EP2233656B1 - Wall element and method for its manufacture - Google Patents

Description

The invention relates to a method for producing a wall element, comprising a masonry, which is joined by a plurality of individual bricks.

Such a wall element is usually erected on a construction site of individual bricks. For this purpose, the individual bricks must be provided on site in the appropriate type and quality and in sufficient quantity, and be added under suitable weather conditions to a masonry. Subsequently, the masonry enclosing reinforced concrete columns and beams are shrouded, reinforced and concreted. This requires a high logistical effort.

A method and an apparatus for producing raw building composite components is known from DE 197 56 207 A1 known. The DE 14 84 067 discloses a reinforced brick masonry with reinforcing elements embedded in concrete.

Another method for producing a wall element using a pivotable formwork support is known from US 5,156,074 WO 01/29337 A2 known.

The invention has for its object to make such a wall element transportable to make it independent of location, and to reinforce the wall element such that it can carry the loads of the building.

In order to solve the object underlying the invention, the invention provides a method for producing a wall element using a pivotable formwork support according to claim 10 and a subsequently manufactured wall element according to claim 1 ready. Such a wall element comprises a masonry, which is joined from a plurality of individual bricks, wherein the masonry is peripherally surrounded by a concrete frame, so that the wall element forms a self-supporting and transportable unit. The concrete frame encases the masonry on the circumference and holds together the masonry composite, which is made up of individual bricks. The resulting, self-supporting and transportable unit is highly resilient. The wall element is intended and suitable in particular for prefabricated construction, wherein the masonry with the concrete enclosure as a whole can assume a supporting function. A building of prefabricated parts is assembled by prefabricated components and provides an interesting alternative, as an example, to a house in construction site due to the generally much shorter construction time, the manageable costs and the consistent quality dar. The wall element can be found in all types of buildings use. A prefabrication option in the factory is given.

For the purposes of this description, masonry is a component made of natural or artificial stones or bricks. The types of masonry are differentiated according to different aspects: According to the used bricks, for example, a distinction between quarry stone masonry, natural stone masonry, brickwork. Depending on the type of composition, for example, a distinction is made between dry masonry, mortar masonry, homogeneous and inhomogeneous masonry. By visibility, for example, a distinction is made between exposed masonry and plastered masonry. By static function, for example, a distinction is made between load-bearing or non-load-bearing masonry. The masonry can be of any of the mentioned types.

The masonry consists of individual bricks, which are stacked on top of each other. Different types of bricks can be used, for example artificial stones such as bricks, clinker bricks, perforated bricks, sand-lime bricks, hollow blocks, cast stones, expanded clay bricks, aerated concrete bricks, etc .; or natural stones such as sedimentary rocks, e.g. Limestone or sandstone, or plutonic rocks such as granite. In addition, in certain types of masonry still a joining agent, preferably mortar, which can fill the joints between the bricks. This joining agent connects the stones positively and ensures better stability of the masonry. Preferably, the masonry of identical bricks, preferably made of bricks using mortar as a joining agent, joined. In principle, the bricks are mixed mixed when building a wall, wherein the bricks are not placed exactly on top of each other to distribute loads and forces evenly in the masonry and to create any unintended breaking points.

For use as a building exterior wall, the masonry can also be provided with insulation or thermal and / or acoustic insulation and have a single or multi-shell, preferably clam shell, construction. The single-shell construction consists of one, preferably on both sides, plastered masonry, the bricks can have an internal insulation. In most cases, additional insulation is advantageous. Here, the so-called thermal insulation composite system offers, according to which the insulation material is mounted due to structural physical reasons on the outside of the masonry. The bivalve construction comprises, for example, a load-bearing wall of bricks of a first type (for example perforated bricks or sand-lime bricks) and external weather protection of bricks of a second type (for example facing bricks or clinker), the load-bearing wall and the weather protection are connected as possible without formation of thermal bridges. Connecting elements between the supporting structure and the external weather protection are preferably installed only in places. By lying between the layers insulation or thermal and / or acoustic insulation, the load-bearing wall is well insulated, with a ventilated or non-ventilated wall construction can be realized.
Preferred embodiments of the invention are claimed in the subclaims.

