Wall exterior concrete and reinforced concrete panels have found the most wide application in the construction of houses, as well as industrial and public facilities. Their appearance more than 50 years ago was a real breakthrough in construction and made it possible to reduce the construction period of buildings several times.
Reinforced concrete is a monolith made of steel reinforcement and concrete. The interaction of these materials is very effective. concrete stone reliably adheres to the metal, protecting it well from rusting. These components complement each other in terms of resistance to different loads.
The resulting structures have significant strength, and only high-tech tools can help in their processing. IN Lately Diamond drilling of holes in concrete has become in demand.
Note!
The volume of reinforced concrete products is mainly occupied by cheap raw materials - gravel, crushed stone, sand.
Therefore, their price is relatively low.
Based on reinforcement, reinforced concrete products are divided into:
By density (specific gravity) and grade of concrete:
The structure is reinforced concrete Wall panels are divided into:
Precast concrete products may be intended for:
Panel production is carried out in factories reinforced concrete products using different methods.
After heating, the walls of the molds are removed, and the panels are removed by an overhead crane. This method produces flat products: wall structures and analogues for floors.
Its tape moves through the technological posts. They are used for: installation of a frame made of reinforcement, pouring of concrete, its compaction by vibration and heat treatment. The instructions recommend using this method to produce partition and ceiling panels, as well as external wall slabs from lightweight concrete.
To wall slabs state standards have the most stringent requirements.
Note!
House from reinforced concrete panels must be constructed from products whose dimensions are within the limits of deviations and tolerances.
They are determined by GOST No. 130/15.4/84.
Large wall slabs were developed to speed up the pace of construction. For example, a cottage made of reinforced concrete panels can be built in just 2 weeks.
The popularity of reinforced concrete panels in mass construction, in addition to the high pace of work, can be explained by their other advantages:
Panel construction can be framed or frameless.
This depends on what kind of wall slabs are used: enclosing and load-bearing or only enclosing.
Factories produce panels for both external and internal walls.
There are different divisions of panels into categories, based on the underlying principle: typical features, purpose, structure, material composition.
Produced panels are divided into monolithic and composite analogues.
In turn, layered products can be solid or have layers of air.
By bearing capacity wall slabs are divided into:
Note!
For the production of partition panels, high-strength ordinary or gypsum concrete should be used.
The material must have good water resistance and frost resistance.
Reinforced concrete three-layer wall panels are most in demand now.
Note!
The thickness of wall slabs should be selected based on the climate conditions in your region.
Also have great importance thermal properties of the building materials used.
Manufacturers produce products with a thickness of 20/50 centimeters
Panels are marked with letters and numbers separated by a dash.
For example:
This brand group includes indications of the design properties of products:
Let's give an example of marking: PST 598-300-20.
598 cm – its length;
300 cm – its height;
20 cm is its width.
Reinforced concrete panels of fences, walls and ceilings are integral part modern mass construction. The use of new technologies, materials and design solutions in their manufacture makes it possible to optimize the construction of buildings.
If you watch the video in this article, you will get a lot more useful information.
Fully complying with the requirements of standards, technology and GOST for multi-storey buildings, we have added a number of improvements regarding more open layouts, increased heat efficiency, appearance, quality of production and installation of panels, so that your home has best characteristics modern private house.
EXTERIOR WALL PANELS
Reinforced concrete panels for building a house (External three-layer reinforced concrete wall panels) are manufactured according to individual design drawings, in accordance with the requirements of the current GOST 31310-2015 “Three-layer reinforced concrete wall panels with effective insulation.” High-rise multi-storey panel buildings are built from the same panels.
A three-layer reinforced concrete panel consists of three layers:
External protective and decorative reinforced concrete layer 70 mm thick.
A middle layer of effective insulation with a thickness of 200-400 mm.
Internal load-bearing reinforced concrete layer 120 mm thick.
The internal and external reinforced concrete layers are made of heavy concrete of class B25 on granite crushed stone and steel reinforcement of class A500C. Depending on the design calculations, a double mesh of reinforcement is laid in inner layer and single in the outside.
