Three-layer outer Wall panels KROHN is a modern material that 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 a high-quality load-bearing element, made in the factory, is obtained. This material does not require additional finishing, so it can be used for construction different types premises.
When is the use of three-layer external wall panels justified?
Since the installation of three-layer external wall panels is carried out very quickly, this material can be used for the construction of small buildings in private households. Today, garages for personal cars, utility blocks, enclosing structures, etc. are built from KROHN panels.
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.
Construction using KROHN soundproof sandwich panels
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, food industry facilities, 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:
Due to the variety of requirements that external wall panels must satisfy, their design is quite challenging task. Besides general requirements requirements for external walls (strength, stability, low thermal conductivity, frost resistance, fire resistance, light weight, cost-effectiveness), the manufacture and installation of the structure of external wall panels should be carried out with a minimum of labor costs; they must contain perfect joint designs and high degree factory ready. The shape and finish of the panels must meet the aesthetic requirements for buildings in the given construction area.
Optimal Constructive decisions panels are also difficult to find because they are constantly being modified and improved. Currently, many options for wall panels have been developed. Below is a description of the most used and promising ones. In Fig. 14, a shows a load-bearing single-layer wall panel of a frameless house, made of expanded clay concrete grade 75 with a volumetric weight of 900-1100 kg/m. Panel thickness 340 mm. The outer surface of the panel has a textured layer 20 mm thick made of decorative concrete, and the inner surface has a finishing layer 10 mm thick made of mortar, placed in the mold when concreting the panel. After installing the panel, all that remains is to putty and paint its inner surface.
Ras. 14. Single-layer wall panels:
a - design of expanded clay concrete panel; b - interface between the outer panel and the inner one; ; c - the same, internal to each other; 1 - lifting loop; 2- expansion joint; 3 - decorative concrete; 4 - effective insulation; 5 - heating panel; 6 — embedded steel parts; 7 — steel connecting rods; 8 - panel outer wall; 9 - the same, internal; 10 - finishing layer; g - from cellular concrete; 1 - reinforcing mesh; 2- lifting loops; 3 - welded frames; 4 - grooves for installing brackets under window sill boards
In Fig. 14, b, c shows the interfacing and fastening of expanded clay concrete panel walls - external and internal and internal to each other. The panels are fastened together by welding steel rods or strips to the embedded steel parts of the panels of the external and internal walls. After welding, the fasteners are sealed with a solution of concrete to protect them from corrosion and from exposure to fire in the event of a fire. Small volume weight have single-layer wall panels made of autoclaved reinforced concrete.
IN standard project Residential large-panel houses of the 1-468 series provide for the use of wall panels the size of a room, made of cellular concrete with a volumetric weight of 600 -700 kg/m3. The thickness of the panels, depending on the climatic region, is taken from 30 to 320 mm (Fig. 14, h). The end walls of houses in this series consist of two walls: the internal load-bearing wall is designed on reinforced concrete, and the external self-supporting one is made of cellular concrete.
Wall panels made of cellular concrete in the first houses built covered the outside with a textured layer of dense mortar 30-35 mm thick. Since this layer makes it difficult for water vapor to escape from the room and complicates the manufacturing technology of the panels, now in the panels of the 1-468 series houses, instead of a textured layer, hydrophobic painting of the outer surface of the panels is carried out, which allows water vapor to pass through and at the same time protects the outer surface from atmospheric humidification.
Rice. 15. An example of the design of a two-layer wall panel made of lightweight concrete:
I - frames; 2 - load-bearing layer; 3 - finishing layer; 4 - window sill board; 5 - drain; 6 — lifting loops; 7 - large-porous (thermal insulating) concrete; 8 — embedded parts; 9 — embedded parts for attaching the radiator
Single-layer wall panels can be considered the most promising: compared to laminated panels, they have many advantages due to the simplicity of the design solution and technologies manufacturing, lower labor costs; in addition, production V.H can be easily mechanized.
In the absence of aggregate suitable for producing lightweight concrete with a volumetric weight of less than 1000 kg/m 3, powerfully use two-layer panels, the load-bearing layer of which consists of dense light or heavy concrete grade 150-200 with a volumetric load of more than 1000 kg/m3, and the insulating layer is made of heat-insulating light or cellular concrete or rigid thermal insulation slabs . The thickness of the load-bearing layer for wall panels must be at least 60 mm.
