U.S. patent application number 11/139576 was filed with the patent office on 2006-04-13 for composite construction element, in particular for manufacturing floor structures and wall structures for buildings and method for manufacturing the same.
This patent application is currently assigned to PLASTEDIL S.A.. Invention is credited to Piero Cretti.
Application Number | 20060075701 11/139576 |
Document ID | / |
Family ID | 36143870 |
Filed Date | 2006-04-13 |
United States Patent
Application |
20060075701 |
Kind Code |
A1 |
Cretti; Piero |
April 13, 2006 |
Composite construction element, in particular for manufacturing
floor structures and wall structures for buildings and method for
manufacturing the same
Abstract
A composite construction element (1) is described, comprising:
a) at least one elongated body (2) made of expanded plastic
material provided with opposite faces (2a, 2b); b) at least one
reinforcing section bar (7, 8) longitudinally extending in the
elongated body (2) and having a first lateral portion (7b, 8b)
protruding from a first face (2a) of the elongated body (2);
wherein the first lateral portion (7b, 8b) of the reinforcing
section bar (7, 8) is provided with a face (9, 10) extending
substantially parallel to the first face (2a) of the elongated body
(2) made of expanded plastic material at predetermined distance
therefrom. Advantageously, the construction element (1) exhibits
improved self-supporting characteristics and improved supporting
characteristics of covering elements externally associated to the
construction element itself.
Inventors: |
Cretti; Piero; (Morbio
Superiore, CH) |
Correspondence
Address: |
SUGHRUE MION, PLLC
2100 PENNSYLVANIA AVENUE, N.W.
SUITE 800
WASHINGTON
DC
20037
US
|
Assignee: |
PLASTEDIL S.A.
|
Family ID: |
36143870 |
Appl. No.: |
11/139576 |
Filed: |
May 31, 2005 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
60636100 |
Dec 16, 2004 |
|
|
|
Current U.S.
Class: |
52/223.8 |
Current CPC
Class: |
E04B 5/026 20130101;
E04B 5/21 20130101; E04C 3/09 20130101; E04B 5/28 20130101; E04B
2/7412 20130101; B62D 33/04 20130101; E04C 2/38 20130101; E04B 5/00
20130101; E04B 9/0464 20130101; E04B 1/14 20130101; E04C 2/22
20130101; E04B 9/001 20130101; E04C 2003/0473 20130101; E04B 9/0435
20130101; E04B 5/02 20130101 |
Class at
Publication: |
052/223.8 |
International
Class: |
E04C 5/08 20060101
E04C005/08 |
Foreign Application Data
Date |
Code |
Application Number |
Oct 13, 2004 |
IT |
MI2004A001934 |
Claims
1. A composite construction element (1) comprising: a) at least one
elongated body (2) made of expanded plastic material provided with
opposite faces (2a, 2b); b) at least one reinforcing section bar
(7, 8) longitudinally extending in said at least one elongated body
(2) and having a first lateral portion (7b, 8b) protruding from a
first face (2a) of said opposite faces (2a, 2b) of the elongated
body (2); wherein said first lateral portion (7b, 8b) is provided
with a face (9, 10) extending substantially parallel to said first
face (2a) of said at least one elongated body (2) made of expanded
plastic material at a predetermined distance therefrom.
2. A construction element (1) according to claim 1, wherein said at
least one reinforcing section bar (7, 8) is substantially shaped as
an L, a C, a Z or an I.
3. A construction element (1) according to claim 1, wherein said at
least one reinforcing section bar (7, 8) is provided with a second
lateral portion (7c, 8c) provided with a face (13, 14) extending
substantially parallel to the second face (2b) of said opposite
faces (2a, 2b) of the elongated body (2) made of expanded plastic
material.
4. A construction element (1) according to claim 3, wherein said
second lateral portion (7c, 8c) of said at least one reinforcing
section bar (7, 8) is extending flush with said second face (2b) of
the elongated body (2) made of expanded plastic material.
5. A construction element (1) according to claim 3, wherein said
second lateral portion (7c, 8c) of said at least one reinforcing
section bar (7, 8) is entirely incorporated in the mass of expanded
plastic material and is arranged at a predetermined distance from
said second face (2b) of the elongated body (2) made of expanded
plastic material.
6. A construction element (1) according to claim 3, wherein said
second lateral portion (7c, 8c) of said at least one reinforcing
section bar (7, 8) protrudes from said second face (2b) of the
elongated body (2) made of expanded plastic material and wherein
said face (13, 14) of said second lateral portion (7c, 8c) is
extending substantially parallel to said second face (2b) of the
elongated body (2) made of expanded plastic material at a
predetermined distance therefrom.
7. A construction element (1) according to claim 1, wherein said
face (9, 10) of the first lateral portion (7b, 8b) or said face
(13, 14) of the second lateral portion (7c, 8c) of said at least
one reinforcing section bar (7, 8) is substantially planar.
8. A construction element (1) according to claim 1, wherein said
first (7b, 8b) or said second (7c, 8c) lateral portion of said at
least one reinforcing section bar (7, 8) is substantially shaped as
a C or as an upturned U.
9. A construction element (1) according to claim 1, wherein said
face (9, 10, 13, 14) of said first (7b, 8b) or said second (7c, 8c)
lateral portion of said at least one reinforcing section bar (7, 8)
is substantially perpendicular to a central portion (7a, 8a) of the
reinforcing section bar (7, 8).
10. A construction element (1) according to claim 1, wherein said
first (7b, 8b) or said second (7c, 8c) lateral portion of said at
least one reinforcing section bar (7, 8) is substantially
hook-shaped.
11. A construction element (1) according to claim 1, wherein said
first (7b, 8b) or said second (7c, 8c) lateral portion of said at
least one reinforcing section bar (7, 8) is associated to a
longitudinal rib (41, 42) projecting in a cantilevered fashion from
said first (2a) or from said second (2b) face of the elongated body
(2) made of expanded plastic material.
12. A construction element (1) according to claim 11, wherein said
face (9, 10, 13, 14) of said first (7b, 8b) or of said second (7c,
8c) lateral portion of said at least one reinforcing section bar
(7, 8) is extending at least in part substantially flush with an
upper face (41a, 42a) of said longitudinal rib (41, 42) of the
elongated body (2) made of expanded plastic material.
13. A construction element (1) according to claim 1, comprising at
least two reinforcing section bars (7, 8) longitudinally extending
in the elongated body (2) made of expanded plastic material at
opposite parts of the longitudinal center plane of said body along
a direction substantially parallel to said center plane.
14. A construction element (1) according to claim 13, wherein at
least a first (7) of said reinforcing section bars is provided with
a respective first lateral portion (7b) protruding from said first
face (2a) of the elongated body (2) made of expanded plastic
material and wherein at least a second (8) of said reinforcing
section bars is provided with a respective lateral portion (8c)
protruding from the second face (2b) of said opposite faces (2a,
2b) of the elongated body (2), said lateral portion (8c) of said at
least one second reinforcing section bar (8) being provided with a
face (14) extending substantially parallel to said second face (2b)
of the elongated body (2) made of expanded plastic material at a
predetermined distance therefrom.
15. A construction element (1) according to claim 13, wherein said
reinforcing section bars (7, 8) are provided with opposite first
(7b, 8b) and second (7c, 8c) lateral portions protruding from said
opposite faces (2a, 2b) of the elongated body (2) made of expanded
plastic material.
16. A construction element (1) according to claim 3, wherein said
second lateral portions (7c, 8c) of the reinforcing section bars
(7, 8) are extending at opposite parts of the longitudinal center
plane of said elongated body (3).
17. A construction element (1) according to claim 1, wherein said
face (9, 10, 13, 14) of said first (7b, 8b) or of said second (7c,
8c) lateral portion of said at least one reinforcing section bar
(7, 8) is provided with at least one stiffening rib (45, 46).
18. A construction element (1) according to claim 1, wherein said
at least one reinforcing section bar (7, 8) is provided with a
plurality of openings (15) formed in a central portion (7a, 8a)
thereof.
19. A construction element (1) according to claim 1, wherein said
at least one reinforcing section bar (7, 8) is coated at least in
part with a fire resistant film obtained from a paint selected from
the group comprising intumescent paints and antifire paints.
20. A construction element (1) according to claim 1, further
comprising a covering element (11, 29, 32) associated to said face
(9, 10) of the first lateral portion (7b, 8b) of said at least one
reinforcing section bar (7, 8).
21. A construction element (1) according to claim 1, further
comprising a covering element (12, 30, 33) associated to the second
face (2b) of said opposite faces (2a, 2b) of the elongated body (2)
made of expanded plastic material or to said face (13, 14) of the
second lateral portion (7c, 8c) of said at least one reinforcing
section bar (7, 8).
22. A construction element (1) according to claim 14, further
comprising a covering element associated to said face (9, 10, 13,
14) of the lateral portions (7b, 8b, 7c, 8c) of said reinforcing
section bars (7, 8) protruding from the opposite faces (2a, 2b) of
the elongated body (2) made of expanded plastic material.
23. A construction element (1) according to claim 20, wherein said
covering element comprises a lath (32, 33) and at least one layer
(36, 37) of a suitable covering material supported by said lath
(32, 33).
24. A construction element (1) according to claim 23, wherein said
covering material is plaster or cement optionally incorporating a
material selected from reinforcing fibers of a suitable material
and at least one fire retardant material adapted to impart an
improved fire resistance to said covering material.
25. A construction element (1) according to claim 20, wherein said
covering element comprises a substantially reticular reinforcement
metal structure (20) and at least one concrete layer supported by
said reinforcement structure (20).
26. A construction element (1) according to claim 20, wherein said
covering element comprises a rigid panel (11, 12, 29, 30).
27. A construction element (1) according to claim 26, wherein said
rigid panel (11, 12, 29, 30) is a panel of plasterboard, wood,
rigid plastic material or other suitable material optionally
incorporating at least one fire retardant material adapted to
impart an improved fire resistance to said rigid panel (11, 12, 29,
30).
