ES2936722T3 - Precast building element and method for manufacturing said precast building element - Google Patents

Abstract

The invention refers to a precast construction element (1) comprising a concrete body (4) and at least one main thermal insulation unit (5) integral with the concrete body of the construction element, said main unit being arranged projecting of a top face. of the concrete body. According to the invention, the element comprises at least one secondary thermal insulation unit (8) comprising a specific concrete block having a thermal conductivity of less than 1 watt per Kelvin meter, the block extending adjacent to the main unit in such a way that said unit is also anchored in said specific concrete block. The invention also refers to a method for manufacturing said precast building element (1). (Automatic translation with Google Translate, without legal value)

Description

DESCRIPTION

Precast building element and method for manufacturing said precast building element The present invention relates to building and construction and, more specifically, to a precast building element, such as a beam or a pre-slab.

The invention also refers to a method for manufacturing said building element.

Technological background of the invention

There are two ways to treat the insulation of a building: by enclosing the entire construction in an insulating envelope or by insulating on the inside of a wall, one side of which is in contact with the outside atmosphere.

In the case of an interior insulation treatment, one of the main problems to be solved is that of thermal bridges, that is, the conduction path of heat or cold through the continuity of a heat-conducting material from the outside of the building to the inside. This is especially true in the case of floors, which form thermal bridges due to their contact with the exterior walls of the building.

In an attempt to deal with this type of thermal bridge between wall and floor, it is known that pre-slabs are used, each consisting of a concrete body and at least two fixing bases anchored inside the concrete body and separated from each other. from each other by a predefined distance. Each pre-slab also has reinforcements anchored in the corresponding concrete body, so that they extend between two consecutive fixing bases. Thus, an operator arranges the pre-slabs along a wall and then inserts a block of heat-insulating material into each fixing base. After the compression slab has been poured to form the floor, the reinforcing bars that protrude into the building are embedded so that they are fixed to the floor. Next, the reinforcing bars that protrude from the other side of the thermal insulating body are embedded in an external concrete element that continues the construction of the wall. In this way, the floor and the wall are connected and the blocks of thermal insulating material arranged between them, through the bases, limit the corresponding thermal bridges.

Such floor tiles are described, for example, in patent FR 2861 767 A1, which discloses the features of the preamble of claim 1.

Document FR 2 861 767 A1 discloses the following features of claim 7: a manufacturing process for a prefabricated building element comprising the steps of:

- pouring concrete inside a space adjacent to at least one main unit and formwork by said main unit, and

- Let the concrete set.

However, although these pre-slabs simplify the insulation of the wall/floor, since the operator only has to manage the introduction of the blocks of heat-insulating material in the fixing bases, the thermal bridge remains relatively high due to the distances between the different fixing bases to allow the passage of the reinforcement and, therefore, to the distances between the different blocks of heat-insulating material.

Object of the invention

It is an object of the invention to provide a prefabricated building element that makes it possible to more effectively treat thermal bridges, in particular, though not exclusively, between a wall and a floor. It is also an object of the invention to propose a manufacturing method for said construction element.

Brief description of the invention

To this end, the object of the invention is a precast construction element with the characteristics of claim 1, comprising a concrete body and at least one main thermal insulation unit attached to the concrete body, the main unit being arranged to protrude from an upper face of the concrete body.

According to the invention, the precast building element comprises at least one secondary thermal insulation and structural support unit comprising a specific concrete block having a reduced thermal conductivity of less than 1 Watt per Kelvin meter and reinforcements arranged in said block, the block adjacent to the main unit being extended so that said main unit is anchored in said specific concrete block.

Therefore, the building element according to the invention allows the continuity of thermal insulation along the entire length of the building element with alternating zones of primary thermal insulation in the primary units and zones of secondary thermal insulation in the secondary units. . This allows a much better solution to thermal bridge problems.