It is recommended to place the supporting layer with inside premises so that it must also be a vapor barrier. Thermal insulation layer the outside is protected with a layer of decorative concrete or mortar grade 50-75, 15-20 mm thick. In the case of using insulation in the form of semi-rigid thermal insulation slabs or laid by pouring, reinforced concrete load-bearing slabs of two-layer panels are designed with ribs along the contour or frequently ribbed. The height of the vertical ribs is set within 1/20 -1/15 of the panel height, the thickness of the slab between the ribs is at least 35 mm.
The width of reinforced concrete ribs should be no less than 40 mm, and in load-bearing panels the width of horizontal ribs should be 60 mm. In Fig. Figure 15 shows the design of a two-layer outer wall panel made of lightweight concrete. Three-layer wall panels consist of and; two reinforced concrete slabs and a layer of insulation between them (Fig. 16). Semi-rigid materials are used as insulation mineral wool slabs, mineral cork, cement fiberboard, asbestos-cement boards, mineral wool mats with a phenolic binder, fiberglass mats, as well as rigid insulation - foam glass, ceramic foam, foam silicate.
Rice. 106. Three-layer wall panel:
1 - welded frames covered with concrete; 2 - lifting parts; 3 - heavy beta; 4 - insulation; 5 - welded mesh; c - overhead parts
The outer and inner reinforced concrete slabs are connected to each other by welded reinforcement frames, pre-concreted with light or heavy concrete. Until now, it was assumed that the use of lightweight concrete should exclude the formation of heat-conducting inclusions that cause the appearance of condensation. However, the practice of using three-layer panels with connecting ribs concreted with lightweight concrete has shown that in winter time in the zone of negative temperatures, the reinforcing bars of the ribs become moistened and corrode.
It is recommended to make the inner slab of a three-layer panel 80 mm thick instead of the 40-50 mm frame used. In this case, the thickened heat-conducting reinforced concrete slab becomes like a heat pump, pumping heat from the heated room into the panel. As a result, the dew point moves towards the outer part of the panel, and the connecting ribs always find themselves in the zone of positive temperatures, which eliminates the possibility of their corrosion when concreting with heavy rather than light concrete.
The thickness of the outer slab of a three-layer panel must be at least 50 mm. The thickness of the insulation layer is determined by thermal engineering calculations. If we take cement fiberboard as insulation, then its thickness for Moscow will be 450 mm and the total thickness of the three-layer wall panel will be 80 + 150 + 50 = 280 mm. The thickness of the stoned connecting ribs of the panel is taken to be at least 40 mm, and the distance between them is no more than 1200 mm.
In foreign construction, the connecting links between the outer and inner slabs of three-layer panels began to be made of stainless steel, which is very expedient from the point of view of the durability of the structure.
In construction practice, the most common are single- and three-layer external wall panels, but the use of two-layer panels is very limited.
Load-bearing panels of the internal walls of large-panel buildings are made of fire-resistant materials: heavy and light concrete (slag concrete, expanded clay concrete, thermosite concrete, etc.); You can also use cellular and silicate concrete.
By design, load-bearing panels of internal walls can be solid (Fig. 17, i), hollow (Fig. 17, b), often ribbed (Fig. 17, c) and with ribs along the contour (Fig. 17, d, 9) . Progressive enclosing wall structures include panels made of asbestos cement, as well as polymer materials. The advantage of these panels compared to reinforced concrete ones is their lightness.
Asbestos-cement wall panels can have frame and frameless structures. The frame wall panel (Fig. 18, a) consists of two asbestos-cement sheets: an outer one with a thickness of 10 mm, internal frame between them from asbestos-cement bars of a special profile (Fig. 18, b).
The frame of asbestos-cement panels can also be mounted from wooden blocks. Insulation is placed inside the panel. Facing asbestos-cement sheets are attached to the frame using durable waterproof polymer glue.
An asbestos-cement panel the size of a room has a frame along its contour and along the perimeter of the window opening, and the horizontal window bars of the frame are installed across the entire width of the panel. To increase the mechanical strength of the bars, they are reinforced with a strip of durable sheet asbestos cement.
