The invention relates to panels designed for making a wall, in particular for walls of houses.
At the present time, different structures exist for erecting a construction such as a house or a building. In conventional manner, prefabricated hollow concrete blocks, or bricks, are used assembled with mortar as construction of the wall progresses. But these walls have to be made on site and these methods are lengthy to implement.
Prefabricated panels made from wood or metal can be manufactured but they do not present the properties of concrete.
It is also possible to use prefabricated panels made from concrete for erecting walls from one or two panels, but these panels are heavy to transport and require a large quantity of concrete. Furthermore, when a wall is made with two concrete panels, the space between the panels is filled with a Z-shaped metal armature to ensure the strength of the panels, which makes the whole assembly very bulky.
French Patent application FR2909695 can be cited disclosing a composite structure for erecting walls, panels, or slabs, comprising a support armature formed by pieces of wood and coated with a binding product composed of cement or lime mixed with wood reinforcement particles. The support armature of the panel does not however provide sufficient reinforcement for constructions of more than two storeys.
French Patent application FR2950910 can also be cited disclosing a panel for erecting a construction comprising two parallel uprights coated with a binder formed by cement and wood chips. The panel further comprises two grooves situated respectively on two opposite surfaces of the panel to house assembly parts designed to be fixed to the uprights. Such a panel is however complex to manufacture and requires the use of at least two uprights to reinforce the panel. Nor does it give the panel sufficient bending resistance.
One object of the invention consists in remedying these shortcomings and more particularly in providing means for speeding up manufacture of walls presenting an enhanced reinforcement.
Another object consists in providing means for making a panel designed to form a wall that can be prefabricated and that is able to be transported from the prefabrication site to the erection site where the walls are to be placed.
According to one feature of the invention, a panel designed for fabrication of a wall is proposed comprising a monobloc part made from concrete inside which pieces of wood are sunk, at least one through aperture being formed inside the monobloc part, the panel comprising at least one reinforcement element providing a bending resistance and housed inside said at least one through aperture, and said at least one reinforcement element being formed by an armature coated with a hardening product comprising a binder.
The reinforcement elements provided with an armature have a better bending resistance. A panel is thus provided that enables a wall to be erected more quickly and that presents an enhanced strength. Advantageously, such a panel can be easily transportable due to the reinforcement elements, and can therefore be prefabricated and then transported to the site to erect the walls of the house or building to be constructed. Furthermore, with such a reinforcement element, panels of great length can be manufactured, for example more than eight metres.
An opening to receive a casement can be formed in the monobloc part, two through apertures are formed on each side of the opening and two reinforcement elements are respectively housed inside the two through apertures and are fixed to the monobloc part.
According to another feature, a panel designed for erection of a wall is proposed, comprising at least one reinforcement element that is resistant to bending, said at least one reinforcement element being formed by an armature coated with a hardening product comprising a binder, and the panel comprises at least two monobloc parts each made from concrete inside which pieces of wood are sunk and which are separated from one another by a housing inside which said at least one reinforcement element is housed and fixed to said at least two monobloc parts.
Such a panel procures the same advantages as the panel comprising a monobloc part as defined in the foregoing.
A first monobloc part can be provided with a first shoulder and a second monobloc part be provided with a second shoulder complementary to the first shoulder so that the first and second shoulders form the housing.
The first monobloc part can be perpendicular to the second monobloc part.
An opening to receive a casement leaf can be formed in the at least one monobloc part, said at least one reinforcement element is fixed to a first surface of said at least one monobloc part and an additional reinforcement element is fixed onto a second surface of said at least one monobloc part opposite the first surface.
According to another feature, a method for manufacturing a panel comprising a monobloc part is proposed, the method comprising pouring a liquid concrete in which pieces of wood are sunk into a mould provided with at least one re-entrant to form a monobloc part, removal of said at least one re-entrant to form at least one through aperture inside the monobloc part, placing an armature in said at least one through aperture, and pouring a hardening product comprising a binder in said at least one through aperture to coat the armature and secure the latter to the monobloc part.
Such a method improves the bond between the reinforcement element and the monobloc part. The monobloc part obtained comprises contact surfaces with the reinforcement elements which present numerous microcavities, i.e. blind holes, created by the pieces of wood. In this way, when the hardening product is cast in a through aperture of the monobloc part, the product will fill the numerous microcavities to increase the contact surface between the reinforcement element and the monobloc part. The contact surface with a through aperture opening out at the level of two ends of the monobloc part is increased all the more.
According to another feature, a method for manufacturing a panel comprising at least two monobloc parts is proposed, the method comprising provision of at least two monobloc parts each made from concrete inside which pieces of wood are sunk and separated from one another by at least one housing, placing an armature in said at least one housing, and pouring a hardening product comprising a binder into said at least one housing to coat the armature and fix the latter to said at least two monobloc parts.
Such a method procures the same advantages as the method for manufacturing a panel comprising a monobloc part as defined in the foregoing.
