Reinforced concrete wall panels. Wall panels. description, technical characteristics - prices for fbs blocks from GC Rosatomsnab GOST wall panels for industrial buildings

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Concrete/reinforced concrete wall panels are used as a building material in house construction. Depending on the type, they are used for the construction of external or internal walls of buildings for various purposes: from residential buildings to industrial ones.
The structural design of wall panels determines their division into load-bearing, self-supporting and hinged. According to their intended purpose, the panels are: for above-ground garages, for basements or for attics. According to the design solution, they can be composite or integral. Based on the number of layers, one-, two- and three-layer ones are distinguished. The type of panel is reflected in its alphanumeric designation.
Technical requirements, as well as designs and standard sizes for external wall panels are regulated by GOST 11024-84, the same for internal ones - GOST 12504-80, industry and local standards, technical conditions, SNiPs are also used.
According to GOST 11024-84 “External concrete and reinforced concrete wall panels for residential and public buildings,” panels made of light and heavy concrete, as well as autoclaved cellular concrete, are used for the manufacture of external walls.
The division into types is related to the purpose of the wall panels, design and number of layers. Based on the number of main layers, they are divided into single-layer and layered: two- and three-layer, which in turn can be with or without air layers (solid); if the air gap is located behind the outer layer, the panels are called screen laminated panels.
Single-layer panels are made of homogeneous material with low thermal conductivity (lightweight or cellular concrete). Their strength class is calculated based on their required loads, and the thickness is selected taking into account climatic conditions. For reinforcement, a welded frame and mesh are used. Single-layer panels are a simple design solution and manufacturing technology.
Double-layer panels consist of layers: load-bearing and insulating. The load-bearing layer is made of dense, heavy or light concrete; this layer is located on the inside of the building. The insulating layer can be made of lightweight, cellular heat-insulating concrete, as well as thermally insulating rigid slabs.
Three-layer panels (sandwich panels) consist of two external reinforced concrete slabs and an internal thermal insulation layer, which serves as insulation. In this case, the outer layers are connected by welded reinforcement cages. To make the inner layer, semi-rigid materials are used: mineral wool boards, corks, asbestos-cement boards, fiberglass, as well as hard ones, such as foam glass and foam keralite.
To finish external wall panels, materials are used that are characterized by the required decorative, protective and performance properties. This can be cladding with ceramic, glass tiles, natural stone or decorative concrete; finishing with layers of concrete of various types or ceramic glaze; sprinkle with decorative crushed stone; painting with weather-resistant dyes, etc. If single-layer panels are made of lightweight concrete, they must be provided with an internal finishing layer (a layer of cement or lime-cement mortar) and a protective and decorative external one. Laminated panels with an outer concrete layer must have an outer protective and decorative layer; and with an internal main concrete layer - an internal finishing layer.
According to GOST 12504-80 “Internal concrete and reinforced concrete wall panels for residential and public buildings,” panels made of light and heavy concrete (slag concrete, expanded clay concrete), autoclaved cellular concrete and dense silicate are used for the manufacture of internal walls.
According to the perception of vertical loads, internal panels can be load-bearing and non-load-bearing (partitions). According to their design, load-bearing internal panels can be solid or hollow, as well as frequently ribbed or with ribs along the contour.
Due to the nature of their application, wall panels must satisfy such requirements as high strength, low thermal conductivity, fire resistance, low specific gravity, as well as efficiency, which is expressed in manufacturability. Important conditions are ease of installation and quality of joint designs.
The stability of wall panels is ensured by fastening them both to each other and to the floor structures. The panels’ own stability is insufficient, which is due to the peculiarities of their design: small thickness with significant length and height.

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When a person thinks about building his own house, he has to solve two main questions:

• Select material for walls, partitions and ceilings;
• Decide on the layout and number of floors of the house.

Some materials, for example, brick or cinder blocks, allow you to create a house with any arrangement and even configuration of rooms. Others, such as logs or reinforced concrete products, with their dimensions affect both the size of the rooms and their configuration. In this article we will discuss how to build a house from concrete panels. Let us immediately make a reservation that most often such products are reinforced concrete.

