facing plates are fixed independently from one another on the support plate. This technical solution is not satisfactory as it provides an insufficient durability and a mediocre thermal resistance while being relatively costly.

Document FR2349696 discloses a building comprising a supporting structure with façade panels fixed to the supporting structure. The façade panels comprise a phenolic foam or a polyurethane foam placed inside a polymer casing. To absorb the relative thermal deformations between the panels and the supporting structure, the panels are fixed by rectangular steel “shovels” with a width comprised between 10 and 20 cm. Such a configuration is not satisfactory as this thermal solution presents a poor durability, a low mechanical strength and a poor thermal resistance.

Document FR1427593 discloses a method for hanging building façades as curtain-walls. The building comprises a supporting structure and façade panels are fixed to the supporting structure. The façade panel is made from concrete, fiber cement, wood, steel or aluminium. The facade panels are mounted on one another and are each fixed to the supporting structure by a disk inserted in a slot of the lateral wall of the façade panel. The panels are fixed to one another and to the supporting structure by means of a mortar layer. This solution is not satisfactory as this technical solution does not provide a good durability from a mechanical and thermal standpoint. This configuration also appears costly.

SUMMARY OF THE INVENTION

One object of the invention consists in providing a construction having façade panels able to provide a good wind resistance and presenting a good trade-off between the thermal insulation procured and the manufacturing cost, while at the same time ensuring a good durability. This result tends to be achieved by means of a construction that has:

- a supporting structure made from concrete reinforced by metal rods, the supporting structure having at least a first level with a first slab and first posts and a second level with a second slab and second posts, and a third slab;
- a plurality of façade panels fixed to the supporting structure to form at least a part of a facade of the construction, the plurality of façade panels having at least one first façade panel mounted under at least one second façade panel.

The construction is remarkable in that:

- each façade panel is made from a mixture containing a curable material in which organic plant-derived elements are embedded, the mixture in the cured state having a density of less than 1000 kg/m³and a compressive strength comprised between 2 and 6 MPa;
- each façade panel is mounted supported by at least 75% of the length of the foot of the façade panel;
- the at least one first façade panel is mounted movable at least with respect to the second slab in a vertical direction;
- the at least one second facade panel is mounted movable at least with respect to the third slab; and
- the at least one second façade panel is supported solely by the second slab or the at least one second facade panel is supported solely by the at least one first façade panel.

In a particular embodiment, the at least one second façade panel is supported solely by the second slab and the at least one second façade panel is separated from the at least one first façade panel by a sealing element configured to perform waterproofing.

Preferentially, the at least one second facade panel is supported solely by the at least one first façade panel. The at least one first façade panel has a recess designed to receive one end of the second slab, the recess being located in a top part of the at least one first facade panel and being separated from the second slab by a resiliently deformable layer.

In an advantageous embodiment, the recess extends over the whole length of the at least one first facade panel. The length of the first slab is greater than the length of the at least one first façade panel.

In a preferential embodiment, the plurality of facade panels are fixed to the supporting structure by means of a plurality of connectors. The façade panels of the plurality of facade panels are made from a mixture of wood elements and cement and/or lime. Connectors are fixed directly in the facade panels of the plurality of façade panels by screw-fastening.

In advantageous manner, the at least one second façade panel is fixed to the at least one first façade panel by an adhesive mortar.

According to another feature, a method for producing a construction panel as defined above is proposed. This result tends to be achieved by means of a method comprising the following successive steps:

- providing a first slab of a first level of a supporting structure made from concrete reinforced by metal rods;
- placing a foot of at least one first facade panel on the first slab;
- adjusting the plumbness of the first facade panel and fixing the first façade panel on the first slab by means of a plurality of connectors;
- forming a second slab of a second level of the supporting structure above the first level, the second slab being made from concrete reinforced by metal rods, the second slab being mounted fixedly on the first slab by means of the first posts, the at least one first facade panel being fixed to the second slab and mounted movable vertically with respect to the second slab;
- placing a foot of at least one second façade panel on the top of the at least one first façade panel;
- adjusting the plumbness of the second facade panel and fixing the second façade panel on the second slab by means of a plurality of connectors;
- forming a third slab of a third level of the supporting structure above the second level, the third slab being made from concrete reinforced by metal rods, the third slab being mounted fixedly on the second slab by means of the second posts, the at least one second facade panel being fixed to the third slab and mounted movable vertically with respect to the third slab.

The method is remarkable in that each façade panel is made from a mixture containing a curable material in which organic plant-derived elements are embedded, the mixture in the cured state having a density of less than 1000 kg/m³and a compressive strength comprised between 2 and 6 MPa.

As an alternative, this result tends to be achieved by means of a method comprising the following successive steps:

- providing a supporting structure made from concrete reinforced by metal rods provided with at least a first slab of a first level and a second slab of a second level arranged above the first level and a third slab of a third level arranged above the second level;
- placing a foot of at least one first façade panel on the first slab;
- adjusting the plumbness of the at least one first façade panel and fixing the at least one first façade panel on the first slab by means of a plurality of connectors;
- placing a foot of at least one second façade panel on the second slab;
- adjusting the plumbness of the at least one second facade panel and fixing the at least one second facade panel on the second slab by means of a plurality of connectors.

