AU2016201316B1 - Prefabricated Insulating Building Panel - Google Patents
Prefabricated Insulating Building Panel Download PDFInfo
- Publication number
- AU2016201316B1 AU2016201316B1 AU2016201316A AU2016201316A AU2016201316B1 AU 2016201316 B1 AU2016201316 B1 AU 2016201316B1 AU 2016201316 A AU2016201316 A AU 2016201316A AU 2016201316 A AU2016201316 A AU 2016201316A AU 2016201316 B1 AU2016201316 B1 AU 2016201316B1
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- AU
- Australia
- Prior art keywords
- panel
- building panel
- casting assembly
- prefabricated
- component
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
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- 238000005266 casting Methods 0.000 claims abstract description 48
- 238000005728 strengthening Methods 0.000 claims abstract description 29
- 239000004567 concrete Substances 0.000 claims abstract description 27
- 239000008262 pumice Substances 0.000 claims abstract description 8
- 229910000831 Steel Inorganic materials 0.000 claims description 13
- 239000010959 steel Substances 0.000 claims description 13
- 239000004793 Polystyrene Substances 0.000 claims description 10
- 229920002223 polystyrene Polymers 0.000 claims description 10
- 238000004519 manufacturing process Methods 0.000 claims description 9
- 239000002184 metal Substances 0.000 claims description 4
- 238000009413 insulation Methods 0.000 description 15
- 239000000203 mixture Substances 0.000 description 4
- 238000012986 modification Methods 0.000 description 4
- 230000004048 modification Effects 0.000 description 4
- 241000238631 Hexapoda Species 0.000 description 3
- 238000000034 method Methods 0.000 description 3
- 239000004033 plastic Substances 0.000 description 2
- 241001253169 Asystasia gangetica Species 0.000 description 1
- 238000007792 addition Methods 0.000 description 1
- 238000005253 cladding Methods 0.000 description 1
- 230000003467 diminishing effect Effects 0.000 description 1
- 231100000206 health hazard Toxicity 0.000 description 1
- 230000009545 invasion Effects 0.000 description 1
- 239000000463 material Substances 0.000 description 1
- 239000003973 paint Substances 0.000 description 1
- 230000035515 penetration Effects 0.000 description 1
- ISWSIDIOOBJBQZ-UHFFFAOYSA-N phenol group Chemical group C1(=CC=CC=C1)O ISWSIDIOOBJBQZ-UHFFFAOYSA-N 0.000 description 1
- 239000011178 precast concrete Substances 0.000 description 1
- 230000002787 reinforcement Effects 0.000 description 1
- 230000003014 reinforcing effect Effects 0.000 description 1
- 230000000717 retained effect Effects 0.000 description 1
- 125000006850 spacer group Chemical group 0.000 description 1
- 239000004575 stone Substances 0.000 description 1
- 230000002195 synergetic effect Effects 0.000 description 1
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 1
- 238000003466 welding Methods 0.000 description 1
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- Building Environments (AREA)
Abstract
Abstract A prefabricated insulating building panel comprising (a) a casting assembly including at least one insulating board with a number of apertures, a first strengthening component, and at least one projecting component configured to pass through one of the apertures of the insulating board and connect to the first strengthening component; and (b) self-compacting lightweight pumice concrete encapsulating the casting assembly.
Description
Prefabricated Insulating Building Panel 2016201316 29 Feb 2016
Technical Field
The present invention relates generally to a prefabricated insulating building panel. In particular, the present invention relates to a tilt slab or precast concrete prefabricated insulating building panel for external cladding of a building.
Background Art
Concrete insulating building panels are known. The manufacture of such insulating building panels involves encapsulating an insulating board (such as polystyrene or rigid phenolic) between two layers of standard weight concrete (see Figure 1). The insulation board (1) is typically 30-50 mm in thickness and is encapsulated between a weather side outer concrete layer of 50-80 mm (2) and a structural outer concrete layer of 100-150mm (3).
