EP0941155A1 - Procedure for casting of building element; the lt-method - Google Patents

Procedure for casting of building element; the lt-method

Info

Publication number
EP0941155A1
EP0941155A1 EP98917920A EP98917920A EP0941155A1 EP 0941155 A1 EP0941155 A1 EP 0941155A1 EP 98917920 A EP98917920 A EP 98917920A EP 98917920 A EP98917920 A EP 98917920A EP 0941155 A1 EP0941155 A1 EP 0941155A1
Authority
EP
European Patent Office
Prior art keywords
mould
concrete
insulation
casting
unit
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Withdrawn
Application number
EP98917920A
Other languages
German (de)
French (fr)
Inventor
George Wegler
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Individual
Original Assignee
Individual
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Individual filed Critical Individual
Publication of EP0941155A1 publication Critical patent/EP0941155A1/en
Withdrawn legal-status Critical Current

Links

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B28—WORKING CEMENT, CLAY, OR STONE
    • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B19/00—Machines or methods for applying the material to surfaces to form a permanent layer thereon
    • B28B19/003—Machines or methods for applying the material to surfaces to form a permanent layer thereon to insulating material
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • E04B1/02—Structures consisting primarily of load-supporting, block-shaped, or slab-shaped elements
    • E04B1/04—Structures consisting primarily of load-supporting, block-shaped, or slab-shaped elements the elements consisting of concrete, e.g. reinforced concrete, or other stone-like material
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B5/00—Floors; Floor construction with regard to insulation; Connections specially adapted therefor
    • E04B5/02—Load-carrying floor structures formed substantially of prefabricated units
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
    • E04C2/02—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials
    • E04C2/26—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups

Definitions

  • the present invention relates to a method pertaining to the casting of prefabricated building units such as walls, building blocks, foundation beams and floor structures, preferably single- course plates to which or in which insulation is fastened or moulded.
  • Patent specification SE 501752 teaches a method of pressing sheets of insulation down into the concrete of the wall plate under vibration. The casting concrete has earlier been poured into the mould.
  • the purpose of the thermal insulation is to thermally insulate the building and to function as a plaster carrier. It has been found that insulation cannot be made too dense from a thermal insulation aspect. It is, after all, the porosity and gas enclosures that provide a thermal insulating effect. A slightly flexible and therewith resilient insulation will yield as it is pressed into the concrete, which must be done whilst exerting heavy pressure against the concrete. The insulation does not have precisel uniform resilient properties and the concrete is not always able to flow out and fill all cavities. This results in walls of uneven thickness. We obtain a smooth surface inside of the building, since the concrete plate is turned inwards, whereas the insulation on the exterior of the building is stepped between the unit parts. These steps may be as much as one centimetre in size. This requires a very thick layer of finishing cement or plaster to be applied in order to obtain a smooth outer surface, therefore greatly adding to costs.
  • This method of producing prefabricated wall elements or units is also encumbered wi l t the drawback of requiring the application of very heavy forces in pressing down the wall insulation, which has a very wide surface area.
  • the method according to our invention enables units of optional lengths and having a width of 2.4 m to be fabricated with no difficulty. It is also conventionally possible to cast a concrete plate on top of the thermal insulation, although this requires a piece of solid workmanship in treating the surface of the concrete plate so that it becomes straight, smooth and free from pores.
  • Upstanding forms are also used for wall fabrication, sometimes in mutually adjacent relationship, so-called battery forms.
  • the height of the wall units must correspond to the height of a storey plus the height of a floor structure. During casting, this height produces a vibrating concrete column (cf. liquid column) that has an enormous explosive effect and generates horizontal forces that greatly exceed a purely stationary "concrete liquid".
  • the insulation is subjected to still greater compression than when the insulation is pressed into a horizontal concrete mass, and still greater variations in thickness occur.
  • the present invention also provides a solution to the aforesaid problem.
  • the object of the present invention is to improve the tolerances on primarily the thickness of a prefabricated wall unit with moulded-in insulation.
  • Face cutting processes waste material and generate a noisy and dusty environment.
  • the insulation is provided with grooves that are filled with concrete as the units or elements are cast. These grooves can be given the form of vertical, horizontal or inclined channels as seen in relation to an upstanding, mounted wall unit.
  • the channel bottoms are made 1 arger inwardly of the insulation as seen from the surface, e.g. have a dovetail shaped cross-section.
  • a suitable tool is a conical cutter with the base at its end.
  • the channels, or grooves may have a depth of from 1 to 2 cm, for instance. These channels will not weaken the sheet of insulation to any appreciable extent, considering that these sheets will normally have a thickness of at least 200 mm.
  • This casting method is intended for use in constructions described in the original application, with toothed or finger-like attachment between floor structure and wall plates. This supporting method results in purely centrally vertical loading in the wall plates and eliminates the need of reinforced T-beam webs.
  • the casting concrete need not rise to a particularly high level when the concrete plate lies undermost, e.g. against a steel mould, as compared to the height it is required to rise in the case of reinforced T-beam webs, which are normally a decimetre in height.
  • casting is carried out in accordance with the following method. Any forms required for window cavities and other cavities in the wall concrete plate are applied conventionally. Wall reinforcement is placed in the mould.
  • the prepared insulation sheets Prior to casting, the prepared insulation sheets are fixed at the correct unit thickness with spacing blocks against the mould for the concrete. Or are lifted from the mould and held in place with the aid of suction cups through the medium of a vacuum, without requiring the use of blocks. There is always a risk of blocks being torn away by the heavy concrete mass; see below. Suitable stop means prevent the insulation sheets moving from the mould as the concrete is poured thereinto. SOLUTION
  • the fastener channels in the insulation to be filled with concrete are suitably orientated in the longitudinal direction of the slope so that no unnecessary air pockets will form.
  • the concrete is poured in from the upper edge of the slope, optionally while vibrating.
  • the upper edge can be formed by any side of the unit whatsoever.
  • the concrete is poured from the long side of the unit.
  • w ioh provides stability and straightness in a conventional manner.
  • concrete may also be injected centrally through such holes or openings provided in the insulation.
  • the mould may very well lie horizontally in this case.
  • Plate reinforcement is spaced from the insulation sheet and holds the sheet m placo, so that the sheet will not float up.
  • This casting method enables the insulation sheets to be made in large units, and also enables holding means to be provided against the overlying mould, to avoid the insulation floating up.
  • the concrete/casting compound poured in the upper edge of the gap in accordance with the aforegoing runs readily down into fastener channels and pockets for windows, etc., wherewith the air is pressed up towards the overlying planar mould and has a much broader way out, which facilitates filling-out the mould with casting compound.
  • Vibrators placed along the sloping mould can be switched on and off respectively as the gap is filled. This will depend on whether or not vibration is required; see below.