The method is remarkable in that each facade panel is made from a mixture containing a curable material in which organic plant-derived elements are embedded, the mixture in the cured state having a density of less than 1000 kg/m³and a compressive strength comprised between 2 and 6 MPa.

DESCRIPTION OF THE DRAWINGS

Other advantages and features will become more clearly apparent from the following description of particular embodiments and implementation modes of the invention given for non-restrictive example purposes only and represented in the accompanying drawings, in which:

FIG. 1 schematically illustrates a vertical sectional view of a first embodiment 25 of a part of a construction according to the invention, at a distance from the posts;

FIG. 2 schematically illustrates a vertical sectional view of the connection between a slab and two façade panels represented in FIG. 1;

FIG. 3 schematically illustrates a vertical sectional view of the embodiment of 30 a panel represented in FIG. 1, at the level of the posts;

FIG. 4 schematically illustrates a vertical sectional view of the connection between two facade panels, a slab and two posts as represented in FIG. 3;

FIG. 5 schematically illustrates a vertical sectional view of a second embodiment of a part of a construction according to the invention;

FIG. 6 schematically illustrates a vertical sectional view of the connection between a slab and two façade panels represented in FIG. 5;

FIG. 7 schematically illustrates a vertical sectional view of the second embodiment of a part of a construction according to the invention at the level of the posts;

FIG. 8 schematically illustrates a vertical sectional view of the connection between two façade panels, a slab and two posts as represented in FIG. 7;

FIG. 9 schematically illustrates a view of the inner face of the construction according to the implementation illustrated in FIGS. 1 to 8 with a first type of connectors;

FIG. 10 schematically illustrates a view of the inner face of the construction according to the implementation illustrated in FIGS. 1 to 8 with another type of connectors;

FIG. 11 schematically illustrates a view of a connector designed to be moulded in a post.

DETAILED DESCRIPTION

Different sectional views of a construction designed to form a residential building, a commercial building or any other type of building are illustrated in FIGS. 1 to 10. The construction has several levels, for example two levels, three levels, at least three levels or at least four levels. The construction can have a ground floor, a first floor and for example at least a second floor.

The construction has a supporting structure made from reinforced concrete. The reinforced concrete is formed by a mixture of concrete reinforced by rods made from metallic material, preferentially steel rods. The reinforced concrete supporting structure is advantageously manufactured using the same techniques and under the same conditions as the reinforced supporting structures of the building and civil engineering sector. The supporting structure provides the mechanical strength of the construction, i.e. the supporting structure ensures the mechanical integrity of the building with or without the presence of the façade panels. The supporting structure defines at least a bottom level and a higher level that is just above the bottom level.

Each level possesses a slab. The construction has at least a first slab 1a and a second slab 1b. The supporting structure has at least first posts 2a and the second posts 2b. The first posts 2a are arranged salient from the first slab 1a and connect the first slab 1a to the second slab 1b. The second posts 2b are arranged salient from the second slab 1b and connect the second slab 1b to the third slab 1c. The slabs 1a and 1b are mechanically connected to one another by posts also called pillars. The third slab 1c can be a slab designed to receive third posts or it can be the structure receiving the roof of the construction. According to the configurations, the third slab 1c can be made from reinforced concrete, from concrete or in another technology.

The supporting structure is covered by a plurality of façade panels 3a/3b. The façade panels comprise one or more first façade panels 3a and one or more second facade panels 3b. The facade panels 3a/3b are arranged on the perimeter of the supporting structure. The façade panels 3a/3b form an enclosure separating the inside of the construction and the outside of the construction. In a particular embodiment, facade panels 3a/3b only form the lateral walls of the construction. The top and bottom of the construction are formed by another technique, for example slabs. The façade panels 3a/3b are said to be “non-structural”, i.e. they are not configured to withstand the vertical stresses applied on the supporting structure or to act as bracing for the supporting structure. The façade panels 3a/3b are configured to form a façade that is watertight and airtight and to form a thermal barrier between the inside of the construction and the outside of the construction.

Façade panels 3a/3b can be apertured with one or more re-entrants 4. A re-entrant 4 can be designed for installation of a door, a window, a French windows or any other element forming a means of communication between the inside and outside of the building. FIGS. 8 and 9 illustrate the re-entrants 4 in the form of windows on the second level and in the form of bay windows on the first level.

It is particularly advantageous to form a construction that is not too heavy and/or with a supporting structure that is not too bulky in order to provide a maximum available interior space. A need therefore exists to use façade panels 3a/3b presenting a low density in order to reduce the weight of the façade. It is also advantageous to form a construction that is thermally insulating using insulating façade panels. It is also desired to provide façade panels 3a/3b having a reasonable manufacturing cost.

