EP0726991A1 - Perfectionnements apportes aux materiaux de construction prefabriques - Google Patents
Perfectionnements apportes aux materiaux de construction prefabriquesInfo
- Publication number
- EP0726991A1 EP0726991A1 EP94929053A EP94929053A EP0726991A1 EP 0726991 A1 EP0726991 A1 EP 0726991A1 EP 94929053 A EP94929053 A EP 94929053A EP 94929053 A EP94929053 A EP 94929053A EP 0726991 A1 EP0726991 A1 EP 0726991A1
- Authority
- EP
- European Patent Office
- Prior art keywords
- preformed
- acrylic polymer
- hydrogen
- preformed element
- substrate
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Withdrawn
Links
Classifications
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
- E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
- E04C2/02—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials
- E04C2/26—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups
-
- C—CHEMISTRY; METALLURGY
- C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
- C09D—COATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR
- C09D133/00—Coating compositions based on homopolymers or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and at least one being terminated by only one carboxyl radical, or of salts, anhydrides, esters, amides, imides, or nitriles thereof; Coating compositions based on derivatives of such polymers
- C09D133/04—Homopolymers or copolymers of esters
- C09D133/06—Homopolymers or copolymers of esters of esters containing only carbon, hydrogen and oxygen, the oxygen atom being present only as part of the carboxyl radical
- C09D133/08—Homopolymers or copolymers of acrylic acid esters
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
- E04C1/00—Building elements of block or other shape for the construction of parts of buildings
- E04C1/40—Building elements of block or other shape for the construction of parts of buildings built-up from parts of different materials, e.g. composed of layers of different materials or stones with filling material or with insulating inserts
Definitions
- This invention relates to building materials, and to methods of improving their characteristics by applying a surface coating.
- building materials such as panels used in cladding structures such as wall, and roof panels, and in particular panels made from hydrocarbon based foams for which the invention may be particularly applicable.
- the invention is not to be limited as such.
- the invention may have other applications it is to be understood that the prior art and possible embodiments of the invention as discussed below are given by way of example only.
- a surface layer of a material such as paint, fibreglass polyester or epoxy resin, plaster, concrete/cement and the like.
- Paint is the most commonly used material for finishing and weather proofing wood based materials
- plaster is used on softer gib- board type materials or with laths but is not generally suitable for exterior surfaces
- concrete/cement is commonly used for finishing external surfaces of cladding materials such as wood, brick or hydrocarbon based foam panels.
- a suitable material such as a mesh may be attached to the surface to improve bonding to the surface. Due to the weight and fragile nature of the cement coating this must generally be applied once the panel has been installed in position.
- the application operation is thus vulnerable to weather conditions and there is a requirement for skilled on site labour, especially when special finishes or curved surfaces such as at corners or around pillars are required. This adds to the cost and construction time. Furthermore, since the coating is applied after the panel has been attached to support members, the coating relies solely on adhesion to the substrate and is thus susceptible to debonding.
- Fibreglass polyester or epoxy resin finishes provide a very tough light weight flexible finish and are commonly used with wood based materials. However due to the cost of the epoxy resin this method is not generally economical for large surface areas. Furthermore, polyester resins tend to dissolve hydrocarbon based foam materials making them unsuitable for this application.
- paints which do not dissolve the foam such as plastic (acrylic) paints may be applied to the surface to provide a certain amount of improvement in strength and weather resistance to the foam panel, however the amount of protection provided is generally not sufficient for building panels.
- additional strength may be provided by applying a thick layer of paint with a reinforcing mesh such as a fibreglass cloth embedded therein, if applied thickly such paints require a considerable time to harden. Furthermore, the cost of the paint makes the process expensive.
- the present invention provides protective coating for application to material comprising cement, and/or sand or -.nother filler and an acrylic polymer.
- the invention provides a method of forming a preformed building element characterised by applying a protective coating to a substrate comprising cement and/or sand or another filler and an acrylic polymer in layers and progressively building up the coating until the desired coating thickness has been reached.
- the substrate can be a hydro-carbon based foam.
- the protective coating can be provided with a reinforcing material.
- the reinforcing material can be a flexible lath.
- the acrylic polymer can include polym ethyl acrylate.
- the acrylic polymer can be a polymer consisting of C ⁇ -18 alkyl acrylates.
- the acrylic polymer can be a polymer consisting of C ⁇ -18 alkyl methacrylates.
- the acrylic polymer can be of the structure
- Rl can consist of one or more of hydrogen, methyl, ethyl, butyl or other suitable aliphatic hydrogen chains.
