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 ( 2 a, 2 b ); b) at least one reinforcing section bar ( 7, 8 ) longitudinally extending in the elongated body ( 2 ) and having a first lateral portion ( 7 b, 8 b ) protruding from a first face ( 2 a ) of the elongated body ( 2 ); wherein the first lateral portion ( 7 b, 8 b ) of the reinforcing section bar ( 7, 8 ) is provided with a face ( 9, 10 ) extending substantially parallel to the first face ( 2 a ) 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.

1 . A composite construction element ( 1 ) comprising: 
 a) at least one elongated body ( 2 ) made of expanded plastic material provided with opposite faces ( 2   a,    2   b );    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 ( 7   b,    8   b ) protruding from a first face ( 2   a ) of said opposite faces ( 2   a,    2   b ) of the elongated body ( 2 );    wherein said first lateral portion ( 7   b,    8   b ) is provided with a face ( 9 ,  10 ) extending substantially parallel to said first face (   2   a) 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 ( 7   c,    8   c ) provided with a face ( 13 ,  14 ) extending substantially parallel to the second face ( 2   b ) of said opposite faces ( 2   a,    2   b ) of the elongated body ( 2 ) made of expanded plastic material.  
   
   
       4 . A construction element ( 1 ) according to  claim 3 , wherein said second lateral portion ( 7   c,    8   c ) of said at least one reinforcing section bar ( 7 ,  8 ) is extending flush with said second face ( 2   b ) of the elongated body ( 2 ) made of expanded plastic material.  
   
   
       5 . A construction element ( 1 ) according to  claim 3 , wherein said second lateral portion ( 7   c,    8   c ) 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 ( 2   b ) of the elongated body ( 2 ) made of expanded plastic material.  
   
   
       6 . A construction element ( 1 ) according to  claim 3 , wherein said second lateral portion ( 7   c,    8   c ) of said at least one reinforcing section bar ( 7 ,  8 ) protrudes from said second face ( 2   b ) of the elongated body ( 2 ) made of expanded plastic material and wherein said face ( 13 ,  14 ) of said second lateral portion ( 7   c,    8   c ) is extending substantially parallel to said second face ( 2   b ) 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 ( 7   b,    8   b ) or said face ( 13 ,  14 ) of the second lateral portion ( 7   c,    8   c ) 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 ( 7   b,    8   b ) or said second ( 7   c,    8   c ) 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 ( 7   b,    8   b ) or said second ( 7   c,    8   c ) lateral portion of said at least one reinforcing section bar ( 7 ,  8 ) is substantially perpendicular to a central portion ( 7   a,    8   a ) of the reinforcing section bar ( 7 ,  8 ).  
   
   
       10 . A construction element ( 1 ) according to  claim 1 , wherein said first ( 7   b,    8   b ) or said second ( 7   c,    8   c ) 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 ( 7   b,    8   b ) or said second ( 7   c,    8   c ) 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 ( 2   a ) or from said second ( 2   b ) 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 ( 7   b,    8   b ) or of said second ( 7   c,    8   c ) lateral portion of said at least one reinforcing section bar ( 7 ,  8 ) is extending at least in part substantially flush with an upper face ( 41   a,    42   a ) 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 ( 7   b ) protruding from said first face ( 2   a ) 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 ( 8   c ) protruding from the second face ( 2   b ) of said opposite faces ( 2   a,    2   b ) of the elongated body ( 2 ), said lateral portion ( 8   c ) of said at least one second reinforcing section bar ( 8 ) being provided with a face ( 14 ) extending substantially parallel to said second face ( 2   b ) 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 ( 7   b,    8   b ) and second ( 7   c,    8   c ) lateral portions protruding from said opposite faces ( 2   a,    2   b ) of the elongated body ( 2 ) made of expanded plastic material.  
   
   
       16 . A construction element ( 1 ) according to  claim 3 , wherein said second lateral portions ( 7   c,    8   c ) 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 ( 7   b,    8   b ) or of said second ( 7   c,    8   c ) 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 ( 7   a,    8   a ) 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 ( 7   b,    8   b ) 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 ( 2   b ) of said opposite faces ( 2   a,    2   b ) of the elongated body ( 2 ) made of expanded plastic material or to said face ( 13 ,  14 ) of the second lateral portion ( 7   c,    8   c ) 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 ( 7   b,    8   b,    7   c,    8   c ) of said reinforcing section bars ( 7 ,  8 ) protruding from the opposite faces ( 2   a,    2   b ) 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 ( 7   b,    8   b ) 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 ( 2   a,    2   b ) 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 ( 7   b,    8   b ) of said at least one reinforcing section bar ( 7 ,  8 ) protrudes from a first face ( 2   a ) of said opposite faces ( 2   a,    2   b ) of the elongated body ( 2 ) made of expanded plastic material and extends substantially parallel to said first face ( 2   a ) 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 ( 7   c,    8   c ) 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 ( 7   b,    8   b ) and second ( 7   c,    8   c ) 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 ( 7   b,    8   b ) and of said second lateral portion ( 7   c,    8   c ) 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 ( 7   c,    8   c ) 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 ( 2   b ) 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 ( 7   c,    8   c ) of said at least one reinforcing section bar ( 7 ,  8 ) protrudes from said second face ( 2   b ) of the elongated body ( 2 ) made of expanded plastic material and wherein said face ( 13 ,  14 ) of said second lateral portion ( 7   c,    8   c ) is extending substantially parallel to the second face ( 2   b ) 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.