The outer and inner reinforced concrete layers are connected to each other using rigid diagonal connections made of of stainless steel PD and PPA of the Finnish manufacturer Peikko Group.
The thickness of the middle layer of insulation is determined thermotechnical calculation and can be up to 400 mm. In the basic configuration of houses from the INPANCE company, the insulation in the panels has a thickness of 200 mm. With an EPS insulation thickness of 200 mm, the coefficient of resistance to heat transfer of the wall is 5.97 (m².˚C)/W, which is 2 times higher than Russian requirements for heat conservation and meets more stringent European standards.
As insulation, we use materials that have appropriate certificates confirming their safety and service life in three-layer reinforced concrete panels for at least 50 years:
Extruded polystyrene foam (EPS). This insulation has one of the lowest thermal conductivity rates among other similar products. It is characterized by chemical resistance, high compressive strength, water and vapor resistance, and resistance to mold and mildew. Thus, extruded polystyrene foam not only provides thermal insulation, but also effectively prevents the effects of a number of other destructive and negative factors.
20% lower than XPS.
*By agreement with the Customer, other types of insulation can be used. In the construction of a three-layer reinforced concrete wall, any insulation is reliably protected by the outer reinforced concrete layer from possible negative impacts at him from environment
(UV radiation, precipitation, and others), and the inner reinforced concrete layer prevents the constituent substances of the insulation from penetrating inside your home. In addition, the inner reinforced concrete layer will protect the insulation from the consequences of a possible fire.
MANUFACTURING WALL PANELS For the production of wall reinforced concrete panels for the construction of a private house, as well as for, requires modern, expensive equipment, which is available only at large concrete factories. Since 2014, the INPANS company has been successfully cooperating with the SiB-Centre reinforced concrete plant, located near St. Petersburg, which is one of the most modernly equipped enterprises in its industry, producing over 250 types of prefabricated reinforced concrete products and structures for industrial and civil construction . Also, we have agreements on the production of wall panels with factories located in Moscow, Nizhny Novgorod, Kostroma, Novocheboksarsk.
The SiB-Centre reinforced concrete plant, in particular, has at its disposal six molding tables/pallets measuring 4.25 x 16.5 m with vibration compaction and lifting systems at an angle of up to 80 degrees, equipped with magnetic beading equipment, which are the basis for the production of three-layer and single-layer wall panels .
Equipment for the production of wall panels allows us to produce wall panels with any individual characteristics(external dimensions, thickness, dimensions of window and door openings) up to 16 meters long and up to 4 meters high, however, delivering such oversized cargo to the construction site is usually very expensive, and often not possible at all. Therefore, to meet the requirements for standard cargo transportation, we produce panels maximum height 3.32 m (floor height 3.1 m) and maximum length 7.8 m.
In most cases such maximum sizes enough to implement any home project and minimize the amount interpanel seams, and make panel joints in alignment with load-bearing internal walls and/or partitions.
Window and door openings are laid based on the project, their sizes can be of almost any width and height, in addition, it is possible to make arched openings, round or any other shape.
For installation of windows and doors in window and doorways installed between reinforced concrete layers wooden plank 50 mm thick over the entire width of the insulation; with the help of fasteners, the board is securely sealed.
Also in the outer reinforced concrete layer in window openings so-called “quarters” are formed for more high-quality installation windows
FACADE SOLUTIONS
Taking into account all the results of accumulated many years of experience in the design, construction and operation of large-panel multi-storey buildings, as well as the possibility of using modern materials and approaches to the manufacture of wall panels, the INPANS company has tested and is ready to offer you a number of reliable and low-cost solutions to give the facade of your home expressiveness and individuality:
Forming the outer surface. Before pouring concrete mixture Special matrix sheets imitating various façade materials are placed on the molding table. After pouring and hardening of the concrete mixture, an imprint remains on the outer surface of the panel that exactly repeats not only the contour, but also the texture, for example, of brick, stone, wooden beam. Matrix sheets can be produced for almost any material. The concrete surface formed in this way will not be erased over time and will always remain unchanged.
