STRUCTURE PANEL AND A JOINT BETWEEN SUCH PANELS AND METHOD OF USING AND MANUFACTURING THE PANEL

Abstract: An element system particularly for manufacturing a wall, comprising a casing (1, 2) which consists of a cast component (1) and a sheeting (2), both adjoining a (light, made of wood, steel or a like material) frame in a manner that casing (1, 2) may extend below the frame to form a footing (10), laterally to form a corner extension or the like (1a, 1b) or a roof structures covering skirt (16) and wherein a joint is achieved by overlapping either sheeting (2) and/or internal covering (5) with respect to the frame. A joint for this type of element which is obtained by means of a symmetrical or asymmetrical overlapping in at least one of the surfaces.

Description: Structure panel and a joint between such panels and method of using and manufacturing the panel. The present invention relates to a construction or the like having in at least one structure, especially in a wall, surface made of a lithoidal surface structure based on casting, tiling or the like as well as on the curing of casting mass, adhesive, mortar or the like, particularly an external wall structure. This type of structures are very common and, for example in Finland, they are the most common wall structures in small houses in new housing projects. At present, the wall structure is most generally built by using a wood-constructed thermally insulated wall with a brick lining on its external surface. Other available solutions include a two-casing brickwork or various partially heat insulating and load-bearing solutions. A third generally employed basic solution is a double-casing concrete element, wherein both internal and external surfaces are produced by applying the concrete casting principle, with a heat insulation and an acierage for structurally connecting the casings being fitted between the casings. According to a fourth alternative principle, a Hthoidal-surface structure can also be obtained by plastering. The base may be a heat insulation or a wood- or steel-framed structure. A plurality of special solutions have been published primarily as development proposals, including e.g. the structures disclosed in Finnish publication print No. 58810 and Finnish Patents Nos. 60752 and 66229. The novel solution of the invention follows partially the same basic principles but the invention is capable of resolving several previously encountered problems and the scope of the invention is more extensive covering the entire construction system. The following list includes 30 different aspects that are essential in terms of the technical embodiment and economy of a wall structure, in which aspects a solution of the invention eliminates drawbacks and/or offers new dimensions: 1. A wall of the invention is most preferably and generally produced as an element solution, the prior an element solution having suffered from the drawback that the element joint has become visible which is particularly undesired in facades. With a solution of the invention the joint can be made both in its aesthetical and technical effect similar to the rest of a wall and e.g. invisible. 2. The separate fasteners generally required in an element joint are not needed. In a wall of the invention, the fastening is effected in the external and/or internal surface by using nails, screws or the like without special fasteners. The joint will be in both its internal and/or external surfaces strong in a force-transmitting manner as well as similar to the rest of a wall. 3. The second surface of a structure, the lithoidal surface, may vary in one and the same element and the same production line can be used without any special procedures to produce various coatings, the parallel alternatives including e.g. coloured concrete, crush, paint, brick tile, stone slab or some of the element area can be completely without a lithoidal surface. 4. In the tile alternative, the spacing and size of the tiles may vary in a single element with respect to both element size and setting, since tile-laying is performed from the outside, the setting being totally free and not bound to any measuring system. 5. The corners of a construction (both external and internal corner) may vary in its embodiment, for example, a corner can be designed analogically the same way, whereby the geometrical shape of a corner can be practically anything without causing particular technical or economical problems. This can be achieved by spreading the casing of an element or a corner can be designed by using a separate comer piece. Due to the construction of a comer, the system dimensional modulus can be anything on either side of the wall and the walls can meet each other at any angle at all. 6. The surface opposite to the lithoidal surface of a wall, generally the internal surface of a building, is typically produced by means of a building board and at the joint the junction of boards is identical to that in the rest of an element e.g. in terms of visual appearance and strength. The joint does not require sealing or jointing and is nevertheless tighter than several available solutions. 