Beautiful house made of concrete panels

The choice in favor of a house made of reinforced concrete is influenced by the presence of a reinforced concrete products plant (RCP) or a house-building plant (DSK) near the construction site, which produces parts for individual construction. You can, of course, use standard designs, but this will impose certain restrictions on the layout of the house.

Panels are different

The base of the foundation must be below the freezing level of the soil. It consists of a sand cushion on which reinforced concrete foundation cushions are laid. Foundation blocks (FBS) are mounted on them in a row, so that the surface of the top row is above ground level. Then the foundation is waterproofed, and floor slabs are installed under the floor of the first floor. After this, the construction of the walls of the house begins.

Organization of work

Even before you start designing a house made of concrete panels, you need to think about who and how will deliver them to the construction site, where they will be stored, and how they will be installed. This is especially important if the site is small and there are already buildings nearby. It is necessary to determine the place where the crane will stand, with which the structures will be installed. In the most cramped conditions, it should be positioned so that the boom reach is enough to install the panel on the opposite side of the building.

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Very often in an apartment we want to hang a TV, a shelf, or maybe just a picture on the wall, but we are afraid to drill holes in the wall of a panel house. What if the drill goes right through? And in order not to be afraid, you need to know the thickness and types of walls in panel houses, which I will talk about in this article.

As a rule, panel manufacturers do not deviate from standard sizes, so the thickness of such walls is, in principle, predictable, unlike the thickness of a brick wall of an individual house.

Walls, as we know, are usually divided into three types:

• external
• internal load-bearing
• internal partitions

External walls of a panel house

These walls are the thickest and come in two types:

• single-layer external walls consisting of lightweight concrete
• multilayer walls consisting of reinforced concrete and, as a rule, polystyrene foam slabs

Single-layer panels

Most often, single-layer panels are made of expanded clay concrete with a thickness of 300-350 mm, depending on the climate zone. Expanded clay concrete is suitable for these purposes, both in strength and thermal conductivity.

There are single-layer slabs consisting of cellular concrete. The thickness of such panels also ranges from 300 to 350mm.

Multilayer panels

Most often, such panels consist of two layers of reinforced concrete (external and internal) and polystyrene foam (foam) slabs between them.
The standard thickness of such a wall is 380mm.

The internal reinforced concrete layer is 80-100 mm (previously the layer was thinner). The outer reinforced concrete layer is at least 60 mm.

Expanded polystyrene is usually used as insulation, since mineral wool is too “soft” a material, and if it is used for the production of panels, it is very rarely.

Thickness of the internal walls of a panel house

Internal walls are also of two types: firstly, these are load-bearing walls, on which the entire structure of the house rests, and secondly, these are internal partitions, which serve exclusively to divide the area of ​​​​the house or apartment into rooms.

Thickness of load-bearing walls of a panel house

Load-bearing panels of reinforced concrete structures are usually from 140 to 200 mm thick. To be more precise, the most common panels have thicknesses of 140mm, 180mm and 200mm.

It is very rare to find a load-bearing wall 120mm thick.

Thickness of internal partitions

In most panel houses, internal partitions consist of gypsum concrete panels, the thickness of which does not exceed 80mm.

Sometimes the thickness of the internal partitions of a panel house varies from 80mm to 100mm.

How to distinguish a load-bearing wall of a panel house from a partition

When remodeling an apartment, you need to know exactly where the load-bearing walls are located, which cannot be touched, and where there are simply internal partitions that can be demolished, moved, etc.

Remember! When moving or demolishing walls in an apartment, you must first order a redevelopment project from a licensed organization. If this is not done and the layout is changed without approval, then in the future problems may arise with the design and re-decoration of your apartment.

And so, let's continue.

The easiest way, without drawings and projects, to determine where the load-bearing wall is and where it is not, is to measure the thickness of the wall with a tape measure or ruler.

I have already talked about the thickness of load-bearing walls, it starts from 120mm. Therefore, we take a ruler and measure the wall, if it is greater than or equal to 120mm, then this wall is load-bearing, if less, then it is a partition.

Using this method, you can quite accurately determine the type of wall, since in most cases the panels of a panel house have standard sizes, but it must be remembered that the thickness of the wall is measured without finishing layers, i.e. without plaster, wallpaper, additional internal insulation, and so on.

