FR2742178A1 - Prefabricated block for sound-proof walls and constructing walls and floors - Google Patents

Abstract

The prefabricated blocks are made in two parts, a honey-comb section (2) which has cells in the central section and half cells (4) at the edges and a notched section (6). The cross section of the blocks shows a series of convex (7) and concave (8) curves. The half cells (4) at the edges have a shorter inner flange (5) allowing the insertion of an H-shaped concrete or metal framework. The prefabricated blocks are used with virtually rectangular slabs to build sound proof walls. The slabs have two small lugs on one side the width of the lugs equals half the thickness of the walls separating the cells from curved section. Slabs can be inserted in the cells (3,4) of the blocks (1). The blocks are made of light, fibrous material, the slabs are made of denser material.

Description

 The present invention relates to a prefabricated block for the production of noise barriers.

 A similar, slightly modified design of the prefabricated block will allow the creation of wall and residential floor elements.

 Current noise barriers made of absorbent materials, such as wood concrete for example, are made on prefab tables in large panels.

 These are effective solutions but cumbersome and expensive.

 The object of the present invention is: - on the one hand to produce noise barriers with prefabricated elements that can be carried, - on the other hand to improve the acoustic characteristics of noise barriers by a better profile of the absorbent facing.

 The blocks will be produced on the presses that make the concrete blocks, the pavers. This ensures much lower manufacturing costs than heavy prefabrication: demolding is immediate and automatic palletizing.

 The materials used can be different light absorbent materials, but especially fibrous materials having good mechanical tensile strength, such as for example wood concrete.

 The block is made up of two parts: - a honeycomb part which will give the longitudinal rigidity to the block and which includes cells in the central zone and half-cells at the ends. The half-cells of the ends have the shorter inner shape and shaped to allow the incorporation between two blocks of concrete or metallic beams in H. This honeycomb part will behave under the effect of the wind like a ladder beam.

The dividing walls between cells of the honeycomb part have their base notched during manufacture by the use of a sheet metal puller.

- a serrated part tangent to the previous one whose section is limited by an alternative series of convex and concave curves. The concave curves provide the blocks with an important noise damping factor which combines with the absorption of the material used. These are real sound traps. In addition, this hollow profile has the non-negligible advantage of saving material and therefore of lightening the block. The section of the convex and concave parts can also be carried out by a series of straight lines.

 To make effective noise barriers, it will be necessary to create a screen of very different nature and density at the back. As an indication, wood concrete for example has a density of the order of 700 kg / m 3 while that of precast concrete is around 2400 kg / m 3, that is to say more than 3.4 times greater.

 Hence the advantage of also pre-fabricating concrete or other dense material slabs and incorporating them for mounting in the cavities of the honeycombed parts of the blocks, also creating a significant offset of joints which will provide noise sealing.

 These practically rectangular slabs (two opposite faces have a slight fruit) have on the same edge two small studs whose width is equal to the half-thickness of the separating walls between cells of the honeycomb part and whose height is equal to the offset of the joints between blocks and slabs. The slabs near the beams will have one of their tenons of width equal to the thickness of the dividing walls between cells.

 The two large faces of the slabs will not be completely parallel but will have a light fruit equal to the mold release fruit from the alveoli of the alveolate part of the blocks.

 The thickness of the slabs will be equal to the thickness of the cells of the honeycomb part of the blocks, taking into account the fruit.

 The mounting of the walls is carried out as follows: - installation of load-bearing beams in linear foundations at the same center distance as the length of the block, - installation of the first row of blocks between beams, - incorporation of the slabs in the alveoli of the alveolate part, the upper part of the slabs will make a continuous tenon on the top of the blocks which will be included in the notched base of the separating walls between alveoli. The height of this post will be relatively large, around one fifth of the height of the block to obtain good noise sealing, - mounting of the second row of blocks then incorporation of the tiles, - and so on to the top of the wall anti noise.

The interest of such a process is very important by its ease of implementation. Apart from the sealing of the joists in partially prefabricated linear foundations which requires little concrete to be placed on site; all the other elements constituting the walls are prefabricated and manuportable by one or two operations. For example a block of
100 x 30 x 20 cm (length x width x height) in wood concrete will have a weight less than 30 kg while the weight of the slabs will be approximately 5 kg.

