EP1249560B1 - Method and apparatus for the production of building wall elements having a mortar coating and corresponding building wall element - Google Patents

Abstract

To produce a wall unit, with a plaster cladding, it lies horizontally in a shell mold (1). A liquid plaster (5) is applied to the layer (4) to be plastered. A vibrator (7) shakes the mold assembly to spread the plaster in an even thickness of 1-10 mm and preferably 3-4 mm over the layer to be cladded, and the plaster is dried.. The layer to be plastered is of concrete or a light concrete, or a brick structure, and the mold vibration ensures that the plaster penetrates into the gaps between bricks. The plaster can be mixed with reinforcement fibers, and acts as an adhesive for applied insulation boards.

Description

The invention relates to the horizontal production of wall components with a plaster coating and corresponding wall components produced by the method.

The prefabricated industry offers wall construction elements for both residential construction and industrial construction. The elements are delivered in the form of cast concrete slabs, lightweight concrete slabs or finished masonry in various sizes from the Elementwerk to the construction sites, where they are assembled and plastered. In many cases, only one leveling is necessary in the interior of the future building, namely, if the wall element is correspondingly smooth, in the outdoor area, however, a primer and a fine plaster must be applied.

Increasingly, the wall components, i. the raw concrete slabs, lightweight concrete slabs or masonry, already plastered by the manufacturer. The time-consuming plastering on the construction site, except for the joints between the individual elements, is no longer necessary.

The production of wall elements with a plaster coating takes place in the elemental works, inter alia lying in a horizontal formwork, in the first a thin layer light plaster is given as an interior or exterior plaster. Subsequently, concrete or lightweight concrete is poured onto the plaster layer. After setting, a further layer of plaster, usually in a thickness of about 1 centimeter, is applied to the concrete surface. This layer must then be processed several times, including by peeling and rubbing, also called felting. After these operations, the plaster layer has a horizontal and smooth surface. If another layer, eg an outer plaster layer, is to be applied to this plaster layer, it also has to be roughened. If the plaster layer serves as interior plaster, then its surface must be felted smoothly so that, for example, the interior paint can be applied directly to the construction site or a wallpaper can be glued on.

However, the production of plastered wall elements in the element factory is very expensive. In particular, the operations of peeling, felting and roughening the upper layer of plaster slow down the production process.

Another disadvantage of the prior art is that when applying a plaster in layer thicknesses of about 10 millimeters and more when drying the wall element and the plaster takes place different drying shrinkage in the wall element and plaster, which can lead to flaking or cracks in the plaster.

From the GB 656 477 A a method for the production of wall components is known, wherein an outer cement or concrete layer is applied to a wall component in lying production.

The EP 0 756 047 A2 relates to a method for producing prefabricated plastered masonry walls, in which an edge formwork for limiting the wall is mounted on a horizontal formwork surface, wherein a bed of plaster is applied to the formwork surface within the edge formwork, with bricks with through holes for making a recumbent wall in the Plaster mortar are inserted at a predetermined distance from each other and the joints and the openings are potted from above with flowable mortar.

From the DE 25 20 773 A1 is a method for producing plaster or cladding layers bearing, optionally reinforced masonry known, wherein a plaster layer is applied by pouring pourable mortar on a masonry and wherein subsequently the plaster layer is removed by means of a Abziehlatte over the edges of a formwork.

The invention is therefore based on the object to simplify the horizontal production of wall components with a plaster coating in the element factory. In this case, both the previously necessary operations are reduced after the application of the upper layer of plaster, and different shrinkage can be avoided. It is a further object of the invention to provide a corresponding wall component produced by the method according to the invention.

The present invention thus relates to a method for the production of wall components according to claim 1 or 2; Further embodiments are the subject of the relevant subclaims.

The present invention thus provides a process for the production of wall elements with a plaster coating, wherein a concrete layer or a lightweight concrete layer is poured in horizontal production in a formwork, wherein after the setting of the concrete or the lightweight concrete on the in-circuit, from the Bonded concrete layer or lightweight concrete layer formed outside, to be plastered layer is given a flow plaster and the shuttering is shaken with the layer to be plastered and the fluid render until the fluidized render forms a layer of uniform thickness, wherein the fluidized surface distributed due to its flowable consistency on the underlying surface , And immediately after the distribution of the flow-smoothing layer insulation boards are glued by the flow-smoothing layer with the layer to be plastered.

Another object of the present invention is a process for the production of wall elements with a plaster coating, wherein the layer to be plastered is a layer of juxtaposed bricks, wherein in lying production on the located in a formwork, outside to be plastered layer given a smoothing plaster and the shuttering is shaken with the layer to be plastered and the flow render until the flow plaster forms a layer of uniform thickness, wherein the flow plaster layer forms the outer plaster layer and wherein the flow plaster due to its flowable consistency distributed on the underlying surface, and immediately after the distribution of the flow-smoothing layer insulation boards be glued by the flow-plaster layer with the layer to be plastered.