7. The element joint will be tight since both the outer casing joint and inside joint are tight (generally) without the use of sealing compounds and/or sealing ledges conventional in joints. 8. The joint can be made both in its internal and external surfaces structurally uniform in terms of force transmission, while in several available solutions the forces are transmitted either spot-like and/or only through the intermediary of internal and/or external casing. In addition, a solution of the invention can be applied to control the rigidity of the outer surface of a joint in a manner that the joint is partially yielding and, thus, the expansion joints conventional in lithopidal surfaces can be completely eliminated or their number reduced. This is effected in a manner that the compound used in a joint is tough at least for the portion below the surface. 9. In the structure of the invention, the lithoidal casing can serve as a structurally integral unit with the rest of the element. Such cooperation is not generally possible and in certain cases, particularly in terms of the load-bearing capacity of wall opening frames and opening lintels, the cooperation offers significant benefits. 10. In a wall structure of the invention, a ventilator slot generally required in a lithoidal (external) surface can be eliminated either partially or completely. This is achieved in a manner that the external surface can be tight against the outside splash and drain water and relatively previous to the inside water vapour or the like. In order to achieve the above condition, it is possible to use alternatively or additionally a partial ventilator slot which in an element of the invention is naturally created between frame timbers and concrete. The elimination of a ventilator slot offers a plurality of technical and economical benefits, such as: a) total structural thickness is reduced, b) a windscreen inside a ventilator slot is unnecessary and c) a fire hazard developed in a ventilator slot is eliminated. 11. The total structural thickness of an element of the invention is small. This is because a ventilator slot is unnecessary but also because the lithoidal surface can be thin, e.g. =10...=30 mm. and the internal lining panel is also thin, =10...=15 mm. Thus, the total structural thickness is typically a heat insulation thickness + =40 mm, while the corresponding thickness in current conventional wall structures is a heat insulation thickness + =150...=250 mm. 12. The external surface tiling may extend over the element joint for avoiding a so-called alignment joint. This is possible because a joint can be made strong and non-deformable over its entire length. In this alternative, the tiles on top of element joints are generally laid only after the installation of elements. 13. The wall structure can be constructed in a manner that the lithoidal section of a wall structure, fig. 3, extends below the actual frame to form a footing. This solution offers e.g. the following benefits: a) the joint between a footing and a wall structure is eliminated, b) the wall is reliable in terms of moisture and c) aesthetically of high quality (possible condensation water drains directly to the ground without soiling the footing surface), d) This type of footing solution is highly economical and light, e) The footing is produced together with the wall without separate working stages. 14. The wall structure can be provided with an overhead skirt which offers e.g. the following benefits: a) The heat insulations of roof structures can be protected against wind or the like without separate working stages, b) The entire wall structure from bottom to top can be provided as a single assembly which improves the architectural dimension since the presently available structures generally require a joint in the bottom surface of a roof framing unit used as a roof structure, c) The number of working stages is reduced since the entire wall is produced simultaneously. 15. Windows and doors can be attached to the wall element already at the plant. Further benefits are gained from the fact that, due to a thin assembly, there is no need for separate covering strips. Sealing is also unnecessary since concrete or the like can be cast directly against or upon a jamb and on the inside a cladding or lining sheet may extend to the top of a jamb, so the joint is tight without special (and necessary in available solutions) sealing operations. Alternatively, windows, doors etc. can be installed -afterwards in a conventional manner which generally requires jointings and battenings. 16. The element can be heat insulated or uninsulated. The heat insulator can be made e.g. of a soft, compressive force non-bearing mineral wool, which type of insulators are generally most preferred in view of insulating power. A loose insulator is also possible and it can be blown to the wall at construction site. In this type of insulation it is preferable that the structure has no closed cavities. In this respect, a structure of the invention is superior to other conventional wall structures. 