EP0756047A2 - Method of making prefabricated plastered masonry walls, and formwork table for executing such a method - Google Patents

Abstract

An edge shuttering (4) for defining the wall is placed on a horizontal shuttering face (3) and a bed of plaster mortar is applied to the shuttering face inside the edge shuttering. Bricks (10) with through openings to produce a horizontal wall are placed at predetermined spacing from each other in the mortar and the gaps (12) and openings are cast with flowable mortar from above. The bricks are placed so that the openings of adjoining bricks align with each other. Reinforcements can be inserted in the gaps (12) and/or openings. Prefabricated wall elements with sanitary fittings can be placed in the mortar bed.

Description

The invention relates to a method for producing prefabricated plastered masonry walls.

It is known to use prefabricated masonry walls to build a building. Various processes are used to manufacture them, including those in which the walls are manufactured horizontally.

A method for producing a transportable brick wall is described in EP 0 242 880 B1. With this The method is placed on a shape corresponding to the dimensions of the wall, which can be in a horizontal position, a soft deformable membrane on which rows of bricks are arranged. Reinforcing bars are introduced through holes in the bricks that are aligned with each other, and then spaces between the individual bricks and holes are filled with liquid mortar. The membrane serves to form a seal on the side edges of the bricks placed on it in order to prevent contamination of the brick surfaces by fine cement particles of the mortar. The membrane also serves to prevent the tiles from moving.

Another method for producing a prefabricated masonry element by aligning bricks on a horizontal formwork base is described in DE 34 28 827 A1. In the process, the bricks are aligned on a lower support plate and the joints are grouted with mortar, whereby the support plate is connected to the masonry element. This creates a combined component.

It is also known to prefabricate a masonry wall horizontally, by inserting special stones in the form of perforated stones with joint spacing into a mortar bed and filling the joints with mortar. The holes in the stones are not filled with mortar in the process.

The object of this invention is to provide a simple and flexible method for producing prefabricated masonry walls that are plastered on one or both sides.

The object is achieved according to claim 1 in that an edge formwork is attached to limit the wall on a horizontal formwork surface, a bed of plastering mortar is introduced on the formwork surface within the edge formwork, bricks with through openings for producing a lying wall in the plastering mortar in a predetermined Spaced from each other and the joints and the openings are poured from above with flowable mortar.

In this way it is achieved that the production of a plaster layer is integrated in the process of the horizontal production of the entire masonry wall in a simple manner, namely by applying the plaster layer horizontally and the bricks are placed directly in this layer. This eliminates the subsequent plastering of a finished brick arrangement. The method according to the invention permits an extremely economical and high-quality production of walls. In addition, the manufacturing process can be automated relatively easily using machines and robots.

In addition to the edge formwork, formwork for masonry recesses, e.g. for window reveals. The bricks can be made of different materials. Depending on the desired type of wall, the stones are arranged in a bandage or joint on joint in the mortar bed, which is usually about 1 to 1.5 cm thick. The joints and the openings of the bricks are quickly and effectively poured using the flowable mortar, which is filled into the joints from above, so that solid stone masonry is created.

The bricks are preferably placed so that openings of adjacent stones are aligned. This initially creates channel-like cavities in the masonry, which extend in the plane of the wall. Reinforcements, for example in the form of steel wires or rods, which extend over the height of the entire wall or a partial surface if the wall has recesses. Reinforcements can also be placed in the joints. The reinforcements can serve the stability of the masonry walls, but are primarily intended for the transport or installation of the walls.

In any case, it must be avoided that stones come loose when handling a finished wall. It must also not happen that the lower corner stone falls on the wall hanging on a crane. Therefore, an embodiment of the invention provides that a mesh reinforcement is placed on the freshly applied plastering mortar on the formwork table. For example, it can consist of a coarse-mesh fiber optic network or a grid or a network of steel wires. If a stone was pushed open, it would be held by nets inserted into the plaster layers. Such a procedure is more advantageous than sticking so-called interception tapes. If a steel net or the like is used, this can simultaneously be used to increase the bending stiffness of the wall over the entire surface.

The openings receiving the reinforcement can have a significantly larger diameter than the bars or wires, so that a mortar layer of a thickness is created between the opening edge and the reinforcements during casting, which enables corrosion protection.

