EP0106297A2 - Structural element for manufacturing concrete walls, and building wall produced with the same - Google Patents

Abstract

The structural element is characterised by a peripheral frame (1) made of a sheet-metal profile, at least one strut (2, 15), connecting two frame sides, made of a sheet-metal profile, a metal lattice (8) which is fastened to at least one outer plane defined by the frame (1) and covers the latter in planar manner, and at least one rod-shaped erection reinforcement (5) which extends inside the frame (1) in each case at a short distance from the metal lattice (8) and connects two mutually opposite frame sides (1) and the strut (2, 15), and connecting elements (9) which interconnect the metal lattice (8) and the erection reinforcement. The metal lattice (8), including the corresponding frame and strut parts, and also the erection reinforcement (5) are embedded in a supporting layer (10) of shotcrete. The inside surface of the shotcrete layer (10) is covered with a layer (11) of a, preferably, foamed insulating material. This insulating-material layer (11) is covered, in the case of vertical building walls, with a further shotcrete layer (12) of corresponding thickness, in which at least one metal lattice (8) and part of the frames and struts are embedded.

Description

The invention relates to a component for the production of building walls made of concrete, which allows the building of building walls, be it in in-situ concrete or in prefabricated construction also without formwork. It is a particular object of the invention to incorporate the required insulation as an integral part of the building wall during manufacture.

The object of the invention is achieved by a component which is characterized by a frame made of a sheet metal profile that runs around the edge, at least one strut made of a sheet metal profile connecting two frame sides, a metal grid attached to at least one outer plane defined by the frame, and flatly covering the frame, and at least one rod-shaped assembly iron, each running a short distance from the metal grid within the frame and two opposite one another Frame sides and the strut connects and connecting elements that connect the metal grille and the assembly iron. Such a wall element can be assembled in a simple manner from prefabricated individual parts on a building yard or, for larger construction projects, also on the building site. By using sheet metal profiles, the fully assembled component can be easily handled with the lifting devices that are customary at the construction site. The height of a component corresponds to the desired floor height, while the length when concreting on site can correspond to the entire length of the building. The number of struts used depends on the length of the component. These can be provided, for example, so that they laterally limit the desired door and / or window openings at the same time. With the exception of the door and / or window openings provided, a metal grid is attached to at least one outer plane defined by the frame, which in a preferred embodiment of the invention is formed by sheets of expanded metal. The expanded metal sheets expediently have openings of approximately 5 mm in width and approximately 10 to 20 mm in length. In order to increase the strength of the building wall created with the aid of such a component, it is expedient if the expanded metal sheets are fastened to the frame in a perpendicular manner with respect to the orientation of the building wall. The metal grill can be attached to the frame by spot welding or with the help of self-tapping screws. In order to simplify the handling of the finished component and to stabilize the relatively large-area metal grille cover, this is fixed at appropriate intervals on the mounting irons running transversely to the orientation of the expanded metal tracks with the aid of connecting elements, for example wire hooks or the like.

The component designed in this way that only on one the frame defined outer level is provided with a metal grid, is only erected and aligned on the prepared foundation of the building to be created. Accordingly, the components for the other walls of the building, namely both outer and inner walls, are erected and connected to one another at the joints. Now sprayed concrete is applied from the outside and from the inside to the metal grid, the metal grid being completely embedded in the sprayed concrete. Here, the shotcrete layer lying on the outside of the wall on the metal grid is thinner than the shotcrete layer lying on the inside, which is so thick that it also completely embeds the assembly iron.

After the applied concrete has hardened, the insulating material is now applied to the concrete layer from the inside, for example in the form of a foamed plastic, in particular polyurethane. After the plastic has hardened, the frame area in the corresponding areas is now covered with a metal grid on the still open frame level, which now forms the inside wall of the building, this being connected to the frame, the struts and the assembly iron. Sprayed concrete is then applied to the outside of this metal grid in the desired thickness, this sprayed concrete layer building up directly on the insulating material layer and being chosen so thick that the outside of the metal grid is again completely covered with concrete. This procedure allows the production of building walls both, as described above, in a fully aligned position as a building, as well as the creation in the form of corresponding prefabricated components, which are only subsequently erected on the construction site as a building wall.

In a preferred embodiment of the invention provided that at least the horizontally extending sheet metal profiles of the frame have a U-shaped cross section. This has the advantage that the sheet profile is enclosed without the formation of voids when the shotcrete is introduced.