Reinforced concrete external wall panels are most often made in a single-row cut, i.e. one floor high and one or two rooms long, and in terms of design they are single-layer, two-layer and three-layer (Fig. 3.4 and 3.5). All wall panels are equipped with lifting loops and embedded parts for attaching one panel to another and for connections with other structural elements of buildings.

a) Single-layer reinforced concrete external wall panels

Such panels are made from lightweight structural and thermal insulating concrete on porous aggregates or from autoclaved cellular concrete (Fig. 3.5). On the outside, single-layer panels are covered with a protective and finishing layer of cement mortar 20–25 mm or 50–70 mm thick, and on the inside with a finishing layer 10–15 mm thick, i.e. such panels can be conventionally called “single-layer”. The thickness of the outer protective and finishing layers is determined depending on the natural and climatic conditions of the construction area, and they are made from vapor-permeable decorative mortars or concrete or from ordinary mortars followed by painting. The finishing of the outer facade layer can also be done with ceramic, glass tiles or thin tiles made of sawn stone or crushed stone materials.

Rice. 3.4. External reinforced concrete one-, two- and three-layer wall panels:

a – single-layer; b – two-layer; c – three-layer; 1 – lightweight structural and thermal insulating concrete; 2 – outer protective and finishing layer; 3 – structural concrete; 4 – effective insulation

Rice. 3.5. Component elements of the cross sections of external reinforced concrete wall panels: a – with an external protective and finishing layer; b – with external protective-finishing and internal finishing layers; c – from cellular concrete; d – two-layer with an internal load-bearing layer; d – three-layer with rigid connections between concrete layers; e – three-layer with flexible connections between layers; 1 – structural thermal insulation or cellular concrete; 2 – outer protective and finishing layer; 3 – internal finishing layer; 4 – outer and inner load-bearing layers; 5 – lightweight thermal insulating concrete; 6 – fittings; 7 and 8 – flexible connection elements made of anti-corrosion steel; 9 – effective insulation; δ – thickness of the insulating layer

Single-layer panels are reinforced along the contour with a welded mesh frame, and above the window openings - with a welded spatial frame. To prevent cracks from opening in the corners of the openings, cross rods or L-shaped meshes are laid outside (Fig. 3.6).

Single-layer panels made of autoclaved cellular concrete cannot be made in height to fit the entire floor wall and walls with linear strip cutting are made from them. The reinforcement of such panels is protected from corrosion by coating with an anti-corrosion compound.

Rice. 3.6. Scheme of reinforcement of a single-layer lightweight concrete panel of an external wall:

1 – lintel frame; 2 – lifting loop; 3 – reinforcement frame; 4 – L-shaped reinforcing mesh in the façade layer

Due to the high vapor permeability of lightweight concrete and, therefore, the possibility of water vapor condensation forming inside single-layer panels and freezing at low outdoor temperatures, it is advisable to use such panels for buildings with low relative humidity of indoor air (no more than 60%). The thickness of single-layer panels is 240–320 mm, but not more than 400 mm.

b) Double-layer reinforced concrete external wall panels

Double-layer wall panels consist of an internal load-bearing layer made of heavy or lightweight structural concrete, and an external insulating layer made of structural and thermal insulating lightweight concrete. The thickness of the internal load-bearing layer is at least 100 mm, and the thickness of the outer insulating layer is determined by calculations for thermal protection. On the outside, double-layer wall panels have a protective and finishing layer of cement mortar 20–25 mm thick with the same finishing as in single-layer panels.

Since the internal load-bearing layer of dense concrete in two-layer panels has low vapor permeability, such panels can be used in buildings with high relative humidity of internal air. Reinforcement of double-layer wall panels is carried out similarly to single-layer panels, i.e. the reinforcement frame is placed in the load-bearing and insulating concrete layers, but the working reinforcement of the lintels is placed in the load-bearing concrete layer. The total thickness of two-layer wall panels is no more than 400 mm (Figure 3.7).

c) Three-layer reinforced concrete external wall panels

Three-layer external wall panels consist of an inner and outer layer made of heavy or dense lightweight structural concrete, between which an insulating layer of effective thermal insulation material is laid. The thickness of the insulating layer is determined by calculations for thermal protection, and the thicknesses of the inner and outer concrete layers depend on the design solution of the wall panel and the magnitude of the perceived loads.