17. The realization of window, door or the like beams required in the wall can be flexibly resolved either entirely in the frame or by a combined effect in the frame and casing or in the casing alone, e.g. by thickening the casing. Another benefit is that the location of a joint can be selected relatively freely, e.g. the joint can be located in an opening. 18. The invented element is manufactured by casting a casing upon a film-like member remaining in the element and serving as reinforcement. This type of solution offers e.g. the following benefits: a) no casting moulds are needed, b) The casting dries quickly as it is relatively thin, c) No heating is needed which is generally required in casting by a mould cycle, resulting in a higher quality concrete, d) Elements can also be cast at working site. 19. The cracks often occurring in lithoidal-surface elements can be easily repaired as the repairing technique is the same as the element manufacturing technique. (Which may further be the same as the jointing technique.) 20. The elements have a weight which is only a fraction of the weight of conventional concrete elements so carrying and lifting is easier and manufacturing of very large elements is also possible. The invented element has such a little weight that transportation is possible in horizontal position on top of each other. Lifting loops or the like can be mounted on the body so the casing need not be reinforced for lifting and/or transportation. 21. In lithoidal-surface elements, arched shapes are expensive and troublesome because of high moulding costs. The invented element does not require separate moulds so it is possible and relatively economical to manufacture elements that are arched in one and/or two directions in horizontal and/or vertical direction. 22. The element casing can be profiled with an arbitrarily low and also high profile without particular extra costs. 23. The element has a relatively good fire resistance because of lithoidal surface and because a ventilator slot is not necessary. 24. The wall structure has a good acoustic insulation because of a lithoidal casing and a reliable tightness. 25. The invented wall structure is typically asymmetrical in that one surface is lithoidal and the other is made of some other material, typically of a building board (but, if necessary, the element is symmetrical , i.e. both surfaces are lithoidal). The lithoidal casing is generally more expensive. This aspect is of major importance in some cases, e.g. when a lithoidal surface is only necessary because of the special qualities of a lithoidal surface, such as reliability in terms of moisture, resistance to damage, visual appearance. This provides a highly favourable result. Such cases include e.g. the walls of livestock buildings, the walls of washing facilities, saunas etc. 26. The invented element serves as an effective protection against damages. In this respect it is more effective than a conventional lithoidal casing since the casing cooperates with the rest of the structure and, in addition, the damage caused by possible blows can be easily repaired. For this purpose, the lithoidal surface often serves as an internal surface. 27. The invented solution is so light and economical that it can also be used as a covering board. This type of application adds to the general versatility of the system and is particularly important in the walls and ceilings of moist facilities. This application is of particular significance in in the walls and ceilings of livestock buildings , wherein the wall must be reliably tight or sealed in its internal surface , e.g. because of the disinfection requirement of the surfaces. 28. The element joint can be set in a wall structure quite freely because the joint is structurally strong and tight as well as visually invisible. 29. The wall structures of today's dwelling houses are often such that some of the wall surface is lithoidal, some of it is wood-based and some of it consists of board sections or the like. With the invented wall structure, various mixed solutions can be realized easier than in available alternatives since the lithoidal casing can be partially omitted. In all available wall structures, the parallel use of a lithoidal, wood-based and/or board-like surface is technically difficult and expensive. 