Landscapes

  • Engineering & Computer Science (AREA)
  • Architecture (AREA)
  • Civil Engineering (AREA)
  • Structural Engineering (AREA)
  • Physics & Mathematics (AREA)
  • Electromagnetism (AREA)
  • Chemical & Material Sciences (AREA)
  • Ceramic Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Building Environments (AREA)
  • Joining Of Building Structures In Genera (AREA)
  • Load-Bearing And Curtain Walls (AREA)

Abstract

The present invention relates to a method of manufacturing prefabricated walls or floor structures. Preferably, single-course cast walls and thin-plate floor structures with insulation moulded therein. To avoid uneven compression of the insulation, the casting concrete is poured into a sloping form or an upstanding form which is brought to a horizontal position after having been filled with concrete. The walls can be made completely free of thermal bridges caused by concrete encroaching in the insulation.

Description

PROCEDURE FOR CASTING OF BUILDING ELEMENT; THE LT-METHOD
The present invention relates to a method pertaining to the casting of prefabricated building units such as walls, building blocks, foundation beams and floor structures, preferably single- course plates to which or in which insulation is fastened or moulded.
BACKGROUND OF THE INVENTION Present-day technology relating to the construction of cellars, split-level houses and multi-storey buildings, and also single- unit dwellings and multi-unit dwellings having concrete walls and concrete floor structures, utilises insulated concrete wall units together with di fferent types of prefabricated floor constructions.
PROBLEMS ENCOUNTERED IN MANUFACTURE
Problems encountered in the fabrication of wall units that incorporate thermal insulation.
Patent specification SE 501752 teaches a method of pressing sheets of insulation down into the concrete of the wall plate under vibration. The casting concrete has earlier been poured into the mould.
Drawbacks:
This method requires the volume of concrete to be determined very accurately, in order for all cavities, slots, etc., in the plate to be filled. Precision weighing devices are used in practice, where each building element or fabricated unit shall contain a precise amount of concrete. Windows, doors and also other minor cut-outs must bp taken into account.
The purpose of the thermal insulation is to thermally insulate the building and to function as a plaster carrier. It has been found that insulation cannot be made too dense from a thermal insulation aspect. It is, after all, the porosity and gas enclosures that provide a thermal insulating effect. A slightly flexible and therewith resilient insulation will yield as it is pressed into the concrete, which must be done whilst exerting heavy pressure against the concrete. The insulation does not have precisel uniform resilient properties and the concrete is not always able to flow out and fill all cavities. This results in walls of uneven thickness. We obtain a smooth surface inside of the building, since the concrete plate is turned inwards, whereas the insulation on the exterior of the building is stepped between the unit parts. These steps may be as much as one centimetre in size. This requires a very thick layer of finishing cement or plaster to be applied in order to obtain a smooth outer surface, therefore greatly adding to costs.
This method of producing prefabricated wall elements or units is also encumbered wi l t the drawback of requiring the application of very heavy forces in pressing down the wall insulation, which has a very wide surface area.
The method according to our invention enables units of optional lengths and having a width of 2.4 m to be fabricated with no difficulty. It is also conventionally possible to cast a concrete plate on top of the thermal insulation, although this requires a piece of solid workmanship in treating the surface of the concrete plate so that it becomes straight, smooth and free from pores.
Other known techniques:
Upstanding forms are also used for wall fabrication, sometimes in mutually adjacent relationship, so-called battery forms. The height of the wall units must correspond to the height of a storey plus the height of a floor structure. During casting, this height produces a vibrating concrete column (cf. liquid column) that has an enormous explosive effect and generates horizontal forces that greatly exceed a purely stationary "concrete liquid". The insulation is subjected to still greater compression than when the insulation is pressed into a horizontal concrete mass, and still greater variations in thickness occur.
The floor to ceiling heights of present-day residential building developments exceed 2.4 m. heights of 2.6 to 2.7 m are not unusual. In the case of battery-mould casting, the explosive effect is worse than the above-mentioned.
The present invention also provides a solution to the aforesaid problem.
OBJECT OF THE PRESENT INVENTION
With respect to moulding-in wall insulation, the object of the present invention is to improve the tolerances on primarily the thickness of a prefabricated wall unit with moulded-in insulation.
This without needing subsequently work the unit with expensive facing cutters. Face cutting processes waste material and generate a noisy and dusty environment.
Solutions of the problems with insulation that is compressed during casting of a prefabricated wall unit and means for fastening the concrete of the wall plate to the insulation: Incorporation of the insulation in the wall concrete plate: Because the wall units of this invention do not have any T-web reinforcements, i.e. any deep channels in the thermal insulation that can weaken it as it is handled prior to casting, sheets that have widths up to the width of the wall unit can be used. Suitable types of insulation are sheets of cellular plastic.