In the particular case that the construction element of the invention is a pre-slab, the continuity of the floor's thermal insulation is thus guaranteed along the entire wall/floor connection, which limits the wall/floor thermal bridge.

In addition, it is observed that the secondary units fulfill both a thermal protection function thanks to the specific concrete block, and a structural support function thanks to the reinforcement but also to the specific concrete block.

In addition, the main unit can be used directly as a formwork part for the production of the secondary unit, which simplifies the production of the building element.

The invention also refers to a method for manufacturing a prefabricated construction element with the characteristics of claim 7, which construction element, as previously described, comprises the steps of:

- pouring specific concrete with a reduced thermal conductivity of less than 1 watt per Kelvin meter inside a space adjacent to at least one main unit of thermal insulation and formwork for at least said main unit,

- allow the specific concrete to set to form a secondary unit of thermal insulation and structural support to which the main unit is also anchored.

In this way, the main unit serves directly as a formwork portion for the manufacture of the secondary unit, thus simplifying the manufacture of the building element.

Of course, the terms "upper", "lower" ... are to be understood based on a position of use of the building element, that is, once the building element has been placed in a building under construction (for example , when the building element is a pre-slab, the use position is when the pre-slab is mounted at the level of the associated wall portion).

Other features and advantages of the invention will become apparent from the following description of certain embodiments of the invention.

Brief description of the drawings

Reference is made to the accompanying drawings, of which:

figure 1 is a perspective view of a building element according to a first embodiment of the invention arranged in the vicinity of a portion of a wall,

- Figure 2 is a view identical to that of Figure 1 after the compression slab has been poured, - Figure 3 is a top view of a building element according to a second embodiment of the invention, the blocks not being shown of thermal insulating material.

Detailed description of the invention

With reference to figures 1 to 2, the building element according to the first embodiment of the invention is a pre-slab 1 which is therefore intended to treat thermal bridges between a floor 2 and a wall 3 adjacent to said floor 2.

The pre-slab 1 comprises a concrete body 4, for example prestressed concrete, comprising prestressing cables oriented longitudinally and parallel to one another.

The pre-slab 1 further comprises main units 5 for thermal insulation. The main units 5 are all connected to the concrete body 4 by being anchored to it. More specifically, the main units 5 are anchored in the concrete body 4 and are separated from each other by a predefined distance. The main units 5 are arranged so that they protrude from the upper part of the concrete body 4. Preferably, the main units 5 have a shape such that they extend substantially at least along the entire height of the pre-slab 1. From In this way, the thermal bridges between the floor 2 and the adjacent wall are reduced. In particular, the main units 5 are arranged on the same longitudinal edge 6 of the pre-slab 1, but displaced with respect to said longitudinal edge 6. In this way, the main units 5 are completely embedded in the concrete body 4, which ensures that the 5 main units remain firmly attached to the concrete body 4. The individual main units 5 all extend parallel to said longitudinal edge 6 in the same X direction.

Preferably, the main units 5 are shaped so that the upper faces of the main units 5 are substantially level with the upper face of the compression slab 14 intended to be cast on the pre-slab 1, as will be seen later. Also preferably, the main units 5 of the pre-slab 1 are all identical to each other and are all separated two by two by the same distance. Two successive main units 5 thus define a space between them at the longitudinal edge 6.

Each main unit 5 consists of a base 10 in the shape of an open container, for example a flower tray. Each base 10 is, for example, made of plastic. Preferably, each base 10 comprises a finger (not visible here) arranged on one of the outer side faces of said base 10 and extending longitudinally towards the outside of base 10, the finger being shaped to define the constant spacing between two bases. 10 consecutive.

In particular, each main unit 5 comprises a block of thermal insulating material 7 that is received in the corresponding base 10. Each block 7 is embedded, for example, in the corresponding base 10. Thus, the block 7 here has a substantially parallelepipedal shape corresponding to that of the base 10.

Each block 7 is made, for example, of mineral wool.