To enhance the thermal insulation of the panel, bonded mineral wool felt (Fig. 18b, c) or insulating fibreboards 12.5 mm thick are placed in its cavity in 2-3 layers with air layers (Fig. 18, d, e).
To prevent felt settlement, the first layer is glued to the asbestos-cement sheathing with a vapor barrier coating, for example, red lead on slate drying oil, and several anti-sediment strips are laid (every 400-500 mm), pressing the bulk of the insulation. Anti-sediment strips are placed either on one outer side (Fig. 18.6) or on both sides (Fig. 18, c). In the latter case, due to the wavy shape, the insulation is less susceptible to settlement.
If the panels are insulated with wood fiber boards, the latter are laid in two layers with three air layers (Fig. 18, d) or in three with two layers (cassock 18.5).
The frameless panel consists of an outer asbestos-cement sheet 10 mm thick, which is given a box-shaped shape, and a second flat asbestos-cement sheet also 10 mm thick, forming inner surface panels. Insulation (mineral wool boards) is laid between the sheets.
Rice. 17. Load-bearing panels of internal walls:
a - solid single-layer; b - multi-hollow; c - often ribbed; g - with edges along the contour; d - supporting the floors on the lower edge of the wall; 1 - welded frames; 2 — lifting loops; 3 — embedded parts; 4 - welded mesh; 5 - wooden plugs for fastening the plinth; c - the same, for fastening the box; 7 - round or oval voids; 8 - soundproofing lining made of wood fiber boards
Panel thickness 140 mm, weight 1 m* about 70 kg. The weight of a frame panel 140 mm thick with a frame made of asbestos-cement bars and mineral wool insulation reaches 80. Frameless fabric also includes three-layer panel, for example, a “sandwich” type made of three layers of fiberboard, glued together with cement mortar and lined on both sides with flat asbestos-cement sheets.
When using asbestos-cement panels, it is necessary to take into account that the asbestos-cement sheets in the panels warp when they are moistened and dried on one side. To reduce water absorption and warping of sheets, it is recommended to coat them with hydrophobic liquid GKZh-10 or GKZh-11 (the letters GKZh mean “hydrophobic organosilicon liquid”). GKZh-10 is an aqueous solution of sodium ethyl siliconate, GKZh-11 is an aqueous solution of sodium methyl siliconate.
Rice. 18. Asbestos-cement foot panels with asbestos-cement frame:
A - general form panels; b - design for recessing the panel with mineral wool felt with anti-sediment strips on one side; c - the same, on both sides; d - insulation with wood fiber boards in two layers; 6 - the same, in three layers; 1 — frame elements; 3 - asbestos-cement sheets; 3 - mineral wool felt; 4 - anti-sediment strips; 5 - fiberboards; 6 - laying made of wood fiber boards.
The issue of using plastics for wall panels has not yet been studied enough, and such panels are used only on an experimental basis. When designing wall panels and other plastic structures, it is necessary to take into account that many polymer materials are combustible, and the decomposition products formed during their combustion are toxic. More fire-safe are polyvinyl chloride foam, which is a fire-resistant material, as well as materials made using urea-formaldehyde polymers.
In Fig. 19, A shows the design of a wall panel made of polymer materials, which was used in a residential building built in Moscow in 4th Vyatsky Lane. The panel has the following layers, counting from the inner to the outer surface: gypsum dry plaster 10 mm, aluminum foil 0.1 mm, hard wood fiber board 4 mm. Next, insulation is laid - plywood honeycombs with foam chips on an adhesive bond 80 mm, fibreboard 4 mm. External cladding consists of two layers of burlap and a layer of fiberglass, impregnated with a polyurethane binder. Window frames and frames are made of aluminum alloys.
Rice. 19. Wall panels made of polymer materials:
a - with window frames made of aluminum alloy; 1 - dry plaster; 2 - solid fiberboard; 3 - insulation; 4 - fiberboard; 5—burlap and fiberglass; 6 - aluminum window frame; 7 — sealing gasket on rubber; b - with window frames made of plastic: 1 - outer layer of fiberglass 5 mm thick; gas - layers of insulation; 4 — window plug element; 9 — elastic pad of al polyurethane foam; b - decorative inserts made of colored fiberglass (solution option).