- 2 can consist of hydrogen and/or methyl.
- Rl can be mainly comprised of methyl groups with R2 being hydrogen.
- the substrate can be provided with a longitudinal cavity to facilitate bending of the element.
- the cavity can be V-shaped.
- the cavity can be dish shaped.
- the method can include the step of applying a protective coating on one surface and a layer of building paper on the opposite surface.
- the filler material may include glass beads, ceramic bubbles, chalk, quartz, perlite marble, silica sands, natural stone or synthetic filling agents.
- the reinforcing material may be polypropolene, glass, nylon, metal, carbon, Olefin, or plastics materials of general or specific forms.
- the material is relatively inexpensive compared to epoxy resins, it can provide a low cost alternative treatment for building panels and the like. Furthermore, since it is relatively light in weight, is flexible, and does not dissolve foam type materials, it can be used for coating foam panels off site. The panels can then be fitted to a building structure without the need for further surface treatment once installed. The installation operation is thus not vulnerable to weather conditions, and there is not the requirement for skilled on site labour. Also since attachment members such as nails pass through the panels there is not the tendency for debonding of the surface coating. Furthermore, the panels can be cut and shaped off site as required.
- the panels can also be bent on installation and if sharp corners are required, the rear of the panel may be relief cut to enable a sharp bend to be made such as for a corner portion.
- the foam coated material may also be formed in a variety of shapes for different building applications. For example coated half cylindrical shapes may be made for fitting over posts to provide a pillar, or corner pieces may be made for fitting between panels at corners.
- Imitation finishes such as of brick, wood, weather board, rough cast concrete and the like, may be formed on the surface of panels of a variety of materials by applying the matrix material to a flat or pre-shaped surface, and then working the matrix material as required prior to setting.
- Reinforcing similar to the front coating, or of other materials such as building paper may also be adhered to the rear surface of the foam panels. This would negate the requirement for on site installation of building paper.
- the panels could also be used as an alternative to gib- board lining and could have the final paint/wallpaper applied in the factory. With suitable reinforcing, roof tiles and the like incorporating a foam type substrate may be possible.
- Panels could also be made with an exterior finish on one side and interior finish on the other side and fitted to a building structure, for example with a simple "I" type connector between the panels to provide a joint, thus enabling cladding of a building to be done in a short time.
- Panels suitable for complete sections such as wall or fence panels may also be possible.
- a thick foam panel may be made with cavities to take roof supports or fence supports, or to form moulds for pouring concrete support pillars. That may provide for roof support.
- This may be prepared and coated with the matrix material off site, and then quickly assembled at the site, without the need for skilled on site labour.
- these may be made with extra reinforcement bands laid into the matrix over the panels to give the required strength for roof support.
- Suitable material clad with the matrix cladding may also be formed with cavities for encasing objects such as existing structural members (i.e. pillars), or. for setting in position and then pouring a material such as concrete into the cavity to form a structural member.
- a method of construction may be applied to the construction of complete structures made up using a substrate material such as polystyrene which is then completely or partially encased with the matrix . Due to the insulation properties and ease of forming of the substrate, and the excellent water resistant properties of the coating, this method of construction may be suitable for the manufacture of articles such as letter boxes, pillars, beams, posts, and containers.
- the matrix material is flexible and tough and adheres strongly to foam materials, it may also be suitable as an alternative to metal cladding used particularly for cool store panels.
- the matrix material could be easily repaired if damaged, and moisture content of the foam substrate could be easily checked by simply inserting a probe through the coating material, and subsequently repairing with a suitable material.
- the strong adhesive properties of the matrix material also make it suitable as an adhesive for attaching foam panels to objects such as a supporting structure. Panels could thus be bonded in position rather than using pins and the like thereby avoiding the need to puncture the foam material and leave it vulnerable to moisture absorption and contamination.
- the tough flexible nature of the coating may also make it suitable for coating floor and decking materials, and for coating materials for use in fencing and as fence panels.
- the excellent water proofing properties of the matrix may make it preferable as a coating for exterior surfaces, compared to conventional plaster coatings and the like.
- a variety of types of the above described matrix material may be used depending on requirements provided they enable a tough flexible coating of relatively low cost suitable for application to building materials.
- the proportions and types of materials used in the flexible modifier PRIMAL® FM-2727 may be varied as required or desired, and additives such as fire retardants may be added, or other fillers used.
- additional coatings of different materials may also be applied as required or desired.