28. A construction element (1) according to claim 27, wherein said
rigid panel (11, 12, 29, 30) is coated at least in part with a fire
resistant film obtained from a paint selected from the group
comprising intumescent paints and antifire paints.
29. A construction element (1) according to claim 1, wherein said
at least one reinforcing section bar (7, 8) is longitudinally
extending in said at least one elongated body (2) made of expanded
plastic material along substantially the entire length thereof.
30. A construction element (1) according to claim 2 further
comprising a filling material interposed between said covering
element and said elongated body (2) made of expanded plastic
material.
31. A construction element (1) according to claim 30, wherein said
filling material incorporates at least one fire retardant material
adapted to impart an improved fire resistance to said covering
material.
32. A method for manufacturing a construction element (1) according
to claim 1, comprising the steps of: a) providing at least one
sheet made of a rigid material having predetermined thickness and
width, said at least one sheet having a central portion and a pair
of lateral portions extending at opposite parts of said central
portion; b) bending said at least one sheet along at least one
longitudinal bending line so as to form at least one reinforcing
section bar (7, 8) comprising a first lateral portion (7b, 8b)
provided with a face (9, 10) extending substantially perpendicular
to the central portion; c) arranging said at least one reinforcing
section bar (7, 8) thus obtained in a molding seat of a suitable
equipment for molding plastics; d) feeding expandable plastics
granules into said molding seat; e) expanding and then bonding
together the plastics granules in said molding seat, so as to form
an elongated body (2) made of expanded plastic material provided
with opposite faces (2a, 2b) and incorporating at least partly said
at least one reinforcing section bar (7, 8); said step e) being
carried out so that the face (9, 10) of said at least one first
lateral portion (7b, 8b) of said at least one reinforcing section
bar (7, 8) protrudes from a first face (2a) of said opposite faces
(2a, 2b) of the elongated body (2) made of expanded plastic
material and extends substantially parallel to said first face (2a)
at a predetermined distance therefrom.
33. A method according to claim 32, wherein said bending step b) is
carried out so as to bend said at least one sheet along at least
two longitudinal bending lines so as to form at least one
reinforcing section bar (7, 8) further comprising a second lateral
portion (7c, 8c) provided with a respective face (13, 14) extending
substantially perpendicular to the central portion of said at least
one sheet.
34. A method according to claim 33, wherein said bending step b) is
carried out by bending said at least one sheet along at least two
longitudinal bending lines substantially parallel to one another so
as to form a pair of first (7b, 8b) and second (7c, 8c) lateral
portions provided with respective faces (9, 10; 13, 14) extending
at opposite parts with respect to the central portion of said at
least one sheet.
35. A method according to claim 33, wherein the faces (9, 10; 13,
14) of said first (7b, 8b) and of said second lateral portion (7c,
8c) of said at least one reinforcing section bar (7, 8) are both
extending above or both below the lying plane of the sheet.
36. A method according to claim 33, wherein said step e) is carried
out so that the face (13, 14) of said second lateral portion (7c,
8c) of the reinforcing section bar (7, 8) is incorporated in the
expanded plastic material and is extending flush with and
substantially parallel to the second face (2b) of said elongated
body (2) made of expanded plastic material.
37. A method according to claim 33, wherein said step e) is carried
out so that said second lateral portion (7c, 8c) of said at least
one reinforcing section bar (7, 8) protrudes from said second face
(2b) of the elongated body (2) made of expanded plastic material
and wherein said face (13, 14) of said second lateral portion (7c,
8c) is extending substantially parallel to the second face (2b) of
the elongated body (2) made of expanded plastic material at a
predetermined distance therefrom.
38. A method according to claim 32, further comprising the step of
forming a plurality of openings (15) in the central portion of the
sheet.
39. A method according to claim 32, further comprising the step of
providing a fire resistant film on at least a portion of said at
least one sheet.
40. A method according to claim 39, wherein said film is provided
by means of the steps of: a) applying a paint selected from the
group comprising intumescent paints and antifire paints on at least
a portion of said at least one sheet and b) drying said paint.
41. A floor structure (18) comprising at least one construction
element (1) according to claim 1.
42. A wall structure (28) comprising at least one construction
element (1) according to claim 1.
Description
BACKGROUND OF THE INVENTION
[0001] In one general aspect thereof, the present invention relates
to a composite construction element, which has a preferred but
non-exclusive use in the manufacture of floor structures or
vertical or horizontal wall structures for living units,
warehouses, and buildings in general, as well as in the manufacture
of external or partition walls of bodies for trucks or similar
containment structures.
[0002] In the following description and in the appended claims, the
expression: composite construction element, is used to indicate an
element comprising an elongated body made of expanded plastic
material, for example expanded polystyrene, and at least one
reinforcing section bar at least partially incorporated in the
elongated body itself.
[0003] In the following description and in the appended claims, the
expression: floor, is used to indicate both a horizontal structure
adapted to support the floor of each storey of a building
(including the floor directly above the ground), and a horizontal
or slanting covering structure adapted to close at the top the last
storey of the building itself.
PRIOR ART
[0004] In the manufacture of construction elements for
manufacturing walls, floor structures or containment structures in
general, and in particular in the building field, it has long
become widespread the use of construction elements made of expanded
plastic material, preferably expanded polystyrene, in the form of
slabs or section bars of suitable shape and size and having the
function of heat and sound insulating material.
[0005] Within the framework of several applications in the building
industry and in order to impart suitable self-supporting
characteristics to such construction elements, the use has become
widespread of incorporating one or more suitably shaped reinforcing
section bars in the mass of expanded plastic material.
[0006] In the following description and in the appended claims, the
term: "self-support", is used to indicate the ability of the
construction element to withstand without structural yielding all
the stresses applied thereon during its transportation and/or
installation.
[0007] Thus, for example, European Patent EP 0 459 924 discloses a
self-supporting construction element of made of expanded plastic
material, in particular a floor element, comprising a central body,
substantially parallelepipedic, inside which a reinforcing section
bar constituted by an I-shaped thin sheet is integrated during the
forming operations.
[0008] While the construction elements of the type indicated above
exhibit characteristics of light weight, comparative ease of
installation and low cost, the Applicant has found that the
mechanical characteristics that they possess are not always
adequate for the various requirements which occur in practice.
[0009] The construction elements of known type, in fact, are not
capable of providing mechanical characteristics other than a simple
"self-support" despite the presence of one or more reinforcing
section bars, generally made of a metal material, incorporated in
the expanded plastic material.
SUMMARY OF THE INVENTION
[0010] The object of the present invention therefore is that of
providing a composite construction element which is provided on the
one side with improved self-supporting characteristics, that is an
improved ability to withstand the stresses applied thereon during
its installation, and on the other side, provided with improved
supporting characteristics of covering elements externally
associated to the construction element itself.
[0011] According to a first aspect thereof, the invention therefore
relates to a composite construction element comprising:
[0012] a) at least one elongated body made of expanded plastic
material provided with opposite faces;
[0013] b) at least one reinforcing section bar longitudinally
extending in said at least one elongated body and having a first
lateral portion protruding from a first face of said opposite faces
of the elongated body.
[0014] wherein said first lateral portion is provided with a face
extending substantially parallel to said first face of said at
least one elongated body made of expanded plastic material at a
predetermined distance therefrom.
[0015] In particular, the Applicant has perceived that the desired
improved characteristics of load-bearing and of mechanical
resistance of a composite construction element of the type
indicated above can be achieved by partially incorporating in the
elongated body made of expanded plastic material the reinforcing
section bar(s) longitudinally extending in the latter, so as to
have a first lateral portion protruding from one of the opposite
faces of the elongated body.
[0016] In this way, the reinforcing section bar(s) advantageously
carry(ies) out--thanks to the protruding lateral portion
thereof--the function of providing a face on which it is possible
to apply mechanical stresses greater than those which can be
withstood by the elongated body made of expanded plastic
material.
[0017] The composite construction elements of the invention
therefore are capable of autonomously withstanding any static loads
applied on the protruding lateral portion of the reinforcing
section bars.
[0018] At the same time, the expanded plastic material of the
elongated body carries out the advantageous function of stiffening
and of firmly holding in position the reinforcing section bar(s),
preventing any deformation of the same as a consequence of the
stresses imparted thereon.
[0019] The Applicant has further perceived that it is possible to
achieve at the same time an improved supporting action of covering
elements external to the composite construction element by
providing in the protruding lateral portion of the reinforcing
section bar(s) the aforementioned face, preferably substantially
planar, extending substantially parallel to at least one face of
the elongated body made of expanded plastic material at a
predetermined distance therefrom.
[0020] In this way, the construction element of the invention is
advantageously provided with an element having a mechanical
resistance (the face of the reinforcing section bar(s)) extending
at a predetermined distance from the elongated body made of
expanded plastic material and capable of supporting a variety of
external covering elements, such as for example reinforcement metal
structures, rigid panels having ornamental or structural function
or one or more layers of covering material by means of an
interposed supporting lath.
[0021] In a particularly preferred embodiment, the first lateral
portion of the reinforcing section bar(s) protruding from the first
face of the elongated body made of expanded plastic material is
provided with a substantially planar face, so as to obtain a more
effective supporting action of the loads applied thereon, and to
have a suitably wide surface for fastening an external covering
element.
[0022] In a preferred embodiment, the aforementioned at least one
reinforcing section bar of the construction element is provided
with a second lateral portion provided with a face extending
substantially parallel to the second face of said opposite faces of
the elongated body made of expanded plastic material.
[0023] Preferably, this second lateral portion of the reinforcing
section bar(s) can be either entirely incorporated in the expanded
plastic material, or it can protrude therefrom so that the
aforementioned face is extending substantially parallel to the
second face of the elongated body made of expanded plastic material
at a predetermined distance therefrom.