In a further advantageous embodiment of the invention it is provided that the sheet metal profile forming the struts and expediently also the vertically running profile parts of the frame have a C-shaped cross section. This results in additional stiffening of both the component and the building wall erected with the aid of this component, since the stiffness of a C-shaped sheet metal profile is considerably higher. The sheet metal profiles are expediently produced by folding or rolling from a galvanized steel sheet with a thickness of approximately 1.25 mm. When using expanded metal, a sheet thickness of 0.8 mm is considered appropriate here on the one hand for reasons of strength and with regard to the weight of the component. A round iron with an 8 mm diameter is sufficient for the assembly irons.

In an expedient embodiment of the invention it is further provided that the webs have openings at least in the vertically running sheet metal profiles of the frame and the struts. These breakthroughs allow the insulating material to be applied correctly, so that a completely closed layer of insulating material results over the entire length and the entire height. When the component is used for an outer wall, the openings also reduce the heat-conducting cross section of the sheet metal profiles in the direction from the inside to the outside and thus significantly reduce the formation of "cold bridges".

The component according to the invention can be used not only for the erection of building walls but also of floor ceilings. In this case, those are related to the frame Struts formed by sheet metal profiles with an I cross section. The metal grid is applied only on the underside and is embedded in a shotcrete layer of appropriate thickness in the manner described above. The other side of the shotcrete layer is covered as described above with an insulating material layer, for example made of foamed plastic.

tn expedient embodiment of the invention for use, les component for the production of ceilings is provided here that the frame is covered on one side only with a metal grid and that on the other side of the surface on the flanges of the I-shaped struts open U-profiles are made of sheet metal for supporting beams. The support beams can be made of reinforced concrete or wood, but are firmly connected to the U-profile of the struts in the ceiling. This arrangement has the advantage that the load on the surface load acting on the ceiling is largely carried out via the supporting beams, while the actual floor ceiling is designed in the manner of a suspended ceiling and, accordingly, considerable weight reductions are achieved. On the other hand, it is possible to fill a substantial part of the available cross-section of the ceiling with an insulating material, so that very good insulation can be achieved in particular when using this construction as a building ceiling in the roof area.

According to the invention, a building wall produced with a component according to the invention is characterized in that at least one of the metal grids covering the frame is embedded in a load-bearing layer made of shotcrete and that the space between the two concrete layers is filled with insulating material.

In an embodiment according to the invention it is further provided that at least in the case of an outer wall of the building on the The outside concrete layer is thicker than the inside concrete layer.

According to the invention it is further provided that the insulating material consists of a foamed plastic, preferably polyurethane, in a manner known per se. This has the advantage that the insulating material layer can also be introduced in corner areas which are difficult to access. All exposed metal surfaces are thereby completely and tightly covered, so that extensive corrosion protection is achieved.

• Fig. 1 eine Gesamtansicht eines Bauelementes mit Tür-und Fensteröffnungen, ohne Metallgitter
• Fig. 2 einen Vertikalschnitt durch eine fertiggestellte Gebäudewand einschl. der Gebäudedecke
• Fig. 3 einen Horizontalschnitt durch eine Gebäudewand im Eckenbereich
• Fig. 4 einen Schnitt durch eine Gebäudedecke.
• Fig. 5 einen Vertikalschnitt einer anderen Ausführungsform

The invention is explained in more detail using exemplary embodiments. Show it:

• Fig. 1 is an overall view of a component with door and window openings, without a metal grid
• Fig. 2 shows a vertical section through a completed building wall including the building ceiling
• Fig. 3 shows a horizontal section through a building wall in the corner area
• Fig. 4 shows a section through a building ceiling.
• Fig. 5 is a vertical section of another embodiment

In Fig. 1, a component is shown in a schematic view. The component has a circumferential frame 1, which is dimensioned so that its height h corresponds to the floor height, while its length 1 corresponds, for example, to the desired length of the building or a "room length". The frame 1 is divided in the longitudinal direction by a plurality of struts 2, the struts 2 'each running diagonally in the end region and providing a corresponding corner stiffener. The struts 2 are arranged at a distance from one another in such a way that they simultaneously delimit a door opening 3 and window openings 4 laterally. The upper and / or lower limit of the door or window opening is limited by horizontally extending interchangeable struts 3 'and 4', 4 ", each with the opening-defining struts 2 are firmly connected. With the exception of the door opening 3 and the window openings 4, the entire surface of the frame 1 is covered with a metal grid, for example made of expanded metal sheets. However, these grid areas are not shown here. The fields of the frame 1 to be covered by the metal grid, insofar as they cover the full floor height, are additionally divided by horizontally running mounting irons 5, for example made of 8 mm round steel, to which the metal grid is still connected by connecting elements in the form of wire hooks or the like. This will be explained in more detail below.

The construction of a building wall with the aid of the component described with reference to FIG. 1 can be seen from the vertical section according to FIG. 2. The embodiment is explained in more detail using an in-situ concrete design.