- the surface may first be coated with a thin priming coat of a suitable material prior to applying the matrix material.
- further coats of other material may be applied over or between layers of the matrix material.
- material such as treated wood chips, or spherical light weight ceramic or polystyrene bubbles may be used as a filler to lighten the coating material, or may be sprinkled on the surface between coatings to provide additional bulk.
- the matrix material may be applied by any suitable means. For example it may be spread by hand, brush, or rolled with a roller, sprayed on, or applied by dipping the panel in the matrix material.
- any suitable type of reinforcing material may be applied to the surface provided this is able to bond with the material and has sufficient strength.
- a glass fibre material may be most suitable however other fibrous materials such as KEVLAR® or carbon fibres or polyester fibres may be used.
- the reinforcing material may be applied in any suitable form such as a mat (unidirectional open weave mesh) or as chopped strand. Chopped strand may provide a greater impact resistance for certain applications due to the ability of the fibres to align with the loading direction in the flexible matrix material. In the case of chopped strand application, the reinforcing material may be applied together with the matrix material. Working of the reinforcing into the matrix may be by any suitable method such as pressing, rolling, brushing, surface pressure or vibration, or by the addition of further matrix material, extrusion or vacuum processes.
- Additional matrix material may be applied over the first coat. This material may be the same as that of the first coat or may be different.
- Various types of building material may be suitable for treatment by the above method.
- polystyrene insulation in sheet form or profiled light weight concrete panels, timber panels, asbestos, cement fibre boards, composites of the above including some insulating or fire retarding materials.
- a first coat of either epoxy, polyurethane, or acrylic, mixed with a hardener may be applied.
- an all acrylic modifier of the type PRIMAL® FM2727 as supplied by Rohm & Haas Ltd may be suitable.
- a possible mixture ratio for this may be 100 parts of PRIMAL® FM2727 modifier and 100 parts of Portland cement conforming to ASTM C-150.
- additional cement may be added along with other ingredients such as #70 grade mesh sand, strengthening fibres, thickener, defoamer, coalescing agent, surfactants and dispersants, plasticisers, water, colorants, mica and white cement as required or desired.
- alkali resistant glass mat reinforcement for the above modified cement mix, this may vary in weight and density. For example 115gm/m 2 gives a moderately light weight reinforcement, whilst 2 layers of 115gm/m 2 or a layer of 250gm/m 2 or even two layers of 250gm/m 2 gives much stronger reinforcement. For general foam wall applications an alkali resistant fibre glass mat of 130gm/m 2 may be most suitable.
- a second coat matrix is applied this can be either a similar mix to the first coat matrix described above or can be made differently to provide different surface characteristics.
- the second matrix may comprise 100 parts of PRIMAL® FM2727 flexible modifier to 200 parts of Portland cement conforming to ASTM C-150. If desired this could also have combinations of the same additional ingredients as the first coat matrix described above.
- Additional layers of the above matrix mixes and reinforcing may be applied in association with a reinforcing material such as alkali resistant glass of woven mesh open construction form (unidirectional alkali resistant reinforcing mesh of open weave) having varying weights from 100gm/m 2 to 600gm/m 2 or more depending on reinforcement requirements.
- a reinforcing material such as alkali resistant glass of woven mesh open construction form (unidirectional alkali resistant reinforcing mesh of open weave) having varying weights from 100gm/m 2 to 600gm/m 2 or more depending on reinforcement requirements.
- Surface finishes may be carried out in the factory or on site. Typical finishes may include, textures, drag type scratching finishes, trowel smooth finishes, formed or profiled finishes to obtain either very smooth or predetermined finishing shapes and patterns, coloured finishes, painted finishes, sponged or special effect finishes.
- An example of a special effect finish may be achieved with a mixture of 100 parts of sand type #50 mesh , 30 parts of Portland cement to ASTM C-1500, 10 parts of PRIMAL® FM2727 modifier, and water as required. To this could be added a range of, or all of, the combinations of additional ingredients as included in the matrix coat mixtures described above.
- Various methods may be used for jointing/sealing the panels on site once installed, and for treating the edges of the panels. To ensure against any seepage into the panels up through the bottom edges additional back wrapping of the panels may be carried out by using a layer of the matrix material with reinforcing as required.
- edges of the panels to be joined may be simply butt jointed together, or joined using edge strips with or without a backing rod and sealant, and a reinforcing fabric such as strips of alkali resistant glass mat may be cut to an appropriate width and attached across the joint with a coating of the above matrix material, or some other adhesive or plaster.
