EP1382759A1 - Prefabricated construction elements for a building and building with such elements - Google Patents

Abstract

The construction system consists of prefabricated components with internal load-bearing and insulating layers and external decorative layers, with spacers to maintain the required air gap between the internal and external layers. The spacers are in the form of tenon and mortise joints (4A) between adjacent prefabricated component, and mechanical supports (4B) that hold the layers apart between assembly and construction. The load-bearing layer of each component has higher acoustic/thermal insulating properties than plain concrete and is made e.g. from cellular concrete or concrete containing expanded clay balls.

Description

The invention relates to prefabricated building elements for the realization of a building.

It also relates to buildings obtained using the elements prefabricated.

There are several methods for constructing a building.

The best known method, after having laid the foundations, is to use bricks or concrete blocks which are assembled with mortar to form the walls of the building.

When you want an additional floor, you sometimes pour a slab in concrete which extends over the entire surface of the building or else a structure is laid wooden support to place a floor before continuing the construction of walls which, very often, are limited to the two gables of the house.

These walls being created and the frame and the roof being laid, we proceed to the insulation of the construction by fixing on the internal face of the construction composite panels comprising a layer of plaster and a layer of material insulator, such as polystyrene.

According to another method, instead of constituting the walls by means of bricks, it is known to pour concrete walls on site using formwork.

This solution is more generally reserved for buildings with several floors rather than traditional dwellings.

The insulation is then placed inside.

It is also known for the construction of walls to use precast concrete panels which, once installed, are coated inside a insulation and on the outside of a facing which, generally, is a coating or sometimes briquettes glued to the outside of the panels.

The latter solution improves the time between ordering the house or building for any other use and delivery but the dwellings thus produced are not better insulated than the others and the construction time is only partially reduced.

In addition, a metallic structure composed of uprights between which the prefabricated panels are placed.

The invention proposes to improve this situation.

• une paroi porteuse composite préfabriquée comprenant elle-même une structure résistante et une couche d'un isolant disposée sur la face externe de la structure portante,
• une paroi dite décorative composite préfabriquée comprenant une couche de parement fixée sur une couche de béton et
• des moyens de maintien à distance des parois porteuse et décorative en vue de délimiter, entre les deux parois précitées, une couche d'air.

To this end, the invention relates to prefabricated construction elements for the realization of buildings, these construction elements being characterized in that they comprise:

• a prefabricated composite load-bearing wall itself comprising a resistant structure and a layer of insulator placed on the external face of the load-bearing structure,
• a so-called prefabricated composite decorative wall comprising a facing layer fixed on a concrete layer and
• means for maintaining the supporting and decorative walls at a distance in order to delimit, between the two aforementioned walls, a layer of air.

The invention also relates to the building obtained with the elements prefabricated.

• figure 1 : une coupe verticale d'une partie d'un bâtiment,
• figure 2 : une coupe horizontale d'une partie d'un bâtiment,
• figures 3 et 4 : variantes de la coupe verticale,
• figures 5 et 6 : détails de réalisation.

The invention will be clearly understood with the aid of the description below given by way of nonlimiting example with regard to the appended drawing which schematically represents:

• Figure 1: a vertical section of part of a building,
• Figure 2: a horizontal section of part of a building,
• Figures 3 and 4: variants of the vertical section,
• Figures 5 and 6: details of construction.

Referring to the drawing, we partially see a building 1.

This building is made in part by 2,3 construction elements prefabricated especially for the realization of walls.

• une paroi porteuse 2 composite préfabriquée comprenant elle-même une structure 2A résistante et une couche 2B d'un isolant disposée sur la face externe de la structure résistante,
• une paroi 3 dite décorative composite préfabriquée comprenant une couche 3A de parement fixée sur une couche 3B de béton et
• des moyens 4 de maintien à distance des parois porteuse et décorative en vue de délimiter, entre les deux parois précitées, une couche 5 d'air.

These building elements include:

• a prefabricated composite supporting wall 2 itself comprising a resistant structure 2A and a layer 2B of an insulator arranged on the external face of the resistant structure,
• a wall 3 known as a prefabricated composite decorative wall comprising a facing layer 3A fixed on a concrete layer 3B and
• means 4 for keeping the load-bearing and decorative walls at a distance in order to delimit, between the two aforementioned walls, a layer 5 of air.