[0024] In this way, the construction element is advantageously
capable of withstanding a second external covering
element--identical or different from that used for the first face
of the elongated body made of expanded plastic material--at or at a
predetermined distance from, the second face of said elongated body
so as to easily meet the most varied requirements of surface
finishing.
[0025] Also in this case, the second lateral portion of the
reinforcing section bar(s) protruding from the second face of the
elongated body made of expanded plastic material is provided with a
preferably substantially planar face, so as to obtain a more
effective supporting action of the loads applied thereon, and to
have a suitably wide surface for fastening an external covering
element.
[0026] Depending upon the selected covering element, having or not
structural features, the construction elements of the invention may
also achieve further improved load bearing characteristics.
[0027] Preferably, the reinforcing section bar is constituted by
any material having suitable structural characteristics and
compatible with the expanded plastic material, for example
cold-rolled and preferably galvanized steel, rigid plastic
materials such as PVC, polyester polymers, polycarbonate,
acrylonitrile-butadiene-styrene (ABS) copolymers and the like.
[0028] According to a preferred embodiment of the invention, the
reinforcing section bar is transversely extending in the central
body of the construction element along substantially the entire
thickness thereof.
[0029] Preferably, the reinforcing section bar is further
longitudinally extending in the central body of the construction
element along substantially the entire length thereof.
[0030] For obvious reasons of construction simplicity and in order
to limit the production costs, the reinforcing section bar is
preferably shaped as an L, a C, a Z or an I, for example by placing
two C-shaped elements side by side matching the respective central
portions.
[0031] Additional preferred features of the composite construction
element of the invention are indicated in the dependent claims
4-31, the content of which is herein integrally incorporated by
reference.
[0032] According to a second aspect thereof, the invention relates
to a method for manufacturing a composite construction element of
the type indicated above as defined in the attached claim 32.
[0033] Advantageously, such a method can be carried out with
shearing, profiling and molding equipment conventional per se and
known in the art.
[0034] Additional preferred features of the method of the invention
are indicated in the dependent claims 33-40, the content of which
is herein integrally incorporated by reference.
[0035] According to a third aspect thereof, the invention also
relates to a floor structure for buildings comprising at last one
composite construction element of the type illustrated in the
present description and, more preferably, comprising a plurality of
said construction elements arranged side by side.
[0036] According to a fourth aspect thereof, the invention also
relates to a wall structure for buildings comprising at least one
composite construction element of the type illustrated in the
present description and, more preferably, comprising a plurality of
said construction elements arranged side by side.
BRIEF DESCRIPTION OF THE DRAWINGS
[0037] Additional features and advantages of the invention will
become more readily apparent from the description of some preferred
embodiments of a composite construction element, of a floor
structure and of a wall structure according to the invention, made
hereinafter by way of a non-limiting example with reference to the
annexed drawings.
[0038] In the drawings:
[0039] FIG. 1 shows a perspective view of a first embodiment of a
composite construction element according to the invention;
[0040] FIG. 2 shows a perspective view, in enlarged scale, of some
details of a second embodiment of the composite construction
element of the invention;
[0041] FIG. 3 shows a perspective view, in enlarged scale, of an
alternative preferred embodiment of the reinforcing section bar
extending in the composite construction element of the
invention;
[0042] FIG. 4 shows a perspective view, in enlarged scale, of a
further preferred embodiment of the reinforcing section bar
extending in the composite construction element of the
invention;
[0043] FIG. 5 shows a perspective view, in partial cross-section,
of a portion of a floor structure obtainable by placing a plurality
of composite construction elements of the invention side by
side;
[0044] FIG. 6 shows a perspective view, in enlarged scale and in
partial cross-section, of an alternative preferred embodiment of a
floor structure obtainable by placing a plurality of composite
construction elements of the invention side by side;
[0045] FIG. 7 shows a perspective view, in enlarged scale, of some
details of the floor structure of FIG. 6;
[0046] FIGS. 8-10 show perspective views of some details of
alternative preferred embodiments of the composite construction
element of the invention;
[0047] FIG. 11 shows a perspective view, in enlarged scale, of an
alternative preferred embodiment of the reinforcing section bar
extending in the composite construction element of the
invention;
[0048] FIGS. 12-13 show perspective views of a portion of a wall
structure obtainable by placing a plurality of composite
construction elements of the invention side by side.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0049] With reference to FIGS. 1-13, a composite construction
element made of expanded plastic material, for example expanded
polystyrene, according to a first preferred embodiment of the
present invention, is generally indicated at 1.
[0050] The construction element 1 of the illustrated example, can
be usefully employed for manufacturing load-bearing and partition
walls or for manufacturing floor structures of a building.
[0051] Alternatively, the construction element 1 of the illustrated
example can also be usefully employed for manufacturing bodies for
trucks or similar structures.
[0052] The composite construction element 1 comprises an elongated
body 2 made of expanded plastic material, preferably substantially
parallelepipedic in shape, provided with opposite faces, both
preferably substantially planar, respectively indicated at 2a and
2b.
[0053] While in the illustrated example the faces 2a, 2b are
substantially planar, it should be understood that their shape is
not critical for the purposes of the invention; such a shape, in
fact, can assume any other geometrical configuration useful for the
intended purpose.
[0054] Preferably, the elongated body 2 has the following
dimensions, determined at the design stage: a thickness comprised
between about 40 and about 120 mm and, more preferably, comprised
between about 60 and about 80 mm, a width comprised between about
500 and about 1200 mm and, more preferably, comprised between about
600 and about 1000 mm and a length greater than about 500 mm, the
maximum length being determined by the design specifications at
values substantially selectable as desired.
[0055] By way of a non-limiting example, the length of the
elongated body 2 can be equal to about 13000 mm.
[0056] Within the framework of the present description and in the
following claims, except where otherwise indicated, all numbers
expressing amounts, quantities, percentages, and so forth, are to
be understood as being modified in all instances by the term
"about". Also, all ranges include any combination of the maximum
and minimum points disclosed and include any intermediate ranges
therein, which may or may not be specifically enumerated
herein.
[0057] In a way known per se, the body 2 is also laterally provided
with opposite sides 3, 4 respectively provided with a groove 5 and,
respectively, with a rib 6, preferably having a mating shape,
longitudinally extending along the entire length of the
construction element 1.
[0058] In this way, a plurality of construction elements 1 arranged
side by side can be firmly connected to one another by means of a
substantially joint-wise coupling. The composite construction
element 1 further comprises at least one reinforcing section bar,
preferably at least two reinforcing section bars 7, 8, preferably
substantially identical to each other, longitudinally extending in
the elongated body 2 and parallel to one another.
[0059] In the preferred embodiment illustrated, the reinforcing
section bars 7, 8 are longitudinally extending in the elongated
body 2 of the composite construction element 1 along substantially
the entire length thereof.
[0060] Preferably, the reinforcing section bars 7, 8 are
longitudinally extending in the elongated body 2 made of expanded
plastic material at opposite parts of the longitudinal center plane
of said body along a direction substantially parallel to said
center plane.
[0061] Still more preferably, the reinforcing section bars 7, 8 are
symmetrically arranged in the elongated body 2 with respect to said
longitudinal center plane thereof.
[0062] Thanks to this arrangement of the reinforcing section bars
7, 8, it is advantageously possible to achieve balanced and
symmetrical reinforcement characteristics of the elongated body at
opposite parts of the longitudinal center plane thereof.
[0063] Preferably, the reinforcing section bars 7, 8 are made of a
material having suitable structural characteristics, such as for
example cold-rolled and preferably galvanized steel, shaped in a
suitable manner.
[0064] In a preferred embodiment, the reinforcing section bars 7, 8
are coated at least in part and, still more preferably, entirely
coated with a fire resistant film, for example obtained from a
paint selected from the group comprising intumescent paints and
antifire paints.
[0065] The composite construction element 1 of the invention is in
this case advantageously capable of achieving suitable
characteristics of fire resistance in case of fire thanks to the
presence of the aforementioned film.
[0066] By way of example, the reinforcing section bars 7, 8 can be
obtained from a sheet having a width comprised between about 100 mm
and about 300 mm and, still more preferably, comprised between
about 120 mm and about 250 mm and a thickness preferably comprised
between about 0.4 mm and about 1.2 mm and still more preferably,
comprised between about 0.5 mm and about 0.8 mm.
[0067] The reinforcing section bars 7, 8 are provided with a
central body 7a, 8a, with a first lateral portion 7b, 8b protruding
from the face 2a of the elongated body 2 made of expanded plastic
material and with a second lateral portion 7c, 8c essentially
incorporated in the elongated body 2.
[0068] The first lateral portions 7b, 8b of the reinforcing section
bars 7, 8 are provided with respective faces 9, 10, preferably
substantially planar, extending substantially parallel to the face
2a of the elongated body 2 made of expanded plastic material at a
predetermined distance therefrom.
[0069] Advantageously, the faces 9, 10 define a surface for
supporting a finishing element, for example a rigid panel of
plasterboard, wood, rigid plastic material or other suitable
material indicated at 11 in FIG. 1, or for supporting a
substantially reticular metal structure for reinforcing a concrete
casting, as illustrated in more detail hereinafter.
[0070] The rigid panel 11 can be fastened to the faces 9, 10 in a
way known per se, for example by means of screws known per se and
not shown.
[0071] In a preferred embodiment, the rigid panel 11 can
incorporate at least one suitable fire retardant material,
preferably in powder, granules or fibers, adapted to impart an
improved fire resistance to the panel itself and, consequently, to
the composite construction element 1 which includes the same.
[0072] Preferably, such a fire retardant material is selected from
mineral fibers, such as fiber glass, mineral wool, inert materials
such as perlite, glass spheres, expanded clay granules or other
materials suitable for the purpose and known to those skilled in
the art.
[0073] In an alternative preferred embodiment, the rigid panel 11
can be coated at least in part with a fire resistant film, for
example obtained from a paint selected from the group comprising
intumescent paints and antifire paints.