To create this texture, during the production process a special composition is applied to the outer surface of the panel, which prevents the hardening of a small layer of concrete 3-5 mm deep. After the bulk of the concrete has hardened and the panel has been lifted into a vertical position, the uncured layer is washed away by the pressure of water and crushed granite stone present in the concrete mixture appears on the surface. The façade appears to be sprinkled with small granite pebbles. This solution does not require painting.
Scratched concrete. This texture is created by running special hard brushes over the surface of just set concrete. The brushes are left on concrete surface traces-grooves, creating the effect of “scratched concrete”. Grooves can be drawn both vertically and horizontally.
Finishing facade materials. At your request, outside surface also, it can be lined with any other facade materials (clinker brick, wooden plank, fiber cement siding and so on.).
Using these textures separately or combining them, you can implement almost any design solution on the facade of your home.
Most façade solutions are implemented in the process of manufacturing wall panels; panels arrive at the site with a finished finish.
INTERNAL LOAD-BEARING PANELS
Internal load-bearing reinforced concrete wall panels are produced on the same equipment as three-layer external panels. They consist of one layer of heavy concrete class B25 and steel reinforcement. Thickness of internal load-bearing panels, depending on design solutions, ranges from 120 to 180 mm.
Openings in internal load-bearing walls, as well as in external ones, can be made rectangular, arched or other shapes.
The quality of the inner surface of the outer and interior panels smooth and does not require leveling plaster, just apply finishing putty, or, for example, in the bathroom, immediately glue the tiles. Tolerances for differences across the entire plane of the panel are no more than 3-5 mm.
Moreover, unlike walls made of block materials, such as brick, gas silicate and other blocks, inner surface reinforced concrete panels do not have technological seams and are homogeneous. It is impossible for cracks to form on them, and the use of reinforcing mesh is not required when finishing walls.
The joints between panels inside the house (interpanel seams) are sealed with concrete during their installation. Corner interpanel seams are only 80-120 mm wide and are made in the plane of the walls. And we design and make interpanel seams of linear panels in the alignment of load-bearing walls or partitions in order to hide them.
When manufacturing external and internal reinforced concrete panels, you can put grooves in them for wiring and other technological holes according to your project. This greatly simplifies and speeds up the process of laying utility lines.
To be able to diversify planning solutions, the designers of the INPANS company try to make a minimum number of internal load-bearing walls, and in some solutions you can do without them altogether. The main task of internal load-bearing walls is to serve as support for floor slabs.
FLOOR PLATES
As interfloor ceilings We use proven and reliable hollow-core floor slabs of the PB and PC brands. Thanks to modern equipment, PB slabs can be made of any length, while floor slabs with a thickness of 220 mm can span a span of up to 7 meters, and slabs with a thickness of 265 mm can span a span of up to 10 meters. The standard width of the floor slab is 1.2 m.
Besides standard width, PB slabs can be cut lengthwise into additional slabs (sizes 290, 470, 650, 830, 1010 mm). In addition, PB slabs can be cut diagonally without loss of load-bearing capacity.
If necessary, do balcony slab, a slab with cantilever support or with non-standard openings (for example, for chimneys large diameter) such slabs are made completely monolithic, by analogy with internal load-bearing walls, according to the relevant drawings with the reinforcement necessary for each specific case.
For making large openings in the ceiling hollow core slabs(for example, for a staircase or installation ventilation shafts) we use standard PETRA® steel brackets from the Finnish manufacturer Peikko Group, which allow you to open an opening up to 2.4 meters wide (the width of 2 standard floor slabs).
The variability of modern floor slabs allows you to implement any space-planning solution for the structure of your home, and their installation takes only a few hours.
DELIVERY AND INSTALLATION OF WALL PANELS
Wall panels are delivered from the factory by panel trucks; a standard panel truck can bring panels total length 2X7.8 meters and a total weight of no more than 20 tons. Typically, wall panels for two-story house 10x10 meters are delivered by 10 flights of standard panel trucks. As a rule, delivery and installation of wall panels are carried out on the same day.