To create the building wall, the construction elements according to FIG. 1, which are covered on a surface with metal grids, are set up and aligned on a prepared foundation 6. As can be seen from the section in FIG. 2, the frame parts delimiting the component at the top and bottom are formed from a U-shaped sheet metal profile 7. The mounting iron 5 are inserted through corresponding holes in the struts 2. One of the struts is indicated here.

A metal grid 8 is fastened to the outside of the frame 1, for example by spot welding or with the aid of self-tapping sheet metal screws. The metal grid, which consists, for example, of expanded metal sheets with a wall thickness of 0.8 mm and openings of approximately 5 mm in width and 10 mm in length, is additionally fixed to the assembly iron 5 via connecting elements 9 in the form of wire hooks. At this point in time, the other outer surface of the component has not yet been covered by a metal grid.

Now, as a first step, a layer 10 of shotcrete in a corresponding thickness is applied to the metal grid from both sides, the assembly irons 5 being completely embedded in the shotcrete layer 10. In this context, it should be pointed out that the openings of the metal grille must be dimensioned such that they also allow shotcrete to be applied to the vertically oriented metal grille surface. Layer 10 is dimensioned as a load-bearing part of the building wall. After the shotcrete layer 10 has set, an additional insulating material layer 11 is applied, for example by a foamed plastic such as polyurethane or the like. After the insulating material layer has hardened, the still open outer surface of the frame is also covered with a metal grid 8, which in turn is connected to the Assembly iron 5 is set. Now a shotcrete layer 12 is again applied in the desired thickness, whereby the second shotcrete layer, as the exemplary embodiment shows, can be thinner than the first shotcrete layer. The two concrete outer surfaces can now be provided with a layer of fine plaster in a conventional manner.

From the above description it can also be seen that with the aid of such a component, not only can building walls be made of in-situ concrete, but that prefabricated parts can also be produced with the aid of the component according to the invention. When determining the frame length, it is only necessary to ensure that the finished parts can also be handled with the available means of transport and hoists.

As can be seen from the section in FIG. 2, the struts 2, the cross-section of which will be explained in more detail with reference to FIG. 3, are provided in the web area with recesses 13, which serve to reduce weight on the one hand and on the other hand free passage of the insulating material when foaming allow.

The horizontal section in Fig. 3 shows that the struts 2, but also the vertically extending parts 1 'of the frame 1 consist of a C-shaped sheet metal profile. The horizontal section in FIG. 3 shows a corner connection from which it can be seen that after the components have been erected using self-tapping screws 14, the elements are firmly connected to one another. Instead of the screw connection, a connection by welding, clamps or the like can of course also be used.

The horizontal section also reveals the course of the mounting iron 5 and the arrangement of the connecting elements 9 between the mounting iron 5 and the metal grid 8. Furthermore, it can be seen from the horizontal section that both the struts 2 and the vertically extending frame parts 1 'are each provided with recesses 13 through which the introduced insulating material or shotcrete can pass, as is the case for the outer frame part 1' of the wall part A. is shown.

From the partial cross section through a building ceiling, which is made with a suitably designed component, it can be seen that the struts of the frame are formed by a sheet profile 15 with an I-shaped cross section for the ceiling construction. These are profiles rolled from a sheet metal strip. The sectional view in FIG. 4 is therefore only purely schematic.

On the underside, the I-shaped struts 15 are again spanned with a metal grid 8, which is fixed to assembly iron 5 with the aid of wire-shaped connecting elements 9. Here, the mounting iron 5 are inserted through corresponding holes in the webs of the struts 15. On the side of the struts 15 facing away from the wire mesh 8, U-shaped sheet metal profiles 16 are fastened, which are dimensioned such that they can accommodate supporting beams 17. The entire ceiling structure is fastened to the support beam 17 via the U-shaped profiles 16. As can be seen from the vertical section in FIG. 2, the struts 15 again have openings 13, so that the insulating material layer 11 applied to the inner surface of the shotcrete layer 10 extends over the entire area of the ceiling.

Depending on the intended use, a board layer 18 serving as floor or roof is attached to the top of the supporting beams 17. A floor covering or a roof skin 19 can be fastened on this board layer 18 in accordance with the intended use.

The space between shotcrete layer 10 and the board layer 18 can either be filled only partially, as shown here, or completely with the insulating material 11.

With a corresponding design of the support, the I-shaped struts 15 can also be included in the construction as a load-bearing part of the ceiling, since despite the design as a rolled sheet metal profile, a considerable moment of inertia is available for the load bearing. This has the advantage that the supporting beams 17 connected to the I-profile 15 can be dimensioned correspondingly smaller, so that overall a considerable weight saving and thus more favorable static values result for the ceiling construction. Depending on the specified load sizes, it may be expedient to make the openings 13 in the webs of the I-profiles 15 smaller in relation to the exemplary embodiment shown, in particular to provide circular openings in order to achieve a favorable stress profile in the web area.