[0074] Preferably, the distance between the upper faces 9, 10 of
the first lateral portions 7b, 8b of the reinforcing section bars
7, 8 and the face 2a of the elongated body 2 made of expanded
plastic material is comprised between about 10 mm and about 60 mm
and, still more preferably, is comprised between about 20 mm and
about 40 mm.
[0075] The reinforcing section bars 7 and 8 therefore carry out the
following advantageous functions: [0076] they impart adequate
load-bearing characteristics to the composite construction element
1; [0077] they support a covering element of the elongated body 2
made of expanded plastic material at a predetermined distance from
its face 2a creating a gap that can be either left substantially
empty or filled with a suitable filling material optionally
incorporating at least one fire retardant material adapted to
impart an improved fire resistance to said material. In the first
case, the composite construction element 1 exhibits improved sound
insulation characteristics (thanks to the presence of air in the
gap) and advantageously allows to house hydraulic pipes or
electrical raceways, whereas in the second case the composite
construction element 1 can exhibit improved characteristics of heat
insulation, of finishing, of mechanical resistance or of fire
resistance depending upon the type of material arranged between the
covering element and the face 2a of the elongated body 2; [0078]
they impart improved characteristics of fire resistance to the
composite construction element 1 if they are partly or entirely
coated with a fire resistant film, for example obtained from a
paint selected from the group comprising intumescent paints and
antifire paints.
[0079] Preferably, the first lateral portion 7b, 8b of the
reinforcing section bars 7, 8 is substantially hook-shaped and has
in this preferred embodiment a substantially C-shaped end
portion.
[0080] In this case, the aforementioned end portion constitutes a
substantially box-shaped structure the back of which defines the
aforementioned upper faces 9, 10 intended in this case to support
the rigid panel 11.
[0081] Preferably, the central portion 7a, 8a of the reinforcing
section bars 7, 8 has a height comprised between about 60 mm and
about 320 mm.
[0082] In the preferred embodiment illustrated in FIG. 1, the
second lateral portion 7c, 8c of the reinforcing section bars 7, 8
is for example constituted by a fin projecting in a cantilevered
fashion from the central portion 7a, 8a of the reinforcing section
bars.
[0083] The fins 7c, 8c of the reinforcing section bars 7, 8 carry
out the function of providing a suitable supporting surface which
an additional suitable covering element of the face 2b of the
composite construction element 1 can be fastened to, such as for
example a second rigid panel of plasterboard, wood, rigid plastic
material, or other suitable material indicated at 12 in FIG. 1 or,
alternatively, a stretched lath for supporting at least one
covering layer (not shown in such figure).
[0084] The rigid panel 12 can be fastened to the fins 7c, 8c in a
way known per se, for example by means of screws known per se and
not shown.
[0085] In this case, the construction element 1 of the invention is
capable of achieving advantageous load-bearing characteristics,
i.e. it is capable of autonomously withstanding any static loads
applied thereon.
[0086] Also in this case, it is possible to impart improved
characteristics of fire resistance to the composite construction
element 1 by using a rigid panel 12 incorporating at least one fire
retardant material adapted to impart an improved fire resistance to
the panel itself or by coating at least in part the rigid panel 12
with a fire resistant film for example obtained from a paint
selected from the group comprising intumescent paints and antifire
paints.
[0087] If the covering element of the face 2b of the composite
construction element 1 is constituted by a covering layer supported
by a stretched lath, such advantageous characteristics can be
achieved by incorporating in the material used for forming the
layer (for example plaster or cement) at least one suitable fire
retardant material, for example one of the materials indicated
hereinbefore, adapted to impart improved fire resistance
properties.
[0088] In the preferred embodiment illustrated in FIG. 1, the fins
7c, 8c of the reinforcing section bars 7, 8 are provided with an
initial portion extending flush with and substantially parallel to
the face 2b of the elongated body 2 and with an end portion forming
with respect to the aforementioned initial portion an angle
comprised between 40.degree. and 120.degree. and, still more
preferably, equal to about 90.degree..
[0089] Preferably, the initial portion of the fins 7c, 8c of the
reinforcing section bars 7, 8 is provided with a face 13, 14
preferably substantially planar.
[0090] Preferably, furthermore, such initial portion of the fins
7c, 8c of the reinforcing section bars 7, 8 has a length comprised
between about 15 mm and about 40 mm and, still more preferably,
comprised between about 20 mm and about 30 mm.
[0091] Advantageously, such initial portion carries out the
function of providing a suitable supporting surface which a
covering element can be fastened to, for example the aforementioned
rigid panel 12 or a lath for supporting at least one covering
layer, for example of plaster, whereas the end portion increases
the reinforcing action carried out by the reinforcing section bars
7, 8 under bending loads.
[0092] Tests carried out by the Applicant, furthermore, have shown
that such a configuration of the fins 7c, 8c contributes to further
stiffen the reinforcing section bars 7, 8, thus further increasing
the self-supporting and compression resistance characteristics of
the composite construction element 1.
[0093] In this preferred embodiment, the substantially planar faces
9, 10 of the first lateral portion 7b, 8b and the substantially
planar faces 13, 14 of the fins (second lateral portions) 7c, 8c of
the reinforcing section bars 7, 8 are both substantially
perpendicular to the central portion 7a, 8a of the latter.
[0094] In this preferred embodiment, furthermore, the reinforcing
section bars 7, 8 of the aforementioned pair are preferably spaced
apart from one another by a predetermined distance, so as to
suitably distribute the reinforcing section bars 7, 8 in the
elongated body 2, achieving in this way some advantageous technical
effects: possibility of homogeneously distributing the reinforcing
action exerted by them; possibility of homogeneously distributing
the loads applied to the reinforcing section bars 7, 8 and finally,
possibility of arranging in a known and reproducible manner the
fins 7c, 8c of the reinforcing section bars 7, 8 so as to know
their position even when such fins are completely embedded in the
mass of expanded plastic material and as such, are not visible from
the outside.
[0095] In the preferred embodiment illustrated in FIG. 1, the
reinforcing section bars 7, 8 are arranged in the elongated body 2
at a predetermined distance from one another; preferably, the
distance d between the centre line of the fins 7c, 8c--measured
along a direction substantially perpendicular to the longitudinal
axis of the elongated body 2--is equal to about 300 mm.
[0096] From the preceding description, the features and the
technical effects that can be achieved by the composite
construction element 1 of the invention are immediately clear.
[0097] Firstly, the composite construction element 1 is provided
with improved load-bearing characteristics thanks to the presence
of the first protruding lateral portions 7b, 8b of the reinforcing
section bars 7, 8, both provided with faces 9, 10 preferably
substantially planar on which it is possible to apply mechanical
stresses greater than those that can be withstood by the elongated
body 2 made of expanded plastic material.
[0098] Secondly, the expanded plastic material of the elongated
body 2 carries out the advantageous function of stiffening and
firmly holding in position the reinforcing section bars 7, 8,
preventing that the same could be deformed as a consequence of the
stresses imparted thereon.
[0099] Thirdly, the composite construction element 1 allows to
easily support external covering elements thanks both to the
substantially planar faces 9, 10 extending substantially parallel
to the face 2a of the elongated body 2 made of expanded plastic
material at a predetermined distance therefrom, and to the fins 7c,
8c extending flush with the face 2b of the elongated body 2 made of
expanded plastic material.
[0100] Fourthly, the composite construction element 1 allows to
achieve improved characteristics of fire resistance thanks to the
partial or total coating of the reinforcing section bars 7, 8 with
a fire resistant film for example obtained from a paint selected
from the group comprising intumescent paints and antifire paints
and/or thanks to the use of a covering element incorporating at
least one fire retardant material adapted to impart an improved
fire resistance, or of a covering element at least partially coated
with a fire resistant film.
[0101] FIGS. 2-13 schematically illustrate additional embodiments
of the composite construction element 1 according to the present
invention. These additional embodiments essentially achieve both
the technical effects and the advantages of the preferred
embodiment illustrated above and the further technical effects and
advantages described hereinafter.
[0102] In the following description and in such figures, the
components of the construction element 1 structurally or
functionally equivalent to those illustrated with reference to the
previous embodiment shall be indicated with the same reference
numerals and will not be further described.
[0103] According to the embodiment illustrated in FIG. 2, the
reinforcing section bars 7, 8 comprise respective second lateral
portions 7c, 8c substantially fin-shaped and provided with a
substantially planar face 13, 14.
[0104] The fins 7c, 8c are in this case entirely incorporated in
the elongated body 2 made of expanded plastic material and are
arranged at a predetermined distance from the face 2b of such
elongated body 2.
[0105] Preferably, the fins 7c, 8c are arranged at a distance d'
preferably comprised between about 5 mm and about 15 mm from the
face 2b of the elongated body 2.
[0106] In this way, it is possible to fasten suitable covering
elements of the face 2b of the elongated body 2 of the composite
construction element 1--for example the aforementioned panel 12
made of plasterboard--to the fins 7c, 8c of the reinforcing section
bars 7, 8 by using fastening elements (not shown) of limited
length.
[0107] Since the fins 7c, 8c of the reinforcing section bars 7, 8
are not visible from the outside, in order to fasten the covering
elements it is necessary in this case to know in advance the
position of such fins inside the mass of expanded plastic material
with respect to a reference element, such as for example with
respect to the sides 3, 4 or with respect to the longitudinal
center plane of the elongated body 2 made of expanded plastic
material.
[0108] With reference to FIGS. 3 and 4, some additional preferred
embodiments of the reinforcing section bars 7, 8 will now be
illustrated.
[0109] According to the embodiment illustrated in FIG. 3, the
reinforcing section bars 7, 8 of the composite construction
elements 1 (of which only the reinforcing section bar 7 is shown in
FIG. 3 for simplicity) are provided with respective first portions
7b, 8b substantially similar to those of the embodiment illustrated
with reference to FIGS. 1 and 2.