The provision step can comprise arrangement of at least one re-entrant in a mould, pouring liquid concrete in which the pieces of wood are sunk into the mould and removal of said at least one re-entrant to form said at least one housing.
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 appended drawings, in which:
In
In general manner, panel 1 comprises at least one monobloc part 2 to 4. More particularly monobloc parts 2 to 4 are each made from a material comprising concrete in which pieces of wood are sunk. Such a material is also called wood-concrete. The concrete is a mixture of different elements, such as gravel, sand, a binder and water. The binder can be a cement or lime. The pieces of wood are wood chips having a length comprised between 10 and 100 mm, preferably between 20 and 60 mm. These wood chips have a thickness comprised between 1 mm and 5 mm. When wood chips having a length of between 20 and 60 mm are used, microcavities are obtained at the surface of monobloc part 2 to 4 on account of the fact that the concrete coats the wood chips. More particularly, a distribution of the cavities at the surface representing between 30% and 50% of the total surface of monobloc part 2 to 4 is obtained. Furthermore, a roughness comprised between 6 and 15 mm is obtained. The roughness corresponds to the maximum height between an apex and a trough of the surface. A sectional view of a surface of monobloc part 2 to 4 and a maximum height D1 between an apex and a trough of the surface has been represented in
The weight ratio of the wood-concrete obtained is comprised between 600 and 1000 kg/m3, and by varying the composition of the material it is preferably equal to 800 kg/m3. A material lighter than rough concrete is thus obtained, i.e. a concrete that does not comprise pieces of wood and that has a weight ratio of about 2300 kg/m3. Furthermore, panel 1 comprises at least one housing 5 to 9 designed to receive a reinforcement element 10 to 12 that is resistant to bending.
A reinforcement element 10 to 12 is an elongate structure configured to give panel 1 a bending resistance. More particularly, each reinforcement element 10 to 12 is formed by an armature 13 coated with a hardening product 14 comprising a binder. Armature 13 also has an elongate shape. Armature 13 comprises one or more elongate elements. Each elongate element can be a rod or a bar. For example, an armature 13 comprising four rods has been represented in the figures. The elongate elements can be made from glass fibre or from carbon and are preferentially made from metal. Hardening product 14 is preferably a concrete. Such a reinforcement element enhances the bending resistance of panel 1.
Generally, a reinforcement element 10 to 12 extends along a vertical axis of panel 1. In particular, the length of a reinforcement element 10 that extends along the vertical axis is greater than its height and width. More particularly, in comparison with a wood or concrete component having the same cross-section as that of reinforcement element 10 to 12, reinforcement element 10 to 12 procures a better bending resistance.
Monobloc parts 2 to 4 made from wood-concrete enable different finishing operations to be performed, such as applying a finish coating (which is difficult to achieve on cast rough concrete), and enable fastening means of the panels to be fixed directly on site, such as for example metal plates which can be easily screw-fastened directly onto the wood-concrete. Wood-concrete does in fact enable screwing and fixing to be performed directly, without prior drilling or wall plugs, to gain time.
Several embodiments of a panel 1 have been represented in
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Furthermore, at least one opening 15, 16 can be formed in a monobloc part 2 to 4. Openings 15, 16 are designed to receive a casement, such as a window or a door. Prefabricated panels 1 equipped with surrounds for the casement leafs can thus be provided.
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Such panels 1 reinforced by reinforcement elements 10 to 12 are resilient and can be transported easily. They can therefore be prefabricated in a plant without necessarily being manufactured on the building site of the house or building. Manufacture of the panels in plant is better mastered. Advantageously, armatures 13 have parts salient from hardening product 14, i.e. free parts, to provide hoisting parts of panel 1. Advantageously these salient parts can be used on the building site to join the panels to one another. A free part of armature 13 can be joined to another free part of another panel or of a floor.
In yet another embodiment, the re-entrant arranged in the mould enables a groove to be defined in the monobloc part. After the hardening product has been poured, the latter forms a part having one surface that is visible and accessible. Preferentially, the visible surface is in the same plane as the surface of the monobloc part.
To manufacture the panels defined in the foregoing, at least one monobloc part 2 to 4 is manufactured from wood-concrete, an armature 13 is placed in a housing 5 to 9, and hardening product 14 is then poured into housing 5 to 9, around armature 13 and in contact with at least one surface of monobloc part 2 to 4. Pouring hardening product 14 into the provided housings 5 to 9 enhances the strength of the bond between hardening product 14 and the wood-concrete in comparison with a concrete-concrete bond. Such a method increases the mechanical strength of reinforcement element 10 to 12 with monobloc part 2 to 4. The bond between reinforcement element 10 to 12 and monobloc part 2 to 4 is moreover strengthened on account of the microcavities created at the surface of monobloc part 2 to 4 and of pouring of liquid hardening product 14 which penetrates into these microcavities. After hardening product 14 has hardened, a strong bond is obtained with a high shear strength.