5 shows a modified embodiment of the component for the production of vertical building walls in a vertical section. The structure essentially corresponds to the structure described with reference to FIG. 2. The main difference from the embodiment according to FIG. 2 is that after the shotcrete layer 10 has been applied, the other outer plane of the frame is covered with a breathable film, in particular a breathable plastic film 20, and is then fixed to the frame together with the metal grid 8. The space between the shotcrete layer 10 and the film 20 is now foamed from bottom to top with a foamable plastic, for example polyurethane. The introduction of the insulating material through the usually at least semi-transparent plastic film can be observed from the outside. If there are cavities in the course of the introduction of the foamable plastic, these can subsequently be filled in from the outside through the film 20. Subsequently, the sprayed concrete layer 12 is applied to the metal grid from the outside with a suitably liquid sprayed concrete, the sprayed concrete passing through the openings in the metal grid and also filling the existing spaces between the metal grid 8 and the film 20. This construction offers considerable advantages when introducing the insulating material compared to the surface application, as described with reference to FIG. 2.

A particular advantage of the construction described with reference to the exemplary embodiments lies in the fact that after the application of the usually load-bearing shotcrete layer 10 in the area of a frame level, the plastered installations, such as empty pipes for the electrical installation, water pipes, drain pipes or the like, in those to be foamed with insulating material Space can be fixed before the insulation material is foamed.

This not only leads to a simplification of the production of buildings, but also has the advantage that the installed water pipes and drain pipes are both heat and soundproof as soon as they are embedded in the preferably foamed insulating material.

Claims (14)

1. Component for the production of building walls made of concrete, characterized by a peripheral frame (1) made of a sheet metal profile, at least one strut (2, 2; 15) connecting two frame sides made of a sheet metal profile, one on at least one by the frame (1 ) defined outer plane, metal frame (8) covering the frame (1) and at least one rod-shaped assembly iron (5), each running a short distance from the metal grid (8) within the frame (1) and two opposite frame sides (1 ) and the strut (2, 2 ', 15) connects and connecting elements (9) which connect the metal grid (8) and the assembly iron (5) to each other. 2. Component according to claim 1, characterized in that the frame (1) forming sheet metal profile has a U-shaped cross section. 3. Component according to claim 1 or 2, characterized in that the strut (2, 2 ') forming sheet metal profile has a C-shaped cross section. 4. The component according to claim 1, 2 and 3, characterized in that the horizontally extending frame parts (7) have a U-shaped cross section and the vertically extending frame parts (1 ') including the struts (2, 2 ¹ ) have a C-shaped cross section. 5. Component according to one of claims 1 to 4, characterized in that the webs have at least the vertically extending sheet metal profiles of the frame (1) and the struts (2, 2 ', 15) openings (13). 6. Component according to claims 1, 2 and 5 in particular for the production of building ceilings, characterized in that the struts (15) are formed by sheet metal profiles with an I cross-section. 7. The component according to claim 6, characterized in that the frame (1) is covered only on one surface side with a metal grid and that on the other surface side on the flanges of the I-shaped struts (15) outwardly open U-profiles (16 ) are arranged from sheet metal for receiving support beams (17). 8. Component according to one of claims 1 to 7, characterized in that the metal grid (8) is formed by sheets of expanded metal. 9. The component according to claim 8, characterized in that the expanded metal tracks are fixed perpendicular to the frame (1) with respect to the orientation of the wall and that the mounting iron (5) runs horizontally to this. 10. The component according to claims 1 to 9, characterized in that at least one of the frame (1) covering metal grid (8) on its side facing the frame (1) is covered with a breathable film (20), preferably made of plastic . 11. Building wall produced with a component according to claims 1 to 10, characterized in that at least one of the frame (1) covering metal grid (8) is embedded in a load-bearing layer (10, 12) made of shotcrete and that the space between the two concrete layers (10, 12) on the inside of the frame are filled with a layer (11) of insulating material. 12. Building wall according to claim 11, characterized in that, at least in one building outer wall, the concrete layer (10) lying on the outside is thicker than the concrete layer (11) lying on the inside. 13. As a building ceiling certain building wall made with a component according to claims 1 to 9, characterized in that the attached on the underside of the ceiling metal grill (8) including the associated mounting iron (5) are embedded in a shotcrete layer that the shotcrete layer (10) its top is covered with an insulating layer and that with the I-shaped struts (15) supporting beams (17) are connected. 14. Building wall according to claims 11, 12 and 13, characterized in that the insulating material consists of a foamed plastic, preferably polyurethane.

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