METHOD FOR MANUFACTURING A STRUCTURAL MODULE WITH A FACADE LAYER AND THE STRUCTURAL MODULE WITH A FACADE LAYER MANUFACTURED BY THIS METHOD

Description

[0001] The invention relates to a construction sector, in particular, to a method of manufacturing a structural module with a heat-insulating layer and a facade layer formed thereon, which performs protective and decorative functions (i.e. a module fully ready for use in the construction) and design features of the structural module thus manufactured and may be used in civil and industrial engineering with high requirements to decorative external facing of external walls, heat insulation and waterproofing of internal premises, such as, residential buildings, cottages, business centers and the like.

[0002] The modular construction of buildings is a preferential development of the construction industry with a view to reduce construction costs and enforce building regulations. Structural modules, the use of which has been known in the prior art, usually comprised bearing monolithic base with holes for placing window and door systems, and, thus, providing necessary parameters of heat insulation and waterproofing for the building as well as meeting requirements for protection of building facades and their decorative options required further equipping the surface of the bearing base of the building so constructed with panels or blocks having a heat-insulting and hydrophobic material. Thus, further development of modular construction of buildings necessitated designing of structures of structural modules with a premounted facade layer that allows meeting requirements to decorative external facing of external walls and heat insulation and waterproofing of interior premises, without additional manufacturing operations in the construction of buildings, as well as provides simplified and improved methods of manufacturing of these modules, given their higher cost compared to that of manufacturing bearing modules having a bearing base only.

[0003] Many similar methods of manufacturing the structural module with a facade layer as well as structural modules manufactured with a facade layer, considered the closest prior art, are known to the applicant including the following.

[0004] A method of manufacturing structural modules with a facade element, wherein a mold for the manufacture of modules is placed on a tray so that elements of such mold intended to form the facade layer of the module are located at the bottom, then the first mixture, comprising crushed clay pellets as a filler, cement, a plasticizing agent and water, is then supplied to the mold to form the facade layer, the first mixture undergoes vibration in the mold, the vibration of the first mixture is then stopped and the second mixture, comprising 5-20 mm clay pellets, cement, a plasticizing agent and water, is then supplied to form an intermediate layer of the structural module followed by vibration of both mixtures at the bottom of the mold, and, along with bottom vibration, the second mixture and the first mixture are pressed, and the third mixture, comprising sand, cement, a plasticizing agent and water, is then supplied onto the intermediate layer to form an inner layer of the module, and all layers of the modules are then pressed by pressure from top to bottom onto the third mixture and the third mixture is them smoothed to form the surface of the inner layer of the module. Following the operations, layers of the module remain in the mold until coupled to each other and partially hardened, and then the module is removed from the mold. The structural module, so manufactured, is a faceted structure of hardened filler material having the front surface of the module located on the outer front side and a facade layer, an intermediate layer and an inner layer, located consistently along its thickness (Invention Patent RU 2 465 415 C1 published on 27.10.2012, Bulletin No. 30, IPC: E04C 1/40 (2006.01), B28B 5/00 (2006.01), B28B 7/00 (2006.01), B28B 15/00 (2006.01)).

[0005] The disadvantage of the manufacturing method known in the art is the relatively reduced manufacturing technology due to the need to form the facade layer by multiple layers to obtain the required heat-insulation and hydrophobic properties, and the lack of opportunities to form a preset profile of the facade layer, in particular, such that imitates brickwork etc.

[0006] A method of manufacturing a decorative facing wall unit is also known in the art that comprises casting of a plaster concrete mixture into a mold, followed by casting a cement mixture and a decorative facing mixture. After the plaster concrete mixture is casted into a mold, scratches are made on the surface of the plaster concrete mixture with a special instrument before the mixture is hardened, and the concrete mixture is then placed onto the surface with addition of lime of 3 to 7 percent of the total weight and, once the plaster mass is cooled to the ambient temperature, a decorative facing layer based on cement with fractional screened broken natural stone as a filler is then casted followed by compacting and rolling of the mixture. After the mixture is allowed to stay for 3 to 5 hours, a mold is bended at an angle to the horizon and cement milk is washed out from the front surface of the unit with water supplied at two-atmosphere pressure. The unit so manufactured comprises parallel layers with plaster cement layers forming the base of such unit and the last layer is covered, on the one side, with a cement lining with the decorative facing layer consisting of cement mixed with fractional screened broken natural stone as a filler applied thereon (Invention Patent RU 2 225 486 C2 published on 10.03.2014, IPC: E04C 1/00, E04C 1/40, E04B 2/40).