Prefabricated wall elements, e.g. Wall elements with sanitary parts or installation boxes are placed in the mortar bed. Furthermore, plastic installation hoses can be placed through the channel-like cavities formed by openings in the bricks. To create wall corners, prefabricated wall-high corners, which can again consist of individual stones, can be inserted into the mortar bed in such a way that one leg lies in the mortar bed and the other leg borders on the edge formwork, a gap being provided between this leg and the edge formwork can to bring in this plastering mortar. Prefabricated T-shaped wall-high elements, which can also consist of individual stones, can also be inserted into the mortar bed in order to connect a vertically adjacent wall, the crossbar being part of the wall.

If a plastered wall is to be produced on both sides, the grouting and openings can also be made on the upward facing side of the lying wall a plaster layer can be applied.

In order to produce an outer wall with a facing shell, a facing shell can be placed directly on the formwork table inside the edge formwork and the mortar bed can be placed on the facing shell. The veneer shell can be pre-produced or manufactured in a manner similar to that described in EP 0 242 880. In the latter case, the elements of the facing shell are first inserted into the mold, i.e. on the table. According to one embodiment of the invention, a heat-insulating material is placed on the inserted facing shell, on which the mortar bed is then applied. In this way, sufficient thermal insulation of a prefabricated wall is also ensured. The further process steps are then carried out as described above.

A formwork table which can preferably be used to carry out the method described above is described below. The formwork table is characterized in that formwork elements for the formwork in different positions for the production of Walls of different dimensions can be attached. Formwork for masonry recesses, for example for window reveals, can also be provided. The different positions of the formwork elements preferably correspond to a grid dimension designed according to the usual dimensions of brick. The positions can be predetermined by a series of holes into which pins or pins connected to the formwork elements are inserted. It can also be provided that unused holes are closed by plugs which are flush with the formwork surface of the table. These plugs can, for example, be inserted from below into through holes in the formwork table and have a length that is greater than the thickness of the formwork table, so that they protrude from the underside of the formwork table and can therefore be gripped more easily. Furthermore, the plugs can have a stop surface with which they rest on the underside of the formwork table in order to allow easy positioning of the plugs.

It may not be easy to keep the holes clean. Therefore, according to another embodiment of the invention, the connection of the formwork elements can take place in that, for example, sections protruding from the ends on opposite formwork elements are provided which contain pins or the like which engage from above in holes in the adjacent formwork elements. The holes on the top of the other formwork elements can in turn be arranged in grid dimensions. For example, the formwork elements that determine the height of a wall can be firmly connected to the formwork table and provided with the holes on the top. The formwork elements extending transversely thereto contain the protruding sections with the pins and the like, which are then inserted into the holes. This allows the length of a wall to vary according to the grid size. In addition, the formwork table can also be much longer than a wall to be finished, for example a multiple length of a predetermined size, for example 12 m long. This length then has the formwork that determines the height, which in turn can be firmly attached, since the height in residential buildings is usually specified according to standard dimensions. In this way it is possible to produce several prefabricated walls at the same time on one formwork table.

Furthermore, the height of the formwork, in particular the edge formwork, can be variable, so that the upper edge is lower than the reinforcements for the introduction of the mortar bed receiving openings in the bricks. This ensures that reinforcements and installation plastic hoses can be guided through the formwork into the openings of the inserted stones without being obstructed. The formwork is then raised so far that it covers the openings. If a further layer of plaster is to be placed on the upward side of the wall, the formwork is preferably raised to such an extent that it protrudes beyond the wall. The formwork elements, which are variable in height, for example having two heights, can be produced in that the sections lying one above the other are hinged to one another. However, it is also conceivable to put them on top of one another. As already described, the top of these edge formwork elements can then be provided with holes in the grid dimension, into which the cross-formworks are inserted according to the grid.

The variability of the formwork height is preferably achieved in that the formwork elements each consist of a first section and a second section which can be fastened vertically on the first section. The two sections can be connected to one another, for example, by means of pins or by means of a tongue and a groove. Alternatively, the formwork elements can also be slotted in the formwork table vertically displaceable. These slits can also be closed by appropriate closure means if no formwork elements are inserted into them. The formwork, in particular that for the masonry recesses, can be profiled or smoothed.