The inner layer of the panels is reinforced with a spatial frame, and the outer layer with reinforcing mesh. Depending on the design, three-layer wall panels are available with flexible or rigid connections between the inner and outer concrete layers (Fig. 3.5 and 3.8). Flexible connections are metal rods in the form of vertical hangers and horizontal struts connecting the reinforcing frame of the inner layer and the reinforcing mesh of the outer layer of the wall panel, i.e. they are attached by welding or tied to the spatial reinforcement frame of the inner layer and the reinforcing mesh of the outer layer. The metal rods of flexible connections are made of corrosion-resistant steel or they have an anti-corrosion coating in the insulation area.

Flexible connections ensure independent operation of the concrete layers of the wall panel and eliminate thermal forces between layers. The outer layer in panels with flexible connections performs enclosing functions and its thickness must be at least 50 mm. The thickness of the inner layer in three-layer panels with flexible connections in load-bearing and self-supporting wall panels is not less than 80 mm, and in non-load-bearing panels - not less than 65 mm.

Figure 3.7. Two-layer concrete panel of the outer wall: 1 and 2 – embedded parts for fastening heating radiators; 3 – lifting loops; 4 – reinforcement frame; 5 – internal load-bearing layer; 6 – outer protective and finishing layer; 7 – drain; 8 – window sill board; 9 – lightweight concrete thermal insulation layer; N– floor height; IN– panel length; h– panel thickness; δ – thickness of the thermal insulation layer

In three-layer wall panels with rigid connections, the inner and outer concrete layers are connected using vertical and horizontal reinforced concrete ribs. Rigid connections ensure joint static operation of the concrete layers of wall panels and protect the connecting reinforcing bars from corrosion. Connecting reinforcing bars are placed in concrete tie ribs and are attached by welding or tied to the reinforcing cage of the inner layer and the reinforcing mesh of the outer layer.

The disadvantage of installing rigid connections in external wall panels is through heat-conducting inclusions formed by the ribs, which can lead to condensation on the inner surface of the walls. To reduce the influence of the thermal conductivity of the ribs on the temperature of the inner surface of the walls, they are made with a thickness of no more than 40 mm and preferably from lightweight concrete, and the inner concrete layer is thickened to 80–120 mm. The thickness of the outer layer is at least 50 mm. Exterior finishing of three-layer wall panels is carried out in the same way as single- and two-layer ones. In all external wall panels, embedded parts for fastening to other structural elements are placed in the load-bearing layer.

Rice. 3.8. Three-layer concrete panels of external walls and connections between their concrete layers:

a – layout diagram of flexible connections; b – the same rigid connections: 1 – suspension; 2 – spacer; 3 – strut; 4 – rib made of concrete outer layers; 5 – rib made of lightweight concrete; 6 – internal concrete layer; 7 – outer concrete layer; 8 – reinforcement frame of the inner layer; 9 – reinforcement mesh of the outer layer; 10 – reinforcement of ribs; 11 – effective insulation

External concrete and reinforced concrete wall panels have found the widest application in the construction of houses, as well as industrial and public facilities. Their appearance more than 50 years ago was a real breakthrough in construction and made it possible to reduce the construction period of buildings several times.

Types of reinforced concrete panels

Reinforced concrete is a monolith of steel reinforcement and concrete. The interaction of these materials is very effective. The concrete stone adheres reliably to the metal, protecting it well from rusting. These components complement each other in terms of resistance to different loads.

The resulting structures have significant strength, and only high-tech tools can help in their processing. Recently, diamond drilling of holes in concrete has become in demand.

Note!
The volume of reinforced concrete products is mainly occupied by cheap raw materials - gravel, crushed stone, sand.
Therefore, their price is relatively low.

What types of them exist?

Based on reinforcement, reinforced concrete products are divided into:

• prestressed products;
• analogues reinforced using the usual method.

By density (specific gravity) and grade of concrete:

• extra heavy ones from 2.5 t/m³;
• heavy analogues, with a density of 1.8/2.5 t/m³;
• light, their specific gravity is up to 1.8 t/m³;
• ultra-light products, their density is 0.7 t/m³.