Advantageously, the resistant structure 2A of the support wall is in material with thermal and / or acoustic insulation properties greater than that of concrete.

It can be aerated concrete or better still concrete with balls of expanded clay.

Using this concrete with clay balls, we then constitute a wall which "Breathes" and which, while being more insulating than concrete, accumulates heat.

The insulating layer 2B covers the entire external surface of the structure resistant 2A.

To avoid thermal bridges, when making an upper slab forming the ceiling of the building and to make a connection between all the walls carriers, the top of the carrier wall 2 has, set back from the external face 6 and this shrinkage being greater than the thickness “e” of the insulating layer, a face 7 called support located under the upper face 8 of said wall, the distance between the face support and the upper face of the load-bearing wall corresponding to the thickness of a slab 10.

Concrete irons 9 waiting, protruding from the inside of the wall load-bearing, make it possible to link load-bearing walls and the ceiling slab or slab 11 from the ground which will later be poured after the walls have been put in place carriers.

To constitute the ceiling slab 10, the construction elements include advantageously a pre-slab 10A which, placed on the bearing faces 7 of the walls load-bearing, serves as lost formwork.

The decorative walls 3 which surround the enclosure formed by the walls 2 carriers are kept at the required distance from the carrier wall, below by means 4A for nesting and at the top by legs 4B fixed on the field of load-bearing and decorative walls.

During the manufacture of these prefabricated walls, provision is made to places a stainless steel screw 50 at various points waiting to receive these legs 4B.

As indicated above, for the immobilization of the foot of the bearing wall, waiting concrete irons protrude laterally and are then embedded in a cement screed which will later receive the floor tiles.

During construction in order to keep the load-bearing walls vertical, struts support the prefabricated elements.

The foot of these struts can be anchored on legs 14 awaiting in the slab or slab receiving the walls.

As can be seen in the drawings, the side edges of the elements prefabricated are provided with a fraction of a fitting means 4A of the type groove and rib.

We will preferably choose a groove and a rib of triangular section which will facilitate the automatic positioning and positioning of the elements prefabricated with each other.

The different panels will therefore be placed side by side fitted without cement.

Regarding the interior walls 16 intended to separate the surface available in several usable parts, at the junction between these walls 16 interior and the supporting wall 2, this supporting wall has a fraction of a fitting means 4A of the groove and rib type provided during manufacture prefabricated elements.

Preferably, it will be the groove.

The fixing of this interior wall is made in the same way as for the wall load-bearing, i.e. using stand-by concrete irons embedded in the slab of the ceiling and floor.

For the handling of the prefabricated elements, lifting rings 17 are provided during manufacture.

For example, it can be a V-shaped concrete iron protruding from the top of the prefabricated element.

These rings 17 will not be located at the level of the means for fixing the legs ensuring the connection between the load-bearing and decorative walls.

They will participate in the connection with the ceiling tile.

As can be seen, for example, the top of the load-bearing walls has sand pits to support the frame.

These sand plates are fixed during manufacture.

At these particular points, the top of the walls will present a notch 18 which will then be filled.

a) première semaine :

• le premier jour à poser les fondations plus le radier 20 en béton,
• le deuxième jour, à tracer sur le radier 20 les emplacements des panneaux et poser les niveaux avec deux cales par panneau,
• le troisième jour, à poser le sous-sol, comprenant tous les murs 30, pré-dalles 31 et couler le béton en compression,
• le quatrième jour, finition du solin coin extérieur et pose du drainage et égouttage,
• le cinquième jour, à tracer et poser des cales pour le rez-de-chaussée et nivellement des terres sur le périmètre du sous-sol.

b) deuxième semaine :

• premier jour, à poser toutes les parois porteuses du rez-de-chaussée, les pré-dalles et à couler le béton 32, 10 de compression de la dalle inférieure et du plafond,
• deuxième jour, à poser des panneaux 3 de parement en briques de façade sur le périmètre extérieur du rez-de-chaussée, poser des pignons de béton et de briques, poser le conduit de cheminée et poser provisoirement la charpente préfabriquée,
• troisième jour, finition des façades, pose des plaquettes de liaison des panneaux, rejointoiement et pose de la charpente,
• quatrième jour, à poser la charpente et à poser les seuils extérieurs,
• cinquième jour, mise à sec provisoire par la sous-toiture plus pose de la zinguerie.

c) troisième semaine : la semaine complète pour la couverture et pose de toutes les menuiseries extérieures. A la fin de la semaine, le bâtiment est terminé en « clos couvert ».