Preferably, the base 10 includes means for retaining the associated block 7 in the base 10. The retaining means comprise, for example, grooves provided on at least two of the internal faces of the base 10 and protruding towards the interior of the base. 10.

Each main unit 5 (formed in this case by a base 10 and a block of heat-insulating material 7) thus forms a thermal bridge break that makes it possible to deal with the thermal bridge between the floor 2 and the wall 3, as we will see later.

The pre-slab 1 includes secondary thermal insulation units 8. Each secondary unit 8 is here a specific concrete block with a reduced thermal conductivity of less than 1 Watt per Kelvin meter. Preferably, the specific concrete of each secondary unit 8 is a concrete with a thermal conductivity of less than 0.6 watts per Kelvin meter, which further improves the treatment of thermal bridges by said secondary unit 8. For example, the concrete used is Thermedia concrete (registered trademark of the Lafarge company).

Each secondary unit 8 is arranged between two successive main units 5 of the pre-slab 1 so as to extend along the X direction. Each secondary unit 8 is anchored in the concrete body 4. Thus, the pre-slab 1 presents a continuous alternation of a main unit 5 and a secondary unit 8 parallel to its longitudinal edge 6.

The secondary thermal insulation units 8 are arranged so as to enclose the two respective main units 5 that surround them. In this way, each main unit 5 is anchored by its two outer lateral faces in two successive secondary units 8.

According to the invention, the secondary units 8 are arranged so as to protrude from the top of the concrete body 4. Preferably, the secondary units 8 are shaped such that they extend substantially further over the entire height of the slab 1 (ie up to the underside of the concrete body 4). In this way, thermal bridges between the floor 2 and the adjacent wall are reduced.

Preferably, the secondary units 8 are arranged so that they protrude the same height from the top of the concrete body 4 as the main units 5. Preferably, the secondary units 8 are here shaped so that their upper faces are substantially level with the upper face of the compression slab 14 intended to be cast on the pre-slab 1, as will be seen later.

The subunits 8 further comprise reinforcement assemblies 9, each reinforcement assembly being arranged to pass through one of the subunits 8 so that the reinforcement of said assembly 9 protrudes on both sides of the associated subunit 8 to extend, for one side, towards the pre-slab 1 above the pre-slab 1 and, on the other side, towards the wall 2 above at least part of the portion of the wall 2 already built as will be seen later. In this way, each set of reinforcement 9 is anchored in the concrete of the secondary unit 8. The reinforcement of the sets of reinforcement 9 is, for example, made of steel.

The pre-slab 1 is arranged in this way during the construction of the building.

For this, the wall 3 is raised to practically the level at which the floor 2 is to be placed. Preferably, the upper part of the erected wall portion 12 has a stop 13 that allows a better connection with the rest of the wall. 3 to build as will be seen later.

Beams (not visible here) are also placed against the assembled portion 12 of the wall 3 so that they extend normal to said assembled portion 12 in order to provide support for the construction of the floor 2.

Subsequently, the pre-slab 1 is arranged on the beams to delimit the floor surface 2. The longitudinal edge 6 of the pre-slab 1, thus partly forming one of the edges of the floor 2, is placed on the assembled portion 12 of the wall 3 in question so that it extends parallel to direction X. Figure 1 thus illustrates the already assembled part 13 of wall 3 and said pre-slab 1.

Next, with reference to figure 2, it only remains to form the compression slab 14 by pouring concrete on the pre-slab 1 so that the projecting reinforcement of the secondary units 8 is embedded in the concrete. The compression slab 14 is poured so that it is level with the different main units 5 and the different secondary units 8 that run along the wall 3.

Concrete is also poured over the already existing portion 12 of wall 3 to continue the construction of wall 3, so that the reinforcement protruding from the other side of the secondary units 8 (and extending over the already built portion 12 of wall 3) is also embedded in concrete. In this way, the reinforcement sets 9 are anchored in the floor 2 and in the wall 3, thus guaranteeing the bearing capacity of the floor 2.