The solution of the problem by the invention thus consists in a method for the production of wall components with a plaster coating, in which on the located in a formwork to be plastered layer in horizontal production a flow plaster, i. a mortar of flowable consistency, is given. Such mortars used here as flowable plasters are e.g. Modified potting and grouting mortar and modifications of the known soil leveling compounds. Due to its flowable consistency, the plaster is already distributed on the underlying surface. The shuttering is additionally shaken with the layer to be plastered there and the flow plaster until the flow plaster forms a layer of uniform thickness.

As the plastering layer is usually the core of the wall component, which may be, for example, a concrete layer, a lightweight concrete layer or a layer of juxtaposed bricks. It is also conceivable, however, for the layer to be plastered to be a first plaster layer previously applied to the upper side of the element core in any desired manner. This is This is the case, for example, when the exterior area of a primer layer is still to be applied with a fluid-repellent layer. In this case, therefore, the flow-coating layer would form the outer plaster layer, ie the outer plaster layer.

It is also conceivable that in an element having a plurality of plaster layers, the application of individual layers can be carried out by other means or methods. But at least the outer layer should be applied by the method according to the invention, as this is particularly smooth and uniform.

Even before filling the core material, e.g. of concrete, lightweight concrete or bricks, a lower layer of plaster can be filled in the lying formwork. Then the wall element would be plastered after stripping both on the later inside as well as on the outside.

The core of a wall element can, as mentioned above, consist of different materials. As a rule, concrete cores, lightweight concrete cores or a layer of bricks are used. The latter can be introduced into the formwork in various ways: For example, a masonry consisting of already mortared bricks, that is solid, can be placed as a whole in the formwork and then plastered with the method according to the invention, such as a concrete layer.

But it is also conceivable that the bricks are placed individually in the mold and not yet connected by mortar. Spacers can be used to obtain a uniform gap between the stones. In the case of individual, yet not mortared stones, the flow plaster can be used at the same time for filling the joints. The floating plaster applied to the stones is then distributed in the joints. This process can be further facilitated by additional shaking the shuttering. A previous Vermörteln the bricks is therefore not necessary. The production of a solid element core and the plastering are then a single operation. By arranging the stones in the formwork, for example by placing them on spacers, the plaster, especially during shaking, not only in the joints and on the stones, but also distribute underneath. In this case, a double-sided plastered wall element is produced with a single operation of loosely adjacent bricks.

The shuttering walls may have different heights, the thickness of which depends on the bricks or concrete layer used as the core. The other dimensions such as length and width of the formwork can vary.

The additional shaking of the shuttering with the materials therein is carried out according to a preferred embodiment by means of a vibrator. This transfers mechanical vibrations to the shuttering and the layer to be plastered in the shuttering. The movement during the vibration or shaking process can take place in different directions. It is also conceivable that the shaking, especially with small wall components, done by hand. By shaking the flowable plaster is even better distributed in the formwork, in addition air inclusions are removed by the movement of the plaster.

According to one embodiment of the method according to the invention it is provided that the flow plaster is roughly distributed, which is e.g. can be done by a screed smoother. In this way, a faster and more uniform distribution of flow plaster is ensured on the underlying layer.

The amount of plaster that is filled in the formwork is preferably such that the layer thickness after its final distribution is 1 to 10 millimeters. In particular, the amount can be such that the plaster layer of the finished element is 3 to 4 millimeters. Subsequent removal and abrasion of the plaster is thus no longer necessary with the method according to the invention. The application of a plaster coating and thus the entire production of horizontal wall elements is thereby significantly simplified in the element factory.

According to the invention, it is further provided that immediately after the distribution of the upper flow-smoothing layer insulation boards are placed on it and so glued to the layer to be plastered. In this way, provided with an insulation wall elements can be made directly in the factory and delivered to the site. The time-consuming bonding and laying the insulation boards and their cutting would therefore no longer be necessary on the site.

If the applied flow plaster should serve as external plaster, it can also be hydrophobic against driving rain. For special embodiments it can be provided that the flow-coating layer additionally has a reinforcement, in particular of fibers. Furthermore, the plaster can be colored both for indoor and outdoor applications of the future building.

Likewise, the invention relates to wall components produced by this method. These elements have in the ideal case after stripping on both sides uniform, provided with insulation boards, plaster layers that require no further processing such as peeling, felting or roughening and barely have air bubbles. The resulting surfaces can be painted or papered directly on request.

• Figur 1a zeigt in perspektivischer Ansicht eine Ausführungsform der erfindungsgemäß einsetzbaren Vorrichtung mit Rüttelvorrichtung und
• Figur 1b zeigt schematisch einen Schnitt durch diese Vorrichtung.