 The lower cost of manufacturing on press, in addition to an easy and quick implementation should lower the price of noise barriers.

 The concave shape of the front part of the wall will constitute a more efficient acoustic screen.

 The supporting structure of beams is set back which gives a continuous aspect of facing, the framework being practically not visible.

 The height offset due to the unevenness of the land in the longitudinal direction of the wall will be at the level of the beams.

 Another type of noise barrier, with a substantially similar front profile, can be manufactured flat on presses in larger longitudinal dimensions.

 The convex zones of the section of the serrated part will be slightly truncated by dishes. The serrated part as well as a small face will be shaped by a shape (sheet metal puller) located at the base of the mold.

 The serrated part is integral and tangent with a solid part made of the same material, such as for example wood concrete. In this area, fresh pouring on fresh pouring together a thickness of concrete.

 The manufacture of such a panel is carried out as follows: - the bottom of the mold will be equipped with a sheet metal puller having the profile of the serrated part as well as a small face of the wood concrete area, - the first drawer of the press will pass alternately over the entire surface of the mold in order to fill it with wood concrete, - a vibration adapted to wood concrete will be made to distribute the material well in the mold and possibly a light blow pounding, - a second press drawer will spread a layer of concrete, - the pestle of the mold will vibrate and pound all of the two materials, - The pestle will come to a standstill while maintaining the newly formed product on the plank manufacturing, - the sheet metal puller will withdraw from the bottom of the mold, - the female mold will rise to remove the product from the mold, - the pestle will also rise, - the product will go to the manufacturing boards to dry it, - after drying the pan will be palletized.

 Two opposite edges of the mold will have been shaped to obtain a small overlap of the panels: - one edge will have a light mold release fruit over the height of its concrete part, - the other edge will have a double mold release fruit offset at the edge of the parts wood concrete and concrete.

 These panels will be fixed on a metallic or concrete framework, the waves of the serrated part being perpendicular to the framework alo s that in the case of the blocks they were parallel.

 If the convex parts of the first block previously described are truncated and its ends transformed, a block for a residential wall is produced.

 At the ends we simply add a rectangular part intended to form a connecting post between blocks.

 The concrete plates of the noise barrier will be replaced by plates of the same shape and the same dimension made with a very thermally insulating material such as for example polystyrene.

Fibrous materials such as wood concrete are good thermal insulators and have a high mechanical resistance to traction. On the other hand the compressive strengths are not very efficient
It is also interesting to increase the bearing capacity of the blocks by a small load-bearing framework made up of small posts cast between the horizontal joints of the blocks. The ends of the blocks form the formwork of these posts.

The assembly of the walls is carried out as follows: - mounting of a first row of blocks on a perfectly horizontal mortar base in both directions, - installation of insulating plates in the cells and in line with the joints between blocks, - dry mounting of the second row: the blocks will possibly be glued, nailed with bias nails, or screwed, - installation of insulating plates and so on to the top of the wall, - Reinforcement and casting of stiffening posts in the joints between blocks and in the corners,
The stiffening posts can be replaced by a small metal frame,
The concave dimples open inwards have a very interesting e.

 Once the structural work is finished, these are real technical sheaths for the passage: - of rainwater downpipes, - of sanitary pipes, - of heating pipes, - of the electrified, etc ...

 The mairisu being noninflammabi we will separate the different natures of canalisabon. In addition, i Jis concrete is easily sawable, which will allow it to be grooved for inclusion, for example at the base of the wall of linear technical boxes.

 Corner blocks are not necessary because the blocks are sawn. One can make an effective connection between a concave cell of a block and the end of another block by the reinforcement and the casting of a stiffening post.

 When the walls are fitted with all their pipes, they will be closed with different nailed or screwed materials: plasterboard, perforated galvanized steel plates and cardboard mesh allowing the application of plaster.

 If walls are buried, it is necessary to reinforce them so that they can resist the pushes of the grounds.

 The reinforcements will be carried out simply in the following manner: - the wall will be assembled in the same way as the wall previously described, - one will set up in the axis of the stiffening posts of the joints between blocks of horizontal steels which will bond the wall to a formwork, - A reinforcement or a welded mesh panel will be put in place, preferably making the vertical steels correspond with the axis of the concave honeycombed parts, - after having carried out the formwork secured to the stiffening posts and offset by a width constant of the interior faces of the blocks, a ribbed slab will be poured in concrete which will be calculated and dimensioned to resist earth pressure.