[0007] The disadvantage of the wall unit described above is the inability to use it as a structural module, since it lacks the bearing base and pre-formed monolithic bearing structure is thus should be used to mount the unit and it lacks means to form a facade layer with certain heat-insulating and hydrophobic properties and respective decorative options, when the production unit method is implemented.

[0008] A structural module comprising a facade layer, an inner layer and a bearing concrete building layers and a heat-insulating layer between these layers is also known in the art. The inner and bearing layers are made of expanded clay concrete and couple with rods penetrating through the heat-insulating layer made of expanded polystyrene grade 25. The facade layer is made of a mixture of gray or white cement, grade M-500 (M-400), broken natural stone, sand and water with addition of 10% plasticizing agent. The manufacturing method allows forming the facade layer during the process of manufacturing the structural module (Patent UA 14846 U published on 15.05.2006, Bulletin No. 5, 2006, IPC: E04C 1/40 (2006.01)).

[0009] The disadvantage of the module described above and the related manufacturing method is the lack of means to enhance heat-insulating and waterproofing parameters as well as the lack of means to improve manufacturability.

[0010] The method of manufacturing a structural module with a facade layer, comprising forming of a bearing monolithic base, followed by forming a heat-insulating layer, a reinforcing layer and a facade layer was chosen as a prototype. The structural module, thus, manufactured comprises the bearing monolithic base, the heat-insulating layer, the reinforcing layer and the facade layer (Invention Patent RU 2 336 395 C2 published on 20.10.2008, Bulletin No. 29, IPC: E04C 2/284 (2006.01), E04B 2/84 (2006.01)). The bearing base is an inner element made of reinforced expanded-clay concrete. The heat-insulating layer is made of foam plastic. The facade layer is made of a water-resistant gypsum-fiber sheet (WRGFS). The reinforced layer is made of fine-porous fiberglass grid. The structural module, also, comprises a heat-insulating, waterproofing and sound-insulating layer of extruded expanded polystyrene. The layers are coupled by gluing with a cavity on the top between the heat-insulating, waterproofing and sound-insulating layer of extruded expanded polystyrene and the heat-insulating of plastic foam. According to the method, the WRGFS facade layer is formed at the bottom of the mold followed by coupling the layer with the reinforcing layer by gluing followed by coupling the reinforcing layer with the heat-insulating, waterproofing and sound-insulating layer of extruded expanded polystyrene and forming an inner bearing base of reinforced expanded-clay concrete on the top.

[0011] The disadvantage of the method chosen as the prototype is a reduction of manufacturability of the structural model, since each layer in the structure of the wall module is formed separately. The structural module according to the prototype comprises the WRGFS facade layer, which may feature insufficient heat-insulating and waterproof properties and compressive strength that is important for external wall structures, thereby reducing the respective parameters of the module and necessitating forming additional layers in the module, in particular, the heat-insulating, waterproofing and sound-insulating layer.

[0012] The invention is based on the task to improve manufacturability of the structural module and, at the same time, to enhance heat-insulating and waterproof properties of the module and its strength as well as to simplify mounting of structural modules manufactured by the method disclosed by providing a certain consequence of actions to make each layer of the structural module and using components with certain properties for this purpose. A further result is simplifying technology for manufacturing the structural module having a facade layer, imitating a natural facing, such as brickwork etc.

[0013] This task is solved, so that in the method of manufacturing a structural module with a facade layer, comprising formation of a bearing monolithic base, followed by formation of a heat-insulating layer, a reinforcing layer and a facade layer, according to the invention, firstly, the facade layer is formed by placing a layer of hydrophobic filler on the bottom of the mold, placing an adhesive mixture, the reinforcing layer, the heat-insulating layer and bearing base thereon, and the adhesive mixture is then allowed to polymerize and spreadability of the adhesive mixture is within 7 cm to 70 cm and adhesion of the adhesive mixture to the heat-insulating layer is at least 0.5 MPa. To fix the heat-insulating layer on the bearing base, a fixing element is used with a dead end buried in the heat-insulating layer before the bearing base is formed followed by embedding an operating end of the fixing element in a layer of the bearing base.

[0014] Further, the adhesive mixture may have Brookfield viscosity within 800...60,000 MPa*sec.