In the following the invention is clarified by way of example with reference to drawings:

• FIG. 1a shows a perspective view of an embodiment of the present invention usable device with vibrator and
• FIG. 1b schematically shows a section through this device.

In FIG. 1a is a Einschalungsrahmen 1 made of metal, which rests on a smooth metal plate 2. Together frame 1 and plate 2 form a shutter. In this one is on both sides with the inventive method to recognize plastered wall element, which is due to the perspective view, only the upper layer of plaster 5, ie the flow-smoothing layer can be seen. In the rear region of the wall element two rows of insulation boards 6 are glued. Under the metal plate 2, a device 7 is arranged, which can put the entire shuttering and their filling in vibration. The vibrations take place in different directions, represented by arrows in the drawing. They improve the uniform distribution of the upper layer of plaster 5 in the flowable state, ie even before sticking the insulation boards 6, in the formwork on the underlying surface, here the top of a concrete slab.

FIG. 1b shows a section through the inventively usable device and the materials therein. Under the device, first of all, the vibrating device 7 can be seen, on which in turn the metal plate 2, which is smooth on the upper side, rests. On the metal plate 2 is the metal frame 1. In the shuttering was first given a plaster layer 3 in a thickness of 4 millimeters, then a concrete layer 4 was poured in a thickness of 18 centimeters. After the setting of the concrete pouring plaster 5 was given to his top, which was first roughly distributed with a screed smoother. By operating the vibrator 7, the flow plaster 5 was distributed to a uniformly thick layer of again 4 millimeters. Subsequently, the two rows of in FIG. 1b invisible insulation board 6 placed on the not yet dried flow plaster 5 and glued in this way with the underlying concrete layer 4.

After drying and setting of all three layers, the formwork can be removed and the wall element lying or stationary transported to the site.

LIST OF REFERENCE NUMBERS

1

Einschalungsrahmen

2

metal plate

3

lower layer of plaster

4

to be plastered layer

5

upper plaster layer of flow plaster

6

Insulation Board

7

shaker

Claims (12)

1. A method for the production of wall construction elements with a plaster coating, wherein a concrete layer or a light concrete layer is cast in a horizontal production operation in a shuttering (1), wherein, after the binding of the concrete or light concrete, a free-flowing plaster (5) is applied on the layer (4) to be plastered externally and formed by the set concrete layer or light concrete layer and located in the shuttering (1), and the shuttering (1) with the layer (4) to be plastered and the free-flowing plaster (5) is vibrated until the free-flowing plaster (5) forms a layer of uniform thickness, wherein the free-flowing plaster (5) is distributed on the surface lying beneath due to its free-flowing consistency, and wherein, immediately after the distribution of the free-flowing plaster layer (5), insulation boards (6) are bonded by the free-flowing plaster layer (5) to the layer (4) to be plastered.
2. The method for the production of wall construction elements with a plaster coating, wherein the layer (4) to be plastered is a layer comprising bricks arranged beside one another, wherein a free-flowing plaster (5) is applied in a horizontal production operation on the layer (4) to be plastered externally and located in a shuttering (1), and the shuttering (1) with the layer (4) to be plastered and the free-flowing plaster (5) is vibrated until the free-flowing plaster (5) forms a layer of uniform thickness, wherein the free-flowing plaster layer (5) forms the external plaster layer and wherein the free-flowing plaster (5) is distributed on the surface lying beneath due to its free-flowing consistency, and wherein, immediately after the distribution of the free-flowing plaster layer (5), insulation boards (6) are bonded by the free-flowing plaster layer (5) to the layer (4) to be plastered.
3. The method according to claim 2, characterised in that the free-flowing plaster (5) is also distributed in the gaps between the bricks, especially during the vibration.
4. The method according to any one of claims 2 or 3, characterised in that the bricks are arranged in such a way that the free-flowing plaster (5) is also distributed beneath the bricks, especially during the vibration.
5. The method according to any one of claims 1 to 4, characterised in that the vibration takes place by means of a vibration device (7).
6. The method according to any one of claims 1 to 5, characterised in that the free-flowing plaster (5) is roughly distributed, especially with a floor smoothing tool.
7. The method according to any one of claims 1 to 6, characterised in that the quantity of the free-flowing plaster (5) is dimensioned in such a way that the layer thickness after its distribution amounts to 1 to 10 mm, preferably 3 to 4 mm.
8. The method according to any one of claims 1 to 7, characterised in that the free-flowing plaster layer (5) is hydrophobised.
9. The method according to any one of claims 1 to 8, characterised in that the free-flowing plaster layer (5) comprises a reinforcement.
10. The method according to claim 9, characterised in that the reinforcement comprises fibres.
11. The method according to any one of claims 1 to 10, characterised in that the free-flowing plaster layer (5) is coloured.
12. A wall construction element which is produced with the method according to any one of claims 1 to 11.

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