30. Tiling can be effected in a comer the same way as a masonry wall. In many cases this is highly economical and it provides new visual dimensions which have not been possible thus far. One embodiment of the invention will be described hereinbelow and in figs. 1...9. Fig. 1 shows a horizontal section of a wall at an element joint prior to the installation of elements. Fig.2 shows a horizontal section of a wall at an element joint following the installation of elements. Fig. 3 shows a vertical section of joining a wall to the foundation in case the element is extended as a footing. Fig.4 shows a vertical section of the top portion of a wall in case the concrete casing is lifted up. Fig.5 shows a horizontal section of a wall comer according to embodiment 1. Fig.6 shows a horizontal section of a wall comer according to embodiment 2. Fig.7 shows a horizontal section of a wall comer according to embodiment 3. Fig. 8 shows a horizontal section of a wall at a window opening in the alternative that the window is fitted in an element already at the plant. Fig.9 shows a horizontal section of a wall at a window opening in the alternative that the window is fitted afterwards (either at plant or at site). One surface, generally the external surface, of a structure carries a lithoidal layer 1 which is typically relatively thin and can be tiled, painted, crush coated etc. and is generally without a reinforcement or the like since a lithoidal surface sublayer 2, which can be a steel sheet (profiled or non-profiled, perforated or non- perforated), a ribbed grid, a fabric, a plastic sheeting, a felt etc., generally serves as reinforcement and also as casting mould. A preferred structure for providing a sheeting and a reinforcement is obtained by using a zinc-coated steel sheet which is provided with a perforation on those sections that lie between frame timbers 4. Thus, the external surface will be reliably sealed at frame timbers which are then reliably protected against splash and drain water. Sheeting 2 overlaps in the joint and overlapping sheetings 2 are nailed together with nails 8 in a manner that, if necessary, the head remains slightly raised to improve the attachment of later produced jointing compound 3. The structural frame comprises a conventional timber frame post 4 used in timber elements but it can also be a steel profile or the like. A typical feature in the solution of the invention is that the frame does not reach all the way to sheeting 2 but there is in between a pressure impregnated rib, a plastic ledge, an air gap or, in the case of a steel frame, a specially treated steel member or the like 9 (either separate and/or mounted on post 4) which remains undamaged even if the surface of sheeting 2 were wet from time to time as a result of condensation and/or casting water. This solution offers the benefit that the actual frame can be conventional in its resistance to water and moisture and, thus, substantially more economical than a moisture and water resistant frame. Another advantage is that the intermediate layer 9 serves to substantially reduce the heat insulation cold bridge developing at the frame. The intermediate layer can be further utilized as a partial ventilation for the insulation. A fourth advantage gained by the intermediate layer has to do with the spreading of casing 1 effected on the bottom or top or side of an element. During casting and transportation, the spreading requires a support and this is achieved by means of wooden or metal brackets placed in the intermediate layer. Such a support also improves strength of the brackets in a finished wall structure. An intemal covering sheet 5 can be any sheet or board used in inside lining or cladding. A typical feature is that the board of one element extends over the joint and on top of the frame post of another element for a strong and tight joint. The intemal covering sheet 5 may extend over the joint onto the same or different side with respect to sheeting 2. It is generally more preferred that the overlapping be made on different sides of a joint. In such lightweight frame structures, the frame is conventionally filled with a heat insulator 6 and the structure may further include a plastic sheeting as a moisture barrier and additional bracings as required by special conditions, e.g. the strength requirements of openings. The joint between frame 4 and sheeting 2 and casting 1 can be obtained by means of a nail or a screw 8 which can extend from casting to frame post. An alternative, more reliable and sturdier structure is obtained by compressing a connector plate 7 into the side of a frame post and by driving the edge of a connector plate through the sheeting into the casting, this being shown in the left-hand post of fig. 1. In fig. 3 there is shown one solution for a wall system of the invention for joining a wall to a foundation and one embodiment of a footing. Here, the lithoidal element casing is extended beyond the rest of the frame to form a skirt 10 below the ground 11. Thus the entire facade comprises a continuous surface and is made in a single operation and there is no joint between the actual element and the footing. The solution is highly preferable and technically effective as it involves no cold bridge and a heat insulation (14) can be in a continuous manner to protect a foundation 12 and to prevent frost from passing below the foundation. The intemal covering sheet 5 can terminate short of the bottom edge of an element frame (as shown in the figure) or it may extend beyond the actual