[0110] In this case, the reinforcing section bars 7, 8 of the
composite construction elements 1 are advantageously provided with
a plurality of openings 15, preferably of circular shape, formed in
the central portion 7a, 8a thereof comprised between the
aforementioned first and second lateral portions 7b, 8b and 7c,
8c.
[0111] The openings 15 carry out the dual advantageous function of
lightening the reinforcing section bars 7, 8 and of allowing an
even more intimate integration thereof in the mass of expanded
plastic material.
[0112] Thanks to the presence of the openings 15, in fact, the mass
of expanded plastic material is capable of interpenetrating with
the reinforcing section bars 7, 8 during the molding operation,
integrating and firmly holding in place the reinforcing section
bars 7, 8 within the elongated body 2 of the composite construction
element 1.
[0113] This intimate integration of the reinforcing section bars 7,
8 in the mass of expanded plastic material, furthermore, prevents
any deformation or bending along the transversal direction of the
reinforcing section bars 7, 8 even though they are essentially
constituted by a fairly thin metal sheet.
[0114] Preferably, the openings 15 have a total area comprised
between about 5% and about 50% of the total area of each
reinforcing section bar 7, 8, where the expression: total area of
each reinforcing section bar, is used to indicate the area of the
overall surface of the section bar including that of the opposite
lateral portions 7b, 7c and 8b, 8c (that is, the area of the total
lateral surface before forming such portions and the openings
15).
[0115] Still more preferably, the openings 15 formed in the central
portion 7a, 8a of the reinforcing section bars 7, 8 have a total
area comprised between about 20% and about 30% of the total area
thereof.
[0116] The openings 15 have a diameter preferably comprised between
about 15 mm and about 100 mm and, more preferably, comprised
between about 40 mm and about 70 mm.
[0117] In a preferred embodiment, the openings 15 are pitchwise
arranged in the central portion 7a, 8a of the reinforcing section
bars 7, 8 along the center plane of the section bars
themselves.
[0118] Preferably, the pitch of the openings 15 is comprised
between about 50 and about 100 mm and, still more preferably, is
equal to about 75 mm.
[0119] According to the embodiment illustrated in FIG. 4, the
reinforcing section bars 7, 8 of the composite construction
elements 1 (of which only the reinforcing section bar 7 is shown in
FIG. 4 for simplicity) are provided with openings 15 entirely
similar to those of the reinforcing section bars of FIG. 3 and with
a first substantially hook-shaped lateral portion 7b, 8b having a
shape substantially resembling an upturned U.
[0120] Thanks to this feature, the first lateral portion 7b, 8b of
the reinforcing section bars 7, 8--preferably essentially
constituted by a fairly thin sheet--substantially acts as a spring
whenever it engages suitably grooved covering elements connectable
in a snap-wise fashion in such first lateral portion 7b, 8b.
[0121] Preferably, such first lateral portion of the reinforcing
section bars 7, 8 is provided in this case with lateral portions,
indicated at 16 and 17, which are substantially tapered so as to
increase the spring effect achieved by this substantially hook-wise
configuration.
[0122] With reference to FIG. 5, a floor structure 18 that can be
manufactured by means of a plurality of composite construction
elements 1 according to the invention, for example each
incorporating a pair of reinforcing section bars 7, 8 according to
the embodiment of FIG. 4, will now be described.
[0123] According to this embodiment, the floor structure 18 is
especially suitable for constructing the so-called "wide span"
floors.
[0124] The floor structure 18 comprises a plurality of composite
construction elements 1 arranged side by side, a plurality of floor
elements 19 made of expanded plastic material supported by the
composite construction elements 1 and a substantially reticular
metal structure 20 for reinforcing a concrete casting,
schematically indicated at 21 in FIG. 5, arranged between the floor
elements 19.
[0125] In the following description and in the appended claims, the
expression: substantially reticular metal structure, is used to
indicate a reinforcement metal structure comprising a plurality of
longitudinal reinforcing elements and a plurality of transversal
reinforcing elements of the casting crossed with one another so as
to form a grid extending substantially along the entire extension
of the floor structure to be manufactured.
[0126] The latter is defined in the field as a floor structure
provided with "crossed reinforcement rods" and allows to
manufacture floors having a length greater than those that can be
achieved by floor structures having the same thickness but riot
provided with substantially reticular reinforcement metal
structures.
[0127] Advantageously, the composite construction elements 1 are
laying at the opposite ends thereof on respective supporting
structures of a building (not shown), such as for example beams
and/or load-bearing walls.
[0128] In this way, the composite construction elements 1 form in
this case as many supporting elements adapted to define a base of
the floor structure 18 adapted to support the floor elements 19 and
the reinforcement metal structure 20 and adapted to receive the
concrete casting 21.
[0129] In this embodiment, the reinforcing section bars 7, 8 of the
composite construction elements 1 carry out the following
advantageous functions: [0130] they impart suitable self-supporting
characteristics to the composite construction elements 1; [0131]
they support the floor elements 19 and firmly hold the same in
place; [0132] they support the reinforcement metal structure 20 of
the casting at a predetermined distance from the upper face 2a of
the elongated body 2 of the composite construction elements 1;
[0133] they impart improved characteristics of fire resistance to
the composite construction elements 1 whenever they are partially
or entirely coated with a fire resistant film, for example obtained
from a paint selected from the group comprising intumescent paints
and antifire paints.
[0134] Since the reinforcement metal structure 20 of the casting is
supported at a predetermined distance from the upper face 2a of the
elongated body 2 of the composite construction elements 1, it is
advantageously ensured in a simple and effective manner that the
concrete casting 21 can easily fill the spaces below the
reinforcement metal structure 20 as required by the building
regulations currently in force.
[0135] Advantageously, furthermore, the first lateral portions 7b,
8b of the reinforcing section bars 7, 8--preferably essentially
constituted by a fairly thin metal sheet--substantially act as
springs upon their engagement with the floor elements 19.
[0136] In the preferred embodiment of the floor structure 18
illustrated in FIG. 5, the reinforcement metal structure 20 can be
advantageously firmly associated to the reinforcing section bars 7,
8 by means of a plurality of staples 38 having a central body 38a
substantially shaped as an upturned U and having opposite free ends
38b, 38c projecting in a cantilevered fashion from the central body
38a and adapted to engage the lateral portions 7b, 8b of the
reinforcing section bars 7, 8.
[0137] Preferably, the staples 38 are constituted by a wire of a
suitable structural material, for example metal, so as to
constitute substantially spring-wise connecting means thanks to the
elasticity of the material.
[0138] Thanks to the ensuing stable association of the reinforcing
section bars 7, 8 to the reinforcement metal structure 20, the
composite construction element 1 advantageously allows to achieve
improved characteristics of fire resistance, since the covering
elements, in this case the rigid panels 12 associated to the face
2b of the elongated body 2, are firmly held by the reinforcement
metal structure 20 embedded in the concrete casting 21 by means of
the reinforcing section bars 7, 8.
[0139] In case of fire, therefore, the rigid panels 12 do not
detach from the composite construction element 1 even in the
presence of a complete collapse of the elongated body 2 made of
expanded plastic material.
[0140] Advantageously, furthermore, the characteristics of fire
resistance of the floor structure 18 can be further improved if the
rigid panels 12 incorporate at least one fire retardant material
adapted to impart an improved fire resistance or are coated at
least in part with a fire resistant film.
[0141] Preferably, the floor elements 19 made of expanded plastic
material supported by the composite construction elements 1 are
arranged at a predetermined distance from one another along the
floor structure 18--both along a longitudinal and along a
transversal direction--so as to define a plurality of transversal
channels 22 and a plurality of longitudinal channels 23 adapted to
house the concrete casting 21.
[0142] In this preferred embodiment, the floor elements 19 are
arranged astride of the composite construction elements 1.
[0143] Thanks to this arrangement, it is advantageously possible to
increase the characteristics of mechanical resistance of the floor
structure 18 since the stresses imparted to the structure by the
concrete casting 21 do not concern the projecting portions of the
elongated bodies 2 made of expanded plastic material (the portion
of plastic material extending between the reinforcing section bars
7, 8 and the sides 3, 4 of the elongated bodies 2).
[0144] In the illustrated example, each floor element 19 comprises
a central body 19a substantially parallelepipedic, in which a
plurality of parallel cavities 24 is longitudinally defined.
[0145] Advantageously, the floor elements 19 made of expanded
plastic material can be realized with any desired height, so as to
regulate as desired the thickness of the floor structure 18 and,
therefore, the maximum length of the final floor.
[0146] Preferably, the floor elements 19 have a thickness comprised
between about 160 mm and about 500 mm and, still more preferably,
comprised between about 180 mm and about 300 mm.
[0147] Preferably, the floor elements 19 have the following further
dimensions, determined at the design stage: a width comprised
between about 450 and about 500 mm and a length greater than about
300 mm, the maximum length being determined by the design
specifications at values substantially selectable as desired.
[0148] By way of a non-limiting example, the length of the floor
elements 19 can be comprised between 300 mm and 13000 mm.
[0149] Preferably, the floor elements 19 are arranged on the
composite construction elements 1 so as to form a grid of
transversal channels 22 and longitudinal-channels 23 substantially
perpendicular to one another.
[0150] Advantageously, the width of the channels 22 and 23 can be
determined by a man skilled in the art on the basis of the design
specifications. By way of an example only, such a width may be
comprised between about 100 and about 200 mm.
[0151] In this preferred embodiment of the floor structure 18, the
composite construction elements 1 thus constitute as many joists on
which the floor elements 19 rest to form a so-called "panelled"
floor structure.
[0152] Within the framework of this preferred embodiment, the floor
elements 19 are preferably provided at a lower side with at least
one and preferably a pair of longitudinal grooves 25 adapted to
house the first lateral portions 7b, 8b of the reinforcing section
bars 7, 8, so as to have a firm connection between the floor
elements 19 and the composite construction elements 1 of the floor
structure 18.