According to their structure, reinforced concrete wall panels are divided into:

• monolithic;
• hollow;
• made from one type of solution;
• made from different types of mixture.

Precast concrete products may be intended for:

• for residential and public buildings;
• for production facilities;
• for engineering structures.

Production methods

The production of panels is carried out at factories of reinforced concrete products using different methods.

1. Bench technology is intended for the production of large-sized products. The solution is poured into stationary molds. Special units: concrete layers and vibrators, take turns approaching the stands and performing technological steps.
2. The cassette method is a modification of the previous method. The panels are produced in fixed cassettes, which consist of several steel compartments. A frame made of reinforcement is placed in the mold, then it is filled with concrete. Heat treatment is carried out by contact, through the walls of the cassettes.

After heating, the walls of the molds are removed, and the panels are removed by an overhead crane. This method produces flat products: wall structures and analogues for floors.

1. With flow-aggregate technology, molds for products move along a chain from one mechanism to the next. Wet and heat treatment is carried out continuously.
2. With the vibratory rolling method, the entire production cycle occurs on a single installation of the flow principle of operation (vibratory rolling mill). It is a conveyor consisting of rubber-protected steel.

Its tape moves through the technological posts. They are used for: installation of a frame made of reinforcement, pouring of concrete, its compaction by vibration and heat treatment. The instructions recommend using this method to produce partition and floor panels, as well as external wall slabs made of lightweight concrete.

Technical requirements

State standards impose the most stringent requirements for wall slabs.

1. Accuracy of standard dimensions, as well as geometric shape.
2. Optimal design of connections and assemblies.
3. The exact location of the mortgages.
4. Compliance of the standard size and weight of concrete products with the capabilities of transport and lifting machines.

Note!
A house made of reinforced concrete panels must be constructed from products whose dimensions are within the limits of deviations and tolerances.
They are determined by GOST No. 130/15.4/84.

1. The dimensions of the mortgages in them must correspond to standard values, the error should not exceed 0.5 cm.
2. The permissible axial displacement of the embedded parts is no more than 1 cm.
3. These elements should be located flush with the plane of the panels or above it - no more than 0.3 cm.

More about wall slabs

Large wall slabs were developed to speed up the pace of construction. For example, a cottage made of reinforced concrete panels can be built in just 2 weeks.

Advantages of reinforced concrete products

The popularity of reinforced concrete panels in mass construction, in addition to the high pace of work, can be explained by their other advantages:

• high strength;
• good load-bearing capacity;
• acceptable level of thermal insulation;
• 100% fire resistant;
• resistance to temperature changes;
• durability of use.

Types of panel construction

Panel construction can be framed or frameless.

This depends on what kind of wall slabs are used: enclosing and load-bearing or only enclosing.

1. In frameless buildings, the load of the floors is carried by the wall panels themselves.
2. In frame analogues, the load-bearing functions are performed by the frames. Wall slabs are used for zoning, fencing, sound and heat insulation.

Factories produce panels for both external and internal walls.

1. External slabs are divided into three categories according to their structure: single-layer, made from cellular or lightweight concrete and consisting of two or three layers. The latter are made of heavy types of concrete and thermal insulation.
2. The outside of the structure is covered with facade ceramic tiles, decorative mortar, weather-resistant paints, etc. The inside of the slabs is trimmed and prepared for finishing.
3. The height of the reinforced concrete wall panels is equal to the height of one floor. Their width extends to 1/2 of the room (300/720 cm), thickness can be 20/50 cm. The dimensions of reinforced concrete wall panels for partitions correspond to the dimensions of the rooms. Their thickness is 3/16 cm.

Classification of wall slabs

There are different divisions of panels into categories, based on the underlying principle: typical features, purpose, structure, material composition.

Slab design

Produced panels are divided into monolithic and composite analogues.

In turn, layered products can be solid or have layers of air.

1. Single-layer analogues are made from homogeneous concrete, which has low thermal conductivity. The thickness of their outer part is 2/4 cm. The inside of the slab is decorated with cladding.
2. Two-layer slabs have a continuous structure. Their supporting layer is made of reinforced concrete mortar. This is the inner part of the panel, which additionally plays the role of a vapor barrier. The outer heat-protective layer is covered with cement-sand mortar.
3. Reinforced concrete three-layer panels are made of two slabs connected to each other by a welded frame made of reinforcement. Insulation is laid between them.