- the edges may be tongue and grooved, slotted, ship-lapped, or straight or bevelled or tapered to take a jointing strip such as a plastic or aluminium "I” or "T” jointing strip. Joints may also be covered with battens such as with Very type buildings.
- Figure 1 is a schematic plan view of foam panel illustrating a building material according to the present invention and its method of treatment
- Figure 2 is a schematic plan view of corner piece for a building illustrating another building material according to the present invention.
- Figure 3 is a perspective view of preformed corner building elements of the present invention.
- Figure 4 is a sectional view of a corner construction in accordance with the present invention.
- Figure 5 is a side perspective view of a typical wall construction using the building elements of the present invention.
- Figure 6 is an end view of a eyebrow building element of the present invention.
- Figure 6a illustrates a fixing detail inclusive of the eyebrow element of Figure 6
- Figure 7 illustrates a number of alternative shapes for building elements of the present invention.
- FIG. 1 a schematic sectional view of a panel generally indicated by arrow 1 comprising a polystyrene foam substrate 2 coated with fibre glass reinforced coating generally indicated by arrow 3.
- the coating 3 consists of a first layer 4 of a material, a layer of alkali resistant glass fibre mat 5, a second layer 6 of a matrix material, a sprinkling of sand and optionally a finishing coat of paint 7.
- the first layer 4 matrix material is made using a mixture of approximately 100 parts by weight of acrylic flexible modifier PRIMAL® FM-2727 and 180 parts by weight of cement.
- the second layer 6 matrix material is of similar composition to that of the first layer 4 matrix material with additional sand.
- a rear surface 8 of the substrate 2 is covered with a layer of building paper 9 which is adhered to the substrate 2 with a coating of the matrix material of similar composition to that of the layer 4.
- the panel 1 is attached to a supporting structure 10 by means of nails 11. The heads of the nails are covered over with a material similar to that of the matrix material of the second layer 6.
- the panel 1 shown in this embodiment is provided with the fibre glass reinforced coating 3 off site. Since the reinforced coating 3 is light in weight and flexible, the panel 1 can then be easily transported to the site and fitted into position on the supporting structure 10, without the possibility of damage to the surface as would be the case with a cement coated foam panels.
- the matrix material 4 is first applied by rolling, spraying or otherwise a mixture of the matrix onto the substrate 2.
- the fibre glass mat 5 is then laid over the layer of matrix 4 and pressed in with rollers so that the matrix material permeates between the fibres of the mat 5.
- a coating of a second matrix material 6 is then applied by spraying and sanding with #70 grade sand, and the panel allowed to dry and subsequently painted as required. Drying may be by air drying but other methods such as snap heating with infra-red radiation dehumidifying or oven curing may be used.
- a finishing coat of paint is then sprayed on the panel ready for transport to the site for installation. After nailing the panel in position on site the nail heads are covered over with a thin layer of a similar matrix material.
- Figure 2 shows another embodiment of the present invention in the form of a corner fitting 20 for a building.
- the corner fitting 20 is used at corners of buildings, and differs from the panel of Figure 1 in that a notch has been cut in the rear of the panel after manufacture so that the panel can be bent though 90°. Due to the flexible nature of the fibre glass reinforced coating 3, this does not crack on bending, enabling curved corner sections to be formed by simply notching the foam and bending, either on site or as pre-formed factory corner pieces.
- the corner element illustrated is provided with a longitudinal V-shaped cut-out 13 in the substrate material 2 which enables sections of the element to be folded at right angles and fixed to corner structure elements 14 as indicated.
- the cut-out 13 can be dish- shaped which is more suitable for fixture to curved structures.
- Figure 5 of the drawings illustrates fixture of the corner elements of Figure 3 to a corner structure (as shown in Figure 4) and adjoining panel elements 1 fixed to wall structure members 15.
- Figures 6 and 6a show an eyebrow element 16 and its method of fixture to a frame structure 17.
- Figure 7 shows alternative cross-section of the building elements in the form of "mouldings", for trimming and finishing using the elements of the present invention.
- the matrix material treatment enables panels such as foam type panels for buildings to be made up off site and then installed without the need for further finishing or with only minimal finishing. Panels can therefore be made in a continuous production process with reduced wastage. Problems relating to delays due to weather conditions and the like are thus avoided, skilled on site labour is not required, and rapid construction is possible enabling reduction in construction costs.