Fig. 1

eine Draufsicht auf einen Schalungstisch,

Fig. 2

eine Teilschnittansicht eines Schalungstisches mit eingelegten Mauersteinen,

Fig. 3

eine Teildraufsicht auf eine Mauerwerkswand mit eingelegten Bewehrungen.

Fig. 4

teilweise im Schnitt den Bereich eines Schalungstisches, bei dem eine Längs- und eine Querschalung aneinanderstoßen.

Exemplary embodiments of the invention are explained in more detail below with reference to drawings. Show it:

Fig. 1

a top view of a formwork table,

Fig. 2

a partial sectional view of a formwork table with inserted bricks,

Fig. 3

a partial top view of a masonry wall with inserted reinforcement.

Fig. 4

partly in section the area of a formwork table where a longitudinal and a transverse formwork meet.

In the figures, the same parts are denoted by the same reference symbols.

1 shows a formwork table 2 with a formwork surface 3, on which four edge formwork elements 4 ', 4' 'are fastened in order to form an edge formwork 4. This has a smaller circumference than the formwork table 2. Within the edge formwork 4, two further formworks 6, 8 each consisting of four formwork elements 6 ', 8' are arranged, which limit the reveal of the masonry wall to be created. The formwork elements 4 ', 4' ', 6', 8 ', are formwork boards. They are fastened to this by means of pins (not shown) connected to them, which are inserted into corresponding through holes in the formwork table. The holes 8 (only a few are shown) are arranged in a grid in the table, which is selected according to the usual dimensions of brick. The holes 8 can be closed by means of plugs (not shown). Some bricks 10 are arranged inside the edge formwork 4 and outside the window reveal formwork 6, 8. These stones 10 directly adjoin the edge formwork 4, but are separated from one another by distances 12 which correspond to the thickness of joints.

A set of formwork boards with different lengths can be available. In order to keep the number of boards required as low as possible, at Edge formwork, the length of two boards should be chosen so that they extend over the entire length or width of the formwork surface, and only the length of the boards to be arranged perpendicular to them can be varied.

FIG. 2 shows a vertical partial section of a formwork table 2. On the formwork table 2 there is a mortar bed 14, in which bricks 10 are inserted, within an edge formwork, of which only one formwork element 4 'is shown. Furthermore, a prefabricated corner 16, which extends over the entire height of the wall to be produced, is inserted into the mortar bed 14 in such a way that it lies with one leg in the mortar bed and lies with the other leg on the edge formwork element 4 '. The bricks 10 have through openings 18 which extend vertically when the wall is erected. The corner 16 is not made of individual stones and therefore has no openings 18 or channel-like cavities for reinforcements. The edge formwork element 4 'consists of a first section 41 and a second section 42 which is fastened to the first by means of pins (not shown). The upper edge of the first section 41 lies below the openings 18.

Fig. 3 partially shows a masonry wall 24, the bricks 10, which are arranged in the association. For better illustration, the wall on the side shown is not plastered. Reinforcing bars 26 are inserted into channel-like cavities, which are formed by aligned openings (not shown) of the bricks 10. The reinforcement bars 26 extend almost over the entire height of the wall and run vertically when the wall 24 is erected. The joints 12 between the stones 10 and space (not shown) between the bars 26 and the edges of the openings 18 are poured with flowing mortar.

The method according to the invention is explained below with reference to FIGS. 1 to 3. In the method, the first sections of the edge formwork boards 4 ', 4'',6', 8 'for forming the edge formwork 4 and the window reveal formwork 6, 8 are first fastened to the formwork surface 3 by means of pins which are inserted into holes 8. Holes 8 that are not used are closed by plugs inserted into them from below so that a flat top of the plugs is flush with the formwork surface 3. Subsequently, the plastering mortar bed 14 is applied to the surface which is surrounded within the edge formwork 4, but not by the window reveal formwork 6, 8, in a thickness of approximately 1 to 1.5 cm. In this mortar bed 14, the bricks 10 and the wall-high corner 16 are inserted at a distance 12 for butt and bed joints. The stones are aligned in such a way that openings 18 of adjacent stones are aligned and form channel-like cavities running parallel to the formwork boards 4 '. When the arrangement of the bricks 10 and the corner 16 is complete, the reinforcing bars 26 are inserted into the cavities. Where there are no window reveal recesses, the bars 26 extend almost over the entire height of the wall to be produced. Where such recesses are located, the bars 26 extend over the height of the partial areas between the corresponding formwork boards of the edge and window reveal formwork. Now the second sections of the shuttering boards 4 ', 4'',6', 8 'are attached to the first sections, whereby the openings 18 on the narrow sides and on the window reveal of the wall to be produced are covered. Then, when, for example, the mortar bed 14 has dried sufficiently, flowable mortar is introduced from above; it is distributed in the joints and the openings 18 until all the joints and openings are completely filled. After a further drying time, a plaster layer may be applied to the upward side of the wall.