It is particularly advantageous to use one or more façade panels 3a/3b made from a mixture of a curable material in which organic plant-derived elements are embedded. An organic plant-derived element can be wood, straw, cellulose, rice husks, bamboo chippings, hemp or cork. An organic element comprises carbon that is natural or only slightly processed in order to have a favourable carbon balance. Preferentially, the curable material comprises a hydraulic binder, i.e. a binder that reacts with water to harden. In other words, to obtain the curable material, the hydraulic binder is mixed with water. When the material dries, it hardens by chemical reaction between the binder and water. The binder is for example a cement or lime. For example, the curable material is a mortar. The mortar is made from cement or lime and can comprise sand or not. In preferential manner, the façade panel or panels 3a/3b are made from wood-concrete, i.e. a mixture comprising a mortar in which wood elements are embedded.

It is particularly advantageous to form a façade panel 3a/3b having a density of less than 1200 kg/m³or even less than 1000 kg/m³or 800 kg/m³to have a façade panel 3a/3b that is easy to transport and to install. To obtain such a façade panel, it is particularly advantageous to use a mixture of a curable material in which organic plant-derived elements are embedded. The mixture comprises at least 50% by volume of organic plant-derived elements. Advantageously, the mixture comprises at least 70% by volume of organic plant-derived elements or even at least 80% by volume of organic plant-derived elements. Such a content of organic plant-derived elements enables a façade panel 3a/3b to be formed that is breathable with regard to water vapour, thereby making it easier to construct a building with a good hygrothermal regulation. As illustrated in the different figures, the mixture extends from one end of the façade panel 3a/3b to the other in a vertical direction and a longitudinal direction to provide the mechanical integrity of the façade panel.

The use of a facade panel 3a/3b comprising a high content of organic plant-derived elements enables a façade panel to be formed that has a considerably lower density than that of its equivalent made from concrete, for example at least 2 or 3 times lower than that of concrete. The weight of the façade is reduced thereby limiting the stresses on the supporting structure.

The use of organic plant-derived elements embedded in a curable material enables a façade panel to be formed that presents a good fire resistance and forms a good insulator against temperature rises. As the organic plant-derived elements has a considerably lower density than that of concrete, the façade panel presents a very low fuel load with respect to the volume of the panel and especially as regards the surface of the panel. The façade panel has a mobilisable combustion heat value MCH<0.4 MJ/kg. This value is substantially lower than that of facades constructed with a wood framework. The mobilisable combustion heat value can be calculated according to annex 2 of Technical Instruction 249, 2010 version (Decree of May 24, 2010).

The facade panel formed by the organic plant-derived elements and the curable material has a textured surface that is particularly advantageous for performing a subsequent step of depositing a surface coating, for example a parge coat.

Preferentially, the organic plant-derived elements are wood elements. The wood elements can be wood chips having a length of less than 75 mm, preferentially comprised between 10 and 75 mm, and even more preferentially between 20 and 60 mm. For example, with respect to the total mass of wood elements, the wood-concrete comprises between 80% and 95% of wood elements having a length comprised between 10 and 60 mm, preferably between 20 and 60 mm.

More particularly, these wood chips have a thickness comprised between 1 mm and 5 mm. When wood chips having a length of 20 and 60 mm are used, micro-cavities are obtained at the surface of the facade panel 3a/3b due to the fact that the concrete coats the wood chips. Such microcavities enhance adhesion of a surface coating on the inner surface and/or the outer surface of the façade panel.

The use of facade panels 3a/3b having a thickness of at least 10 cm also procures a good sound absorption and a good airtightness and watertightness.

The use of a facade panel 3a/3b comprising a high content of organic plant-derived elements and a non-negligible concrete content enables a façade panel to be formed having a thermal inertia at least equal to about 0.6 h/cm for façade panels having a thickness of at least 10 cm. In preferential manner, the façade panels have a thermal inertia at least equal to 8 h. In other words, it takes at least 8 hours for the heat applied on the outer surface of the facade panel to reach the inner surface of the facade panel. Such a result cannot be achieved easily with a panel having a wooden frame or with a concrete panel.

The construction has a plurality of the facade panels 3a/3b fixed to the supporting structure to form at least a part of a facade of the construction. The façade panels 3a/3b are self-supporting and do not provide the supporting structure with any mechanical strength able to perform force take-up and/or bracing. The facade panels 3a/3b have a compressive strength comprised between 2 and 6 MPa which enables the latter to take up the securing forces, the lateral forces with respect to the outer surface of the panel and the pressure forces due to the wind. The plurality of the façade panels 3a/3b have at least a top façade panel mounted above a bottom façade panel. The first façade panel or panels 3a form the bottom panel or panels. The second façade panel or panels 3b form the top panel or panels.