[0153] Preferably, the longitudinal grooves 25 are configured so as
to have a shape substantially mating the shape of the first lateral
portions 7b, 8b of the reinforcing section bars 7, 8 projecting
from the composite construction elements 1, so as to increase the
stability of the connection between the reinforcing section bars 7,
8 and the floor elements 19.
[0154] Thus, for example, in the preferred embodiment illustrated
in FIG. 5, the longitudinal grooves 25 are substantially
dovetail-shaped with opposite lateral walls tapered in such a way
as to firmly hold in the grooves 25, with a substantially
snap-wise-connection, the first lateral portions 7b, 8b of the
reinforcing section bars 7, 8, having in turn tapered lateral
portions 16, 17 as better illustrated in FIG. 4.
[0155] According to the invention and as described above, the
reinforcement metal structure 20 of the concrete casting 21 is
supported by the first lateral portions 7b, 8b of the reinforcing
section bars 7, 8 at a predetermined distance from the upper face
2a of the elongated body 2 made of expanded plastic material.
[0156] Within the framework of this preferred embodiment, the
reinforcement metal structure 20 of the casting comprises a
plurality of transversal reinforcement elements of the casting 21,
generally indicated at 26, and a plurality of longitudinal
reinforcement elements of the casting, generally indicated at 27,
respectively housed in the aforementioned transversal and
longitudinal channels 22, 23.
[0157] In this way, it is advantageously possible to realize,
within the framework of the aforementioned "panelled" floor
structure, zones of reinforced concrete arranged only where needed
on the basis of the design parameters, with a reduction of the
weight and of the costs for manufacturing the final floor.
[0158] Preferably, the transversal reinforcement elements 26 of the
casting lay on the first lateral portions 7b, 8b of the reinforcing
section bars 7, 8 and in particular, lay on the substantially
planar faces 9, 10 of such first lateral portions 7b, 8b and are
firmly associated to the reinforcing section bars 7, 8 in way
conventional per se, for example by means of the staples 38
described hereinbefore.
[0159] In this preferred embodiment, the longitudinal reinforcement
elements 27 of the casting 21 lay on the transversal reinforcement
elements 26 and are firmly associated to the same in way
conventional per se, for example by means of strings 39 of
conventional type and constituted by the conventional iron wires
used to this end in the art.
[0160] Thanks to the aforementioned supporting configuration of the
transversal and of the longitudinal reinforcement elements 26, 27
of the casting 21 provided by the composite construction elements 1
of the invention, it is advantageously possible to arrange the
lower portion thereof--the portion which is subjected to the
tensile stresses--near the lower portion of the floor structure 18
with an increase of the characteristics of resistance to external
loads of the final floor.
[0161] For the purposes of the invention, the specific shape and
structure of the transversal and of the longitudinal reinforcement
elements 26, 27 of the reinforcement metal structure 20 is not
critical, provided that they supply the necessary amount of metal
according to the design specifications. Thus, for example, the
transversal and the longitudinal reinforcement elements 26, 27 of
the reinforcement metal structure 20 can be constituted by a
plurality of iron rods suitably spaced from one another or they can
be constituted by substantially trestle-shaped structures according
to what is known to a man skilled in the art.
[0162] From the foregoing description, the features and the
technical effects that can be achieved by the floor structure 18 of
the invention are immediately clear.
[0163] Thanks to the structural characteristics of the composite
construction elements 1 and, in particular, to their
self-supporting characteristics and to their ability of supporting
the reinforcement metal structure 20, it is possible in the first
place to minimize the labor required to manufacture the final floor
at the yard.
[0164] The operations required to manufacture the final floor, in
fact, essentially comprise the steps of laying a plurality of
composite construction elements 1 on the load-bearing structures of
the building being erected, of arranging thereon the floor elements
19 and the reinforcement metal structure 20 and then, of casting
the concrete on the floor structure 18 thus assembled.
[0165] Once the floor structure 18 has been assembled, the function
of containing the concrete casting 21 is ensured by the transversal
and by the longitudinal channels 22, 23 defined between the floor
elements 19 and the composite construction elements 1.
[0166] Advantageously, the aforementioned operating steps can be
carried out without using temporary supports for lengths of the
floor structure 18 up to about 2 meters or using a limited number
thereof for greater lengths.
[0167] Advantageously, furthermore, the aforementioned laying step
of the composite construction elements 1 can be readily carried out
with a minimum labor, thanks to the compactness, lightness and
handiness of the elements themselves.
[0168] Finally, the floor structure 18 according to the invention
achieves improved characteristics of fire resistance in case of
fire thanks to one or more of the following features: [0169] to the
fact that the covering elements associated to the face 2b of the
elongated body 2, in this case constituted by the rigid panels 12,
are firmly held by the reinforcement metal structure 20 embedded in
the concrete casting 21 by means of the reinforcing section bars 7,
8; [0170] to the fact that the reinforcing section bars 7, 8 can be
coated at least in part with a fire resistant film; [0171] to the
fact that the covering elements associated to the face 2b of the
elongated body 2 can incorporate at least one fire retardant
material adapted to impart an improved fire resistance or to the
fact that the covering elements can be coated at least in part with
a fire resistant film.
[0172] According to an another preferred embodiment of the floor
structure 18 illustrated in FIGS. 6 and 7, the elongated body 2 of
the composite construction elements 1 is provided with a plurality
of cavities 40 substantially parallel to one another and
longitudinally extending in a central portion of the elongated body
2 between the reinforcing section bars 7, 8.
[0173] Advantageously, the cavities 40 contribute to lighten the
elongated body 2 making the same easier to handle during the
installation.
[0174] The elongated body 2 made of expanded plastic material is
further provided with a plurality of longitudinal ribs 41, 42 made
of expanded plastic material, substantially parallel to one
another, projecting in a cantilevered fashion from the upper face
2a of the elongated body 2 at opposite parts of the longitudinal
center plane thereof.
[0175] In this preferred embodiment, the elongated body 2 made of
expanded plastic material is also provided with a pair of
projections 43, 44 laterally and longitudinally extending at
opposite parts of the longitudinal ribs 41, 42 towards the opposite
sides 3 and 4 of the elongated body 3 in which the groove 5 and,
respectively, the rib 6 are formed.
[0176] Preferably, the longitudinal ribs 41, 42 integrally extend
substantially perpendicularly to the upper face 2a of the elongated
body 3 and are preferably obtained at the molding stage of the
elongated body 2.
[0177] In this preferred embodiment, the reinforcing section bars
7, 8 of the composite construction elements 1 are substantially
Z-shaped and each of them comprises respective first lateral
portions 7b, 8b substantially fin-shaped associated to the
longitudinal ribs 41, 42 made of expanded plastic material
projecting in a cantilevered fashion from the upper face 2a of the
elongated body 2.
[0178] In this preferred embodiment, the second lateral portions
7c, 8c of the reinforcing section bars 7, 8 are constituted by
respective fins perpendicularly extending from the ends of the
central portion 7a, 8a opposite to that of the fins 7b, 8b and at
opposite side of the central portion 7a, 8a.
[0179] Preferably, furthermore, the upper face 9, 10 of the first
fins 7b, 8b of the reinforcing section bars 7, 8 is extending at
least in part substantially flush with an upper face 41a, 42a of
the longitudinal ribs 41, 42 of the elongated body 2 made of
expanded plastic material.
[0180] In this way, the assembly constituted by the longitudinal
ribs 41, 42 and by the first fins 7b, 8b forms a rigid structure
adapted to effectively support the reinforcement metal structure
20.
[0181] Similarly to what has been described hereinabove with
reference to the previous embodiment of the floor structure 18, the
floor elements 19 are provided with longitudinal grooves 25 having
a shape substantially mating the shape of the longitudinal ribs 41,
42 incorporating the first fins 7b, 8b of the reinforcing section
bars 7, 8 and are engageable with a substantially snap-wise
connection on such ribs. In this preferred embodiment, the fins 7b,
8b and 7c, 8c comprise a first portion substantially rectilinear
and substantially perpendicular to the central portion 7a, 8a of
the reinforcing section bars 7, 8 and an second portion, or end
portion, inclined and forming an angle of predetermined value with
the first portion.
[0182] Preferably, the first portion of the fins 7b, 8b and 7c, 8c
has a width equal to about 40 mm, whereas the end portion has a
width equal to about 5 mm and forms with respect to the first
portion an angle equal to about 90.degree. in the case of the
second fins 7c, 8c and equal to about 45.degree. in the case of the
first fins 7b, 8b.
[0183] In an additional embodiment, the end portion of the first
fins 7b, 8b can be radiused to the first portion by means of a
substantially curvilinear joining zone.
[0184] Preferably, the reinforcing section bars 7, 8 are arranged
in a mirror fashion at opposite parts of the longitudinal center
plane of the elongated body 2 so as to impart optimum
characteristics of load resistance to the composite construction
element 1 as a whole. Thanks to this arrangement, the reinforcing
section bars 7, 8 are provided with second fins 7c, 8c extending at
opposite parts of the longitudinal center plane of the elongated
body 2 made of expanded plastic material so as to form a
configuration that advantageously improves the characteristics of
resistance to the bending loads of the composite construction
element 1, in particular those to the loads applied to the
projections 43, 44 of the elongated body 2 made of expanded plastic
material arranged between the reinforcing section bars 7, 8 and the
opposite sides 3, 4 of the aforementioned body.
[0185] In the preferred embodiment illustrated in FIGS. 6 and 7,
the first fins 7b, 8b and the second fins 7c, 8c of the reinforcing
section bars 7, 8 are provided with respective longitudinal ribs
45, 46 adapted to stiffen the structure thereof, and in the case of
the second fins 7c, 8c, adapted to form a notch for the
introduction of the tip of fastening means, for example screws, for
anchoring a rigid covering element, for example the panel 12 made
of plasterboard, to the reinforcing section bars 7, 8.