The insulation is provided with grooves that are filled with concrete as the units or elements are cast. These grooves can be given the form of vertical, horizontal or inclined channels as seen in relation to an upstanding, mounted wall unit. The channel bottoms are made 1 arger inwardly of the insulation as seen from the surface, e.g. have a dovetail shaped cross-section. A suitable tool is a conical cutter with the base at its end. The channels, or grooves, may have a depth of from 1 to 2 cm, for instance. These channels will not weaken the sheet of insulation to any appreciable extent, considering that these sheets will normally have a thickness of at least 200 mm. This casting method is intended for use in constructions described in the original application, with toothed or finger-like attachment between floor structure and wall plates. This supporting method results in purely centrally vertical loading in the wall plates and eliminates the need of reinforced T-beam webs.
Consequently, in manufacture, the casting concrete need not rise to a particularly high level when the concrete plate lies undermost, e.g. against a steel mould, as compared to the height it is required to rise in the case of reinforced T-beam webs, which are normally a decimetre in height.
DESCRIPTION OF CASTING PROCEDURE
According to the present invention, casting is carried out in accordance with the following method. Any forms required for window cavities and other cavities in the wall concrete plate are applied conventionally. Wall reinforcement is placed in the mould.
Prior to casting, the prepared insulation sheets are fixed at the correct unit thickness with spacing blocks against the mould for the concrete. Or are lifted from the mould and held in place with the aid of suction cups through the medium of a vacuum, without requiring the use of blocks. There is always a risk of blocks being torn away by the heavy concrete mass; see below. Suitable stop means prevent the insulation sheets moving from the mould as the concrete is poured thereinto. SOLUTION
Pouring concrete into a sloping mould.
One end of the moul i .<- lifted so that the mould bottom builds an inclined plane or surface.
The fastener channels in the insulation to be filled with concrete are suitably orientated in the longitudinal direction of the slope so that no unnecessary air pockets will form. The concrete is poured in from the upper edge of the slope, optionally while vibrating. The upper edge can be formed by any side of the unit whatsoever. When casting extremely tall units, e.g. two-storey units, the concrete is poured from the long side of the unit.
After having filled th mould with concrete, the mould is lowered to a horizontal position back on its foundation or pallet attachment, w ioh provides stability and straightness in a conventional manner.
Pressure against the insulation also ceases therewith. Light vibration can be employed to ensure that the concrete will flow out towards the steel mould. In this stage of the process, supplementary concrete can be supplied in the case of complicated forms, e.g. around windows apertures in which windows shall be fitted slightly out towards the outside of the wall and when wishing to provide in the aperture internal concrete linings that do not need subsequent treatment. Rising vents that allow air to escape in the concrete pouring operation can be readily provided at such locations, by providing holes in the insulation.
With modern-day casting techniques and effective methods of enhancing the flow of concrete during casting, concrete may also be injected centrally through such holes or openings provided in the insulation. The mould may very well lie horizontally in this case.
A check is made in the rising vents that all cavities to be filled with concrete have actually been filled.
In a reverse procedure with the grooved insulation forming an inclined mould bottom in accordance with the above, and an overlying mould, e.g. a steel mould, that is held spaced from the mould bottom to form a gap for receiving the supporting plate.
Plate reinforcement is spaced from the insulation sheet and holds the sheet m placo, so that the sheet will not float up. This casting method enables the insulation sheets to be made in large units, and also enables holding means to be provided against the overlying mould, to avoid the insulation floating up. The concrete/casting compound poured in the upper edge of the gap in accordance with the aforegoing runs readily down into fastener channels and pockets for windows, etc., wherewith the air is pressed up towards the overlying planar mould and has a much broader way out, which facilitates filling-out the mould with casting compound.
As the gap is filled with casting compound, vibrators placed on the upper mould result in requisite packing of the relatively thin concrete plate right down to the insulation sheet. Vibrators placed along the sloping mould can be switched on and off respectively as the gap is filled. This will depend on whether or not vibration is required; see below.
Because the mould is inclined whilst being filled, the "liquid height" is reduced and therewith the pressure on the insulation. This will not be compressed to the same extent as if the mould was upright or as in the case when the insulation is pressed down into the concrete mass. When the mould is returned to a horizontal position, the load acting on the insulation is removed completely. And the object achieved => a unit of uniform thickness. Also straight with a concrete surface that is cast against a steel mould: Ready to paint.
It should be pointed out that particularly plastic concrete compositions which need not be vibrated during a casting operation are now commercially available. It will be seen that this gives typical interest to the aforedescribed casting procedure.
The invention is defined in the accompanying independent Claim. Further developments of the invention are set forth in the dependent Claims.
Only walls that incorporate insulation have been included in the examples, although it will be understood that the invention can be applied with respect to foundation beams having thin, preferably vertical sheets. Or roof plates in which insulation is firmly embedded.
It will also be understood that the present invention is not restricted to the aforedescribed exemplifying embodiments thereof and that the invention includes all of the embodiments and similar solutions that lie within the scope of the following Claims.