 In these wall parts, of course, the concave alveolate parts will not be used as a technical alveolus.

 By modifying the end of the initial block and possibly reducing its length, it is possible to obtain a slab for the construction of the floor.

 Consider for example a slab composed of two honeycombed parts as well as a serrated part comprising two concave zones. This slab could also be made up of n dimpled parts as well as n concave zones. We examine in the example the case where n = 2 because it corresponds to the lightest slabs.

The ends of the slabs are modified: - the serrated parts are cut straight, - the ends include rectangular heels of a large thickness allowing very good mechanical resistance to be obtained
These slabs assembled with the insulating plates previously described for the walls will make it possible to create prefabricated floor elements.

 The pre-floor manufacturer will assemble on a form possibly having a slight counter-beam a set of slabs previously fitted with insulating plates. In the concave parts of the serrated zone, it will introduce the usual elements of reinforcement of the floors and pour concrete there.

 This will constitute prefabricated floor elements with a width of 60 cm for example and a length equal to the free span.

 These relatively light elements will be delivered to the site and set up with a small crane.

 The installation will be done without props on the walls or the beams, the elements being placed side by side. On the heels of the prefabricated elements, rectangular insulating plates will be placed.

 This type of floor is very interesting, because in addition to its advantages (installation without props and insulation) it is a real technical floor.

 Currently on concrete floors, we are witnessing a heresy that combines lack of coordination and inadequate regulation. The floors are often loaded with 15 to 20 cm of various materials: - backfilling where all trades manage to pass all their pipes often with very little coordination, - thermal and sound insulation, - wire screed, - tiling or other floor coverings.

 All this leads to significant overloads which translate into increases in the quantities of steel in the floors, larger foundations and even greater seismic forces due to the increase in loads.

 With the prefabricated floor described above, a real technical sheath will be available between the insulation put at the junction of two elements and the floor compression table. We will take care to match these technical sheaths with those described for the wall elements (the two products being of course modulated at the same pitch, of 20 cm for example). A pipeline can descend along a wall, pass through the technical duct of the floor and go up in a plasterboard partition for example. Good coordination should be able to avoid any changes, which would constitute an important cost item.

 Once the various pipes have passed through the technical ducts of the floor; after the installation of a welded mesh we will pour the concrete by making a screed of 4 to 5 cm for example. This screed passed by helicopter (large rotary trowel) shortly after pouring will allow to obtain a perfectly erected screed which can receive glued tiles or any other coating.

 When a substantial reinforcement of the floor is necessary, it will be possible in the technical sheaths to add reinforcement reinforcements similar to the other reinforcement elements of this floor.

The accompanying drawings illustrate the invention:
Figures I to 16 relate to the block for noise barrier.

Figure I shows in cross section the block for noise barrier.

 The block (1) is made up of two parts: - a honeycomb part (2) which will give the longitudinal rigidity to the block and which comprises cells (3) in the central area and half - cells (4) at the ends. The half-cells (4) of the ends have the inner wing (5) shorter and shaped to allow incorporation between two blocks of concrete or metal beams in H.

- a serrated part (6) tangent to the previous one, the section of which is limited by an alternative series of convex (7) and concave (8) curves.

Figure 2 shows in plan the slabs (9) which will be associated with the Jocs (1) to form the noise barriers.

These practically rectangular slabs (two opposite faces (10) have a slight fruit) have on the same edge (11) two small studs (12) whose width is equal to half - thickness of the separating walls between cells of the celled part and whose height will be equal to the offset of the joints between the blocks and the slabs.

Figure 3 is a cross section in the height direction of the slabs (9).

 The two large faces (13) of the slabs (9) will not be entirely parallel but will have a slight fruit equal to the fruit from demolding the cells of the alveolate part of the blocks.

 The thickness of the slabs will be equal to the thickness of the cells of the honeycomb part of the blocks, taking into account the fruit.

Figure 4 is a cross section in the horizontal direction of the slabs (9). The slabs (9) have a rectangular cross section which includes slight roundings (14) at the corners.