Therefore, it is very simple for an operator to erect a floor using the precast slabs 1. Indeed, the operator only has to place the precast slabs 1 and pour the concrete from the compression slab 14 directly on the precast slabs 1. Delivery in situ of the pre-slabs 1 already equipped with the reinforcement sets 9 and the main and secondary units 5 and 8 greatly simplifies the placement of the slab 2 by the operator.

Advantageously, the bases 10, the main thermal insulation units 5 and the secondary thermal insulation units 8 together constitute a part of the formwork for the compression slab 14 intended to be cast on the pre-slab 1. The formwork of the compression slab 14 is very simple to do. The anchoring of the main units 5 to the secondary units 8 also guarantees a good formwork of the compression slab 14.

In addition, the thermal bridges that can form between the floor 2 and the wall 3 are very limited, since:

- the main thermal insulation units 5 form a thermal insulation barrier between the floor 2 and the wall 3 by being arranged between the floor 2 and the wall 3 over the entire height of the floor 2 (as best seen in figure 2) , in particular due to the fact that the blocks of insulating material 7 extend over the entire height of the floor 2,

- the secondary thermal insulation units 8 form a thermal insulation barrier between the floor 2 and the wall 3 by being arranged between the floor 2 and the wall 3 over practically the entire height of the floor (remember that the concrete of each secondary unit 8 is a specific concrete that is much more thermally insulating than the concretes traditionally used in the field of construction and that has a thermal conductivity of at least 2 watts per meter-kelvin).

The thermal bridges that can form between the floor 2 and the wall 3 are therefore reduced over the entire length of the wall 3 and over the entire height of the floor 1.

In addition, the union of the different secondary units 8 and the main units 5 guarantees both a good thermal insulation of the floor 2 at the level of the wall 3 and a good load capacity of the floor 2.

It should be noted that the secondary units 8 also fulfill a structural support function thanks to the concrete that constitutes them and also to the sets of reinforcements 9 that are anchored in said secondary units 8.

In addition, the use of mineral wool for the blocks 7 of the main units 5 allows, in addition to the thermal insulation function, to fulfill an additional fire protection function, as well as an additional sound insulation function.

Furthermore, it is possible to dispense with the relatively large conventional beam support of the prior art. In this case, a simple beam support for pre-slab 1 is enough.

The manufacturing process of the pre-slab 1 according to the first embodiment will be described below. In a first stage, the fixing bases 10 are arranged in a manufacturing mold for the concrete body 4 of the pre-slab 1 in such a way that said bases 10 are placed along one of the edges of the manufacturing mold, thus extending the edge parallel to the X-direction. The different bases 10 are separated from each other by a predefined distance that is identical for all the bases. The finger on each base 10 ingeniously facilitates correct disposition of the different bases 10 in the manufacturing mould, which facilitates the work of the operator. Therefore, the bases 10 rest on the bottom of the mold.

Next, in a second stage, a block of thermal insulating material 7 is inserted into each base 10 by interlocking.

In a third step, the space remaining free between two successive base 10s is filled.

To do this, between each pair of successive bases 10, a first formwork element facing the edge of the mold and a second formwork element facing the future concrete body 4 are arranged, thus extending the two formwork elements parallel to the direction X. For each pair of successive main units 5, the two main units 5 and the two shuttering elements define a substantially parallelepipedal volume.

In a fourth stage, the reinforcement assemblies 9 are arranged in the production mold. For this, the formwork elements have holes adapted to allow the passage of the reinforcement through them or are shaped like a comb for the passage of the reinforcement through them. Alternatively, the reinforcing bars can, of course, be arranged in the production mold before closing the space left free between the two successive bases 10.

The shuttering elements are, for example, plate-shaped. The shuttering elements are made of metallic material, for example steel, or of wood or plastic. Formwork elements are reusable or disposable. In a fifth stage, the concrete is poured into the production mold.

