EP2146018B1 - Prefabricated wall and its method of production - Google Patents

Abstract

The prefabricated wall has a carrier wall body (3), which is partly made of concrete. A fine layer (4) is applied on the wall body at an inner side of the prefabricated wall, on which a fleece (5) is arranged. The fine layer is made of a mineral mortar. An independent claim is included for a method for manufacturing a prefabricated wall.

Description

The invention relates to a finished wall according to the preamble of the main claim and a method for producing a finished wall according to the preamble of the independent claim.

Various methods are already known for producing coated prefabricated walls. For example, the document discloses DE 195 27 275 A1 a method for producing prefabricated and plastered masonry walls, which are produced by means of an edge formwork on a horizontal formwork surface. In the process, plaster is poured into the formwork, on which insulation elements are aligned, which are poured with mortar. The document also discloses a plaster layer above the stone layer, which can be applied after a drying time of the mortar. The use of masonry leads the prefabricated walls from the cited document to a disadvantageous consuming manufacture.

Prefabricated walls in which a load-bearing wall body is formed by pouring concrete, for example, from the document DE 25 48 959 B1 known. The previously known prefabricated walls of this type have the disadvantage that curing of the load-bearing concrete layer must take place before the application of a plaster layer. Accordingly, after installation on the construction site, these walls typically still have to be smoothly plastered on the inside, so they are not yet ready for wallpapering.

The object of the present invention is to propose a prefabricated wall which is ready for use inside and outside after the manufacturing process and which can be produced between individual production steps without dry or interim storage time. The invention is accordingly also the object of proposing a simple production method for a precast wall, which requires as little rework on a construction site.

This object is achieved by the characterizing features of the independent claims in conjunction with the features of the preambles.

The claimed prefabricated wall has a load-bearing wall body, which consists at least partially of concrete and preferably of concrete reinforced with a steel grid. The finished wall has on the inside of the wall body on a plaster layer, which is formed from mineral mortar and on which a fleece is attached. The mineral plaster layer offers decisive advantages when making the wall. First, the plaster layer on fresh, On the other hand, the mineral plaster layer is weatherproof, so that the wall can be stored outdoors after completion and thus no additional, covered storage areas are needed. By arranged on the plaster layer fleece finally a smooth and ready-to-use surface is realized on the inside of the finished wall, which requires no reworking on the site, such as additional plastering and smoothing.

The measures specified in the dependent claims advantageous refinements and improvements are possible.

In a preferred embodiment of the invention, the nonwoven used is a glass fiber fleece. This brings the advantage of good weather resistance, which allows the wall to be stored outdoors.

In a preferred embodiment, the nonwoven spans the inside of the finished wall over its entire surface, wherein the nonwoven integrally spans a height of a floor at least in one strip. This avoids web impacts on the insides of the prefabricated walls.

A good and stable connection between the nonwoven and the plaster layer can be achieved by partially embedding the nonwoven in the plaster layer. Unlike a merely plastered prefabricated wall, this gives a particularly flat wall with a paper-finished surface.

By an advantageous coating of the inside With a nonwoven so smooth walls are achieved, in which after setting up otherwise usual operations, such as spatulas, can be saved. In a preferred version, the walls can even be provided with wallpaper or other decorative materials at the factory so that no additional work is required after setting up the prefabricated walls. This can save costs on the construction.

Advantageously, the prefabricated wall additionally has an external insulation, preferably an insulation with reinforcement. In a preferred embodiment, the insulation may consist of insulating panels, which may be reinforced by a reinforcing fabric so that the finished wall on the outside is sufficiently stable. For this purpose, the reinforcing fabric can be embedded between two mortar layers. By applying the insulation, with or without reinforcement, in the manufacturing process additional work on the construction site is saved again.

The advantageously simple and feasible in a short time proposed method for producing a finished wall described type with a wall body formed at least partially of concrete provides that the concrete is poured to form the wall body in a mold typically formed by a formwork, after which a mineral mortar for Forming a plaster layer is applied to the concrete, after which a fleece is applied to the plaster layer and is connected to this, which forms an inside of the finished wall.