In Fig. 19, b depicts another version of a plastic wall panel used in Moscow in an experimental house in the 10th quarter of New Cherepushki. This panel is three-layer: the outer layer is made of fiberglass with a thickness of 5 mm, insulation layer - made of polyvinyl chloride foam boards with a thickness of 103 mm and internal - from chipboards with a thickness of 12 mm. Window frames and frames are made of glass-vlastik (see Fig. 174). The panels are bolted to the transverse reinforced concrete beam-walls.
Rice. 20. Pairing the balcony slab with the wall:
a - section; b - facade; c - plan; 1 - wall panel; 2 - balcony slab; 3 - steel; planks; 4 - insulation; 5 - cutout in the panel for the balcony slab.
The design of fastening balcony slabs in panel buildings is more complex than in brick buildings due to the insignificant thickness of the panel walls. In Fig. Figure 20 shows the connection of the balcony slab with panel wall made of two-layer panels with an external reinforced concrete slab. The cantilever balcony slab is between the wall panels and is attached to steel connecting strips welded to the embedded parts of the wall and ceiling panels.
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 outer 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 – from 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; 9 – effective insulation; δ – 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
Double-layer wall panels consist of an internal load-bearing layer made of heavy or lightweight structural concrete, and an external insulating layer made of structural and thermal insulating lightweight concrete. The thickness of the internal load-bearing layer is at least 100 mm, and the thickness of the outer insulating layer is determined by calculations for thermal protection. On the outside, double-layer wall panels have a protective and finishing layer of cement mortar 20–25 mm thick with the same finishing as in single-layer 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. Rigid connections ensure joint static operation of the concrete layers of wall panels and protect the 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
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 class B25 on granite crushed stone and steel reinforcement class A500C. Depending on the design calculations, a double mesh of reinforcement is laid in the inner layer and a single mesh in the outer layer.
The outer and inner reinforced concrete layers are connected to each other using rigid diagonal ties made of PD and PPA stainless steel from the Finnish manufacturer Peikko Group.
The thickness of the middle layer of insulation is determined by thermal engineering calculations 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 values 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.
Stone wool. For three-layer reinforced concrete panels, we use specially developed high-strength stone wool with vertical and horizontal grooves, forming a ventilation gap to ventilate the insulation and remove condensate. Stone wool is a non-flammable material, and its thermal conductivity is stone wool 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 on it 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
The production of wall reinforced concrete panels for the construction of a private house, as well as for multi-storey buildings, requires modern, expensive equipment, which is available only at large reinforced 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 makes it possible 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 it is 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 a maximum length of 7.8 m.
In most cases, such maximum dimensions are enough to implement any house project and minimize the number of interpanel seams, and make panel joints in the alignment of 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 Between the reinforced concrete layers, a wooden board 50 mm thick is installed across the entire width of the insulation; using fasteners, the board is securely sealed.
Also, so-called “quarters” are formed in the outer reinforced concrete layer in window openings for better installation of 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 production of wall panels, the INPANS company has tested and is ready to offer you a number of reliable and inexpensive solutions to give the facade of your house expressiveness and individuality:
Forming the outer surface. Before pouring the concrete mixture, special matrix sheets are placed on the molding table to imitate various façade materials. 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. Brushes leave marks-grooves on the concrete surface, creating the effect of “scratched concrete”. Grooves can be drawn both vertically and horizontally.
Finishing with facade materials. At your request, the outer surface can also be lined with any other façade materials ( clinker brick, wooden planks, fiber cement siding, etc.).
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. The thickness of the 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 internal surface of the external and internal panels is smooth and does not require leveling plaster; it is enough to 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.
In addition, unlike walls made of block materials such as brick, gas silicate and other blocks, the inner surface of reinforced concrete panels does not have technological seams and is 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 floors, we use proven and reliable hollow-core floor slabs of the PB and PC brands. Thanks to modern equipment, PB slabs can be manufactured to any length, while floor slabs with a thickness of 220 mm can cover a span of up to 7 meters, and slabs with a thickness of 265 mm can cover a span of up to 10 meters. The standard width of the floor slab is 1.2 m.