[0015] Further, an external surface of the facade layer imitating brickwork may be made when the facade layer is formed.

[0016] The facade layer imitating brickwork may be formed by placing means to form a brickwork imitating surface on the bottom of the mold followed by placing the filler, the adhesive mixture and the reinforced layer into the mold.

[0017] A grid with a surface having antiadhesive properties for subsequent removal of the grid from the structural module once the facade layer is formed may be used as a means to form such brickwork imitating surface.

[0018] Protruding elements on the bottom of the mold may be used as a means to form such brickwork imitating surface.

[0019] Further, an external surface of the facade layer may be coated with an acrylic, mineral, silicon, silicate or alkyd-based lacquer.

[0020] Further, stone chippings may be used as filler.

[0021] Further, a frost-resistant adhesive mixture may be used.

[0022] Further, a fiberglass grid or metal wire or metal fittings or composite fittings may be used for the reinforcing layer.

[0023] Further, extruded expanded polystyrene or plastic foam or basalt wool or glass wool may be used as a heat-insulating material.

[0024] Facade concrete nails, metal fittings or composite fittings may be used as a fixing element to fix the heat-insulating layer onto the bearing base.

[0025] A reinforced base or expanded polystyrene concrete base may be used as a bearing monolithic base.

[0026] The further task of the invention claimed is to develop a structural module with a facade layer placed performing protective and decorative functions and having certain strength parameters allowing using of the structural module in the construction of one- and multistoried building to meet the required construction regulations and, at the same time, to reduce manufacturing costs of such structural module by changing the composition of the facade layer and certain ingredients used for that purpose.

[0027] This task is solved, so that in the structural module with the facade layer manufactured by the method above, comprising the bearing monolithic base, the heat-insulating layer, the reinforcing layer, the facade layer and the fixing element to fix the heat-insulating layer on the bearing base, according to the invention, the facade layer is formed by pouring a layer of the adhesive mixture onto the filler layer, and the facade layer is made so to achieve compressive strength of at least 16 MPa (as required by DSTU B.V.2.6-36:2008, Table 1). The dead end of the fixing element is buried in the heat-insulating layer, while the operating end of the fixing element is embedded in the bearing base.

[0028] Further, the facade layer may provide water absorption capacity within 0.1...0.6 kg/m².

[0029] Further, the facade layer may provide frost resistance of the structural module of at least 100 cycles.

[0030] Further, the external surface of the facade layer may be formed with separate brickwork imitating segments.

[0031] Further, thickness of the facade layer may be within 3...150 mm.

[0032] Further, it comprises decorative elements, coupled with the surface of the facade layer.

[0033] Facade concrete nails, metal fittings or composite fittings may serve as a fixing element to fix the heat-insulating layer on the bearing base.

[0034] A reinforced base or expanded polystyrene concrete base may be used as the bearing monolithic base.

[0035] The structural module manufactured by the method disclosed in the invention has the facade layer performing protective and decorative functions, that simplifies manufacturing of a building block and simplifies the design of such block and its weight, since there is no need for making separate means, such as a separate decorative layer, a protective layer and a layer providing heat-insulating properties. This is achieved by forming the facade layer, using the filler with certain properties and by coupling the filler with an adhesive mixture with other layers (such as reinforcing and heat-insulating ones), intended to form a heat-insulating and strong structure. The adhesive mixture further gets certain heat-insulating properties upon polymerization that enhances heat-insulating properties of the entire module in combination with heat-insulating properties of the facade layer made with the filler upon polymerization. Such structural module is ready-to-use for construction of buildings and there is no need to face walls constructed with further layers of a heat-insulating or water-resistant material. This simplifies construction of buildings considerably, since there is no operation of further facing walls with heat-insulating or water-resistant plates, that is quite a complicated process, especially at high heights. This further allows improving the quality of heat-insulating or waterproofing layers, thus, formed since such quality cannot be achieved when the walls constructed are further faced due to presence of various elements of building structured on the external surface of the wall of the building constructed and such heat-insulating and waterproofing layers should be coupled together. Further, a facade of a building made with the structural module with the ready facade layer made in consistent style will have higher esthetical standards in particular because there is no need to couple decorative elements at various sites together.