[0186] Similarly to the embodiments illustrated hereinabove,
furthermore, the reinforcing section bars 7, 8 are provided with a
plurality of openings 15, preferably of circular shape, formed in
the central portion 7a, 8a comprised between the first fins 7b, 8b
and the second fins 7c, 8c.
[0187] Also in this case, the openings 15 carry out the dual
advantageous function of lightening the reinforcing section bars 7,
8 and of allowing a still more intimate integration thereof within
the mass of expanded plastic material.
[0188] In this preferred embodiment, furthermore, the staples 38
engage at their ends 38b, 38c the lower portion of the longitudinal
ribs 41, 42 which forms an undercut which is hooked by the
aforementioned ends of the staples 38.
[0189] Unlike what is illustrated in FIG. 5, the floor elements 19
are arranged so that each longitudinal row of floor elements 19 is
supported by one and the same composite construction element 1.
[0190] In this case, it is therefore advantageously possible to
pre-assemble at the factory a plurality of floor elements 19
longitudinally aligned on one and the same composite construction
element 1 with an additional simplification of the laying
operations of the floor structure 18 carried out at the yard.
[0191] In an additional embodiment, not shown, the composite
construction elements 1 of the invention can be provided with
longitudinal ribs projecting in a cantilevered fashion from both
faces 2a, 2b of the elongated body 2 made of expanded plastic
material, in which case the second lateral portions 7c, 8c of the
reinforcing section bars 7, 8 will assume a configuration similar
to that of the first lateral portions 7b, 8b illustrated with
reference to FIGS. 6 and 7.
[0192] According to the preferred embodiment illustrated in FIG. 8,
the reinforcing section bars 7, 8 of the construction element 1 are
substantially Z-shaped and each of them comprises a plurality of
openings 15 pitchwise formed in the central portion 7a, 8a thereof
as described hereinbefore.
[0193] In this preferred embodiment, the second lateral portion 7c
of the reinforcing section bar 7 protrudes from the face 2b of the
elongated body 2 made of expanded plastic material and is provided
with a face 13, preferably substantially planar, extending
substantially parallel to the face 2b at a predetermined distance
therefrom.
[0194] Preferably, the distance between the face 13 of the second
lateral portion 7c of the reinforcing section bar 7 and the face 2b
of the elongated body 2 made of expanded plastic material is
comprised between about 10 mm and about 60 mm and, still more
preferably, comprised between about 20 mm and about 40 mm.
[0195] The first lateral portion 7b of the reinforcing section bar
7 is on the other hand substantially incorporated in the expanded
plastic material, so that the face 9 is extending flush with the
face 2a of the elongated body 2 made of expanded plastic
material.
[0196] Conversely, the first lateral portion 8b of the reinforcing
section bar 8 protrudes from the face 2a of the elongated body 2
made of expanded plastic material and is provided with a face 10,
preferably substantially planar, extending substantially parallel
to the face 2a at a predetermined distance therefrom, preferably at
a distance similar to that indicated above for the face 13 of the
lateral portion 7c.
[0197] The second lateral portion 8c of the reinforcing section bar
8 is on the other hand substantially incorporated in the expanded
plastic material, so that the face 14 is extending flush with the
face 2b of the elongated body 2 made of expanded plastic
material.
[0198] In this preferred embodiment, the first and the second
lateral portions 7b, 8b and 7c, 8c of the reinforcing section bars
7, 8 are for example constituted by respective fins extending
perpendicularly from the ends of the central portion 7a, 8a of the
section bars 7, 8 at opposite sides thereof.
[0199] Similarly to the embodiments illustrated hereinabove, the
fins 7b, 8b and 7c, 8c comprise also in this case a first portion
rectilinear and substantially perpendicular to the central portion
7a and 8a of the reinforcing section bars 7, 8 and a second end
portion inclined and forming an angle of predetermined value with
the first portion. Preferably, such an angle is equal to about
90.degree..
[0200] This additional embodiment of the composite construction
elements 1 advantageously allows both to have improved
characteristics of resistance to the bending loads and to support
external covering elements (for example rigid panels made of
plasterboard and/or laths supporting plaster layers, not shown) at
opposite parts of the elongated body 2 made of expanded plastic
material and at a predetermined distance from both faces 2a, 2b of
said body.
[0201] This additional embodiment of the composite construction
elements 1 further allows to achieve improved characteristics of
fire resistance in case of fire, either by coating at least in part
the reinforcing section bars 7, 8 with a fire resistant film, or by
arranging a suitable filling material incorporating at least one
fire retardant material adapted to impart an improved fire
resistance in the gap defined between the rigid covering element
(where present) and the face(s) 2a, 2b of the elongated body 2 made
of expanded plastic material.
[0202] According to the preferred embodiment illustrated in FIG. 9,
the reinforcing section bars 7, 8 of the construction element 1 are
substantially Z-shaped in a manner entirely similar to what has
been illustrated in FIG. 8.
[0203] In this preferred embodiment, however, the reinforcing
section bars 7, 8 are provided with opposite first and second
lateral portions 7b, 8b and 7c, 8c respectively protruding from the
opposite faces 2a, 2b of the elongated body 2 made of expanded
plastic material.
[0204] The substantially planar faces 9, 10, 13 and 14, therefore,
are extending substantially parallel to the faces 2a and 2b at a
predetermined distance therefrom, preferably at a distance similar
to that described above with reference to FIG. 8 (10-60 mm).
[0205] This additional embodiment of the composite construction
elements 1, therefore, advantageously allows both to have improved
characteristics of resistance to the bending loads and to support
external covering elements (for example panels made of plasterboard
and/or laths supporting plaster layers, not shown) at opposite
parts of the elongated body 2 made of expanded plastic material and
at a predetermined distance from both faces 2a, 2b of said
body.
[0206] Also this additional embodiment of the composite
construction elements 1 allows to achieve improved characteristics
of fire resistance in case of fire, either by coating at least in
part the reinforcing section bars 7, 8 with a fire resistant film,
or by arranging a suitable filling material incorporating at least
one fire retardant material adapted to impart an improved fire
resistance in the gap defined between the rigid covering element
(where present) and the face(s) 2a, 2b of the elongated body 2 made
of expanded plastic material.
[0207] According to the preferred embodiment illustrated in FIG.
10, the reinforcing section bars 7, 8 of the construction element 1
are substantially Z-shaped in a manner entirely similar to what has
been illustrated in FIG. 8.
[0208] In this preferred embodiment, however, the arrangement of
the planar faces of the first and of the second lateral portions
7b, 8b and 7c, 8c of the reinforcing section bars 7, 8 is similar
to that of FIG. 1, that is, with only the substantially planar
faces 9, 10 protruding from the elongated body 2 made of expanded
plastic material at a predetermined distance therefrom.
[0209] This additional embodiment of the composite construction
elements 1, therefore, allows to have improved characteristics of
resistance to the bending loads in addition to the technical
effects already described above with reference to FIGS. 1, 8 and
9.
[0210] According to the preferred embodiment illustrated in FIG.
11, the reinforcing section bars 7 and 8 of the composite
construction elements 1 (of which only the reinforcing section bar
7 is illustrated in FIG. 11 for simplicity) are substantially
C-shaped and each of them comprises respective first portions 7b,
8b and respective second portions 7c, 8c substantially fin-shaped
and provided with faces 9, 10 and 13, 14, preferably substantially
planar, projecting in a cantilevered fashion from the central
portion 7a, 8a of the section bars themselves.
[0211] In the preferred embodiment illustrated, the fins 7b, 8b and
7c, 8c are extending substantially perpendicular to the central
portion 7a, 8a.
[0212] With reference to FIGS. 12 and 13, some preferred
embodiments of a wall structure 28 will now be described by way of
a non-limiting example, which wall structure may be realized by
means of a plurality of composite construction elements 1 according
to the invention, for example each incorporating a pair of
substantially C-shaped reinforcing section bars 7, 8 according to
the embodiment of FIG. 11.
[0213] According to the preferred embodiment of FIG. 12, the wall
structure 28 comprises a plurality of composite construction
elements 1 arranged side by side and each of which is provided with
a pair of reinforcing section bars 7, 8 having respective first
lateral portions 7b, 8b protruding from the face 2a of the
elongated body 2 made of expanded plastic material and provided
with respective substantially planar faces 9, 10 extending
substantially parallel to the face 2a at a predetermined distance
therefrom. In this case, the lateral portions 7b, 8b are
substantially fin-shaped and are projecting in a cantilevered
fashion from the central portion 7a, 8a of the section bars
themselves.
[0214] The reinforcing section bars 7, 8 are also provided with
respective second lateral portions 7c, 8c--also substantially
fin-shaped--incorporated in the mass of expanded plastic material
and provided with respective faces 13, 14, preferably substantially
planar, extending substantially flush with the face 2b of the
elongated body 2.
[0215] Similarly to what has been described above with reference to
the preferred embodiment of FIG. 1, the composite construction
elements 1 of the wall structure 28 support a plurality of rigid
covering elements, for example matchboarded wood panels indicated
at 29 and a plurality of plasterboard panels indicated at 30, at
opposite parts of the elongated body 2 made of expanded plastic
material.
[0216] The panels 29 and 30 are fastened in a way known per se to
the substantially planar faces 9, 10 and, respectively, 13, 14 of
the reinforcing section bars 7, 8 for example by means of screws
not shown.
[0217] Thanks to the configuration of the composite construction
elements 1, a gap 31 is defined in this case between the panels 29
and the face 2a of the elongated body 2 made of expanded plastic
material, which is filled in this case with a suitable heat and
sound-proofing filling material M, such as glass wool, mineral wool
or a foamed polyurethane material.
[0218] The composite construction elements 1 of this embodiment
advantageously achieve improved supporting and heat and sound
insulation characteristics.