4a shows part of the formwork table 2 in section. A formwork element 30 which extends in the longitudinal direction and which, for example, defines the top or bottom of a wall, is firmly connected to the table 2. A transverse formwork element 32 has at the end an arm 34 on the top, which is fastened, for example, by means of screws to the top of the formwork element 32 and which projects over the end of the formwork element 32 and is provided with a pin 36 on its underside. As can be seen from FIG. 4b, the upper side of the formwork element 30 has holes 38 which are arranged in the grid dimension. From Fig. 4a it can now be seen how the formwork element 32 can be fixed to the formwork element 30. It is understood that the attachment to the other end of the formwork element 32 can also take place accordingly.

Claims (18)

Method for producing prefabricated plastered masonry walls (24), in which an edge formwork (4) for limiting the wall is attached to a horizontal formwork surface (3), a bed (14) made of plastering mortar on the formwork surface (3) inside the edge formwork (4) is introduced, bricks (10) with through openings (18) for producing a lying wall are inserted into the plastering mortar at a predetermined distance from one another and the joints (12) and the openings (18) are poured with flowable mortar from above. Method according to claim 1, characterized in that the bricks (10) are placed in such a way that openings (18) of adjacent stones are aligned. Method according to claim 1 or 2, characterized in that reinforcements (26) are inserted into the joints (12) and / or openings (18). Method according to one of the preceding claims, characterized in that prefabricated wall elements, For example, which are placed in the mortar bed (14) with sanitary parts or installation boxes. Method according to one of the preceding claims, characterized in that a prefabricated wall-high corner (16) is inserted into the mortar bed (14) with one leg and adjoins the edge formwork (4) with the other leg. Method according to one of the preceding claims, characterized in that after the casting, a plaster layer is applied to the upward-facing side of the lying wall. Method according to one of the preceding claims, characterized in that a prefabricated facing shell is placed directly on the formwork surface within the edge formwork (4) and the mortar bed (14) is placed on the facing shell for the production of external walls. A method according to claim 5, characterized in that a heat-insulating layer is placed on the facing shell, on which the mortar bed is then applied. Method according to one of claims 1 to 8, characterized in that a net or grid with relatively coarse meshes made of tensile material, for example glass fibers or steel, is placed on the mortar layer. Formwork table for carrying out the method according to claim 1, characterized in that on the table (2) formwork elements (4 ', 4' ', 6', 8 ') for formwork (4, 6, 8) in different positions for the production of walls different dimensions can be attached. Table according to claim 10, characterized in that formwork (6, 8) for masonry recesses, e.g. for window reveals are provided. Table according to claim 10 or 11, characterized in that the different positions correspond to a grid dimension designed according to the usual dimensions of the bricks (10). Table according to one of claims 10 to 12, characterized in that the positions are each predetermined by a series of holes (8) into which the Formwork elements (4 ', 4'',6', 8 ') connected pins or pins can be used. Table according to one of the preceding claims 10 to 13, characterized in that the height of the formwork (4, 6, 8) is variable. Table according to one of claims 10 to 14, characterized in that the formwork elements (32) on opposite sides of the table (2) have holes (38) on the top in the grid dimension and the formwork elements (32) running transversely thereto with pins or pins ( 36) are provided, which are attached to a section (34) projecting beyond the end on the upper side of the formwork element and can be inserted into the holes (38) of the first formwork elements. Table according to one of claims 10 to 15, characterized in that the length of opposing edge formwork is a multiple of the length of a wall to be manufactured. Table according to claim 10, characterized in that at least the formwork elements (4 ', 4'',6', 8 ') each have a first section at opposite ends (41) and a second vertically on the first, preferably articulated section (42). Table according to one of the preceding claims 10 to 17, characterized in that formwork elements, in particular those for the masonry recesses, are profiled or smoothed.

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