[0036] Further, forming of the facade layer in one technological cycle of manufacturing the structural module, i.e. concurrently with forming all layers of the structural module (such as the reinforcing layer, the heat-insulating layer and the bearing base) provides significant improvement of manufacturability of the structural module by reducing the time for forming the facade layer and simplifying the related technological operations. This is achieved by forming the facade layer by placing the hydrophobic filler on the bottom of the mold, placing the adhesive mixture thereon, pressing the adhesive mixture by the reinforcing layer, the heat-insulating layer and the bearing monolithic base on the top, followed by exposure in the mold, until the adhesive mixture polymerizes and adheres to the heat-insulating layer, so the adhesive mixture penetrates the required depth of the layer of the filler layer until the facade layer of the required thickness is obtained, at the one side, and adheres to the heat-insulating layer, on the other side, followed by formation of the structural module.

[0037] The facade layer, thus, formed in combination with other layers, such as heat-insulating layer and the bearing one should meet the requirements of the building standards applicable to climatic conditions, where the module is to be used, in particular, heat insulation and waterproofing standards, and should have sufficient strength parameters considered crucial for construction of external walls of a building. The above parameters will apparently be defined by certain components used in the facade layer and the properties thereof as well as by parameters of the technological process, i.e. facade layer formation stage.

[0038] To ensure compliance with the building standards above, the inventor conducted a series of studies identifying properties of components to form the facade layer, specifically the adhesive mixture, and parameters of the technological process when the mixture is used. During the series of studies, the inventor found out that the strength of the facade layer depends on the parameters of spreadability of the adhesive mixture. The findings of tests are presented in Table 1 (spreadability of the adhesive mixture was defined on a Vicat apparatus by methods described in DSTU B V.2.7-126:2011 (Table 5), compressive strength of the facade layer was defined by methods, described for wall materials ,using samples as required by GOST 8462-85 and DSTU B V.2.6-36:2008, Section 13).

Table 1. Strength of the facade layer vs. spreadability of the adhesive mixture

Spreadability of the adhesive mixture, cm	Compressive strength of the facade layer, MPa
5	36
7	35
10	34
20	32
30	30
40	29
50	27
60	25
70	18
80	16
90	10

[0039] As a part of studies, optimal parameters of spreadability of the adhesive mixture were identified to form thickness of the facade layer that meets heat insulation and waterproof requirements and provides compressive strength of the facade layer. The findings are presented in Table 2 below. The method of measuring spreadability was similar to that used in testing presented in Table 1 above.

Table 2. Thickness of the facade layer vs. spreadability of the adhesive mixture

Spreadability of the adhesive mixture, cm	Thickness of the facade layer, mm
5	Not formed
7	150
10	100
20	80
30	50
40	30
50	15
60	10
70	5
80	5
90	5

[0040] According to Tables 1 and 2, spreadability parameters of the mixture are optimal within a certain range, in particular, when spreadability of the adhesive mixture is within 7 to 70 cm, i.e. in this particular interval of values spreadability of the adhesive mixture is necessary to achieve the required parameters of compressive strength for the facade layer and to keep thickness of the facade layer within 3 to 150 mm, so the requirements to heat-insulation and waterproofing are ensured for the entire structural module. Using the adhesive mixture having spreadability above the range defined, i.e. with high spreadability value, may cause relatively low compressive strength, caused by quite low degree of polymerization of the adhesive mixture and uneven spreading of the adhesive mixture along thickness of the filler. Using the adhesive mixture having spreadability below the range defined, i.e. quite thick mixture, may, instead, cause insufficient filling of gaps between particles of the filler and its inner pores, which eventually reduces compressive strength of the facade layer and does not allow obtaining the required thickness of the facade layer.

[0041] Providing the adhesive mixture having Brookfield viscosity within 800...60,000 mPa*sec at casting is related to spreadability parameters, and keeping this range is also required to form the facade layer having strength parameters of at least 16 MPa and thickness of the facade layer within 3...150 mm as discussed above. To identify the optimal range of viscosity of the adhesive mixture, ISO 2555 testing methods (Rotor N 4, 20 rpm, t = 23 °C.) were applied.

[0042] Further, such spreadability and viscosity parameters of the adhesive mixture allow improving manufacturability of the structural module by simplifying application of the adhesive mixture onto the surface of the filler and reducing the need to control the quality of penetration of the mixture into the filler as well as to mitigate a human factor on the quality of filling with the adhesive mixture.

[0043] To achieve the required compressive strength the inventor found out, that adhesion of the adhesive mixture with the heat-insulating layer should be at least 0.5 MPa, since lower values of adhesion may cause insufficient strength of the protective layer and its early damage caused by external factors.