The facade panels are formed from a material that is a good thermal insulator, has a low density and presents a low manufacturing cost thereby enabling an attractive building to be constructed. The façade panels 3a/3b in association with their attachment part do not however present mechanical performances providing a good strength of the facade panel under all conditions. It is therefore important for each of the façade panels to be supported over at least 75% of its length, preferably over 100% of its length. The weight of the façade panel is supported by bearing on a very large majority of the foot of the façade panel, which is much more advantageous than pin-point support on two or three support studs to obtain a good durability. The weight of the façade panel is applied almost solely on the foot of the facade panel. Depending on the configurations, the façade panel 3a/3b is bearing directly on a slab and/or on a bottom facade panel. The mixture is pressing on at least 75% of the length of the façade panel so as to provide a façade panel having a strong support from the supporting surface immediately underneath, thereby ensuring a good transfer of forces over the whole height of the facade of the building. This also makes for a good distribution of forces over the whole length of the panel.

Each of façade panels 3a/3b is fixed to the supporting structure. Each façade panel 3a/3b has a foot bearing on a bottom slab or a bottom façade panel and a head fixed to an upper slab. Each facade panel 3a/3b is preferably fixed at its two longitudinal ends on the supporting structure. A façade panel has a height measured vertically, a length measured horizontally and a thickness measured horizontally in a direction perpendicular to the two previous directions. The thickness is substantially smaller than the length.

As the day goes by and as the year progresses, the temperature outside the construction and the temperature inside the construction vary. Other parameters also vary, such as the hygrometry for example. The façade panel 3a/3b tends to deform differently from the supporting structure. Deformation of the supporting structure also exists as a result of application of loads or when an earth tremor occurs. The supporting structure has to be prevented from applying stresses on the lateral panel to prevent the facade panel from fracturing and possibly coming loose.

It is therefore particularly advantageous for each façade panel 3a/3b to be mounted movable vertically with respect to the supporting structure by introducing a vertical functional clearance with the upper slab to which each façade panel is fixed. The value of the vertical functional clearance is preferentially comprised between 0.5 and 1.5 cm. It is then possible for the façade panel 3a/3b to adjust its deformation between the two slabs to reduce as far as possible the forces between the facade panel 3a/3b and the slabs 1a/1b/1c securing the latter. The first facade panel 3a is mounted movable vertically with respect to the second slab 1b. The second façade panel 3b is mounted movable vertically with respect to the third slab 1c. Each functional clearance enables the differential expansion between the facade panel and the supporting structure to be absorbed.

To reduce their weight, the facade panels 3a/3b are preferentially devoid of metal reinforcements, for example devoid of a metal mesh extending over the whole surface of the panel inside the panel. However, on the peripheries of the re-entrants, it is advantageous to install a reinforcement structure that is preferentially a wooden reinforcement structure, for example wooden battens. In preferential manner, the reinforcement structure can be a prefabricated wooden frame advantageously treated against rain, for example a frame made from a multilayer plywood panel.

The facade panels are configured to withstand a threshold compressive stress before breaking. This threshold compressive stress can represent a threshold number of façade panels supported by the bottom panel before breaking. If this compressive stress corresponds to three façade panels, it is possible to erect a construction comprising four levels or less than four levels. It is advantageous to stack façade panels 3a/3b on one another. In other words, an upper façade panel 3b is bearing on a lower façade panel 3a. For example, the façade panel of the ground floor supports the weight of the façade panels of the upper storeys.

On the contrary, if the construction comprises more than four storeys, it is then advantageous to fix each facade panel 3a/3b independently to the supporting structure, and each panel is placed on a slab. It is further possible to combine the two techniques in one and the same construction, for example by placing the second façade panel on the first façade panel and placing the third façade panel on the slab.

In preferential manner, a façade panel 3a/3b has a length at least equal to 1 metre, preferably comprised between 1 and 10 metres. Advantageously, the height of a facade panel 3a/3b is at least equal to 80 cm. It is advantageous for the height of the façade panel 3a/3b to be less than 400 cm. It is also preferable for the thickness of the facade panel 3a/3b to be greater than 10 cm and less than 80 cm, even more preferentially less than 40 cm. It is particularly advantageous to form façade panels having a thickness comprised between 15 and 20 cm.

For ease of installation of the facade panel 3a/3b on the supporting structure, each façade panel 3a/3b comprises one or more hoisting rings designed to perform hoisting of the facade panel 3a/3b by means of a crane. In preferential manner, the hoisting rings are installed in the mould designed to form the façade panel 3a/3b when the mixture is poured into the mould.

Preferentially, the peaks of the hoisting rings are salient from the top side wall of the facade panel 3a/3b. The hoisting rings are arranged in the median plane of the façade panel 3a/3b. The facade panel is hoisted by a crane pulling on the hoisting ring or rings to place the façade panel on the supporting structure.

The foot of the first facade panel 3a is fixed to the first slab 1a by one or more first connectors 5. The first connector or connectors can be angle brackets. The the first connectors 5 can be installed in irremovable or removable manner. The first connectors 5 enable the position of the facade panel in the thickness direction to be defined.