Important! It is necessary to have or install an access road for panel trucks and a platform for a truck crane at the construction site.
The installation of wall panels on the foundation is carried out by a truck crane, which is located between the foundation and the panel carriers. The truck crane removes the wall panels from the panel truck and immediately installs them in the design position on the foundation. The installation process of one panel takes on average 15-20 minutes. And all wall panels on one floor are installed within one to two days, depending on their quantity.
Important! The choice of truck crane is made based on the weight of the wall panels and the distance over which the panel needs to be moved. In our practice, we used cranes with a lifting capacity from 25 to 120 tons.
Wall panels are mounted in the design position, previously marked on the foundation, on the underlying layer of mortar and secured to temporary supports (struts):
Immediately after installing the wall panels, floor slabs are laid on them, the gaps between the floor slabs are reinforced:
The connection of wall panels to each other is made by embedding the joints of the internal load-bearing layer with heavy concrete. To connect the wall panels to each other, steel cable loops from the Finnish manufacturer Peikko Group are laid at the horizontal ends of the load-bearing layer in increments of 400-500 mm. When installing wall panels side by side, the cable loops of adjacent panels intersect, forming a node into which the reinforcement is inserted.
With this technology of joining the internal reinforced concrete layer of wall panels, the interpanel seam becomes airtight, it does not let in either wind or moisture from the street.
After the concrete has set monolithic areas, temporary supports (struts) are removed and you can begin installing the panels of the next floor.
This technology for installing wall panels is also used in the construction of modern multi-story buildings. panel houses, and is rightfully considered the most advanced in the industry.
Wall panels practically do not shrink, and interior decoration You can start immediately after completion of construction and installation work.
CAULKING INTER-PANEL JOINTS
After embedding, the internal load-bearing reinforced concrete layer completely eliminates the penetration of moisture and wind into the house from the street; a strip of mineral wool or this space is being filled polyurethane foam. Then, a bundle of foamed polyethylene is inserted into the outer reinforced concrete layer and a sealant for interpanel seams is applied on top, which can be painted in the color of the facade. Unlike multi-storey buildings, for our houses we make joints only 20-25 mm wide.
To hide the interpanel seams on the outside of the house, you can simply paint them the same color as the facade, or cover them, for example, with corner clinker or fiber cement tiles, or use other materials.
INTERIOR PARTITIONS
Not load-bearing interior walls(partitions) can be made of any materials at your request. The INPANS company offers to manufacture partitions from moisture-resistant solid tongue-and-groove slabs (GGP). The partitions can be made of single-layer PGP with a thickness of 80 or 100 mm, as well as multi-layer with the inclusion of a layer of mineral wool between two partitions to increase sound insulation between rooms.
Installation time internal partitions is 1-2 weeks, and is carried out simultaneously with the installation of the attic floor and roof.
ATTIC COVER
If you have a cold attic in your home, attic floor carried out according to wooden beams with a pitch of 600 mm, between which a layer of insulation (mineral wool) 200 mm thick is laid, then another layer of mineral wool 100 mm thick is laid crosswise on top of the ceiling.
Thus, the total thickness of the insulation is 300 mm; such insulation is included in the basic equipment of our houses.
The ceiling is hemmed from below vapor barrier film to prevent moisture from entering the insulation from inside the room.
PITCHED ROOF
The pitched roof is made according to wooden rafters, then a wind-moisture-proof membrane, sheathing and counter-lattice are attached. Depending on your wishes and architectural solutions, the finishing coating is arranged. The most common are metal tiles or soft bitumen shingles.
When choosing materials finishing coating roofs, we recommend using only high-quality materials with a confirmed manufacturer’s warranty.
FLAT ROOF
Device flat roof produced according to reinforced concrete slabs floors, with the installation of reinforced concrete parapets along the entire perimeter of the house. The ceiling is insulated with extruded polystyrene foam, a slope is made, a lower layer of waterproofing and a double layer of upper waterproofing are made. Drainage funnels, ventilation and chimney ducts are also installed.