frame to be nailed directly to a lower alignment timber 15. In this case, an intermediate layer 9a between frame 4 and casing 1, 2 in the lower section can be partially or completely omitted because of the bracing brackets required by a footing. In fig. 4 there is shown a typical attachment of a wall structure to the roof. Here, the lithoidal casing is extended beyond the actual frame to form a skirt 16 to protect the heat insulations of roof structures. The same way, an intemal covering sheet can be extended beyond the frame to be nailed directly to an upper alignment timber. This type of embodiment is highly preferred when the roof structure comprises a timber truss which at present is the most common roof support in private houses. Fig. 5 shows an external comer of a building in horizontal section and designed in a manner that casings 1 are extended beyond the actual frame to f oπn a splice. Thus, a gap 20 created in the comer can be sealed by conventional means. An essential feature in the construction system is that the dimensioning is flexible. The comer can always be designed by using standard-sized frame elements e.g. by positioning the elements as follows: the wall side whose outer casing is designated at lb is first placed in the comer and this is followed by the element of side la. Since the reference point of the first frame post of side la and also the modular dimensioning of an element can be freely located with respect to the comer, the standardized and modulated elements can be used for constructing a building of arbitrary dimensions. In fig.6 there is shown the construction of a comer by using standardized elements in a manner that a comer 21 is made at the site the same way as an element joint. In the figure, the comer has been made arched and that represents the flexibility and practicality of the construction system for creating various designs and shapes in a preferred manner. A similar comer can also be achieved by means of a separate (arched) comer element. This basic principle can be applied also partially with the altemative shown in fig.6. In fig. 7, a corner is built by means of a conventional bricklaying technique. Such technique brings new architectural dimensions in the planning of a building facade. Fig. 8 illustrates the attachment of a window or door frame 24 to a wall in horizontal section. An essential feature is that the attachment does not require any covering strips or sealings since an extemally sealed joint is obtained by casting concrete or the like directly on top (as in the figure) or on the side of a frame. An internally sealed joint is obtained by extending the internal covering sheet upon the frame. In fig. 9 there is shown a window assembly in the altemative in which the window is installed after the production of an element, whereby it is necessary to use strips 25, 26 and a sealing 27.

Claims: Claims 1. A building element, comprising on one side at least partially a lithoidal (based on the curing of concrete or mortar, tile laying, plastering, crush coating and/or adhesive, resin, bitumen or the like) surface, c h a r a cterizedin that the element comprises a cassette-shaped assembly .including at least a frame (4), a sheeting (2), a separating intermediate layer (9) (separating frame (4) and sheeting (2) from direct contact) as well as fasteners (7, 8) (and possibly also e.g. an insulation (6) and lining (5)) and that sheeting (2) comprises a sheet metal formed by a set of fastening brackets and said lithoidal surface (1) is secured to sheeting (2) by casting, gluing or a like process. 2. An element as set forth in claim ^characterized in that at least the retention of external liquid and/or the resistance to intemal vapour is higher at frame posts (4) than within the area therebetween. 3. A joint for (two) elements as set forth in claim 1 or 2, characterized in that said sheeting (2) is overlapped at the joint and attached with a fastener (8). 4. A joint for (two) elements as set forth in claim 1, 2 or 3, characterized in that the joint of sheeting (2) and lining (5) is located at different frames (4). 5. An application for an element as set forth in any of the preceding claims, characterized in that said element is used as an intemal covering plate and/or an element for the wall and/or ceiling of moist facilities, especially livestock buildings. 6. A joint for two elements as set forth in any of the preceding claims, characterized in that the joint (3) is treated to become identical to the rest of the surface (1). 7. A method for the manufacture of an element as set forth in any of the preceding claims, characteri z e d in that the cassette assembly (frame (4), sheeting (2) etc.) is produced first and surface (1) is cast thereupon by using the cassette as a mould.

Inventors: KOSONEN HEIKKI JUHANI, POUTANEN TUOMO TAPANI, KOSONEN, HEIKKI, JUHANI, POUTANEN, TUOMO, TAPANI
Applicants: TERASJUSSI OY, TERAESJUSSI OY
Application year: 1989
Main classification: E04C2
IPC codes: E04B1, E04B2, E04C2, E04D1