The panels can either be cast on site on top of an existing floor slab, tilted to a vertical position and braced into position (using a "tilt slab" method); or precast in a concrete factory on purpose-made steel casting beds and delivered to the building site.
The resultant concrete insulating building panels comply with typical residential insulation requirements such as the New Zealand Building Code. Because the insulation is on the exterior of the structural layer it maximizes the benefits of the thermal mass of the concrete: the insulation isolates the external temperature and helps keep the internal temperature stable. The thickness of the insulation board can be varied to increase the required R-value. A typical method of manufacturing these prefabricated insulating building panels is as follows: 1. A thin concrete face mix (typically 50 mm thick) incorporating a layer of strengthening steel mesh is placed on the casting bed. 2. When the face mix is set, an insulating polystyrene board is placed on top and shear connector pins are drilled through the polystyrene into the face mix in a 600 mm gird pattern and around the perimeter at 600 mm centres. The connector pins protrude out through the top face of the insulating board. 3. A layer of strengthening steel (typically 12 mm bars at 300 mm centre grids) is installed on plastic spacers which sit on top of the insulation board. 1 4. A structural concrete layer (typically 120 mm) is poured on top of the insulating board and over the ends of the shear connector pins and later trowelled to surface finish the panel. 2016201316 29 Feb 2016
The disadvantages with these types of manufacturing methods are that they: • require a two-stage casting process which is labour and time intensive; • are prone to thermal bridging with resulting heat loss in some areas such as at panel edges if the insulation board stops short of the edge; • are prone to invasion from insects and penetration of moisture between the layers at an exposed insulation board if the panel edges are not fully encapsulated by the concrete, as required in some systems; • require expensive shear connector pins with bulbous ends to have purchase in both the concrete layers; • require vibration during the manufacture method to remove air voids from the concrete mix during setting; the ensuing noise is environmentally unfriendly and a health hazard to factory staff working in the vicinity; and • require surface finishing of the open face of the concrete panel.
Object of the Invention
It is an object of the invention to provide a prefabricated insulating building panel that addresses at least some of the problems of the prior art, such as those discussed above.
Alternatively, it is an object of the invention to at least provide the public with a useful choice.
Disclosure of the Invention
According to a first aspect of the invention, there is provided a prefabricated insulating building panel comprising: a) a casting assembly including: at least one insulating board with a number of apertures; a first strengthening component; and at least one projecting component passing through one of the apertures of the insulating board and connected to the first strengthening component; and b) self-compacting lightweight pumice concrete encapsulating the casting assembly. 2
Preferably, the self-compacting lightweight pumice concrete completely encapsulates the casting assembly so as to leave no exposed edges of the casting assembly. 2016201316 29 Feb 2016
Preferably, the at least one insulating board is formed from polystyrene.
Preferably, the first strengthening component is positioned at least 50 mm within the panel away from a face of the panel.
Preferably, the first strengthening component is a sheet of metal mesh. Preferably, wherein the sheet of metal mesh is formed from steel.
Preferably, the casting assembly comprises a second strengthening component on an opposite side of the insulating board from the first strengthening component. Preferably, the second strengthening component is connected to the projecting component.
Preferably, the second strengthening component is a steel bar grid.
Preferably, the at least one projecting component is steel re-bar.
According to a second aspect of the invention, there is provided a method of manufacturing an insulating sandwich panel which includes the steps of: a) placing a casting assembly into a mould, the casting assembly including: at least one insulating board with a number of apertures; a first strengthening component; and at least one projecting component passing through one of the apertures of the insulating board and connected to the first strengthening component; and b) filling the mould with self-compacting lightweight pumice concrete to encapsulate the casting assembly.