Next, the specific concrete is poured inside these volumes from above to finish filling them and form the secondary thermal insulation units 8. In this way, the main units 5 (in this case, the bases 10 and the blocks 7 ) are cleverly used directly as formwork portions. The two concretes are then allowed to set. In this way, the bases 10 can be anchored to the concrete of the concrete body 4 of the pre-slab 1, on the one hand, and to the specific concrete of the secondary thermal insulation units 8, on the other. This also allows the blocks 7 to be anchored to the specific concrete of the secondary thermal insulation units 8 (since the blocks 7 also serve as part of the formwork for the formation of the secondary units 8). Finally, this allows the reinforcement assemblies 9 to be anchored to the secondary units 8, as well as to the concrete body 4. In addition, the secondary units 8 are also anchored to the concrete body 4.

In this way, the body of the pre-slab 1, the main units 5 and the secondary units 8, as well as the reinforcement units 9, are connected to each other.

The pre-slab 1 created in this way and delivered to the site is therefore very easy to handle and move, which facilitates the task of the people working on the site. The pre-slab 1 supplied in this way already has fully integrated both the structural support reinforcements and the secondary and main thermal insulation units.

A second embodiment of the building element according to the invention will now be described with reference to figure 3. The elements common to the first embodiment retain the same numbering increased by one hundred.

Each base 110 again has the shape of an open container, for example of the flower tub type, substantially parallelepiped in shape. Unlike the first embodiment, however, each base 110 further comprises two additional walls: a first wall 121 extending in the extension of one of the longitudinal walls from a first external side face of the base 110 and a second wall 122 extending in the extension of the other of the longitudinal walls of the base 110 from the second external side face of the base 110, each wall 121, 122 being shaped in such a way as to define the constant interval between two consecutive 110 bases.

In this way, when the bases 110 are arranged one behind the other, their longitudinal walls 121, 122 make it possible to directly define the longitudinal formwork of the volume to be formed to create the secondary thermal insulation units 108. This eliminates the need for additional formwork elements. for the manufacture of the pre-slab 101. Of course, the longitudinal walls 121, 122 are adapted to allow the passage of reinforcements through them.

Of course, the invention is not limited to the described embodiments and variants of the embodiments may be provided without departing from the scope of the invention as defined in the claims.

In particular, the building element may not be a floor slab but, for example, a beam, a beam.

Furthermore, although the construction element has been used here for the treatment of thermal bridges between the non-load-bearing edge of a floor and the wall adjacent to said edge, the construction element can be used for the treatment of thermal bridges between a load-bearing edge of a floor and a wall adjacent to said edge. For the same building, the construction element can be used to isolate the floor, at its two non-load-bearing edges, from the adjacent walls and a prior art device, such as the construction element described in application FR 2 861 767, can be used to isolate the floor, on its two load-bearing edges, from the adjacent walls.

The main unit may be different from the one described. In particular, the main unit may not comprise a fixing base and may, for example, only comprise the block of thermal insulating material. Although the main unit is anchored to the building element (i.e. by being fixed directly into the concrete of the building element body), the main unit can be fixed to the building element in another way, for example by screwing, gluing, etc., regardless of whether the main unit has a motherboard or not. In this way, the main unit can be connected to the concrete body of the building element after its creation or during the formation of the concrete body of the building element.

If the main unit has a base, this can be made of wood or metal, for example.

The base may have anchor feet embedded in the concrete body of the building element to facilitate anchoring of the base in the building element. In this case, the block of heat-insulating material will not extend to the full height of the building element, but up to a few centimeters above the bottom of the building element.

The base can also have a different shape than described. For example, the base may not be in the shape of a planter, but may have vertically extending rods into which the blocks of heat-insulating material are inserted.