FIG. 5 represents a slab (9) incorporated in the cells (3) of the block (1). We can see the notched base (15) of the separating walls between cells.

Figure 6 shows a cross section of the noise barrier which shows us between the prefabricated beams (16) the blocks (1) fitted with slabs (9).

Figure 7 shows a section of the noise barrier in the height direction. The upper part of the slabs (9) is included in the notched base (15) of the separating walls between the cells of the blocks (1).

FIG. 8 shows another type of noise barrier, with a substantially similar front profile which can be manufactured flat on presses with larger longitudinal dimensions.

 The convex zones (7) of the section of the serrated part (6) will be slightly truncated by dishes (17) The serrated part (6) and a small face (18) will be shaped by a shape (sheet metal screw located at the base of the mold.

 The serrated part (6) is integral and tangent with a solid part (19) made of the same material, such as for example wood concrete. In this area, a cool pour on cool pouring together a thickness of concrete (20).

 Two opposite edges (21) and (22) of the mold will have been as ace to obtain a small overlap of the panels: - a edge (21) will have a slight mold release over the height of the concrete part, - the other edge ( 22) will have a double mold release fruit offset at the limit of the wood concrete (19) and concrete (20) parts.

 Figures 9 to 16 relate to the block for residential walls.

Figure 9 shows in cross section the block for residential walls.

 The block (23) is made up of two parts: - a honeycomb part (24) which will give the longitudinal rigidity to the block and which comprises cells (25) in the central zone and half-cells (26) at the ends. The half-cells (26) of the ends have the inner wing (27) shorter.

- a serrated part (28) tangent to the previous one, the section of which is limited by an alternative series of truncated convex (29) and concave (30) curves. At the ends of the block on the serrated parts (28) is added a rectangular part (31) intended to form a connecting post between blocks.

FIG. 10 shows in plan the insulating plates (32) which will be associated with the blocks (23) to constitute the residential walls.

 These practically rectangular insulating plates (two opposite faces (33) have a slight fruit) have on the same edge (34) two small studs (35) whose width is equal to the half-thickness of the separating walls between cells of the celled part and whose height is equal to the offset of the joints between the blocks and the insulating plates.

Figure II is a cross section in the height direction of the insulating plates (32).

 The two large faces (36) of the insulating plates (32) will not be completely parallel but will have a slight fruit equal to the mold release fruit from the alveoli of the alveolate part of the blocks.

 The thickness of the insulating plates will be equal to the thickness of the cells of the celled part of the blocks, taking into account the fruits.

Figure 12 is a cross section in the horizontal direction of the insulating pads (32).

 The insulating plates (32) have a rectangular cross section which includes slight roundings (37) at the corners.

FIG. 13 represents an insulating plate (32) incorporated in cells (25) or the half-cells (26) of the block (23). We can see the notched base (38) of the dividing walls between cells.

Figure 14 shows a cross section of the residential wall. We can see between the stiffening posts (39) the blocks (23) fitted with insulating plates (32). We can also observe the detail of a corner of the walls, the connection will be made by the reinforcement and the casting of a stiffening post (40) between a concave cell (30) of a block and the end of another block.

Figure 15 shows a section of the residential wall in the height direction. The upper part of the insulating plates (32) is included in the notched base (38) of the separating walls between the cells of the blocks (23).

Figure 16 shows a buried wall. The reinforcement of the wall is produced by a reinforcement or a welded mesh panel (41) which will be put in place by preferably making the vertical steels (42) correspond with the axis of the concave honeycomb parts (30). A ribbed concrete slab (43) will be poured into the concave parts (30) and into the part (44) between the interior face of the blocks and the formwork.

 Figures 17 to 25 relate to the precast floor slabs.

FIG. 17 represents a model of slabs (45) composed of two honeycombed parts (46) as well as a serrated part (47) comprising two concave zones (48) for the production of the floor.

 The ends of the slabs are modified: - the serrated parts (49) are cut straight, - the ends include rectangular heels (50) of a large thickness allowing very good mechanical resistance to be obtained.

FIG. 18 shows in plan the insulating plates (51) which will be associated with the slabs (45) to constitute insulating floors of the dwelling.