The top of the first facade panel 3a is fixed to the second slab 1b by one or more second connectors 6. The second connectors 6 ensure the vertical mobility between the top of the first facade panel 3a and the second slab 1b. The second connector or connectors 6 can be angle brackets.

The foot of the first facade panel 3a is placed on the first slab 1a and fixed to the first slab 1a by means of the first connector 5. Depending on the configurations, the supporting structure can be formed on site in one or more operations. In an alternative, the supporting structure is formed by prefabricated elements that are fixed to one another, for example by keying. Depending on the method for producing the supporting structure, different configurations of connectors 5/6 are available.

In the embodiment illustrated in FIGS. 1 to 4, the façade panels 3a/3b are placed on one another. The lowest facade panel 3a supports the weight of the other façade panels 3b.

In preferential manner, the first façade panel 3a, i.e. the lowest façade panel, is placed bearing on the first slab 1a that represents the lowest slab. It is particularly advantageous to place the first façade panel 3a on the first slab 1a to be able to control the alignment of the first facade panel 3a with respect to the supporting structure. Adjustment of the plumbness of the first façade panel 3a is performed once the first façade panel 3a has been placed on the first slab 1a. Adjusting the plumbness enables the verticality of the first façade panel 3a to be fixed.

Once the plumbness has been adjusted, the connectors fix the position and more particularly the verticality of the first facade panel with respect to the supporting structure.

Securing of the first facade panel 3a with the supporting structure is however preferably performed so as to prohibit a transverse functional clearance, i.e. in the thickness direction of the facade panel 3a/3b. The vertical and possibly longitudinal functional clearance mechanically separates the supporting structure and the vertical façade panel.

Once the first façade panel 3a has been fixed, the second façade panel 3b is placed on its support. Depending on the embodiments, the support is formed by the top of the first facade panel 3a or by the second slab 1b. Once the second façade panel 3b has been fitted in place, the plumbness of the second façade panel 3b with respect to the supporting structure is adjusted. Adjustment of the plumbness defines the verticality of the second façade panel 3b with respect to the slabs and the bottom façade panel 3a.

Once the verticality of the second façade panel 3b has been adjusted, the angle of incline with respect to the vertical direction is fixed by means of several connectors. Connectors secure the foot of the second facade panel 3b with the second slab 1b. Connectors secure the top of the second façade panel 3b with the third slab 1c. Connectors secure the foot of the second façade panel 3b with the second posts 2b.

The connectors securing the foot of the second facade panel 3b with the second slab 1b can be used independently from the configuration chosen for its support (the second slab 1b or the first façade panel 3a).

The top facade panel 3b is mounted bearing on its support, i.e. on the common length between the facade panel 3b and its support, i.e. at least 75% of the length of the panel 3b, thereby enabling the bearing stress to be taken up efficiently. The second facade panel 3b is fixed to the supporting structure at its foot and at its apex by means of first connectors and second connectors. The longitudinal ends of the second façade panel 3b are preferably fixed to the supporting structure by connectors.

Fixing each facade panel 3a/3b on the supporting structure enables the plumbness of each façade panel 3a/3b to be adjusted so as to deliver a façade having a better appearance and a better management of water drainage along the facade. Securing the facade panel 3a/3b with the supporting structure enables the high and low pressure forces related to the wind flow around the construction to be taken up without giving rise to any force transmission in the vertical direction.

As illustrated in FIGS. 2 and 4, the first façade panel 3a is covered by a separating layer 7. The separating layer 7 is made from a curable and deformable material in liquid or pasty state. When the second façade panel 3b is assembled on the first facade panel 3a, the separating layer 7 deforms to homogenise the bearing stresses between the two panels 3a and 3b. Increasing the bearing surface improves the lifetime of the lowest façade panels. The curable material hardens and acts as an adhesive between the first façade panel 3a and the second façade panel 3b.

In another particular embodiment illustrated in FIGS. 5 to 8, each façade panel 3a/3b is bearing on one of slabs 1a/1b of the supporting structure and not on another façade panel 3a/3b. Each façade panel 3a/3b is totally supported by a slab 1a/1b of the supporting structure. When the façade panel is mounted bearing on a slab 1a/1b, it is advantageous to deposit a layer of adhesive mortar between the slab 1a/1b and the façade panel 3a/3b. The adhesive mortar layer secures the facade panel 3a/3b on the slab to reduce the displacements between the slab 1a/1b and the facade panel 3a/3b and also improves the airtightness and watertighness at the foot of the façade panel 3a/3b.

In the same way as for the previous embodiment, each façade panel 3a/3b is fixed to the supporting structure at its foot and at its apex by first and second connectors, and also preferentially at its longitudinal ends.

It is particularly advantageous for each façade panel 3a/3b to be pressing on and supported by the end of the slab 1a/1b and for the foot of the façade panel 3a/3b to be salient from the end of slab 1a/1b. Preferentially, the façade panel is bearing on the slab over a distance at least equal to 10% but not more than 70% of the thickness of the façade panel.