Brief Description of the Figures
The invention will now be described by way of example only and with reference to any one of the accompanying drawings in which:
Figure 1 shows a schematic cross-sectional view of a prior art prefabricated concrete building panel; and
Figure 2 shows a schematic sectional view of a preferred embodiment of the present invention in 3 the form of a prefabricated insulating building panel. 2016201316 29 Feb 2016
Summary of the Invention
The present invention employs the use of self-compacting lightweight pumice concrete (which may be known as SCLWPC) in the manufacture of a prefabricated insulating building panel, in a one-stage casting process. The prefabricated insulating building panels so produced include a casting assembly comprising an insulating board with a number of apertures; at least one strengthening component positioned within an interior space of the mould; and at least one projecting component passing through one of the apertures of the insulating board and connected to the at least one strengthening component. The SCLWPC is used as an insulating medium to encapsulate the casting assembly.
Prior to filling the mould with the SCLWPC the interconnected casting assembly is positioned inside the mould to a required position. For example, by not abutting an interior surface of the mould the SCLWPC medium totally encapsulates the components of the casting assembly leaving no exposed edges. In this way, thermal bridging is minimized as the SCLWPC itself also has an in-built insulation value and ingress of water or insects in the cast panels is prevented. Alternatively, the SCLWPC can partially fill the mould to leave a proportion of the casting assembly components exposed. If required a decorative concrete face can be later applied (e.g. paint or stone chips).
There is a synergistic effect provided through the use of the casting assembly together with the SCLWPC in forming precast insulating building panels according to embodiments of the invention. The SCLWPC has a low density, is therefore of a low weight, and provides good insulation itself. Simultaneously, the casting assembly provides ample reinforcement as well as some additional insulation to the SCLWPC, by virtue of the bar grid and mesh being interconnected, yet having an insulating board, provided therebetween. This casting assembly design allows for a single stage casting process, and a resulting panel in which the casting assembly is fully encapsulated by SCLWPC.
Detailed Description of the Invention and Best Modes
Referring to Figure 2, the prefabricated insulating building panel according to a preferred embodiment of the present invention is generally indicated by arrow 10. The panel (10) is made from SCLWPC (100) and has a casting assembly therein including an insulating board in the form of a 40 mm thick polystyrene sheet (12) with a number of apertures (12A) in the form of 75 mm diameter holes punched through at 600 mm center grids; a first strengthening component in the form of a steel mesh (13), such as 338 tank mesh) in a face side of the panel (11); a second strengthening component in form of a 12 4 mm steel bar grid (14) in a structural face of the panel (10); and a reinforcing component in the form of a 10mm thick steel re-bar (15) member which passes transversely through the aperture (12A) of the polystyrene sheet (12) and connects to the mesh layer (13) and bar grid (14) via a connection method known in the art such as welding or tying. The ends of the projecting component (15), which connect to the mesh (13), support the polystyrene sheet (12) thereon during casting. The interconnection of the components of the casting assembly means that the casting assembly can be lifted as one "cassette" into the mould prior to filling. The distance from the casting assembly to the panel perimeter edges is 70 mm in this embodiment. The panel (10) uses the SCLWPC (100) as a medium which completely encapsulates the casting assembly. 2016201316 29 Feb 2016
The panel (10) complies with NZS 4218:2009, R-value = 1.2. However, the thickness of the insulating board can be varied to comply with a required insulation R-value. The prefabricated insulating building panel of the present invention exceeds the following New Zealand Building Code 2011 Clause HI Energy Efficiency (concrete and masonry) insulation requirements:
Climate Zone 1 - Northland, Auckland and Coromandel, 220 mm thick with an R-value of R0.8;
Climate Zone 2 - rest of North Island except the Volcanic Plateau, R1.0;
Climate Zone 3 - Volcanic Plateau and South Island, R1.2.