In addition to the 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, make a balcony slab, a slab with cantilever support or with non-standard holes (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 opening or installation of ventilation shafts), we use standard PETRA® steel brackets from the Finnish manufacturer Peikko Group, which allow opening an opening up to 2.4 meters wide (the width of 2 standard floor slabs).
Variability modern slabs ceilings allow 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 with a total length of 2x7.8 meters and a total weight of no more than 20 tons. As a rule, wall panels for a two-story house of 10x10 meters are delivered by 10 flights of standard panel carriers. 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 in monolithic areas, the temporary supports (struts) are removed and the installation of the panels of the next floor can begin.
This technology for installing wall panels is also used in the construction of modern multi-story panel buildings, 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 from the street into the house; a strip of mineral wool is installed in the gap between the insulation or this place is 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.
The installation time for 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 is carried out along 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 built on 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 roof finishing materials, we recommend using only high-quality materials with a confirmed manufacturer’s warranty.
FLAT ROOF
Device flat roof is carried out on reinforced concrete floor slabs, 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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The elevator shaft is equipped with embedded elements for subsequent assembly of the structure located along the entire height of the building. In some cases, mortgages are not included in the structure, then the blocks are mounted on spacer dowels. The use of tubing makes it possible to use the in-line method of installing elevators in any standard construction.
Since the installation of elevator shaft blocks can be carried out in buildings with different heights ceilings, structures of various standard sizes are produced, as well as additional elements.
The task of reinforced concrete products is to ensure safe, comfortable movement of people inside the building, therefore special attention is paid to the quality of materials, accuracy of compliance with design requirements and professional installation. In order for elevator cabins to move freely inside the shaft, the following parameters must be observed during the manufacturing process of reinforced concrete products:
Precise geometry;
- absence visible defects– cracks, shells;
- absence of reinforcement parts not covered with a layer of concrete of the required thickness.
Features of elevator shafts
The products are designed taking into account the location of the elevator counterweight - behind or to the side of the elevator cabin. The main characteristics of reinforced concrete elevator shafts are:
High strength characteristics;
- wear resistance and durability - the service life of the shaft is several decades and is comparable to the service life of the main load-bearing structures building;
- fire resistance. Fire resistance limit - 1 hour or more;
- easy installation and high maintainability;
- resistance to moisture.
The installation of elevator shafts helps strengthen the main structures of the building and increase its stability.
Elevator shaft markings
Like any mass-market reinforced concrete products, the product is subject to mandatory labeling. Alphanumeric designations are applied to the inner surface of the block located at the rear of the elevator car.
The designations ШЛ stand for elevator shafts. The next letter characterizes the type of lift. L – passenger elevator; G-freight elevator.
The numbers after the letters indicate the dimensions of the block. The marking may also indicate the presence of additional structural elements and mortgages.
Delivery of elevator shafts
Delivery of elevator shafts is carried out by our own transport to Moscow, Moscow, Oryol, Ryazan, Kaluga and other regions of Russia! Delivery estimates can be ordered in the Delivery section.
When delivering elevator shafts, precautions must be taken. According to GOST, heavy cargo can be transported only in a horizontal position in special vehicles. When loading/unloading, it is prohibited to move several pieces at a time. Exception: rigging work with special devices, where lifting several products at the same time is allowed.
When storing at open ground a gasket with a thickness of at least 10 cm is placed at the base of the stack; a drain for water is required.
Elevator shafts price in Moscow
Elevator shafts price per piece. The price depends on their size, thickness, presence/absence of strengthening additives, reinforcement. In order not to overpay for the goods, it is advisable to order elevator shafts directly from the manufacturer PSK Perspektiva LLC plant. This way you will receive certified reinforced concrete products with a laboratory report and at the best cost.
Our company can offer you the optimal balance between quality and cost.
You can request our price list and place an order in the section of the site that interests you.
Come check out the prices and make sure that cooperation with us will be beneficial for you.
Our plant LLC PSK "Perspektiva" has been operating since October 2003.
Buy elevator shafts at the concrete products plant
It is profitable to buy elevator shafts without intermediaries at the Perspektiva reinforced concrete products plant. New elevator shafts are always available in our warehouses. We are now increasing production capacity and looking for new reliable partners.
If you are serious about cooperation, contact us at the numbers listed in the “Contacts” tab.