DE102010011213A1 - Construction unit for roof structure, has intermediate cover made from foamed prefabricated elements for buildings, where individual parts are foam-filled according to modular system - Google Patents

Abstract

The construction unit has an intermediate cover made from foamed prefabricated elements for buildings. The individual parts are foam-filled according to a modular system in forms with an expanding, fine pored hardening and tough-hard plastic. The forms are formed by integrated components. All individual parts are built and connected such that a complete production unit for roof covering of a building is formed.

Description

A complete roof body is foamed in composable parts in forms with fine-pored tough-hardening foam. A stable, weather-resistant outer coating of the roof surface, if necessary. Reinforced polyester resin, and interior trim elements are mold components.

The roof parts receive dimensional stability guaranteeing elements. In foamed pipes run round steel inserts, around which straps are looped. With them, the roof items are securely connected by means of belt tensioner.

• – rundum fest verbunden.
• – mehrfach wird der Dachaufbau quer verbunden.

The joined roof items will be:

• - firmly connected.
• - several times the roof structure is connected across.

The seated roof is fixed vertically with screws. These are anchored in the ring anchor. These anchor bolts can, in other construction, also extend into the concrete foundation.

Exterior walls, possibly also with false ceiling and roof, now form a solid unity.

The transverse clamping seals the appropriately prepared roof tops externally.

A false ceiling is filled to size in a mold. It is made load-bearing with cast-in elements, receives in the same casting a floor covering and a ceiling facing.

After installation, the roof structure and false ceiling become one unit.

State of the art

A roofing according to conventional design is a complex construction as completion on a building.

Even at a single-family home, it is a significant cost factor. Many disciplines, specialist trades and craftsmen contribute their experience and skills. Many different materials are used and work, especially for physical reasons, not always optimally together.

There are stones, metals, wood, plastic films and massive components, minerals of different consistency, colors, sealants, etc. in use. Nevertheless, especially in the roof area, the heat loss, which is so important for the life cycle assessment, can only be contained to a certain extent - usually in a complex, costly construction or retrofitting process.

A roof construction always means a greater expenditure of time in a construction work. Despite many optimizations, it often takes weeks to complete a roof.

Decades ago, it was enough to meet the requirements of a roof that protected against wind and weather. In recent decades, the question of thermal insulation has increasingly come to the fore. Energy loss became a dreaded term when it came to roof construction.

A traditional construction roof has been continually optimized, re-equipped and equipped to curb heat losses in countless ways. Every small success became more and more expensive and in the end hardly pays off. Government grants should provide incentives for conversion and expansion. The general LCA is used as a justification for the expensive investments.

Nevertheless, the conversions and extensions of roof structures remain patchwork, the borders are visible.

A complete rethinking of a new construction process and execution is now urgently needed.

The goal

My goal is to reduce the energy loss through the roof structure to zero.

simultaneously

• - Costs should be reduced.
• - The energy loss should be as close to zero as possible.
• - The assembly or assembly time on site should be greatly reduced.
• - The neighborhood should not be bothered by construction noise and air pollution.
• - The entire structure should weigh only fractions.
• - The structure should be homogeneous and can be put together to form a roof piece.
• - The roof surface should be designed by a special color and technical design so that heat and sunlight is largely reflected and a storm largely the attack surfaces are taken for destructive action. No roof parts are allowed to fly around anymore.
• - All parts for the roof should be prefabricated in terms of production. Low loaders should bring them to construction.
• - The roof unit should be technically connected directly to the foundation.
• - The roof unit should be collapsible.
• - Light weight should be sufficient for lightweight construction.
• - The roof unit should be together with a new, appropriately crafted false ceiling, by suitable fasteners to a unit.
• - In connection with a new construction method for the house construction in general, from the foundation to the roof ridge a single, firmly interconnected construction should be possible without mortar and concrete.

The individual parts of the roof are to be manufactured as molded parts and injected with an advanced assembly foam type. They are made in such a way that they can be completely assembled with a room or ceiling ceiling created in the same way.