Claims

1. A method of fabricating a thermally insulated unit which includes a supporting layer of cast material and a layer of thermally insulating material which is fastened against and orientated generally parallel with the cast layer, c h a r a c t e r i s e d b y providing an openable mould that has a mould cavity whose shape corresponds to the shape of said unit; in that the layer of thermally insulating material is introduced into the mould and held firmly against and generally parallel with a main surface of the mould cavity; in that the mould is positioned to define an angle between said main surface and the horizontal plane; and in that the casting material is introduced into the mould via a high point in the mould cavity whilst keeping the mould at an angle relative to the horizontal plane.
2. A method according to Claim 1, c h a r a c t e r i s e d b y lowering the mould after filling said mould and prior to the casting material having hardened, so as to cause the cast sheet to lie generally horizontally during the hardening or curing process.
3. A method according to Claim 1 or 2, c h a r a c t e r i s e d i n that the thermally insulating layer has undercut recesses in its main surface facing the casting material.
4. A method according to Claim 3, c h a r a c t e r i s e d i n that that the recesses have the form of elongated grooves having an undercut cross-sectional shape; and in that the mould is orientated so that the grooves will extend in a direction that deviates from the hori zontal during the casting process .
5. A method according to Claim 3, c h a r a c t e r i s e d i n that that the mould is orientated so that the grooves lie generally in vertical planes that are perpendicular to the plane of the layers.
6. A method according to any one of Claims 1-5, c h a r a c t e r i s e d i n that the unit is a prefabricated building unit; and in that the casting material is concrete.
7. A method according to any one of Claims 1-6, c h a r a c t e r i s e d i n that the insulating sheet is formed by edge- joining sheets of insulating material.
8. A method according to any one of Claims 1-7, c h a r a c t e r i s e d i n that the sheet of thermally insulating material extends over at least a part of the main surface area of said unit.
EP98917920A 1997-04-20 1998-04-20 Procedure for casting of building element; the lt-method Withdrawn EP0941155A1 (en)