Landscapes
- Engineering & Computer Science (AREA)
- Architecture (AREA)
- Chemical & Material Sciences (AREA)
- Civil Engineering (AREA)
- Structural Engineering (AREA)
- Materials Engineering (AREA)
- Life Sciences & Earth Sciences (AREA)
- Wood Science & Technology (AREA)
- Organic Chemistry (AREA)
- Finishing Walls (AREA)
- Laminated Bodies (AREA)
- Paper (AREA)
- Panels For Use In Building Construction (AREA)
- Application Of Or Painting With Fluid Materials (AREA)
Abstract
Applications Claiming Priority (3)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
NZ24837293 | 1993-10-10 | ||
NZ24837293 | 1993-10-10 | ||
PCT/NZ1994/000103 WO1995010674A1 (fr) | 1993-10-10 | 1994-10-10 | Perfectionnements apportes aux materiaux de construction prefabriques |
Publications (2)
Publication Number | Publication Date |
---|---|
EP0726991A1 true EP0726991A1 (fr) | 1996-08-21 |
EP0726991A4 EP0726991A4 (fr) | 1997-01-02 |
Family
ID=19924439
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
EP94929053A Withdrawn EP0726991A4 (fr) | 1993-10-10 | 1994-10-10 | Perfectionnements apportes aux materiaux de construction prefabriques |
Country Status (4)
Country | Link |
---|---|
EP (1) | EP0726991A4 (fr) |
AU (1) | AU686243B2 (fr) |
CA (1) | CA2173842A1 (fr) |
WO (1) | WO1995010674A1 (fr) |
Families Citing this family (3)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
ES2310140B1 (es) * | 2007-06-13 | 2009-12-04 | Desing Cork, S.L. | Pieza para construccion. |
AR089548A1 (es) * | 2011-04-12 | 2014-09-03 | Enrique Cibeira Daniel | Procedimiento para fabricar ladrillos inertes, a partir de una mezcla compuesta de suelos contaminados con hidrocarburos, con arcillas comunes, aglomerantes y agua y mezcla utilizada en dicho procedimiento |
ITUD20110075A1 (it) * | 2011-05-23 | 2012-11-24 | Maria Sabina Cester | Pannello di rivestimento e relativo metodo di realizzazione |
Citations (1)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US4067164A (en) * | 1975-09-24 | 1978-01-10 | The Dow Chemical Company | Composite panels for building constructions |
Family Cites Families (4)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US4430463A (en) * | 1982-09-15 | 1984-02-07 | Michigan Hanger | Acrylic polymer Portland cement coating composition |
JPS60195049A (ja) * | 1984-03-14 | 1985-10-03 | ペリ− デイ マリナツクス | アクリルポリマ−.ポルトランドセメントコ−テイング組成物 |
JPS6192809A (ja) * | 1984-10-13 | 1986-05-10 | 難波 蓮太郎 | 複合パネル捨て型枠 |
BE901692A (fr) * | 1985-02-08 | 1985-05-29 | G Levasseur Sa Sa | Revetement pour materiaux de construction et procede de fabrication des constituants de ce revetement. |
-
1994
- 1994-10-10 WO PCT/NZ1994/000103 patent/WO1995010674A1/fr not_active Application Discontinuation
- 1994-10-10 CA CA002173842A patent/CA2173842A1/fr not_active Abandoned
- 1994-10-10 EP EP94929053A patent/EP0726991A4/fr not_active Withdrawn
- 1994-10-10 AU AU78245/94A patent/AU686243B2/en not_active Expired - Fee Related
Patent Citations (1)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US4067164A (en) * | 1975-09-24 | 1978-01-10 | The Dow Chemical Company | Composite panels for building constructions |
Non-Patent Citations (3)
Title |
---|
DATABASE WPI Section Ch, Week 8546 Derwent Publications Ltd., London, GB; Class A93, AN 85-286173 XP002017815 & JP-A-60 195 049 (MARINAX P D) , 3 October 1985 * |
DATABASE WPI Section Ch, Week 8625 Derwent Publications Ltd., London, GB; Class A93, AN 86-159513 XP002017814 & JP-A-61 092 809 (TOYO PILE HUME-KAN) , 10 May 1986 * |
See also references of WO9510674A1 * |
Also Published As
Publication number | Publication date |
---|---|
AU686243B2 (en) | 1998-02-05 |
AU7824594A (en) | 1995-05-04 |
EP0726991A4 (fr) | 1997-01-02 |
CA2173842A1 (fr) | 1995-04-20 |
WO1995010674A1 (fr) | 1995-04-20 |
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