The binding of the individual roof parts with each other should create a simple but safe construction structure. The bindings should be designed so that they practically, both laterally and in the seat on the outer wall, the joints without joints.

For a mounting of the roof largely trainees should be able to be used.

The roof, including false ceilings, should be dismantled without problems and then reassembled and reused elsewhere.

For the ceiling or false ceiling, the same construction principle should apply. Simple, commercially available, inexpensive deposits, such as z. As aluminum ladders, should ensure the desired carrying capacity after calculation.

This is a floor covering, such. B. chipboard or plywood panels, and for the underside of the ceiling a complete panel -. B. Rigips or plywood - can be used as mold parts. Thus, the floor and the ceiling should be largely finished without aftertreatment. The ceiling edges should be coated with plastic.

The so-called attic is to become an exceptionally protected space, given by the perfect insulation on all sides, in which heat storage, buffers, boilers, heat exchangers, heat recovery systems, etc., can be installed without great expense of insulation technology. Expensive effort for their individual insulation should be eliminated.

Photovoltaic systems and solar collectors should be able to be integrated into the roof surfaces on the manufacturer's side, if possible without further operations.

In conjunction with an outer wall insulation, z. B. existing buildings, the zero energy house should be possible.

A real zero energy house should, with the same construction principle of all supporting and separating walls, in connection with the roof unit and the room or false ceiling, arise.

Due to the compact, yet lightweight construction, the construction should survive even severe wind phenomena or strong earthquakes without damage. Especially the roof damage should belong to the past.

The assembly technique should allow a simple dismantling by loosening the vertical screw and belt connections. Also, a transport and reuse of the roof body on another, uniform dimensioned structure, should thus be possible.

After dismantling all components should be recycled and / or made reusable.

Description of the invention

Part 1.

Summary

The description is based on a one-storey residential building or bungalow with approximately 100 m ² living space as an example.

The roof shape is preferably a hipped roof.

All dimensions are based on the valid building regulations.

The complete roof construction consists of assembled, firmly connected, large-scale individual parts. (Referred to as roof items) 3 and 4

To the roof construction belongs the final ceiling over the living units. Roof construction and ceiling are combined into one unit. 8th . 10 , and 11 ,

The roof and the ceiling construction consist of composite and permanently connected large-scale individual parts. The ceiling as a ceiling body, is custom made according to the space size to be covered. 8th ,

All individual parts or bodies are formed dimensionally accurate in a mold. The shape is partially formed by roof or ceiling components. It is completed and limited with suitable plastic parts, panels. The internal parts of the mold are filled with a filling compound. For this purpose, a fine-pored foaming, tough-hard-hardening foam mass is used. This filling material can consist of both natural and synthetic substances.

The roof components used are z. B .: The roof itself, possibly with solar panels and photovoltaic panels, the covering of the roof overhang, an interior wall cladding, the internal connection and hardening elements and cables or other lines. 5 . 6 . 7 and 9 ,

The following components are integrated in the room or suspended ceiling: sturdy flooring, the ceiling covering, lamps, ventilation, cables or other cables. In the foam body reinforcing elements are integrated, which ensure the carrying capacity. The edges of the ceiling are true to size with apertures, which form the completion of the components. They are formed on the outer edge as a contact connections with the roof body. 8th and 10

Part 2.

The roof, a production process

• (1.) The roof surface is molded from plastic. Particularly strong, even with thin wall thickness, is glass fiber reinforced Poyester.

The color or structuring can be chosen. The surface should however be coated for the lowest possible heat absorption and offer no attack surfaces for strong wind.

Either the roof surfaces are designed so that they overlap at the joint with the neighboring part or the shock itself gives the possibility of covering the joint.

The edge of the roof is structured and receives a protective layer of also robust, weather-resistant, prefabricated plastic parts. 9 ,

The inside of the roof part receives a coating that can be called wall cladding. It consists of Rigips, plywood, chipboard or similar. The loft will present itself fully lined. 10 ,

A border with a plastic layer closes the auszuschäumenden volume of the roof part form. After curing of the foam, the roof part is ready for installation.