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
SE9701500A SE9701500D0 (en) 1997-04-20 1997-04-20 Device for wall mounting
SE9701500 1997-04-20
PCT/SE1998/000712 WO1998047679A1 (en) 1997-04-20 1998-04-20 Procedure for casting of building element; the lt-method

Publications (1)

Publication Number Publication Date
EP0941155A1 true EP0941155A1 (en) 1999-09-15

Family

ID=20406672

Family Applications (2)

Application Number Title Priority Date Filing Date
EP98917919A Expired - Lifetime EP1012415B1 (en) 1997-04-20 1998-04-20 Arrangement at wall support
EP98917920A Withdrawn EP0941155A1 (en) 1997-04-20 1998-04-20 Procedure for casting of building element; the lt-method

Family Applications Before (1)

Application Number Title Priority Date Filing Date
EP98917919A Expired - Lifetime EP1012415B1 (en) 1997-04-20 1998-04-20 Arrangement at wall support

Country Status (9)

Country Link
EP (2) EP1012415B1 (en)
CN (1) CN1138899C (en)
AU (2) AU7095398A (en)
CA (1) CA2287313A1 (en)
DE (1) DE69828622T2 (en)
DK (1) DK1012415T3 (en)
PL (1) PL198167B1 (en)
SE (1) SE9701500D0 (en)
WO (2) WO1998048123A1 (en)

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* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP5630764B2 (en) * 2007-10-03 2014-11-26 キャフォール フィンチ，スティーブン Railway arched lining and mezzanine
EP2767373A1 (en) * 2013-02-15 2014-08-20 Bayer MaterialScience AG Method for producing a multilayer, reinforced concrete element
CN105201079A (en) * 2014-06-20 2015-12-30 任丘市永基建筑安装工程有限公司 Floorslab and wallboard welding technique
CN106245806B (en) * 2016-08-22 2018-11-27 沈阳建筑大学 The whole hook bolt connection without heat bridge board wall of assembly concrete
CN110206158B (en) * 2019-04-22 2020-10-09 中国航空规划设计研究总院有限公司 Horizontal connecting structure of precast concrete double-T plate and construction method thereof
CN110821022A (en) * 2019-11-28 2020-02-21 怀化远大建筑工业有限公司 Full-prefabricated high-strength PC floor in steel construction that can install fast
CN113846746A (en) * 2021-10-13 2021-12-28 成都建工第一建筑工程有限公司 Basement structure beneficial to efficient construction and construction method

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FR1394123A (en) * 1964-02-13 1965-04-02 Veran Costamagna & Cie Manufacturing process of lightweight brick and plaster partition panels
DE2120144C3 (en) * 1971-04-24 1973-12-13 Nordis Handels- Und Finanz- Ag, Vaduz Building made of tunnel-shaped room elements and table-shaped ceiling elements
DE2239736A1 (en) * 1971-09-30 1973-04-05 Bauakademie Ddr PROCESS FOR ERECTING BUILDINGS FROM PREFABRICATED ELEMENTS
GB1448714A (en) * 1973-10-12 1976-09-08 Bekaert Sa Nv Construction panels
US5095674A (en) * 1988-02-22 1992-03-17 Huettemann Erik W Concrete building panel with intermeshed interior insulating slab and method of preparing the same
US5081805A (en) * 1989-08-23 1992-01-21 Jazzar M Omar A Precast concrete building units and method of manufacture thereof
US5588272A (en) * 1994-11-28 1996-12-31 Haponski; Edward L. Reinforced monolithic concrete wall structure for spanning spaced-apart footings and the like

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Also Published As

Publication number Publication date
SE9701500D0 (en) 1997-04-20
PL336725A1 (en) 2000-07-03
DE69828622D1 (en) 2005-02-17
DE69828622T2 (en) 2005-09-29
CA2287313A1 (en) 1998-10-29
EP1012415A1 (en) 2000-06-28
AU7095298A (en) 1998-11-13
WO1998047679A1 (en) 1998-10-29
PL198167B1 (en) 2008-06-30
CN1138899C (en) 2004-02-18
DK1012415T3 (en) 2005-06-06
CN1258331A (en) 2000-06-28
AU7095398A (en) 1998-11-13
EP1012415B1 (en) 2005-01-12
WO1998048123A1 (en) 1998-10-29

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