In preferential manner, the height of the first façade panel 3a is slightly smaller than the distance separating the two upper surfaces of the two slabs 1a and 1b on which the first facade panel 3a is fixed. It is particularly advantageous to provide for the height of the facade panel to be smaller than said distance separating the two upper surfaces by a value comprised between 1 cm and 4 cm. The same can be the case for each façade panel 3a/3b.

As illustrated in FIGS. 5 to 8, the gap existing between the first façade panel 3a and the second facade panel 3b enables a sealing means 8 to be installed that is configured to provide the watertightness between the two façade panels 3a and 3b. It is also advantageous to fill a part of the gap with a layer of adhesive mortar or any other curable separating material 9 ensuring a continuous contact between the two facade panels, thereby sealing off the space between the two façade panels to deliver a flat outer surface enhancing water drainage. In preferred manner, the sealing part is installed after the façade panels have been fixed on the supporting structure.

As illustrated in FIGS. 1 to 8, in advantageous manner, the top of the façade panel 3a/3b has a recess 10 extending inside the façade panel 3a/3b over a first distance. The recess 10 receives the slab nosing and/or a thermal insulation layer 11. The thermal insulation layer 11 separates the slab 1a/1b and the façade panel 3a/3b.

It is advantageous to prevent any direct contact between the façade panel 3a/3b and the slab 1a/1b. It is preferable for the slab 1a/1b and the façade panel 3a/3b to be separated by one or more resiliently deformable elements, and more particularly by a sealing means. It is advantageous to install a resiliently deformable element forming a thermal insulator 11 between the slab 1a/1b and the façade panel 3a/3b in the thickness direction of the façade panel 3a/3b.

The resiliently deformable element extends in the lengthwise direction of façade panel 3a/3b. It is also advantageous to install a resiliently deformable element that is preferentially a thermal insulator and/or a sealing element 12 between slab 1a/1b and the façade panel 3a/3b in a vertical direction inside the recess 10.

A thermal insulator is a layer made from a material having a higher thermal resistivity than the thermal resistivity of the material forming the slab.

In the embodiment illustrated in FIGS. 5 to 8, the slab is embedded over a predetermined distance in the recess 10. The foot of the façade panel 3a/3b is bearing on the slab 1a/1b with the same distance. This configuration enables the plumbness of each façade panel 3a/3b to be better controlled. In preferential manner, the recess 10 extends over less than 50% of the thickness of the façade panel.

In preferential manner, at least one or each façade panel 3a/3b has a recess 10 designed to receive the upper slab 1b to which it is fixed. The recess 10 is arranged in a top part of the façade panel 3a, i.e. the apex of the façade panel. The recess 10 is illustrated in the vertical sectional views of FIGS. 1 to 8.

In an advantageous embodiment, the thermal insulator 11 is replaced by a sealing element configured to provide fire resistance and/or sound proofing. In advantageous manner, the sealing element 12 is configured to provide airtightness.

In a particular embodiment, the recess 10 extends over the whole length of the facade panel 3a/3b. The length of slab 1b is greater than the length of the façade panel 3a. Several façade panels 3a and/or 3b can be arranged side by side in the lengthwise direction.

In preferential manner, in a sectional view, two façade panels 3a/3b of the same level are separated from one another by a second separating layer made from a curable and deformable material in liquid or pasty state, for example an adhesive mortar. The use of an adhesive mortar installed to fill the gap between two adjacent facade panels reduces the water infiltration and prevents the formation of an air flow circuit. This configuration improves the waterproofing and thermal insulation of the façade.

To facilitate independent or almost independent deformation between two adjacent façade panels 3a or 3b of the same level, it is particularly advantageous to leave a gap of at least 1 cm or even 2 cm.

As illustrated in FIGS. 1, 2, 3, 5, 6, 7, 8 and 10, it is particularly advantageous to form recesses 14 in the bottom surface of the façade panels 3a/3b to facilitate installation of connectors 5 and 6 between the facade panel 3a/3b and one of the two slabs 1a/1b on which the latter is fixed. The recesses 14 are provided when the facade panel is moulded and they define the position of the connectors 5 and 6. This enables the position and number of connectors to be defined simply. This also makes it possible to detect quickly whether a connector has been forgotten in the installation.

As illustrated in FIGS. 1 to 8, to limit the heat flow between the outside and the inside of the construction, it is advantageous to fit a thermal insulator 15 between a post 2a/2b and the facade panel 3a/3b. The thermal insulator 15 is for example a foam gasket, preferably a closed-pore gasket. The thermal insulator is resiliently deformable so as to accept a displacement between the elements in contact with the thermal insulator. The thermal insulator is preferentially airtight.

Preferentially, the foam gasket is made from polyurethane. It is even more preferable to use a strip of rock wool or of another insulator in the form of a felt or a strip, and to add a polyurethane foam gasket at each end of the latter. In preferential manner, the thermal insulator comprises a foam separating two gaskets in the longitudinal direction of the façade panel. In a particular embodiment, before assembly is performed, the façade panels define a groove designed to receive the foam to ensure a good fixing and a good insulation. The groove is preferentially formed when the façade panel is moulded.