The method is particularly easy to implement when the wall body in the mold in lying Orientation is formed. The plaster layer and / or the fleece can then be applied to the wall body, if this is still in the mold. This allows a simple smoothing of the respective layer.

Advantageously, the plaster layer can be applied to the concrete before it is completely cured. Only the use of mineral mortar makes that possible. This avoids waiting times that would otherwise elapse until the concrete cures. The nonwoven, in turn, may conveniently be superficially embedded in the plaster layer before the plaster layer has cured.

In a preferred embodiment, the plaster layer is smoothed by machine after application. In particular, with a horizontal orientation of the resulting prefabricated wall so a quick and accurate smoothing of the wall is possible, for which it is e.g. It is sufficient to draw a smoothing rail only with a constant height over the plaster layer.

In an advantageous embodiment, an insulation is inserted into the mold prior to the formation of the wall body and connected during the casting of the concrete with the resulting wall body. Furthermore, a reinforcing layer can be formed there before the insulation is inserted into the casting mold, wherein the reinforcing layer is connected to the latter when the insulation is inserted. The reinforcing layer may e.g. are formed by a reinforcing fabric between two mortar layers is embedded.

Embodiments of the invention are described below with reference to the FIGS. 1 to 3 explained in more detail.

Fig. 1

einen Querschnitt durch eine entste- hende Fertigwand bei einem Herstel- lensprozess in vier aufeinander fol- genden Verfahrensschritten a)- d),

Fig. 2

eine entsprechende Darstellung einer entstehenden Fertigwand in einem ande- ren Ausführungsbeispiel und

Fig. 3

als Querschnittszeichnungen die fer- tiggestellten Fertigwände in zwei ver- schiedenen Ausführungsformen.

Show it:

Fig. 1

a cross section through an emerging prefabricated wall in a production process in four successive process steps a) - d),

Fig. 2

a corresponding representation of a resulting prefabricated wall in another embodiment and

Fig. 3

as cross-sectional drawings the finished finished walls in two different embodiments.

Fig. 1 shows process steps in the manufacturing process of a finished wall in one embodiment. The finished wall is formed in a mold in a horizontal orientation. After setting up formwork elements as a casting mold 1, an insulation 2 is introduced into the formwork element ( Fig. 1a ). As insulation 2 insulation boards are used. This insulation 2 forms after completion of the wall an outside 9 of the finished wall.

After the introduction of the insulation 2, concrete is poured into the casting mold 1 in order to form a wall body 3, in which a steel reinforcement is embedded and which is subsequently removed by machine and compacted ( Fig. 1b ).

Before the concrete has completely hardened, a plaster layer 4 is applied to the wall body 3 still lying in the casting mold 1 ( Fig. 1c ). The plaster layer 4 is formed from a mineral mortar and is machine smoothed after application with a pulled over the plaster layer 4 rail.

After applying the plaster layer 4, a glass fiber fleece 5 is placed on the plaster layer 4 and partially embedded in this ( Fig. 1d ). At the time, the plaster layer 4 is not yet cured. The fleece 5 covers the plaster layer 4 of the finished wall over the entire surface and spans it, possibly in several strips, a height of a floor in one piece. The surface of the finished wall formed with the fleece 5 forms its later inner side 8.

Fig. 2 shows a further embodiment of a finished wall of the proposed type at the end of a corresponding manufacturing process, wherein the finished wall is still shown in the mold 1, ie before removing the formwork, and wherein recurring features are again provided with the same reference numerals. It differs from that on the basis of Fig. 1 described embodiment in that the insulation 2 is reinforced on the outside 9 of the finished wall. For this purpose, in the production in a first step, mortar is brought as reinforcing compound 6 in the mold 1. Subsequently, a reinforcing fabric 7 is placed on the reinforcing compound 6 and then another layer of reinforcing compound 6 is added to the casting mold 1, so that the reinforcing fabric 7 is embedded in the reinforcing compound 6. On the reinforcing layer thus formed from the reinforcing compound 6 and the reinforcing fabric 7 insulation boards, so-called speed-wall slats are placed, which form an insulation 2. Of course, other insulation materials are possible. The reinforcing layer is connected when inserting the insulation 2 with this. The remaining steps of the manufacturing process correspond to those of the previously Fig. 1 described method, more precisely, the method steps b) to d) Fig. 1 ,