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After provision step T1, an armature 13 is placed inside each housing 8, 9 in a second step T2 illustrated in
Panel 1, illustrated in
Monobloc part 2 to 4 obtained comprises contact surfaces with the reinforcement elements that present numerous microcavities, i.e. blind holes, created by the pieces of wood. The concrete in fact coats the pieces of wood, which creates the microcavities at the surface of monobloc part 2 to 4. In this way, when hardening product 14 is cast in a housing 5 to 9 provided in monobloc part 2 to 4, product 14 will fill the numerous microcavities to increase the binding surface between reinforcement element 10 to 12 and monobloc part 2 to 4. The binding surface is increased all the more with a through aperture opening out at the level of two ends of monobloc part 2 to 4. A strong bond is thus obtained between hardening product 14 and the wood-concrete, which gives reinforcement element 10 to 12 a strong adhesion to monobloc part 2 to 4.
A panel is thus provided that enables a wall meeting earthquake-resistance standards to be erected more quickly, as it incorporates reinforcement elements having an enhanced bending resistance. Furthermore, such a panel is simple to achieve. Advantageously, the panel is strong and lighter than a panel made from rough concrete. Such a panel can be prefabricated and then transported to site to form the walls of the house or building to be built.
In a particular embodiment, the concrete in which pieces of wood are sunk has a chemical composition that is different from the chemical composition of the hardening product comprising a binder. This difference of chemical composition is advantageously chosen to procure a difference in the mechanical performances and in particular the Young's modulus. In a particular embodiment, the Young's modulus of the hardening product comprising a binder is higher than that of the concrete in which pieces of wood are sunk and preferentially at least 10% higher. In other words, reinforcement element 10 to 12 has different mechanical properties from the part formed from wood-concrete regardless of whether one or more armature parts 13 are used.
The area of hardening product comprising a binder extends from one end of the panel to the other with a lateral dimension, i.e. perpendicular to the longitudinal axis of the reinforcement element, of at least 1 cm and preferably at least 5 cm.
The hardening product comprising a binder is preferentially a product that comprises a volume content in pieces of wood that is lower than the volume content in pieces of wood of the concrete in which pieces of wood are sunk. It is advantageous for the volume content in pieces of wood in the hardening product to be less than or equal to 90% of the content in pieces of wood in the wood-concrete, preferentially less than or equal to 80% and even more preferentially less than or equal to 50%. The volume of pieces of wood is reduced which improves the mechanical strength between the armature and the hardening product in comparison with the mechanical strength between the armature and the wood-concrete in an equivalent configuration.
When the hardening product is added to the monobloc part, it enters the microcavities thereby procuring the mechanical strength between the monobloc part and the part formed by the hardening material that hardened. It is advantageous for the hardening material, when it hardens, to be less porous than the material forming the monobloc part thereby facilitating formation of an interface procuring a high mechanical strength.
In preferential manner, the hardening product comprising a binder is devoid of pieces of wood and more preferentially a concrete devoid of pieces of wood. Armature 13 is sunk in hardening product devoid of pieces of wood to ensure a good mechanical cohesion and the hardening product devoid of pieces of wood anchors onto the side walls of the wood-concrete part where a re-entrant was made.
In a particular embodiment, the volume content of pieces of wood is decreasing from monobloc part 2 to the area immediately around the reinforcement elements. In preferential manner, the decreasing volume content of pieces of wood is configured so that the reinforcement element is only in contact with hardening product, preferably concrete, i.e. the reinforcement element has no contact with a wood part.
When several armatures 13 are installed in the monobloc part, it is preferable for the material arranged between armatures 13 to be devoid of pieces of wood and preferentially a concrete devoid of pieces of wood.
In another particular embodiment that can be combined with the previous embodiments, the hardening product comprising a binder is a product that contains pieces of wood the average size of which is smaller than the average size of the pieces of wood contained in the wood-concrete. By using smaller pieces of wood, the cavities formed in the wood-concrete are smaller which improves the mechanical performances of the hardening product. In advantageous manner, the average size of the pieces of wood in the hardening product is less than 70% of the average size of the pieces of wood contained in the wood-concrete, more preferentially at least less than 50% of the average size of the pieces of wood contained in the wood-concrete.
In a preferred embodiment, reinforcement element 10 to 12 is a rod or a bar made from metal, for example from steel.
In an advantageous embodiment, one or more screws are screwed into the walls of the monobloc part after the re-entrant has been removed and before the hardening product is poured. The hardening product is poured and the screws are sunk in the hardening product which improves the mechanical strength between the wood-concrete part and reinforcement element 12. In preferential manner, the screws are screwed directly into the wood-concrete, i.e. without making a hole beforehand and without adding a wall plug.
Number | Date | Country | Kind |
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FR1915563 | Dec 2019 | FR | national |
Filing Document | Filing Date | Country | Kind |
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PCT/EP2020/087890 | 12/24/2020 | WO |