[0044] Further, using of expanded polystyrene concrete bearing monolithic base provides more light-weighted structural module and, at the same time, improves its heat resistance compared with that of the reinforced concrete base.

[0045] Placing the fixing element to fix the heat-insulating layer on the bearing base with a dead end buried in the heat-insulating layer before the bearing base is formed followed by embedding the operating end of the fixing element with a layer of the bearing base provides significant improvement to the manufacturability of the module, since there will be no need for such technological operations as providing a site for installing the operating end of the fixing element in the bearing base (in particular, boring a hole in a monolithic base), embedding the dead end of the fixing element in the heat-insulating layer (in particular, boring a through hole in expanded polystyrene), spreading the operating end of the fixing element in the bearing base (e.g. installing a spread bar in the fixing element). Further, embedding the operating end of the fixing element inside the bearing base allows enhancing reliability and strength of the bearing element and the heat-insulating layer, which may be impacted by boring operations (especially, in the bearing element) etc. Embedding the fixing element inside the bearing base of the module at a length of 5 to 15 cm helps to improve the reliability of fixation of the heat-insulating layer on the bearing base and achieve compliance with building standards, in particular, DSTU B.V.2.6-36:2008 (Table A.6 and Addendum G). A facade concrete nail e.g. made of plastic and used as a fixing element to fix the heat-insulating layer on the bearing base allows preventing heat bridges on the facade surface of the building, so constructed, which, when taken together, decrease heat-insulation properties of the wall structure to a considerable extent.

[0046] Making the brickwork imitating external surface of the facade layer, when the facade layer is formed, helps to further simplify manufacturability of the structural module, which facade surface should have certain decorative properties. Forming the brickwork imitating surface of the facade layer by placing means for forming the brickwork imitating surface on the bottom of the mold followed by placing a layer of the filler, the adhesive mixture and the reinforcing layer, allows separating the structural module with the facade layer, so formed from the mold or means for forming the brickwork imitating surface.

[0047] Making the means for forming the brickwork, imitating surface as a grid with a surface, having antiadhesive properties or as protruding elements located on the bottom of the mold allows simplifying removing of the means for forming surface from the structural module, when the facade layer is formed.

[0048] Coating of the external surface of the facade layer with an acrylic, mineral, silicon, silicate or alkyd-based lacquer allows fixing the filler on the facade layer, such as stone chippings, thus to provide additional protection for external surface of the facade layer and enhance its hardness and improve heat-insulating and waterproofing properties of the facade layer and to achieve certain hardness of the facade layer surface. Using such coat will provide stability of decorative parameters of the external surface of the facade layer, such as in particular colour, for a long period of time.

[0049] Using stone chippings as filler allows simplifying manufacturability of the structural module by simplifying formation of the facade layer, since the adhesive mixture penetrates cavities between particles of the filler (stone chippings).

[0050] Using the frost-resistant adhesive mixture provides frost resistance of at least 100 cycles for the entire structural module.

[0051] Using a fiberglass grid or metal wire or metal fittings or composite fittings to form the reinforced layer allows enhancing strength of the module and, at the same time, to enhance of manufacturability.

[0052] Using extruded expanded polystyrene or plastic form or basalt wool or glass wool as a material for the heat-insulating layer provides improved heat-insulating properties of the module and fire safety when it is manufactured and used in the construction.

[0053] Manufacturing of the structural module with the facade layer made by casting a layer of the adhesive mixture onto a layer of the filler and having compressive strength of at least 16 mPa, water absorption capacity within 0.1...0.6 kg/m² and frost resistance of at least 100 cycles provides the required strength parameters which allow using the structural module in the construction of one- and multistoried buildings as required by the applicable building standards.

[0054] Forming of the external surface of the facade layer with separate segments imitating brickwork by casting a layer of the adhesive mixture onto a layer of the filler allows simplifying the technology of manufacturing the module and reduces its production costs.

[0055] Making the facade layer having thickness within 3...150 mm provides the required heat-insulating and waterproofing parameters as well as compressive strength with due consideration of climatic conditions in which the module is used.

[0056] Available decorative elements, such as hanged elements made of expanded polystyrene having the form of architectural elements - columns, cornices and the like - couple with the surface of the facade layer allow making a pre-designed facade of a building without further facing operations after mounting of modules and ensuring further protection of the facade surface in terms of strength, heat insulation and waterproofing. Thus, using decorative elements allows using the same means to form the external appearance of the building and to achieve the required heat-insulating and waterproofing properties.