Fig. 3 shows the finished prefabricated walls of the two described embodiments in an upright position after removal of the formwork. Fig. 3a ) shows the finished wall of the embodiment Fig. 2 with the insulation 2 and with the reinforcing layer, which is formed from the reinforcing compound 6 and the reinforcing fabric, as well as with the wall body 3 made of concrete, the mineral plaster layer 4 and the web 5 of the inside 8 of the finished wall. The outside 9 of this finished wall is formed by the reinforcing layer. Fig. 3b ) shows the finished wall of the embodiment Fig. 1 in which no reinforcing layer is arranged on the insulation, so that the outside 9 of the finished wall is formed here by the insulation 2.

Claims (17)

1. A prefabricated wall, with a supporting wall body (3) which is formed at least partially of concrete, characterised in that a plaster layer (4) is applied to the wall body (3) on an inside (8) of the prefabricated wall, on which layer a mat (5) is arranged, the plaster layer (4) being formed from a mineral mortar.
2. A prefabricated wall according to Claim 1, characterised in that the mat (5) is a glass fibre mat.
3. A prefabricated wall according to Claim 1 or 2, characterised in that the mat (5) spans the entire surface of the inside (8) of the prefabricated wall, the mat (5), at least in one strip, spanning the height of a storey in one piece.
4. A prefabricated wall according to one of the preceding claims, characterised in that the mat (5) is partially embedded in the plaster layer (4).
5. A prefabricated wall according to one of the preceding claims, characterised in that insulation (2) is arranged on the wall body (3) on an outer side (9) of the prefabricated wall.
6. A prefabricated wall according to Claim 5, characterised in that a reinforcement layer is arranged on the insulation (2).
7. A prefabricated wall according to Claim 6, characterised in that the reinforcement layer has a reinforcement fabric (7) embedded between two mortar layers (6).
8. A prefabricated wall according to one of the preceding claims, characterised in that the supporting wall body (3) has a steel reinforcement.
9. A method for producing a prefabricated wall with a wall body (3) formed at least partially of concrete, in which the concrete for forming the wall body (3) is poured into a casting mould (1), characterised in that a mineral mortar is applied to the concrete for forming a plaster layer (4), whereupon for forming an inside (8) of the prefabricated wall a mat (5) is applied to the plaster layer (4) and is connected thereto.
10. A method according to Claim 9, characterised in that the wall body (3) is formed in the casting mould (1) in a horizontal orientation.
11. A method according to one of Claims 9 or 10, characterised in that the plaster layer (4) is applied to the wall body (3) before the concrete has completely hardened.
12. A method according to one of Claims 9 to 11, characterised in that the plaster layer (4) and/or the mat (5) is applied to the wall body (3) when it is still in the casting mould (1).
13. A method according to one of Claims 9 to 12, characterised in that the mat (5) is partially embedded in the plaster layer (4) before the plaster layer (4) is hardened.
14. A method according to one of Claims 9 to 13, characterised in that the plaster layer (4) is machine-smoothed after application.
15. A method according to one of Claims 9 to 14, characterised in that before the formation of the wall body (3) insulation (2) is laid in the casting mould (1), which insulation is joined to the resulting wall body (3) upon casting the concrete.
16. A method according to Claim 15, characterised in that before the insulation (2) is laid in the casting mould (1) a reinforcement layer is formed by embedding a reinforcement fabric (7) between two mortar layers (6), the reinforcement layer being joined to the insulation (5) upon the laying thereof.
17. A method according to one of Claims 9 to 16 for the production of a prefabricated wall according to one of Claims 1 to 8.

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