The principle of the installation consists:

a) first week:

• the first day to lay the foundations plus the concrete slab 20,
• on the second day, mark the locations of the panels on the raft 20 and lay the levels with two shims per panel,
• on the third day, to lay the basement, including all the walls 30, pre-slabs 31 and pour the concrete in compression,
• on the fourth day, finish the external corner flashing and apply drainage and drainage,
• on the fifth day, to draw and place shims for the ground floor and leveling of the land on the perimeter of the basement.

b) second week:

• first day, laying all the load-bearing walls of the ground floor, the pre-slabs and pouring the concrete 32, 10 for compression of the lower slab and the ceiling,
• second day, lay facade brick facing panels 3 on the outside perimeter of the ground floor, lay concrete and brick gables, lay the chimney flue and temporarily lay the prefabricated frame,
• third day, finishing of the facades, installation of the panels connecting panels, repointing and installation of the framework,
• fourth day, to lay the frame and to lay the external thresholds,
• fifth day, provisional drying by the roofing plus laying of zinc works.

c) third week: the full week for covering and installing all exterior joinery. At the end of the week, the building is finished in “closed enclosure”.

1) après avoir le bon sol pour les murs porteurs, les fondations se terminent toujours par un radier général. Au moment de couler le béton, il est placé toutes les attaches 33 panneaux (suivant le plan de pose) ;

2) le niveau du sol-sol comprend trois solutions, en vide sanitaire, en cave ou en sol-sol avec rampe d'accès. Pour les trois cas, la structure est identique, il n'y a que la hauteur des murs qui varie,

3) au moins un jour avant la pose du sous-sol, il faut prévoir :

• de tracer sur le radier tous les murs ainsi que la longueur des panneaux 30,
• de poser au mortier des cales de niveaux à plus ou moins cinquante centimètres des extrémités de chaque panneau (cale métallique 50/5 suivant largeur du mur),

4) pose dans un bain de mortier frais de tous les panneaux 30 du sous-sol ; le premier panneau aura deux attaches panneaux, ensuite une attache panneaux du côté opposé de l'emboítement avec le précédent pour le réglage des panneaux. Le problème ne se pose pas horizontalement puisque les panneaux se posent sur des les cales. Verticalement, il suffit de visser ou dévisser les étais 34 pour être d'aplomb ;

5) une fois tous les panneaux dressés et stabilisés par les étais-attaches, on peut commercer à poser les pré-dalles en prenant soin :

• de garder tous les crochets de levage de chaque panneau pour relier dans le béton de compression,
• de placer des filières et des étais pour supporter les pré-dalles ;

6) plier toutes les barres acier en attente de chaque panneau et mettre des barres d'ancrage à chaque crochet de levage, le tout pour être enrobé dans le béton de compression,

7) au moins un jour avant la pose du rez-de-chaussée, faire la préparation identique au sol-sol ;

8) la pose du rez-de-chaussée comprend deux journées, le premier jour pour poser toute la partie murs en béton y compris le plancher haut rez-de-chaussée ; pour le principe de pose, se reporter aux points 4, 5 et,

9) le lendemain ou plus tard :

• commencer par poser sur le périmètre extérieur du rez-de-chaussée les panneaux de parement en briques de façade, voire le profil à la base de ces panneaux qui correspond au profil de la tête des panneaux sous-sol et le maintien vertical des panneaux est assuré par les fers plats galvanisés environ tous les un mètre cinquante,
• une fois le périmètre placé, pose des pignons en béton au mortier frais sur la dalle et maintenus verticalement par deux étais à vis, ensuite pose du panneau parement en briques de façade (même principe que le point 9),
• pose du conduit de cheminée ou de conduit technique, maintenu verticalement par deux étais opposés et profiter de la grue de montage pour monter les éléments de charpente ;

10) le jour suivant : finition des parements par pose des briques de liaison panneaux dans un bain de mastic et ensuite rejointoiement en finition avec mortier de la même composition que celui de l'usine.