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Reinforced concrete external wall panels are most often made in a single-row cut, i.e. one floor high and one or two rooms long, and in terms of design they are single-layer, two-layer and three-layer (Fig. 3.4 and 3.5). All wall panels are equipped with lifting loops and embedded parts for attaching one panel to another and for connections with other structural elements of buildings.
a) Single-layer reinforced concrete external wall panels
Such panels are made from lightweight structural and thermal insulating concrete on porous aggregates or from autoclaved cellular concrete (Fig. 3.5). On the outside, single-layer panels are covered with a protective and finishing layer of cement mortar 20–25 mm or 50–70 mm thick, and on the inside with a finishing layer 10–15 mm thick, i.e. such panels can be conventionally called “single-layer”. The thickness of the external protective and finishing layers is determined depending on the natural and climatic conditions of the construction area, and they are made from vapor-permeable decorative mortars or concrete or from ordinary mortars followed by painting. The finishing of the outer facade layer can also be done with ceramic, glass tiles or thin tiles made of sawn stone or crushed stone materials.
Rice. 3.4. External reinforced concrete one-, two- and three-layer wall panels:
a – single-layer; b – two-layer; c – three-layer; 1 – lightweight structural and thermal insulating concrete; 2 – outer protective and finishing layer; 3 – structural concrete; 4 – effective insulation
Rice. 3.5. Components cross sections of external reinforced concrete wall panels: a – with an external protective and finishing layer; b – with external protective-finishing and internal finishing layers; c – made of cellular concrete; d – two-layer with an internal load-bearing layer; d – three-layer with rigid connections between concrete layers; e – three-layer with flexible connections between layers; 1 – structural thermal insulation or cellular concrete; 2 – outer protective and finishing layer; 3 – internal finishing layer; 4 – outer and inner load-bearing layers; 5 – lightweight thermal insulating concrete; 6 – fittings; 7 and 8 – flexible connection elements made of anti-corrosion steel; δ 9 – effective insulation;
– thickness of the insulating layer
Single-layer panels are reinforced along the contour with a welded mesh frame, and above the window openings - with a welded spatial frame. To prevent cracks from opening in the corners of the openings, cross rods or L-shaped meshes are laid outside (Fig. 3.6).
Single-layer panels made of autoclaved cellular concrete cannot be made in height to fit the entire floor wall and walls with linear strip cutting are made from them. The reinforcement of such panels is protected from corrosion by coating with an anti-corrosion compound.
Rice. 3.6. Scheme of reinforcement of a single-layer lightweight concrete panel of an external wall:
1 – lintel frame; 2 – lifting loop; 3 – reinforcement frame; 4 – L-shaped reinforcing mesh in the façade layer
Due to the high vapor permeability of lightweight concrete and, therefore, the possibility of water vapor condensation forming inside single-layer panels and freezing at low outside temperatures, it is advisable to use such panels for buildings with low relative humidity of indoor air (no more than 60%). The thickness of single-layer panels is 240–320 mm, but not more than 400 mm.
b) Double-layer reinforced concrete external wall panels
Since the internal load-bearing layer of dense concrete in two-layer panels has low vapor permeability, such panels can be used in buildings with high relative humidity of internal air. Reinforcement of double-layer wall panels is carried out similarly to single-layer panels, i.e. the reinforcement frame is placed in the load-bearing and insulating concrete layers, but the working reinforcement of the lintels is placed in the load-bearing concrete layer. The total thickness of two-layer wall panels is no more than 400 mm (Figure 3.7).
c) Three-layer reinforced concrete external wall panels
Three-layer external wall panels consist of an inner and outer layer made of heavy or dense lightweight structural concrete, between which an insulating layer of effective thermal insulation material is laid. The thickness of the insulating layer is determined by calculations for thermal protection, and the thicknesses of the inner and outer concrete layers depend on the design solution of the wall panel and the magnitude of the perceived loads.