To manufacture the panel, the casting assembly is placed into a mould, and may be raised 50 mm off the mould so that no surface of the casting assembly contacts the internal surface of the mould. The casting assembly may be supported above the casting bed by any suitable means, for example, by using plastic support chairs, as is commonly used in the art. SCLWPC is pumped into the mould from the bottom. The SCLWPC, with a thick creamy viscosity, gradually fills up the mould, flowing around the strengthening steel and up through the holes in the insulating board, encapsulating the components of the casting assembly so that the SCLWPC molds to the casting assembly. The polystyrene board may be retained in place, to prevent it from floating on top of the SCLWPC, as the level rises. This may be accomplished in a variety of ways without departing from the scope of the present invention. In one preferred embodiment, the polystyrene board may be tied to the casting assembly with wire. No further casting steps are needed as the SCLWPC is self-compacting and therefore does not require finishing. The mould and casting bed can be positioned horizontally prior to filling. The overall panel thickness can be varied to suit structural/insulation requirements.
After manufacture, the prefabricated insulating building panels (10) can be transported on-site and positioned via a crane with the use of brackets or eye bolts (not shown) which are cast-in to the top edge of the panel (1). 5
Advantages 2016201316 29 Feb 2016
The present invention offers a number of advantages over the prior art including: • a one-stage casting process saving labour and time; • thermal bridging is minimised as the SCLWPC itself also has an in-built insulation value; • ingress of insects and moisture, etc, is minimised as the SCLWPC totally encapsulates the insulating board leaving no exposed edges; • obviates the need for shear connector pins; • obviates the need for vibration of the mould after it has been filled with SCLWPC; • minimises the need for surface finishing as the SCLWPC is self-levelling; • SCLWPC is a lower density material in comparison to conventional concrete, meaning that the finished panel is lighter compared to the prior art type of prefabricated concrete panel shown in Figure 1; • lighter panels mean trucks can carry more volume with each load compared to the prior art type of prefabricated concrete building panel shown in Figure 1; and • R-values can be increased by increasing the thickness of the insulating board.
The invention may also be said broadly to consist in the parts, elements and features referred to or indicated in the specification of the application, individually or collectively, in any or all combinations of two or more of said parts, elements or features.
Where in the foregoing description reference has been made to integers or components having known equivalents thereof, those integers are herein incorporated as if individually set forth.
It should be noted that various changes and modifications to the presently preferred embodiments described herein will be apparent to those skilled in the art. Such changes and modifications may be made without departing from the spirit and scope of the invention and without diminishing its attendant advantages. It is therefore intended that such changes and modifications be included within the present invention.
Unless the context clearly requires otherwise, throughout the description and the claims, the words "comprise", "comprising", and the like, are to be construed in an inclusive sense as opposed to an exclusive or exhaustive sense, that is to say, in the sense of "including, but not limited to".
Aspects of the present invention have been described by way of example only and it should be appreciated that modifications and additions may be made thereto without departing from the scope of the appended claims. 6
Claims (12)
- Claims1. A prefabricated insulating building panel comprising: a) a casting assembly including: at least one insulating board with a number of apertures; a first strengthening component; and at least one projecting component configured to pass through one of the apertures of the insulating board and connect to the first strengthening component; and b) self-compacting lightweight pumice concrete encapsulating the casting assembly.
- 2. The prefabricated insulating building panel of claim 1, wherein the self-compacting lightweight pumice concrete completely encapsulates the casting assembly so as to leave no exposed edges of the casting assembly.
- 3. The prefabricated insulating building panel of claim 1 or claim 2, wherein the at least one insulating board is formed from polystyrene.
- 4. The prefabricated insulating building panel of any one of claims 1-3, wherein the first strengthening component is positioned substantially 50 mm from a face of the panel.
- 5. The prefabricated insulating building panel of any one of claims 1-4, wherein the first strengthening component is a sheet of metal mesh.
- 6. The prefabricated insulating building panel of claim 5, wherein the sheet of metal mesh is 338 steel mesh.
- 7. The prefabricated insulating building panel of any one of claims 1-6, wherein the casting assembly comprises a second strengthening component on an opposite side of the insulating board from the first strengthening component.
- 8. The prefabricated insulating building panel of claim 7, wherein the second strengthening component is connected to the projecting component.
- 9. The prefabricated insulating building panel of claim 7 or claim 8, wherein the second strengthening component is a steel bar grid.