Regarding technical information for installation on site:

1) after having the right soil for load-bearing walls, the foundations always end with a general raft. When pouring the concrete, all the 33 panel fasteners are placed (according to the laying plan);

2) the ground-floor level includes three solutions, in crawl space, in a cellar or in ground-floor with an access ramp. For the three cases, the structure is identical, only the height of the walls varies,

3) at least one day before laying the basement, you must plan:

• to trace on the raft all the walls as well as the length of the panels 30,
• place level shims more or less fifty centimeters from the ends of each panel in the mortar (metal shim 50/5 depending on the width of the wall),

4) laying in a fresh mortar bath all the panels 30 of the basement; the first panel will have two panel fasteners, then a panel fastener on the opposite side of the socket with the previous one for adjusting the panels. The problem does not arise horizontally since the panels are posed on wedges. Vertically, it suffices to screw or unscrew the struts 34 to be plumb;

5) once all the panels are erected and stabilized by the props, we can start installing the pre-slabs, taking care:

• to keep all the lifting hooks of each panel to connect in the compression concrete,
• to place dies and props to support the pre-slabs;

6) bend all the steel bars awaiting each panel and put anchor bars on each lifting hook, all to be embedded in the compression concrete,

7) at least one day before laying the ground floor, make the preparation identical to the ground-floor;

8) the laying of the ground floor includes two days, the first day to lay all the concrete walls part including the high ground floor; for the installation principle, see points 4, 5 and,

9) the next day or later:

• start by placing the facade brick facing panels on the outside perimeter of the ground floor, or even the profile at the base of these panels which corresponds to the profile of the head of the basement panels and the vertical support of the panels is supplied by flat irons galvanized approximately every 1.5 meters,
• once the perimeter has been placed, put concrete gables in fresh mortar on the slab and held vertically by two screw stays, then install the facing brick facing panel (same principle as point 9),
• installation of the chimney or technical conduit, held vertically by two opposite props and take advantage of the assembly crane to mount the structural elements;

10) the following day: finishing of the facing by laying the bricks connecting the panels in a bath of mastic and then repointing in finishing with mortar of the same composition as that of the factory.

Claims (10)

Prefabricated construction elements for the realization of a building, these construction elements being CHARACTERIZED in that they include: a prefabricated composite bearing wall (2) itself comprising a resistant structure (2A) and a layer (2B) of an insulator disposed on the external face of the resistant structure, a prefabricated composite decorative wall (3) comprising a facing layer (3A) fixed on a concrete layer (3B) and means (4) for keeping the load-bearing and decorative walls at a distance in order to delimit, between the two aforementioned walls, a layer (5) of air. Construction elements according to claim 1, characterized in that the resistant structure (2A) of the load-bearing wall is made of a material having thermal and / or acoustic insulation properties superior to that of concrete. Construction elements according to claim 2, characterized in that the material consists of aerated concrete or concrete with expanded clay balls. Construction elements according to claim 1, characterized in that the insulating layer (2B) covers the entire external surface of the resistant structure (2A). Construction elements according to claim 1 characterized in that the top of the load-bearing wall (2) has, set back from the external face (6) and this setback being greater than the thickness (e) of the insulating layer, a face (7) said support located under the upper face (8) of said wall, the distance between the support face and the upper face of the bearing wall corresponding to the thickness of a slab (10). Construction elements according to claim 1, characterized in that they include a pre-slab (10A) which, placed on the bearing faces (7) of the load-bearing walls, serves as lost formwork. Construction elements according to claim 1, characterized in that the decorative walls (3) which surround the enclosure formed by the supporting walls (2) are kept at the required distance from the supporting wall, below by means (4A) of nesting and at the top by legs (4B) fixed on the field of the load-bearing and decorative walls. Building elements according to claim 7, characterized in that a groove and a rib of triangular section facilitate the positioning and the automatic positioning of the prefabricated elements together. Construction elements according to claim 1, characterized in that, at the junction between the interior walls (16) and the load-bearing wall (2), the load-bearing wall has a fraction of a fitting means (4A) of the type groove and rib provided during the manufacture of the prefabricated elements Building characterized in that it is constituted by means of the construction elements according to any one of claims 1 to 9.

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