In a particular embodiment, façade panel 3a/3b is separated from a post 2a/2b or from a shear wall of the supporting structure by a thermal insulator that can be rock wool. The thermal insulator 9 is configured to block the heat flow between the slab and the façade panel.

It is particularly advantageous to provide for a façade panel 3a/3b to be fixed at each of its longitudinal ends on a post 2a/2b of the supporting structure or on a shear wall of the supporting structure. It is also very advantageous for a post or a shear wall of the supporting structure to perform securing of two adjacent façade panels 3a/3b. It is preferable to use a third connector 16, a particular embodiment of which is illustrated in FIG. 11.

The third connector 16 has oblong holes 17 oriented in the vertical direction when the third connector is fixed to the facade panel 3a/3b. In the particular embodiment illustrated in FIG. 11, the connector 16 is configured to connect two adjacent facade panels. The connector 16 has hooks or rings 18 designed to be inserted in a post when the latter is moulded. The hook/hooks prevent extraction of the connector with respect to the post once the concrete has dried.

In preferential manner, the third connector 16 is fixed to one or more façade panels by screws 19 inserted directly in the mixture forming the façade panel.

It is particularly advantageous to use a façade panel 3a/3b made from a mixture containing a curable material in which organic plant-derived elements are embedded and containing an organic plant-derived element content of at least 50% by volume. Such an organic plant-derived element content enables a façade panel to be provided that is able to be cut by means of a saw. A sawing step of the façade panel enables the shape of façade panel 3a/3b to be modified to compensate a manufacturing uncertainty on the supporting structure.

The use of such a facade panel also enables the façade panel 3a/3b to be attached directly with the connector providing the mechanical connection between the slab 1a/1b and the façade panel 3a/3b. It is particularly advantageous to perform attachment by screwing directly into the façade panel 3a/3b thereby facilitating installation of the façade panel 3a/3b. Such an embodiment makes it possible to adjust the plumbness of the façade panel 3a/3b and the alignment of the facade panels 3a/3b with respect to one another on the different levels. Screw-fastening is performed directly without forming a hole beforehand and without using a dowel.

The construction can be erected in different ways with different degrees of progression of the supporting structure when one or more façade panels of a level are installed.

In a first embodiment, a supporting structure is provided having at least a first slab 1a, a second slab 1b, a first set of first posts 2a connecting the first slab 1a to the second slab 1b, and a second set of second posts 2b salient from the second slab 1b and separated from the first set of second posts 2a by the second slab 1b. The supporting structure can also have a third slab 1c installed on the second set of the second posts 2b to form a roof or a support for the roof.

A first facade panel 3a is fitted in place and is then fixed to the supporting structure. A second façade panel 3b is fitted bearing on the first façade panel 3a and is then fixed to the supporting structure. If a third facade panel is used, the latter is fitted bearing on the second facade panel and is then fixed on the supporting structure. The facade panels are placed and fixed one after the other.

Each facade panel 3a/3b is fixed to the supporting structure by means of one or more first connectors 5 performing the mechanical connection between the foot of each facade panel 3a/3b and the slab 1a/1b facing the foot in a horizontal direction. In preferential manner, the first connectors 5 are fixed to the slab before the first facade panel is fitted facing the corresponding level of the construction.

It is preferable to install the first connectors 5 flush with the slab nosing, i.e. the end of the slab, to adjust the plumbness of the façade panel 3a/3b.

In preferential manner, the façade panel 3a/3b is also fixed at each of its longitudinal ends to a post 2a/2b or possibly to a shear wall by means of third connectors 16. Third connectors 16 can be installed on the façade panel 3a/3b or on the second posts or shear walls before the top façade panel is installed.

Each facade panel is fixed to the supporting structure by means of one or more second connectors 6 performing the mechanical connection between the top of each facade panel 3a/3b and the slab facing the top in a horizontal direction. In preferential manner, the second connectors 6 are fixed to the slab 1b/1c before the first facade panel 3a/3b is fitted facing the corresponding level of the construction.

The facade panel 3a/3b is fixed to the supporting structure via its foot and its apex and preferentially via its lateral ends. Each of the connectors allows vertical movement of the first facade panel with respect to the supporting structure. Preferentially, the same is the case for all the facade panels of the same level and even more preferentially for all the façade panels of the construction. Each connector preferentially has vertical oblong holes ensuring a vertical functional clearance. It is also possible to have a connector having horizontal oblong holes ensuring a horizontal functional clearance.

In a second embodiment, the second slab 1b is cast after the first façade panel 3a has been installed. In more general manner, the slab of a level n+1 is cast after the façade panel or panels of level n have been fixed. The supporting structure has a first slab 1a with a set of first posts 2a. The first posts 2a are posts that are salient from the first slab 1a and are designed to support the second slab 1b.