[0219] Finally, the wall structure 28 according to the invention
can achieve improved characteristics of fire resistance in case of
fire thanks to one or more of the following features: [0220] to the
fact that the reinforcing section bars 7, 8 can be coated at least
in part with a fire resistant film; [0221] to the fact that the
rigid covering elements associated to the reinforcing section bars
7, 8 can incorporate at least one fire retardant material adapted
to impart an improved fire resistance or to the fact that they can
be coated at least in part with a fire resistant film; [0222] to
the fact that the filling material M can incorporate at least one
fire retardant material adapted to impart an improved fire
resistance.
[0223] According to the preferred embodiment of FIG. 13, the wall
structure 28 comprises a plurality of composite construction
elements 1 arranged side by side, each of which is provided with a
pair of reinforcing section bars 7, 8 substantially C-shaped and
having respective first and second lateral portions 7b, 8b and 7c,
8c protruding from the faces 2a and 2b of the elongated body 2 made
of expanded plastic material.
[0224] The aforementioned lateral portions 7b, 8b and 7c, 8c are
provided with respective faces 9, 10 and 13, 14, preferably
substantially planar, extending substantially parallel to the face
2a and, respectively, 2b at a predetermined distance therefrom, for
example at a distance similar to that described above with
reference to FIG. 8 (10-60 mm).
[0225] Similarly to the previous embodiment illustrated in FIG. 12,
the lateral portions 7b, 8b and 7c, 8c of the reinforcing section
bars 7, 8 are substantially fin-shaped and are projecting in a
cantilevered fashion from the central portion 7a, 8a of the section
bars themselves.
[0226] In this preferred embodiment, the faces 9, 10 and 13, 14 of
the opposite lateral portions 7b, 8b and 7c, 8c of the reinforcing
section bars 7, 8 support a pair of laths 32, 33 at a predetermined
distance from the faces 2a, 2b of the elongated body 2 made of
expanded plastic material so as to define two gaps 34, 35 between
the laths 32, 33 and the aforementioned faces 2a, 2b. In this case,
these gaps are not filled with any material and define respective
air chambers which improve the sound insulation properties of the
wall structure 28.
[0227] In the following description and in the subsequent claims,
the expression: lath for supporting at least one covering layer, is
used to indicate not only conventional laths having a mesh
structure--either smooth or provided with protruding ribs--obtained
by stretching a suitably notched metal sheet, but also any
sheet-like member adapted to support a suitable covering
material.
[0228] Preferably, each of the laths 32, 33 is a stretched metal
lath essentially formed by a rhomb-shaped mesh having a
length-to-height rhomb ratio of 2:1.
[0229] Preferably, the rhomb length varies between about 20 and
about 60 mm, while the rhomb width varies between about 10 and
about 30 mm.
[0230] Preferably, furthermore, such stretched laths have a
thickness comprised between about 0.4 mm and about 1.0 mm and,
still more preferably, comprised between about 0.4 mm and about 0.8
mm.
[0231] The laths 32, 33 support in turn at least one layer 36, 37
of a suitable covering material, such as for example plaster or
cement, optionally incorporating at least one material selected
from reinforcing fibers of a suitable material and at least one
fire retardant material adapted to impart an improved fire
resistance to the covering material, which can be applied after
laying the wall structure 28.
[0232] The composite construction elements 1 of this embodiment
advantageously achieve improved load-bearing characteristics,
improved heat and sound insulation characteristics and improved
characteristics of fire resistance thanks to the firm connection of
the laths 32, 33 and of the covering material supported thereby to
the reinforcing section bars 7, 8.
[0233] In an additional embodiment, not shown, the faces 9, 10 and
13, 14 of the opposite lateral portions 7b, 8b and 7c, 8c of the
reinforcing section bars 7, 8 can support a pair of arc welded
meshes constituted by metal reinforcement rods of a concrete
casting applied outside the composite construction elements 1.
[0234] The composite construction element 1 illustrated hereinabove
in some of the possible embodiments thereof, can be advantageously
obtained by means of known operations for manufacturing the
reinforcing section bars 7, 8 and known equipment for the
continuous or discontinuous molding of the elongated body 2 made of
expanded plastic material incorporating such section bars.
[0235] With reference to the preferred embodiments described above
of the construction element 1, a preferred embodiment of a method
according to the invention will now be described.
[0236] In a preliminary step, carried out in a way known per se, at
least one sheet--preferably a pair of sheets--made of a structural
rigid material, for example galvanized steel, intended to form the
reinforcing section bars 7, 8, are provided.
[0237] Advantageously, the aforementioned sheets have a
predetermined thickness and a width comprised, for example, between
about 0.4 and 1.5 mm and, respectively, between about 140 and about
340 mm.
[0238] The sheets further comprise a central portion and a pair of
lateral portions extending from axially opposite parts with respect
to the central portion, which portions are intended to constitute,
as it will appear more clearly hereinafter, the central portion 7a,
8a and, respectively, the lateral portions 7b, 8b and 7c, 8c of the
reinforcing section bars 7, 8 being manufactured.
[0239] In a subsequent step, the sheets are bent in a way known per
se--for example by means of a forming machine--along a pair of
longitudinal bending lines substantially parallel to one another so
as to form the reinforcing section bars 7, 8 comprising the first
lateral portions 7b, 8b provided with the faces 9, 10, preferably
substantially planar, extending substantially perpendicular to the
central portions 7a, 8a of the section bars being manufactured.
[0240] Preferably, the bending step is carried out so as to form at
the same time also the second lateral portions 7c, 8c provided with
the faces 13, 14, also preferably substantially planar and
extending substantially perpendicular to the central portions 7a,
8a of the section bars being manufactured.
[0241] In a variant of this embodiment, the faces 9, 10 and 13, 14
of the first and of the second lateral portions 7b, 8b and 7c, 8c
of the reinforcing section bars 7, 8 are both extending above or
both below the lying plane of the sheet.
[0242] Preferably, the bending step is carried out so that the
faces 9, 10 and 13, 14 of the first and of the second lateral
portions 7b, 8b and 7c, 8c of the reinforcing section bars 7, 8
form an angle of about 90.degree. with respect to the lying plane
of the sheet central portion.
[0243] Preferably, furthermore, the sheet bending step can be
carried out, still using equipment known per se, so as to further
bend for example at an angle equal to about 90.degree., the faces
9, 10 and 13, 14 so as to obtain the aforementioned first portion
substantially perpendicular to the central portion 7a, 8a of the
reinforcing section bars 7, 8 and the second end portion inclined
and forming an angle of predetermined value with the aforementioned
first portion.
[0244] According to additional preferred embodiments, the
aforementioned bending step can be carried out by bending the
sheets along at least two longitudinal bending lines substantially
parallel to one another, so as to form a pair of first and second
lateral portions 7b, 8b and 7c, 8c, provided with respective faces
9, 10 and 13, 14 extending at opposite parts with respect to the
central portions 7a, 8a of the section bars being manufactured, in
order to obtain the structures of the reinforcing section bars 7, 8
illustrated in FIGS. 8, 9 and 10.
[0245] In a subsequent step, the reinforcing section bars 7, 8 thus
obtained are arranged in a molding seat of a suitable equipment for
molding plastics, conventional per se and not shown.
[0246] Once the reinforcing section bars 7, 8 have been arranged in
the molding seat, the steps of feeding expandable plastics granules
into said molding seat and of expanding and then bonding together
the plastics granules in the molding seat, so as to form the
elongated body 2 of the construction element 1 incorporating the
reinforcing section bars 7, 8, are carried out.
[0247] In a first embodiment, the step of molding the elongated
body 2 made of expanded plastic material is carried out in such a
way that the faces 9, 10 of the first lateral portions 7b, 8b of
the reinforcing section bars 7, 8 protrude from the face 2a of the
elongated body 2 and extend substantially parallel to said face at
a predetermined distance therefrom.
[0248] According to additional preferred embodiments, the
aforementioned step of molding the elongated body 2 made of
expanded plastic material is carried out in such a way that the
opposite faces 13, 14 of the lateral portions 7c, 8c of the
reinforcing section bars 7, 8 are essentially incorporated in the
mass of expanded plastic material and, as such, are extending
parallel to and substantially flush with the opposite face 2b of
the elongated body 2 or, alternatively, protrude from the face 2b
and extend substantially parallel to said face at a predetermined
distance therefrom.
[0249] In a preferred embodiment, the method of the invention
further comprises the step of forming a plurality of openings 15 in
the central portion of the sheet or of the sheets from which the
reinforcing section bars 7, 8 are obtained.
[0250] Preferably, such openings have a circular shape and are
extending in longitudinal direction along the sheet preferably
astride of the longitudinal axis of the sheet itself.
[0251] The operation of forming the openings 15 can be carried out
in a way conventional per se, for example by punching.
[0252] In a preferred embodiment, the method of the invention
further comprises the step of providing a fire resistant film on at
least a portion of the sheet or sheets from which the reinforcing
section bars 7, 8 are obtained.
[0253] Preferably, the aforementioned film is provided by means of
the steps of: [0254] a) applying a paint selected from the group
comprising intumescent paints and antifire paints on at least a
portion of the sheet or sheets from which the reinforcing section
bars 7, 8 are obtained; and [0255] b) drying said paint.
[0256] The steps a) and b) are carried out with methods and
equipment known to those skilled in the art.
[0257] In an additional embodiment of the method of the invention,
it is also possible to begin the manufacture of the construction
element 1 starting from a pre-drilled sheet, optionally already
incorporating a fire resistant film on at least a portion of the
external surface thereof, wound on a reel and arranged upstream of
the bending station.
[0258] If the manufacture of the construction element 1 is carried
out continuously, the method finally provides for a final step,
also carried out by means of equipment known per se, in which the
body 2 is cut to size so as to obtain a construction element having
the desired length.
[0259] In this way, it is possible to obtain the structures of
construction element 1 illustrated in FIGS. 1-13.
[0260] Clearly, a man skilled in the art may introduce
modifications and variants to the invention described hereinbefore
in order to meet specific and contingent application requirements,
variants and modifications which anyway fall within the scope of
protection as defined in the attached claims.
* * * * *