- 10. The prefabricated insulating building panel of any one of claims 1-9, wherein the at least one projecting component is steel re-bar.
- 11. The prefabricated insulating building panel of any one of claims 1-10, wherein the panel comprises one or more brackets or eye bolts cast in to the panel for lifting the panel.
- 12. A method of manufacturing an insulating sandwich panel which comprises the steps of: a) placing a casting assembly into a mould, the casting assembly including: at least one insulating board with a number of apertures; a first strengthening component; and at least one projecting component passing through one of the apertures of the insulating board and connected to the first strengthening component; and b) filling the mould with self-compacting lightweight pumice concrete to encapsulate the casting assembly.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| AU2016201316A AU2016201316B1 (en) | 2016-02-29 | 2016-02-29 | Prefabricated Insulating Building Panel |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| AU2016201316A AU2016201316B1 (en) | 2016-02-29 | 2016-02-29 | Prefabricated Insulating Building Panel |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| AU2016201316B1 true AU2016201316B1 (en) | 2017-06-08 |
Family
ID=59011444
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| AU2016201316A Ceased AU2016201316B1 (en) | 2016-02-29 | 2016-02-29 | Prefabricated Insulating Building Panel |
Country Status (1)
| Country | Link |
|---|---|
| AU (1) | AU2016201316B1 (en) |
Cited By (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN107237449A (en) * | 2017-08-02 | 2017-10-10 | 蔡映峰 | A kind of concrete thermal-insulating material composite construction and preparation method thereof |
| WO2019114178A1 (en) * | 2017-12-14 | 2019-06-20 | 江苏跃发建设工程有限公司 | Light steel structure wall panel having insulating layer |
Citations (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US4069629A (en) * | 1977-02-18 | 1978-01-24 | Maso-Therm Corporation | Anchored composite building module |
| US6260329B1 (en) * | 1999-06-07 | 2001-07-17 | Brent P. Mills | Lightweight building panel |
| CN102312516A (en) * | 2010-07-05 | 2012-01-11 | 马国晏 | Sandwich composite external wallboard |
| CN202131706U (en) * | 2010-10-20 | 2012-02-01 | 广州市壁神新型建材有限公司 | Heat-insulation sound-insulation lightweight concrete composite wallboard |
-
2016
- 2016-02-29 AU AU2016201316A patent/AU2016201316B1/en not_active Ceased
Patent Citations (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US4069629A (en) * | 1977-02-18 | 1978-01-24 | Maso-Therm Corporation | Anchored composite building module |
| US6260329B1 (en) * | 1999-06-07 | 2001-07-17 | Brent P. Mills | Lightweight building panel |
| CN102312516A (en) * | 2010-07-05 | 2012-01-11 | 马国晏 | Sandwich composite external wallboard |
| CN202131706U (en) * | 2010-10-20 | 2012-02-01 | 广州市壁神新型建材有限公司 | Heat-insulation sound-insulation lightweight concrete composite wallboard |
Non-Patent Citations (1)
| Title |
|---|
| PAPANICOLAOU, C. G. et al., 'Lightweight Aggregate Self-Compacting Concrete: State-of-the-Art & Pumice Application', Journal of Advanced Concrete Technology Vol. 9, No. 1, 15-29, February 2011 * |
Cited By (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN107237449A (en) * | 2017-08-02 | 2017-10-10 | 蔡映峰 | A kind of concrete thermal-insulating material composite construction and preparation method thereof |
| CN107237449B (en) * | 2017-08-02 | 2022-12-27 | 蔡映峰 | Concrete-thermal insulation material composite structure and preparation method thereof |
| WO2019114178A1 (en) * | 2017-12-14 | 2019-06-20 | 江苏跃发建设工程有限公司 | Light steel structure wall panel having insulating layer |
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Legal Events
| Date | Code | Title | Description |
|---|---|---|---|
| FGA | Letters patent sealed or granted (standard patent) | ||
| MK14 | Patent ceased section 143(a) (annual fees not paid) or expired |