For example, the base may have a formwork portion or portions that are slidable and/or rotatable between a first position in which the portion extends along one of the walls of the base and a second position in which the portion extends in line with said wall, in order to unfold to form a formwork portion for the pouring of the specific concrete to form the secondary thermal insulation and structural support unit. This wall can be arranged to allow the longitudinal formwork of the secondary thermal insulation and structural support unit or to allow the lateral formwork of the secondary thermal insulation and structural support unit. Alternatively, the formwork portions may be rigidly fixed to the bases or comprise means to engage them in the bases. According to another variant, these shuttering portions can be rigidly fixed to the blocks of heat-insulating material or comprise means to engage them in the blocks of heat-insulating material or be mounted so that they pivot or slide on the blocks of heat-insulating material.

The formwork can be completed with two separate formwork portions, as described in the present application, or it can be completed with a single formwork portion in the form, for example, of a gallows comprising two wings, each of which allows the formwork longitudinal of the space that remains free between the main units, and a plate that connects the two wings to join them together. This plate can rest at the bottom level of the mold or, on the contrary, protrude from the space to be formworked, the plate including, of course, a hole to pour the specific concrete into the space.

In all cases, the part or parts of the formwork may, of course, receive reinforcement through them.

The blocks can be received in the bases in a way other than interlocking, for example, by gluing, screwing, etc.

The block can be made of a material other than that described above, for example, based on polystyrene, based on expanded polystyrene, based on mineral wool, based on expanded perlite, etc.

Also, the secondary thermal insulation and structural support unit may be different from those described. In particular, the height of the secondary unit for thermal insulation and structural support may be different from that of the main unit or the base.

Primary and/or secondary units may also have an additional layer of fire protection, such as a layer of mineral wool. Alternatively, the material of the blocks of the main units and/or individual sub-units can itself provide a fire protection function.

Also, in the case of the ground, although here the concrete is first poured at ground level before being poured at wall level, it is of course possible to first pour the concrete at wall level to continue the construction of the wall before pour concrete at ground level.

In the same way, as far as the manufacturing of the building element is concerned, the reinforcement units, the main units and the shuttering elements can be arranged in the manufacturing mold in a direction other than that described. It is possible to cast the specific concrete before the concrete body or simultaneously. It is also possible to create the concrete body of the building element first, before connecting the main units to it. The concrete body of the building element can also be created first before creating the secondary units.

Claims (7)

1. Precast construction element (1; 101) comprising a concrete body (4) and at least one main unit (5; 105) of integral thermal insulation with the concrete body, the main unit being arranged to protrude from a upper face of the concrete body, where the element is characterized in that it comprises at least one secondary unit (8; 108) for thermal insulation and structural support that comprises a specific concrete block with a thermal conductivity of less than 1 watt per Kelvin meter and reinforcements arranged in said block, the block extending adjacent to the main unit so that said unit is anchored in said specific concrete block, the secondary unit (8; 108) being arranged to protrude from the upper face of the concrete body. Element according to claim 1, wherein the block (7) of heat-insulating material is mineral wool. Element according to any of claims 1 to 2, wherein the concrete of the secondary unit block (8; 108) is a concrete with a thermal conductivity of less than 0.6 watts per Kelvin meter. Element according to any of claims 1 to 3, wherein the secondary unit (8; 108) is arranged to protrude the same height from the upper face of the concrete body (4) as the main unit (5; 105). ). Element according to any of the preceding claims, wherein the construction element is a pre-slab (1; 101). Element according to any of the preceding claims, wherein the main unit (5; 105) is anchored in the concrete body (4). 7. Process for manufacturing a prefabricated building element (1; 101) according to any of the preceding claims, comprising the steps of: - pour specific concrete with a reduced thermal conductivity of less than 1 watt per Kelvin meter inside a space adjacent to at least one main unit and formwork by said main unit, - allow the specific concrete to set to form a secondary unit of thermal insulation and structural support to which the main unit is also anchored.