At the point where the roof part on the outer edge region of the false ceiling (2.) above up and laterally applied, a seal is installed. 9 and 10 ,

In the inner mold thick-walled plastic pipes are laid according to plan and forecasts, in the partial round steel inserts are introduced. Around these straps are looped, which are intended for the binding of the roof parts with each other by means of belt tensioner. 9 ,

The roof section is reinforced with a tubular mesh construction, which is designed according to the forces acting on it. For this purpose, a range of plastic pipes and fasteners is provided. Tubes are cut to length as needed, inserted into the fasteners and glued. 5 ,

For the assembly and binding of the individual roof parts appropriately sized recesses are embedded. 11 ,

The straps, at least of the quality used to fasten a truck load, are tangible in the inserted tubes on the sides of the roof parts. They are introduced in belt tensioners, so that the roof parts are pulled together and firmly connected with a correct fit. 11 ,

About joints and joints of the inner wall panels strips are set.

Each roof part is connected, across the attic, with the opposite roof part in the same way. A belt is stretched near the ridge and a second near the floor of the false ceiling. For the same purpose straps can secure the seat and the connection of the roof body along the structure. These last-mentioned longitudinal and transverse stresses cause, by the dimensionally accurate production, a pressure of the protruding roof body part on the outside of the false ceiling. (2.) 2 . 9 . 10 and 12 ,

In cooperation with the vertical screw thus creates a compact, hermetically sealed assembly of roof body and false ceiling, which is firmly connected as a whole with the foundation or at least with the ring anchor. The lightweight full-body construction has a secure stability.

The strained and running on the floor belt is covered with a screwed cover strip. 2 . 9 . 10 and 12 ,

The inserted in the tubes of the roof parts round steel parts are heavily corrugated or it is used for simplicity because of commercial threaded rods. M25-M30. Reason: Due to the oblique approach of the straps for the cross connections, these are secured by the threads against slipping. To prevent this, it is also possible to retract cross-laid steel parts in the roof body part. 6 and 7 ,

• (2.) Die Zwischen- oder Zimmerdecke wird ebenfalls in einer Form ausgeschäumt. Die Oberseite wird von einem großflächigen Belag, auch als Fußbodenbelag gebildet. Die Unterseite erhält eine Verkleidung die aus Rigips, Schichtholz, Spanplatten, Holz, Kunststoff oder anderen Materialien besteht. 2.

Do a deconstruction, all components can be reused (steel and straps) or recycled.

• (2.) The intermediate or ceiling is also filled with foam in a mold. The top is made of a large surface, also as a floor covering. The underside receives a cladding made of plasterboard, plywood, chipboard, wood, plastic or other materials. 2 ,

The mold to be filled with foam consists of the floor covering and the lining of the underside. The edges around are finished with suitable plastic parts. 8th and 10 ,

Each room in a building structure is given its own, according to the dimension of room or ceiling tile. She separates the room from the attic. It contains elements that provide the desired load and ensure the load capacity. The safest, cheapest and simplest is to use an aluminum conductor construction as an insert - also commercially available ladders are suitable. This ladder structure is inserted into the mold and locked at desired locations. The false ceiling mold is foamed with synthetic plastic. The foam itself should be fine-pored and tough-hard after curing. It makes an intimate connection with the floor covering, the underside covering and the reinforcing inserts, such as the ladder structure. 8th and 10 ,

In an intermediate ceiling part an opening is left to the attic. It must be such that it does not become leaky after the fitting has been fitted.

Near the outer edge vertically arranged pipe sections are embedded as passages for the continuous from the ground to the roof anchor bolts.

After complete installation of the intermediate ceiling parts, the roof is put on. Due to the pressure of the roof body tension, all intermediate ceiling parts are pressed together immovably. You can also have their own fasteners on the seat of the walls.

• (3.) Die Energiebilanz für das beschriebene Haus ist gegenüber der herkömmlichen Bauweisen unschlagbar. Dass sich ein solcher Bau durch eine positive Energiebilanz auszeichnen kann, ist offensichtlich, sollte aber erst durch die Praxis bewiesen werden.

The so-called attic is such an exceptionally protected space, given by the all-round perfect insulation. In it can be installed without great effort to insulation, heat storage, buffers, boilers, heat exchangers, heat recovery systems, etc .. A simple insulation of these technical facilities is sufficient. Expensive effort for their individual insulation can be omitted for the devices.

• (3.) The energy balance for the house described is unbeatable compared to conventional construction methods. That such a building can be characterized by a positive energy balance is obvious, but should only be proven by the practice.

Due to the lightweight construction of roof construction and false ceiling, the layout of the building can be designed in lightweight construction. Savings can also be made on the foundations.

LIST OF REFERENCE NUMBERS

1

Integrierte oder vom Hersteller montierte Sonnenkollektoren

2

Integrierte oder vom Hersteller montierte Fotovoltaikpanelen

Fig. 2

3

Querschnitt durch Dachteil, einseitig

4

Rohrstutzen für die Verschraubung der Gewindestange mit dem Dach

5

Stahleinlage mit Gewinde

6

Firstabdeckung

7

Speichergeräte für Strom und Warmwasser

8

Wärmeaustauscher

9

Dachrinne

10

Dachrinnenabfluss

11

Gewindestange verankert im Betonfundament

12

Fundament

Fig. 3

1

Leerrohre für die Dachteilebindung rundum

Fig. 4

2

Leerrohre für die Dachteilebindung zur Mittellinie-Querverbindung

3

Dachteil

Fig. 5

1

Die Montageform des Dach(teile)herstellers

2

Dachteil

3

Beispiel für eine Gittereinlage in einem Dachteil

4

Steckverbindungen

Fig. 6

1

Die Stahleinlage besteht aus einer Gewindestange mit D 20–25 mm.

2

Rohrstutzen zur Aufnahme der Gewindestangen aus dem Fundament

3

Leerrohre zur Aufnahme der Stahleinlage und des Gurtes für die Bindung zur Mittellinie-Querverbindungen

4

Wandstarke Leerrohre zur Aufnahme der Stahleinlagen. Die Gurtschlaufen für beide Bindungsrichtungen werden hier eingeklinkt.

5

Rohrstutzen zur Aufnahme der Gewindestangen aus dem Fundament. Eine Klammer auf der Gewindestange wird über die Stahleinlage gelegt und mit einer Mutter festgezogen. Der Rohrstutzen steht über und wird nach der Befestigung verschlossen.

Fig. 7

1

Giebelteil

2

Stahleinlage

3

Leerrohre zur Aufnahme des Gurtes für die Rundumbindung, der obere Teil

4

Auflage für die Außenwand

5

Wandstarke Leerrohre zur Aufnahme von Stahleinlagen für die Bindung zur Mittellinie-Querverbindung

6

Gitterartige Einlage zur Versteifung, Stabilisierung und Verbesserung der Tragfähigkeit

7

Stahleinlage 25–30 mm

Fig. 8

1

Bodenbelag Spanplatte oder Schichtholz

2

Rund um das Deckenteil wird eine Winkelleiste als Deckenteil-Abschluss auf das Leitergestell aufgeschraubt.

3

Integrierte Deckenleuchte

4

Deckeninnenverkleidung

5

Aluleiter

6

Formenelemente für außen oder innen

Fig. 9

1

Bedachung aus faserverstärktem Kunststoff

2

Stahleinlage 25–30 mm

3

Gurtschlaufe um die Stahleinlage

4

Versiegelung mit Kunststoff

5

Gitterkonstruktion zur Stabilisierung des geschäumten Dachteils, auf der Abbildung doppelte Lage

6

Überblendung Außenteil der Decke mit Dichtungseinlage

7

Gurtspanner

8

Außenwandverkleidung

9

Gurt

Fig. 10

1

Bedachung aus faserverstärktem Kunststoff

2

Dickwandiges Rohr zur Aufnahme der Stahleinlage

3

Spannbügel

4

Abdeckung des Rohrstutzens

5

Stahleinlage 25–30 mm

6

Geschäumter Dachkörperteil

7

Rohrstutzen für die Verschraubung der Gewindestange mit dem Dach

8

Geschäumter Dachkörperteil

9

Überblendung Außenteil der Decke

10

Dichtungseinlage

11

Montagedurchgang im Deckenteil

12

Deckenverkleidungsteil

13

Trageelement Aluleiter

14

Deckenverkleidung

15

Belastbare Lauffläche aus Spanplatte oder Schichtholz

16

Gitterkonstruktion zur Stabilisierung des geschäumten Dachteils, hier einfach innenliegend

17

Außenwand

18

Außenwandverkleidung

19

Innenwandverkleidung

20

Betonfundament

21

Fliesen

22

Gewindestange im Fundfament verankert

23

Innenbeschichtung oder Wandverkleidungselement

Fig. 11

1

Dachrandseite

2

Der Gurt hat die Stahleinlage mit einer Schlaufe umfasst

3

Fügung zweier Dachkörperteile

4

Der Gurt

5

Dickwandige Rohre, Panzerrohre, zur Aufnahme der Stahleinlagen

6

Dachgiebelseite

7

Stahleinlage 25–30 mm

8

Montageaussparung; Freiraum zum Gurtspannen

9

Gurtspanner

10

Einfache Plastikrohre zur Führung des Gurtes

Fig. 12

1

Schlaufe um die Stahleinlage

2

Gurtspanner

3

Obere Dachkörperbindung

4

Abdeckleiste zum Schutz eines Gurtes und des Gurtspanners

5

Untere Dachkörperbindung

6

Dickwandiges (Panzerrohr) Rohr zur Aufnahme der Stahleinlage

7

Durch das Festziehen der unteren Dachkörperbindung wird, nach entsprechender Vorbereitung, die Deckenlage durch die besondere Ausformung des Dachrandes abgedichtet.

Fig. 1

1

Integrated or manufacturer-mounted solar panels

2

Integrated or manufacturer-mounted photovoltaic panels

Fig. 2

3

Cross section through roof part, one-sided

4

Pipe socket for screwing the threaded rod to the roof

5

Steel insert with thread

6

First cover

7

Storage devices for electricity and hot water

8th

heat exchangers

9

gutter

10

Gutter drain

11

Threaded rod anchored in concrete foundation

12

foundation

Fig. 3

1

Empty pipes for the roof part binding all around

Fig. 4

2

Empty pipes for the roof part binding to the center line cross connection

3

roof part

Fig. 5

1

The mounting form of the roof (parts) manufacturer

2

roof part

3

Example of a grid insert in a roof part

4

connectors

Fig. 6

1

The steel insert consists of a threaded rod with D 20-25 mm.

2

Pipe socket for receiving the threaded rods from the foundation

3

Conduits for receiving the steel core and the belt for binding to the centerline cross connections

4

High-walled empty pipes for receiving the steel inserts. The belt loops for both binding directions are latched here.

5

Pipe socket for receiving the threaded rods from the foundation. A clamp on the threaded rod is placed over the steel insert and tightened with a nut. The pipe socket stands over and is closed after fixing.

Fig. 7

1

gable

2

steel insert

3

Conduit for receiving the belt for the Rundumbindung, the upper part

4

Pad for the outer wall

5

High-walled conduits for receiving steel inserts for binding to the center line cross-connection

6

Grid-like insert for stiffening, stabilizing and improving the carrying capacity

7

Steel insert 25-30 mm

Fig. 8

1

Flooring chipboard or plywood

2

Around the ceiling part, an angle bar is screwed as a ceiling part completion on the ladder rack.