[0057] The invention claimed is illustrated by the following exemplary embodiment of the method of manufacturing the structural module with the facade layer and the structural module, thus manufactured.

[0058] Figurative materials, that illustrate the invention claimed as well as a particular embodiment of the structural module with the facade layer are merely exemplary in nature and are in no way intended to limit the claims appended hereto but to explain the essence of the invention.

[0059] According to the method of manufacturing the structural module disclosed herein, firstly, the facade layer is formed by placing a layer of hydrophobic filler on the bottom of the mold. Stone chippings of mineral or artificial origin, such as marble or granite, may be used as such hydrophobic filler. Further, the adhesive mixture is placed until it is spread over the entire surface of the filler filling pores and gaps between particles of the filler. The layer of the adhesive mixture may be smoothed on the surface of the filler mechanically using methods known in the art, which, in particular, are used for liquid floor mixtures. The reinforcing layer and the heat-insulating layer are then placed over the layer of the adhesive mixture. Before the heat-insulating layer is placed, fixing elements should be embedded therein to fix the heat-insulating layer on the bearing base. When facade concrete nails are used as such fixing elements, through holes are bored inside the heat-insulating layer, concrete nails are inserted in such holes, and the heat-insulating layer is then fixed on the layer of the adhesive mixture with operating ends of fixing elements upwards. The bearing base is then formed on the top of layers of the filler, the adhesive mixture and the heat-insulating layer by placing the reinforcing frame manufactured in the mold over the heat-insulating layer followed by filling the mold with concrete, until the required thickness of the bearing base is achieved. Operating ends of fixing elements are placed inside the layer of the bearing base (concrete) followed by embedding fixing elements until concrete hardens. To form a bearing monolithic base, expanded polystyrene concrete may be used.

[0060] Further, the multilayered structure, thus, produced is then allowed to stand until the adhesive mixture penetrates to the bottom of the mold (i.e. along entire thickness of the filler layer) and the adhesive mixture polymerizes followed by removing the finished structural module from the mold.

[0061] When the module is manufactured, window or door systems or external decorative elements or hanged systems (e.g. balconies and the like), may be installed, and this will further simplify construction of the building using such structural modules. Decorative elements may have mechanical fastening to the facade layer and bearing base, e.g. using coupling fixing elements, anchor bolts etc.

[0062] Spreadability of the adhesive mixture when placed must be within 7 to 70 cm and Brookfield viscosity must be within 800...60,000 MPa*sec. The adhesive mixture is frost-resistant. A fiberglass grid or a grid structure based on metal wire, metal fittings or composite fittings, in particular, of circular section is used as the reinforcing layer. Extruded expanded polystyrene or plastic foam or basalt wool or glass wool having low combustibility without gas emission meeting the required fire safety regulation is used as the heat-insulating material.

[0063] When the brickwork imitating external surface of the facade layer is required, means to form such brickwork imitating surface are placed on the bottom of the mold, followed by placing the layer of the filler, the adhesive mixture and the reinforced layer into the mold, and the bearing base is then formed as disclosed above. A grid with a surface having antiadhesive properties to remove the grid from the structural module once the facade layer is formed may be used as a means to form the brickwork imitating surface. The profile of the grid is made, so that when its elements are filled with the filler followed by polymerization of the adhesive mixture, a pattern is formed on the external surface of the facade layer which, in particular, imitates brickwork.

[0064] In one embodiment, protruding elements located on the bottom of the mold made in the way similar to that used for a grid to form a certain pattern on the external surface of the facade layer may be used as a means to form the brickwork imitating surface.

[0065] Antiadhesive properties of means to form the surface ensure a chemical reaction between the material of such means and that of the filler, e.g. stone chippings, to allow removing the grid or the mold from the structural module.

[0066] Further, external surfaces of the facade layer may be coated with an acrylic, mineral, silicon, silicate or alkyd-based lacquer.

[0067] The finished structural module comprises the bearing monolithic element, the heat-insulating layer, the reinforcing layer and the facade layer, i.e. made so to have all components required to construct a building and provide all heat-insulating and waterproofing parameters so required. The facade layer made by pouring a layer of the adhesive mixture onto the layer of filler followed by polymerization features compressive strength of at least 16 MPa and water absorption capacity within 0.1...0.6 kg/m², thus providing improved resistance of the facade layer and stability of heat-insulating and waterproofing parameters for a long period of time.