According to their load-bearing capacity, wall slabs are divided into:

• self-supporting products;
• load-bearing analogues.
• hanging panels.

Partition panels

1. These large-sized slabs have a floor height and a length of up to 600 cm. They are intended for the construction of fully prefabricated buildings.

Note!
For the production of partition panels, high-strength ordinary or gypsum concrete should be used.
The material must have good water resistance and frost resistance.

1. Such plates are reinforced with iron wire mesh or rods made of thermally and mechanically stable steel, class A/III, AT/IIIC. All steel parts of the product must be coated with anti-corrosion primer.

Single layer boards

1. For the production of single-layer wall panels, concrete is used, which has a uniform structure and a high level of thermal insulation. Most often it is a light (cellular) material.
2. The outer side of the slabs is covered with a layer of cladding, 2/4 cm thick, to protect them from atmospheric influences.
3. Various plaster, tiles, etc. are used to decorate the interior.

Double-layer panels

1. The two-layer type of slabs, as a rule, has a solid structure. The first load-bearing layer is made of dense reinforced concrete. The other layer is heat insulating.
2. It is located on the outside and covered with cement-sand mortar.
3. The load-bearing layer is located indoors and at the same time serves as a vapor barrier.

Three-layer type of products

Reinforced concrete three-layer wall panels are most in demand now.

1. The basis of the three-layer slab is the outer load-bearing side, and the inner panel is attached to it with reinforcement. Thanks to the gap between them, heat losses in the structure are reduced.
2. The thermal insulator in such products can be mineral wool, cement-based fiberboard, foam silicate, or polyurethane.
3. Three-layer slabs have standard sizes and vary in thickness. It is selected by designers based on the climate conditions of the area and the thermal parameters of the building.
4. This type of panels is made from a mixture of either heavy types of concrete with a class of at least B-12.5.
5. Products are reinforced with welded mesh or three-dimensional steel frames. All metal parts of the plates are protected with anti-corrosion primers.
6. The characteristics of three-layer panels for walls are determined by the standards of State Standard No. 31310/2005 and State Standard No. 13015/2003.
7. If it is necessary to process the slabs during their installation, reinforced concrete is cut with diamond wheels.

Product sizes

1. The main criterion for choosing wall slabs with your own hands is their size. They must be indicated in the building design, taking into account its structural diagrams and floor plans.
2. Dimensions and thickness, size and number of openings, technical characteristics of panels are determined based on the project.
3. Typical dimensions of slabs for residential buildings: height equal to one floor, width equal to one or two rooms. External panels have door and window openings. Partition slabs are solid or have doorways.
4. Panels for industrial facilities have a length of 6 meters, 9 and 12.

Note!
The thickness of wall slabs should be selected based on the climate conditions in your region.
The thermal properties of the building materials used are also of great importance.
Manufacturers produce products with a thickness of 20/50 centimeters

Product labeling

Panels are marked with letters and numbers separated by a dash.

1. The first group indicates the type of slab and its dimensions: length, height (in decimeters), thickness (in centimeters).
2. The following fragment determines the class and type of concrete: L - light, T - heavy, I - cellular.
3. The third part reports on additional product qualities.

For example:

• seismic resistance more than 7 points - C;
• frost resistance below -40 degrees - M;
• permeability: especially low - O, reduced - P, normal - N.

This brand group includes indications of the design properties of products:

• their shape;
• end configuration;
• type and location of openings, if any;
• the shape of the grooves (if they are present) at the junctions of adjacent elements;
• type and location of releases of reinforcement and embeds;
• the presence of a reinforcing structure to reduce loads due to uneven deformations of the foundation.

Let's give an example of marking: PST 598-300-20.

• PST – three-layer wall panel;

598 cm – its length;

300 cm – its height;

20 cm is its width.

Conclusion

Reinforced concrete panels for fences, walls and ceilings are an integral part of modern mass construction. The use of new technologies, materials and design solutions in their manufacture makes it possible to optimize the construction of buildings.

If you watch the video in this article, you will get a lot more useful information.