A first façade panel 3a is fixed on the supporting structure. The first façade panel 3a is fixed to the first slab 1a. The first facade panel 3a is fixed by means of one or more first connectors 5 performing the mechanical connection between the first facade panel 3a and the first slab 1a. The first connectors are advantageously removable connectors or comprise removable connectors. The first facade panel 3a is fixed to the first posts 2a or shear walls by the third connectors 16. Preferentially, each of the longitudinal ends of the first façade panel 3 is fixed to one of second posts 2a or to a shear wall.

As indicated in the foregoing, it is advantageous to secure the first connectors 5 to the first slab 1a before installing the first façade panel 3a.

Once the first façade panel 3a has been fixed to the supporting structure, a second slab 1b is formed on the supporting structure. The second slab 1b is preferably cast. When the second slab 1b is poured, it is advantageous to install a sealed film in the upper recess of the first façade panel 3a. The sealed film is configured to prevent the concrete of the second slab 1b from attaching directly on the top of the first facade panel 3a and transmitting large stresses coming from the supporting structure. The formwork of the second slab 1b is installed and the second slab 1b is cast. Once the concrete of the second slab 1b is dry, the removable connectors can be removed.

Before forming the second slab 1b and the second posts 2b, it is preferable to install the second connectors 8 on the top of the first façade panel 3a. In preferential manner, the second connector 8 of the top has one or more hooks and/or one or more rings. The hook or ring is embedded in the concrete used to form the second slab. Installing the hook or ring in the second slab secures the first facade panel and the second slab to one another. The second connector 8 preferentially has oblong holes to allow the first facade panel to slide vertically with respect to the second slab. Once the second slab 1b has been cast and dried, the second connector 8 is indissociable from the second slab 1b. The second connector 8 can be in the form of an angled bracket with a hook or a ring such as the one illustrated in FIG. 11. Other configurations preventing removal of the second connector 8 are possible.

After the concrete forming the second slab 1b and the second posts 2b has dried, the second façade panel 3b can be installed. The second façade panel 3b is placed on the first facade panel 3a. The second facade panel 3b is fixed to the second slab 1b by means of a connector which allows the vertical functional clearance between the second facade panel 3b and the second slab 1b.

In advantageous manner, casting of the second slab 1b uses the first façade panel 3a as part of the mould. In preferential manner, the upper part of the first façade panel 3a defines a recess and the recess is used to terminate the mould that defines the shape of the slab, it forms a part of the formwork. A longitudinal end of the slab is defined by a facade panel. Preferentially, the two opposite horizontal ends of the slab are defined by two façade panels. It is particularly advantageous to make the sealed film from a thermal insulation layer 11 to form a part of the mould. Once the plumbness of the first façade panel 3a has been adjusted, the second slab 1b is formed using the first façade panel 3a thereby enabling the end of slab 1b to be adjusted with respect to the first façade panel 3a, thus limiting the stresses on the horizontal directions. The stress applied on the thermal insulation layer 11 is limited, which results in the insulating quality of the material used not being impaired when the first façade panel 3a is moved. The thermal insulation layer 11 is kept, thereby enhancing the thermal resistance between the external surface of the first facade panel 3a and the first slab 1a.

This embodiment is particularly advantageous when the façade panels are fitted directly on one another. The second facade panel 3b can have a slight recess in its bottom wall to avoid pressing on the second slab 1b.

In one configuration, the second posts 2b are cast after formation of the second slab 1b. As an alternative, the second posts 2b are manufactured beforehand and are fixed on the second slab 1b.

In a third embodiment, the first facade panel 3a is fixed to the first slab 1b before the second slab 2b is formed. As for the previous embodiment, the first façade panel is used to perform moulding of the second slab 1b.

The first facade panel 3a is used to perform moulding of one or more first posts 2a. In preferential manner, two adjacent façade panels 3a in a longitudinal direction are used to perform moulding of a first post 2a. Advantageously, each of the two panels 3a is fixed or will be fixed to post 2a. The first façade panels 3a are previously shored up to ensure a good moulding.

In a particular embodiment, the two facade panels 3a are fixed to one another by means of a third connector 16 such as the one illustrated in FIG. 11. The connector 16 has a hook and/or a ring that are located in the mould designed to form a first post 2a. When moulding of the post 2a is performed, the hook and/or ring 17 are embedded in the concrete of the post 2a thereby rendering the connector 16 indissociable from the post 2a. The connector has oblong holes in a vertical direction to allow the facade panel 3a to slide vertically with respect to the supporting structure. What is stipulated for the first façade panel 3a can be applied to a façade panel of another level.

It is particularly advantageous for the first façade panel to be covered by a layer of thermally insulating material, for example a rock wool layer. The thermally insulating material forms the wall of a mould designed to form the slab.

CONSTRUCTION PROVIDED WITH FAÇADE PANELS AND METHOD FOR PRODUCING SUCH A CONSTRUCTION

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