[0068] When surface forming means having the form of a grid or protruding elements inside the mold are used to form the facade layer, its surface will be made with separate segments imitating brickwork. The module may further have decorative elements fixed on the surface of the facade layer. Decorative elements may have the form of columns, poles, cornices and the like and may be made of expanded polystyrene and fixed on the facade layer with the adhesive mixture.

[0069] Thickness of the facade layer is within 3...150 mm considering the climate conditions and the applicable building standards. Frost resistance of at least 100 cycles for the structural module allows using it in the climate of northern countries.

[0070] Thus, the invention claimed provides enhanced manufacturability of the structural module, especially, when the facade layer imitating natural facing, such as brickwork etc. should be made and, at the same time, heat-insulating and waterproofing properties and strength of the module should be enhanced and provides easier-to-mount structural modules, constructed by the method claimed and simplified the technology of manufacturing such structural module.

Claims

1. A method of manufacturing a structural module with a facade layer which comprises formation of a bearing monolithic base followed by formation of a heat-insulating layer, a reinforcing layer and a facade layer, wherein, firstly, the facade layer is formed by placing a layer of hydrophobic filler on the bottom of the mold, placing an adhesive mixture, a reinforcing layer, a heat-insulating layer and a bearing base thereon, and the adhesive mixture is then allowed to polymerize and spreadability of the adhesive mixture is within 7 cm to 70 cm and adhesion of the adhesive mixture to the heat-insulating layer is at least 0.5 MPa, and, to fix the heat-insulating layer on the bearing base, a fixing element is used with a dead end buried in the heat-insulating layer before the bearing base is formed followed by embedding an operating end of the fixing element in a layer of the bearing base.

2. The method of manufacturing the structural module of claim 1, wherein Brookfield viscosity of the adhesive mixture is within 800...60,000 MPa*sec.

3. The method of manufacturing the structural module of claim 1, wherein an external surface of the facade layer imitating brickwork is made when the facade layer is formed by placing a means to form the brickwork imitating surface on the bottom of the mold followed by placing the filler, the adhesive mixture and the reinforced layer into the mold and protruding elements on the bottom of the mold may be used as a means to form the brickwork imitating surface.

4. The method of manufacturing the structural module of claim 3, wherein a grid is used as a means to form the brickwork imitating surface and the surface of the grid has antiadhesive properties to remove the grid from the structural module once the facade layer is formed.

5. The method of manufacturing the structural module of claim 1, wherein the external surface of the facade layer is further coated with an acrylic, mineral, silicon, silicate or alkyd-based lacquer.

6. The method of manufacturing the structural module of claim 1, wherein a fiberglass grid or metal wire or metal fittings or composite fittings are used for the reinforcing layer.

7. The method of manufacturing the structural module of claim 1, wherein extruded expanded polystyrene or plastic foam or basalt wool or glass wool are used as the heat-insulating material.

8. The method of manufacturing the structural module of claim 1, wherein facade concrete nails or metal or composite fittings are used as a fixing element to fix the heat-insulating layer onto the bearing base.

9. The method of manufacturing the structural module of claim 1, wherein a reinforced base or an expanded polystyrene concrete base is used as a bearing monolithic base.

10. A structural module with a facade layer manufactured by the method of claim 1, comprising a bearing monolithic base, a heat-insulating layer, a reinforcing layer, a facade layer and a fixing element to fix the heat-insulating layer on the bearing base, wherein the facade layer is formed by pouring a layer of the adhesive mixture onto the filler layer, and the facade layer is made so to achieve compressive strength of at least 16 MPa, and a dead end of the fixing element is buried in the heat-insulating layer, while an operating end of the fixing element is embedded in the bearing base to the length of the fixing element within 5...15 cm.

11. The structural module of claim 10, wherein the external surface of the facade layer is made by separate segments imitating brickwork.

12. The structural module of claim 10, wherein thickness of the facade layer is within 3...150 mm.

13. The structural module of claim 10, wherein there are decorative elements coupled with the surface of the facade layer.

14. The structural module of claim 10, wherein a facade concrete nail or an element of metal or composite fittings serve as a fixing element to fix the heat-insulating layer on the bearing base.

15. The structural module of claim 10, wherein the reinforced concrete base or the expanded polystyrene concrete base is used as a bearing monolithic base.