The inner layer of the panels is reinforced with a spatial frame, and the outer layer with reinforcing mesh. Depending on the design, three-layer wall panels are available with flexible or rigid connections between the inner and outer concrete layers (Fig. 3.5 and 3.8). Flexible connections are metal rods in the form of vertical hangers and horizontal struts connecting the reinforcing frame of the inner layer and the reinforcing mesh of the outer layer of the wall panel, i.e. they are attached by welding or tied to the spatial reinforcement frame of the inner layer and the reinforcing mesh of the outer layer. The metal rods of flexible connections are made of corrosion-resistant steel or they have an anti-corrosion coating in the insulation area.
Flexible connections ensure independent operation of the concrete layers of the wall panel and eliminate thermal forces between layers. The outer layer in panels with flexible connections performs enclosing functions and its thickness must be at least 50 mm. The thickness of the inner layer in three-layer panels with flexible connections in load-bearing and self-supporting wall panels is not less than 80 mm, and in non-load-bearing panels - not less than 65 mm.
Figure 3.7. Two-layer concrete panel of the outer wall: 1 and 2 – embedded parts for fastening heating radiators; 3 – lifting loops; 4 – reinforcement frame; 5 – internal load-bearing layer; 6 – outer protective and finishing layer; 7 – drain; 8 – window sill board; 9 – lightweight concrete thermal insulation layer; N– floor height; IN– panel length; h– panel thickness; δ – thickness of the thermal insulation layer
In three-layer wall panels with rigid connections, the inner and outer concrete layers are connected using vertical and horizontal reinforced concrete ribs. Tight connections ensure joint static work concrete layers of wall panels and protect connecting reinforcing bars from corrosion. Connecting reinforcing bars are placed in concrete tie ribs and are attached by welding or tied to the reinforcing cage of the inner layer and the reinforcing mesh of the outer layer.
The disadvantage of installing rigid connections in external wall panels is through heat-conducting inclusions formed by the ribs, which can lead to condensation on the inner surface of the walls. To reduce the influence of the thermal conductivity of the ribs on the temperature of the inner surface of the walls, they are made with a thickness of no more than 40 mm and preferably from lightweight concrete, and the inner concrete layer is thickened to 80–120 mm. The thickness of the outer layer is at least 50 mm. Exterior finishing of three-layer wall panels is carried out in the same way as single- and two-layer ones. In all external wall panels, embedded parts for fastening to other structural elements are placed in the load-bearing layer.
Rice. 3.8. Three-layer concrete panels of external walls and connections between their concrete layers:
a – layout diagram of flexible connections;
b – the same rigid connections: 1 – suspension; 2 – spacer; 3 – strut; 4 – rib made of concrete outer layers; 5 – rib made of lightweight concrete; 6 – internal concrete layer; 7 – outer concrete layer; 8 – reinforcement frame of the inner layer; 9 – reinforcement mesh of the outer layer; 10 – reinforcement of ribs; 11 – effective insulation KROHN three-layer external wall panels are
modern material , which is widely in demand in Moscow and other regions of Russia both in capital construction and in the reconstruction of buildings. Thanks to the use of these sandwich panels, an energy-efficient wall structure with high-quality load-bearing element, made in the factory. This material does not require additional finishing, so it can be used for construction
premises.
The technical characteristics of sandwich panels allow them to be used for the construction of car washes, hangars, warehouses, and supermarkets. Wherein main feature of this process will be high efficiency of work execution, practicality finished walls(easy to clean, do not require painting, etc.) and reliable thermal insulation.
The expansion of highway infrastructure places special demands on civil engineering. The materials used must provide high-quality sound insulation of the premises. The three-layer KROHN panel easily copes with this task. Walls built from our “sandwiches” effectively suppress noise (insulation index from 35 dB per 50 mm panel).
Taking into account all the operational (heat and sound insulation) indicators of the material, today it is used for the construction of refrigeration and freezers, objects Food Industry, Catering, agricultural buildings, administrative buildings etc. Thanks to three-layer external wall panels, energy consumption in buildings is sharply reduced and, as a result, heating costs are reduced.
Technical characteristics of KROHN PIR sandwich panels:
