DE29821180U1 - Formwork system for buildings - Google Patents

Description

PFISTER & PFISTER PATENT ATTORNEYS . Dipl.-Ing. Helmut Pfister

i European Patent Attorney

Dipl.-Phys. Stefan Pfister

D-87700 Memmingen/Bayem 17/4 Office 1: Herrenstraße 11

Telephone 0 83 31/2412 Fax 0 83 31/24 07 Office 2: Buxacher Straße 9

Telephone 08331/65183 Fax 08331/65185 Postgiroamt München ^: 1343 39-805 (bank code 700100 80) Bayer. Vereinsbank Memmingen 2 303 396 (bank code 731 200 75) VAT ID No. · VAT Reg. No. ■ N" CEE DE 129 066 032

2 4 NOV 1998

Company HM-BetonFertigteilwerk Hans Mauthe GmbH & Co. KG Hermann-Krum-Str. 13

88319 Aitrach

"Formwork system for buildings"

The invention relates to a formwork system for buildings, in particular for the construction of basement walls and/or basement ceilings, wherein the formwork is designed as permanent formwork.

Prefabricated houses now account for around 13% of single-family homes, and the trend is increasing. With prefabricated houses, it is common practice for the prefabricated house to be built by the prefabricated house company on a basement that has already been prepared.

is used, which means that the prefabricated house company does not take over the construction of the basement at the same time. This means that a second company is required to re-establish the construction site in order to build the basement. This results in additional, avoidable high costs.

It is known, for example, to fill the basement with in-situ concrete using a formwork that is constructed on site, i.e. the concrete is transported to the construction site and poured there.

Another solution is to build the basement out of precast concrete elements, but this requires complex lifting equipment such as cranes, etc., as the precast concrete elements are very heavy. This solution is also comparatively expensive and complex.

The invention therefore has the task of providing a formwork system as described above, with the help of which the construction of the basement can be carried out more cost-effectively.

To solve this problem, the invention is based on a formwork system for buildings, wherein the formwork system is designed as a system prefabricated in the workshop.

The main effect of the design according to the invention is that the formwork system can be prefabricated in the workshop, which results in a corresponding cost advantage in the manufacture of the formwork system. The cost savings can be up to 50%. The formwork system is used twice, it not only serves as formwork, but is left in the building afterwards as permanent formwork. This also saves the disposal or cleaning of the otherwise common formwork panels. At the same time,

At an early stage, the permanent formwork forms the visible surface, which can already be prepared with cladding in the workshop.

The formwork system is manufactured according to the plan for the house, whereby a modular structure of the formwork system is advantageous, as this type of design allows certain elements to be produced in large quantities, which in turn reduces the cost of producing these formwork elements. Special formwork may only be manufactured for special circumstances or differences in size.

It is also possible to build a cellar "according to a catalogue" and to optimally match different variants to certain types of prefabricated houses. Of course, this also has the advantage of large quantities, which means that such a formwork system can be manufactured and offered inexpensively.

It is advantageous to provide the formwork system as a modular system with individual formwork parts. In this way, the different needs for the basement dimensions can be taken into account and special parts such as basement window openings, door openings, corner parts, etc. can be provided.

Since prefabricated houses of a type always have the same dimensions, it has proven to be particularly advantageous to prefabricate the basement formwork system in the workshop, since the same parts are always needed for a basement of the same house.

The design according to the invention also makes it easier to create the formwork, which is particularly useful for do-it-yourselfers who want to do their own work on the house. The modular structure is chosen so that the formwork elements

elements can reach a maximum weight that can be transported by one or, if necessary, two people. The plan is to deliver the formwork elements on pallets, for example, with the formwork elements already sorted in the way they are then best installed. For self-assembly, appropriate assembly instructions are included, with the individual, modular formwork elements provided with corresponding code numbers or the like to enable orientation and arrangement according to the plan.

It is particularly advantageous if the formwork system is used to build several or all of the walls on a floor and, if necessary, the ceiling resting on the walls, and the various building elements, walls, beams and ceilings are created simultaneously by pouring concrete into the composite formwork system. This saves time, as the drying and hardening times of the concrete are the same for all parts. As the formwork system is designed as permanent formwork, this does not need to be removed again and the inner formwork parts form the walls and ceilings of the finished basement. This design makes it particularly easy to build yourself, as there is no need to dismantle the formwork panels and the delivered formwork elements can be installed.

It is also planned to construct the floor element or floor slab using the formwork system.

The applicability of the formwork system is not limited to basements, but can also be used to construct side walls or other parts of houses.

In the preferred embodiment of the invention, the formwork parts are made of glass fiber reinforced concrete. Glass fiber reinforced concrete produces a substantially smooth surface,

so that the formwork walls, ceilings and walls are ready for use immediately, even without plastering or wallpapering. It is also possible to use elements that are already coated. Furthermore, glass-fibre reinforced concrete is relatively inexpensive to produce and after the concrete has been poured in, no material stresses arise, especially during hardening or when temperatures change.

Another advantage of glass fiber reinforced concrete is its waterproofness, so that the formwork system can also be used on swimming pools, cisterns or the like. In addition, this waterproof concrete is also suitable for protecting the building or basement from the outside against moisture or water.

It has proven to be advantageous if formwork parts are provided for the outer and inner boundaries of the wall to be constructed.

In this way, both forms of formwork can be manufactured and joined separately, with the two forms of formwork then being connected to each other at certain points before the concrete is poured. Spacers placed between the two forms of formwork ensure that the wall to be concreted has a certain thickness. This is particularly important in terms of statics, as the basement also serves as the foundation for the building.

It has proven to be advantageous if the individual parts have connecting surfaces at their ends or flanges or the like that protrude at an angle from the formwork surface.

It is advisable to provide connecting means that

Connecting parts to one another at their flanges or connecting surfaces. These connecting means are preferably clips, screw-nut connections or the like.

The connecting surfaces or flanges preferably face inwards, which means that they are surrounded by concrete in the finished wall. This increases durability and creates a smooth surface, which is particularly advantageous inside the room. The flanges or connecting surfaces can be provided with holes at certain intervals into which the corresponding screws or rivets or even clips can be inserted. This has proven to be particularly advantageous for prefabrication in the workshop.

In some cases, such as when building a swimming pool or cistern, it may be desirable to seal the gaps between the parts with butyl. This creates a waterproof surface.

Because several formwork elements are assembled together for a wall, the individual parts remain relatively small and their weight is also limited. In this way, they can easily be carried by one or two people. Thanks to precise manufacturing, the elements fit together seamlessly. This means that snap-in connections can also be provided for connecting them, for example.

For the ceiling, a U-shaped element is also preferably provided, which forms the boundary to the inside of the basement. The legs of the U are significantly shorter than the web and protrude towards the inside of the wall, so that they are surrounded by concrete when finished. Towards the inside of the basement, a smooth wall appears, which without

can be painted or wallpapered without any further effort, or can also be used as a visible surface. The U's legs are provided with connecting elements that connect the elements to one another. The ceiling elements also rest on the wall elements. In order to improve the mechanical stability of the concrete ceilings, it is possible to place the reinforcement mats on spacers. The spacers are advantageously combined with the formwork elements in order to clearly define the position of the reinforcement mats. Of course, the side boundary elements of the ceiling element have a higher edge, which ultimately defines the thickness of the ceiling.

The length of the web depends on the size of the basement to be constructed, so that the weight of the formwork element does not increase too much. The individual ceiling elements are connected at the inward-protruding legs.

It is planned that the prepared ceiling elements will be several meters long and will thus extend over the entire room. In order to bridge large spans, it is also conceivable that several ceiling elements can be combined with one another in length.

It has proven to be advantageous if the outer wall formwork part in the ceiling area extends upwards above the inner wall formwork part by the amount of the thickness of the ceiling. These elements can also be prefabricated in the workshop and ensure that the ceiling has a uniform side finish. This creates a uniform surface, as is required for building the prefabricated house.

Of course, it is also planned to install modules in the ceiling elements, which, for example, provide a recess for a staircase. These modules are also used as formwork elements.

elements and integrated into the ceiling.

Since the outer and inner wall formwork parts can be manufactured and installed separately, it is advantageous to provide spacers, particularly Z-shaped spacers, between the outer and inner formwork parts. These Z-shaped spacers ensure a uniform distance and thus a uniform thickness of the wall or basement walls and are provided in preferred locations, particularly at the corners or at the corner connections of the formwork elements. For example, additional flanges are provided on the formwork elements to attach the Z-shaped spacers. The Z-shape of the spacers also provides additional stiffening in the vertical direction.

In order to achieve better insulation, especially in the basement area, an insulation layer is provided in the formwork on the outside of the building.

This insulation can be rock wool, glass wool, polystyrene or similar. The insulation layer is placed in the formwork before it is filled with concrete. However, the formwork can also be provided with an appropriate insulation layer in the workshop. The advantage of manufacturing the cellar wall is obvious. The insulation material can be attached to the formwork elements during production. It is clear that such a design is particularly advantageous for do-it-yourselfers, as it allows them to create an optimally insulated cellar with relatively little effort and personal effort.

It is advantageous if the formwork part standing on the ground can be aligned by means of fixing devices provided on the ground

The fixing means also serve as connecting means. For this purpose, bolts, threaded bolts, pins or similar can be used as fixing means, which interact with holes in the flanges or with the connecting surface of the formwork part.

The basement floor is usually made as a screed so that no formwork is required on the inside. This screed is then provided with the fixing or connecting elements at the edge or at the points that are to support the interior walls. For example, holes are provided to accommodate the connecting elements. Grooves are provided for the exterior walls into which the concrete from the exterior walls of the formwork flows and gives the exterior wall additional support. Thanks to the high-precision manufacturing, after the screed has been laid and the connecting elements have been attached, the formwork parts can then simply be aligned on the basement floor and firmly connected to it, after which the concrete can be poured.

Additional support is provided by the fact that the ceiling is also integrated into the formwork system. This also creates a cross connection between the walls and prevents the side walls from twisting.

In a further embodiment of the invention, the formwork system is used when the foundation or floor slab is being constructed in the basement, in particular to define the position of the fixing means or the grooves in the floor slabs from the outset. The wall is then oriented on the fixing means or the groove, or the formwork elements of the wall are attached and aligned.

When concreting a ceiling, it has proven to be advantageous

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if fixing means are arranged on the formwork part provided for this purpose. This means that the ceiling formwork elements can be connected to the formwork elements of the side walls in such a way that the concrete can flow in unhindered. It is advantageous to provide a Z-shaped spacer near the connection so that the outer wall formwork part does not gap outwards even after the concrete has been poured in.

As mentioned above, it is advantageous if the wall formwork elements are arranged next to a groove provided in the floor slab, so that the concrete poured into the wall formwork elements fills this groove like a spring. This creates a firm connection between the side walls and the floor, which applies to both external and internal walls. To give the walls additional support, holes are provided in the area of the grooves, for example in the floor, which interact with connecting elements in the flanges of the formwork elements.

In order to keep the distance between the outer and inner formwork elements stable, Z-shaped spacers are also installed near the ground.

It is particularly advantageous if the ceiling and wall elements form a closed system. This also achieves the necessary lateral stability, which is particularly important before pouring the concrete. In this way, the basement with side walls and ceiling can be built particularly quickly. Long and complex curing times for the various walls are also eliminated, as the ceilings and walls are poured at the same time. The remaining, visible interior formwork ensures a uniform appearance of the interior basement walls and the individual parts of the formwork can be put together as desired, like in a construction kit. The closed

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Ceiling and wall system also ensures that these elements are created in a single concreting process. This reduces the costs for the concrete to be delivered, as it is not needed twice for smaller quantities, once for the wall and once for the ceiling, but only needs to be delivered once for the entire floor.

In order to achieve optimum corrosion protection, the metal parts used, such as sheets, flat iron, screws, nuts and the like, are intended to be made of stainless steel.

In a further advantageous embodiment of the invention, the formwork parts accommodate installation lines or empty pipes for installation lines. Cutting slots in the walls for laying gas, water, electrical or sewage lines is very complex and can be saved by this further development according to the invention. The formwork parts designed in this way may have a very large thickness in order to compensate for the weakening caused by the channels. The formwork parts then have a smaller width in order not to make the transport and handling of these elements more difficult.

The drawing shows a schematic representation of an embodiment of the formwork system according to the invention.

Fig. 1 a top view of the side walls

of a basement before concreting with a formwork system according to the invention, >

Fig. 2 a section through a ceiling

Wall connection of the formwork system according to the invention,

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• *

Fig. 3 Fig. 4

a section through a floor-wall connection of the formwork system according to the invention,

a plan view of a wall corner, with inserted insulation of the formwork system according to the invention,

Fig.5

a section through a connection of two formwork parts of the formwork system according to the invention,

Fig.6

a section through another connection of two formwork parts and

Fig.7

a section through a detail of the connection of the formwork system according to the invention.

The outer formwork system 1 consists of several differently shaped elements, such as a formwork part 10 for corners, formwork parts 11 for straight walls or, as can be seen in Fig. 2, the wall formwork part 12, which is arranged at the transition from the side wall to the ceiling and has a greater height than, for example, the corresponding formwork part 23 of the basement interior 2. The overhang of the wall formwork part 12 over the formwork part 23 corresponds to the thickness of the finished ceiling 30.

The ceiling 3 0 is supported by the U-shaped elements 22, which can, for example, have a length of several meters and thus extend over the entire width of a room. The elements

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22 can have iron reinforcement. The length of the web, however, is only about one meter or less, so that the parts are not too heavy and bulky and can be transported by a few people. The U-shaped elements 22 have legs a few centimeters long, which are surrounded by concrete when concreted and serve to connect the individual U-shaped elements 22 to one another. A smooth ceiling surface results towards the inside of the cellar 2.

The formwork elements typically have a thickness of 1.5 cm to 5.0 cm, but preferably 2.0 cm to 2.5 cm. For the variant according to the invention in which installation lines or empty pipes are provided in the formwork part, the formwork part wall thickness is 2.0 cm to 8.0 cm, but preferably 3.0 cm to 5.0 cm. It is considered equivalent whether the empty pipes are built into the formwork part or whether the formwork part has shafts for laying the lines.

Walls 3 and ceilings 3 0 are cast simultaneously by pouring in concrete 8. The concrete 8 is located between the inner formwork parts 20, 21, which form corners and straight walls in the same way as the outer formwork parts 10, 11. In the area of the ceiling 3 0, the concrete 8 rests on the U-shaped element 22.

The individual formwork parts for the outer and inner formwork 10, 11 and 20, 21 can be manufactured separately and joined together, with flanges 4 being provided at the connection points for joining them together. The parts are connected to one another by the connecting means 5. The connecting means 5 are, for example, screws 5 0 with nuts 51, which are guided through holes 4 0 and thus connect the individual parts to one another.

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In order to achieve a uniform distance between the outer and inner formwork parts, spacers 6 in the shape of a Z are provided, which can be made of metal, plastic or the like, for example, and are mounted on the outer and inner formwork parts in the floor and ceiling area, for example. With the help of these Z-shaped spacers 6, a certain vertical stability of the walls 3 is also achieved, which is additionally increased by attaching the U-shaped ceiling elements 22.

To fix the formwork parts 10, 11, 20, 21 that form the wall 3, grooves 33 are provided at the base point 32 of the basement floor 31. These grooves are filled by the inflowing concrete 8, so that a type of spring connection is created. In addition, holes 34 are provided in the area of the base point 32, which accommodate, for example, pins 35 or the like. These pins 35 are guided through a hole 36 in the end flange 37, so that the formwork parts are firmly connected to the basement floor.

The groove 33, which is located in the basement floor 31, is formed by a corresponding formwork part that is inserted during the concreting of the basement floor 31. It is intended that, before the basement floor 31 is concreted, corresponding formwork elements of the formwork system are laid on the floor of the excavated pit in order to precisely define the later position of the walls in particular. On these formwork elements, which in turn are connected to one another in a rigid and torsion-resistant manner, are the formwork parts that form the grooves 33 in the basement floor 31 after it has been concreted.

These formwork elements, which are applied before the concreting of the floor element 31, then also have, for example, the pins 35 to which the flange

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37. In another variant, as shown, the pins 35 are inserted into holes 34, whereby the holes 34 are worked into the screed using a template, for example. The formwork system thus offers the choice of whether the floor slab should be planned and implemented using the formwork system, or whether the formwork system should first be used on an existing basement floor. It is also intended to cut the groove 33 out of the basement floor using a concrete cutter.

An insulation 7 can be provided on the outer formwork parts 10, 11, for example in the form of an insulation layer made of polystyrene, rock or glass wool or the like applied in the workshop.

Such an insulating layer can of course also be provided on the inner formwork parts 20, 21. It is also possible to only add the insulating layer when the formwork has already been mounted on the basement floor 31.

In addition to glass fiber reinforced concrete, concrete, fiber reinforced concrete, plastic and wood can also be used as materials for the formwork system.

The claims filed now with the application and subsequently are attempts to formulate without prejudice to achieve more extensive protection.

The references cited in the dependent claims indicate the further development of the subject matter of the main claim through the features of the respective subclaim. However, these are not to be understood as a waiver of the achievement of independent, objective protection for the features of the referenced subclaims.

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Features that have so far only been disclosed in the description can be claimed in the course of the procedure as being of essential importance to the invention, for example to distinguish it from the prior art.

Claims (21)

1. Formwork system for buildings, in particular for the construction of basement walls and/or basement ceilings, wherein the formwork is designed as permanent formwork, characterized in that the formwork system ( 1 ) is designed as a system prefabricated in the workshop. 2. Formwork system according to claim 1, characterized in that the formwork system ( 1 ) is designed as a substantially modular construction kit system with individual formwork parts ( 10 , 11 , 20 , 21 ). 3. Formwork system according to one or both of the two preceding claims, characterized in that several or all walls of a storey and optionally also the ceiling resting on the walls can be constructed with the system, and the various building elements, wall or ceiling, are created simultaneously by pouring concrete ( 8 ) into the composite formwork system. 4. Formwork system according to one or more of the preceding claims, characterized in that the formwork parts ( 10 , 11 , 20 , 21 ) consist of glass fiber reinforced concrete. 5. Formwork system according to one or both of the preceding claims, characterized in that formwork parts ( 10 , 11 , 20 , 21 ) are provided for the outer and inner boundaries of the wall ( 3 ) to be manufactured. 6. Formwork system according to one or more of the preceding claims, characterized in that the individual parts have connecting surfaces or flanges ( 4 ) or the like projecting at an angle from the formwork surface at their ends. 7. Formwork system according to one or more of the preceding claims, characterized in that adjacent parts can be connected by connecting means ( 5 ) which cooperate with the flanges ( 4 ) or connecting surfaces. 8. Formwork system according to one or more of the preceding claims, characterized in that clips, screw-nut connections or the like are provided as connecting means ( 5 ). 9. Formwork system according to one or more of the preceding claims, characterized in that a substantially U-shaped element ( 22 ) is provided for the ceiling ( 30 ), which forms the boundary to the basement interior ( 2 ). 10. Formwork system according to one or more of the preceding claims, characterized in that the outer wall formwork part ( 12 ) projects upwards in the ceiling area over the inner formwork part ( 22 ) by the amount of the thickness of the ceiling ( 30 ). 11. Formwork system according to one or more of the preceding claims, characterized in that spacers, in particular Z-shaped spacers ( 6 ) are provided between outer and inner formwork parts. 12. Formwork system according to one or more of the preceding claims, characterized in that insulation ( 7 ) is provided in the formwork parts ( 10 , 11 ) on the outside of the building. 13. Formwork system according to one or more of the preceding claims, characterized in that the formwork part ( 20 ) standing on the ground can be aligned by fixing means provided on the ground. 14. Formwork system according to one or more of the preceding claims, characterized in that the fixing means also serve as connecting means ( 5 ). 15. Formwork system according to one or more of the preceding claims, characterized in that bolts, threaded bolts or the like are provided as fixing means, which cooperate with bores ( 36 ) on the end flange ( 37 ) or the connecting surface of the formwork part. 16. Formwork system according to one or more of the preceding claims, characterized in that fixing means are arranged on the formwork parts ( 12 ) provided for concreting a ceiling. 17. Formwork system according to one or more of the preceding claims, characterized in that a formwork element is provided on the fixing means during the concreting of the floor slab, which forms a groove in the floor slab. 18. Formwork system according to one or more of the preceding claims, characterized in that the wall formwork elements ( 10 , 11 , 20 , 21 ) are arranged next to a groove ( 33 ) provided in the base plate, such that the concrete ( 8 ) poured into the wall formwork element fills this groove ( 33 ) in a spring-like manner. 19. Formwork system according to one or more of the preceding claims, characterized by ceiling and wall elements ( 10 , 11 , 20 , 21 , 22 ) as a closed system. 20. Formwork system according to one or more of the preceding claims, characterized in that the formwork parts are provided with an identification symbol or are numbered and these correspond to an assembly or installation plan. 21. Formwork system according to one or more of the preceding claims, characterized in that the formwork parts accommodate installation lines or empty pipes for installation lines, or have shafts for installation lines.