 These practically rectangular insulating plates (two opposite faces (52) have a slight fruit) comprise on the same edge (53) two small studs (54) whose width is equal to the half-thickness of the separating walls between cells of the celled part and whose height is equal to the offset of the joints between the slabs and the insulating plates.

Figure 19 is a cross section in the horizontal direction of the insulating pads (51).

 The two large faces (55) of the insulating plates (51) will not be completely parallel but will have a slight fruit equal to the mold release fruit from the cells of the honeycombed part of the slabs.

 The thickness of the insulating plates will be equal to the thickness of the cells of the honeycombed part of the slabs, taking into account the fruit.

Figure 20 is a cross section of the insulating pads (51).

 The insulating plates (51) have a rectangular cross section which includes slight roundings (56) at the corners.

FIG. 21 represents an insulating plate (51) incorporated in the cells (46) of the slab (45). We can see the notched base (57) of the separating walls between cells.

FIG. 22 represents the slabs (45) assembled with the insulating plates (51) which will make it possible to create prefabricated floor elements (58). The pre-floor manufacturer will assemble on a form possibly having a slight counter-beam a set of slabs (45) previously fitted with insulating plates (51) In the concave parts (48) of the serrated zone ((47), it will introduce standard reinforcing elements (59) into the floors and pour concrete (60) into them.

Figure 23 shows the juxtaposition of the prefabricated floor elements (58).

Figure 24 shows a cross section of the prefabricated floor. A real technical sheath (61) will be available between the insulation (62) placed at the junction of two elements 58) and the floor compression table. Once the various pipes have passed through the technical ducts (61) of the floor, after the installation of a welded mesh (63), the concrete (64) will be poured, making a screed of 4 to 5 cm for example.

Figure 25 shows a longitudinal section of the prefabricated floor. We can see the reinforcement elements (59).

Claims (9)

 REVENDICA TIONS  1) Prefabricated blocks (1), (23) or (45) made up of two parts: an abolished part (2), (24) or (46) which comprises cells (3), (25) or (46) central area and half-cells (4) or (26) at the ends and a serrated part (6), (28) or (47) tangent to the previous one, characterized by its section limited by a series of alternating convex curves (7 ), (29) or (47) and concaves (8), (30) or (48).  2) Prefabricated blocks (t) or (23) according to claim 1, characterized in that the half-cells (4) or (26) of the ends have the inner wing (5) or (27) shorter and shaped to allow incorporation between the blocks of a concrete or metallic H-frame.  3) Prefabricated blocks (1) according to claims 1 and 2, in combination with practically rectangular slabs (9), to constitute noise-reduction walls characterized in that the slabs have two small studs (12) on the same edge (11) ) whose width is equal to the half thickness of the separating walls between cells of the honeycomb part and whose height will be equal to the offset of the joints between the blocks and the slabs.  4) Prefabricated blocks (1) and slabs (9) according to claim 3 characterized in that the slabs (9) are incorporated in the cells (3) and (4) of the blocks (1) and that their upper part s' included in the notched base (15) of the separating walls between the cells (3) and the cells (3) and (4) of the blocks (1).  5) Prefabricated blocks (1) and slabs (9) according to claims 3 or 4 characterized in that they are of very different nature and density, fibrous and light materials for the prefabricated blocks (1) and dense material for the tiles (9).  6) Prefabricated blocks (1) according to claims 1 and 2 characterized in that the section of the convex (7) and concave (8) parts can also be limited by a series of straight lines.  7) anti-noise panel, consisting of blocks according to claims 1 and 6, characterized in that the convex zones (7) of the section of the serrated part (6) are slightly truncated by flats (17) and that the serrated part ( 6) is integral and tangent with a solid part (19) made of the same material and possibly secured to a thickness of concrete (20).  8) Prefabricated blocks (23) according to claims 1 and 2, in combination with insulating plates (32) to form driebitetion walls, characterized in that the convex curves (29) are truncated and. that the ends of the blocks comprise on the serrated parts (28) a rectangular part (31) intended to form a connecting post between blocks.  9) Prefabricated blocks (45) according to claim 1, in association with insulating plates (51), to constitute residential floors, characterized in that the ends of the blocks have the serrated parts (49) cut straight and comprise rectangular heels (50) of significant thickness allowing very good mechanical resistance to be obtained.