3

Integrated ceiling light

4

Ceiling interior trim

5

aluminum ladder

6

Mold elements for outside or inside

Fig. 9

1

Roof made of fiber-reinforced plastic

2

Steel insert 25-30 mm

3

Belt loop around the steel insert

4

Sealing with plastic

5

Lattice construction for stabilization of the foamed roof part, on the picture double layer

6

Crossfade outer part of the ceiling with sealing insert

7

Belt tensioner

8th

Wall cladding

9

belt

Fig. 10

1

Roof made of fiber-reinforced plastic

2

Thick-walled tube for receiving the steel insert

3

tensioning bow

4

Cover of the pipe socket

5

Steel insert 25-30 mm

6

Foamed roof body part

7

Pipe socket for screwing the threaded rod to the roof

8th

Foamed roof body part

9

Crossfade Outer part of the ceiling

10

gasket

11

Mounting passage in the ceiling part

12

Roof trim member

13

Carrying element aluminum ladder

14

ceiling panel

15

Resilient tread made of chipboard or plywood

16

Grid construction for the stabilization of the foamed roof section, here simply inside

17

outer wall

18

Wall cladding

19

Interior wall paneling

20

concrete foundation

21

tiling

22

Threaded rod anchored in the foundament

23

Interior coating or wall cladding element

Fig. 11

1

Roof edge side

2

The strap has the steel insert with a loop included

3

Filling two roof body parts

4

The belt

5

Thick-walled pipes, armored pipes, for receiving the steel inserts

6

Gable page

7

Steel insert 25-30 mm

8th

Mounting recess; Free space for belt tensioning

9

Belt tensioner

10

Simple plastic tubes to guide the belt

Fig. 12

1

Loop around the steel insert

2

Belt tensioner

3

Upper roof body binding

4

Cover strip for protecting a belt and the belt tensioner

5

Lower roof body binding

6

Thick-walled (armored tube) tube for receiving the steel insert

7

By tightening the lower roof body binding is, after appropriate preparation, the ceiling layer sealed by the special shape of the roof edge.

Claims (9)

The construction unit of a roof construction with false ceiling made of foamed prefabricated components for buildings is characterized in that the individual parts are foamed according to a modular system individually in forms with an expanding, fine-pore hardening and tough-hard plastic. The molds are formed by integrated components. The construction unit of a roof construction with false ceiling is characterized according to claim 1, characterized in that all items can not be assembled and joined together so that a complete production unit for roofing a building arises. The construction unit of a roof construction with false ceiling is characterized according to claim 1, that in the production and foaming the components of the roof such as roof surface, roof base, Fotovoltaikpanelen, solar panels, facing the roof overhang, joint parts for joining with other roof parts, reinforcements for stability and load capacity , Conduits, conduits and guides and the like serve as mold parts. Likewise, components of the false ceiling such as flooring, cladding elements of the ceiling underside, reinforcements for stability and sustainability, conduits, conduits, cables, lamps, fasteners, frames as joining with terminal cover parts, bushings for the anchor bolts, wall pads and the like as mold parts all serve with the construction foam firmly connected. The construction unit of a roof construction with false ceiling is characterized according to claim 2, that in all parts of the roof structure plastic pipes are incorporated, are embedded in the rod-shaped metal parts so that they can be covered by belt loops and the straps in transverse to empty conduits so over the edge area be led out that a bond between the individual roof components is possible. The construction unit of a roof construction with false ceiling is characterized according to claim 4, characterized in that the roof items are contracted according to claim 2, by means of straps and Gurtenspannern and firmly connected. The construction unit of a roof construction with false ceiling according to claim 1, characterized in that in the false ceiling, with the aim of producing a load-bearing component, aluminum profile tubes or similar suitable technical aids are incorporated in a ladder structure in the foam material. The construction unit of a roof construction with false ceiling according to claim 1 and 2, characterized in that it is connected to an anchor bolt, which is guided from the foundation through the outer walls to the outer roof level, fixed to the building part to a structural unit. The construction unit of a roof construction with false ceiling is characterized according to claim 7, characterized in that the anchor bolt is anchored in the ring anchor of the outer walls. The construction unit of a roof construction with false ceiling is characterized according to claim 2, that are compressed by the transverse stresses of the roof part on the one hand and tightening the vertical anchor bolts on the other hand, the false ceiling with the roof part on the top and the outer edge, thereby forming a seamless, solid connection ,

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