The concrete frame is closed around the entire circumference of the masonry. The wall element is particularly compact and stable due to the encircling, preferably reinforced concrete frame. However, it is considered to be particularly advantageous that the concrete frame extends along the entire outer and inner circumference of the masonry (e.g., in window openings) and is fully closed.

It may prove advantageous if the bricks are positively connected and / or with a joining agent, preferably mortar. In the wall element according to this embodiment, the masonry assumes a supporting function.

It may prove useful when the wall element extends substantially in a plane. In this form, the wall element is particularly easy to manufacture and is easily stackable and transportable. It can be provided that the masonry, preferably each brick of the masonry, at least to one side, preferably on both sides of the wall element is visible. The wall element according to this embodiment includes the appearance of a conventional, locally made masonry, but is designed to be self-supporting due to the concrete frame and can be made far from the site without sacrificing the visual and aesthetic appearance in purchasing. But the wall element can also be plastered in one or both sides of the factory.

It can prove to be advantageous if the wall element has at least one of the following equipment: a reinforcement, a transport device, an empty piping, preferably for electrical, sanitary, heating, ventilation or air conditioning devices, a connection for electrical, sanitary , Heating, ventilation or air conditioning equipment, a switch, preferably for the operation of electrical, sanitary, heating, ventilation or Air conditioning equipment, a door or lintel, a roller shutter box, a one- or two-sided exterior plaster. Through these features, the wall element can be so far prefabricated in an almost unlimited variety of possible variants specifically on customer request in the factory that the measures still to be taken on the site are significantly reduced. Other equipment is also possible.

It may prove to be beneficial if the masonry is constructed of substantially identical bricks. In the wall element according to this embodiment, the production is particularly simple, since a use of false bricks is substantially excluded. Moreover, the storage of bricks is simplified, because only one type of bricks is installed.

It may be advantageous if the bricks are flush with the circumference of the masonry. The wall element according to this embodiment has a particularly attractive appearance.

It may be useful if the masonry and / or the wall element has a substantially rectangular outline. The wall element according to this embodiment is particularly well suited for most standardized applications, in particular for the construction of prefabricated houses. In general, however, it is possible that the masonry and / or the wall element has a circular, an oval or at least partially an arcuate outline.

It may be advantageous if the bricks are arranged on the periphery of the masonry unbound, so that individual bricks protrude into the concrete frame. The wall element according to this embodiment has due to the positive connection of concrete frame and masonry a particularly high stability and is particularly well suited for applications in which the wall element performs a supporting function and large vertical and horizontal loads acting on the wall element.

It may be useful if the wall element has at least one door and / or window opening. The door and / or window opening can be factory-made so that frames and doors or window frames and windows can already be used in the factory. The degree of prefabrication can therefore even go to the application of the exterior plaster, so that only a few work on the site itself must be done. If required, the installation of the frames and doors can also be done later on the site. The wall element according to This embodiment can greatly simplify the manufacture of a prefabricated building or structure.

A method for producing a wall element described herein comprises the steps of: a) building a masonry by joining a plurality of individual bricks, and b) pouring over the masonry with concrete, so that the masonry is circumferentially surrounded by a concrete frame. The wall element produced by this method may comprise all the features of the preceding embodiments of the wall element, in particular at least one reinforcement, a transport device and / or an empty casing, a door and / or window opening or an applied external plaster on one or both sides of the wall element, wherein the necessary measures for the realization of these features are preferably taken chronologically advantageous.

According to the masonry is erected in a vertical plane. The bricks are compressed under the influence of gravity, because the weight of the upper bricks acts on the lower bricks. This creates a particularly solid and stable masonry.

Then the masonry is poured around in a horizontal plane with concrete. The re-casting of the masonry is much easier in the horizontal alignment of the masonry, as it can be performed on a horizontal formwork underlay. According to the invention, the masonry is transferred from a vertical plane to a horizontal plane using a pivotable formwork support. In this way, the masonry can be erected standing or in a vertical plane and then transferred particularly gently into a horizontal plane to encase the masonry with the concrete frame. In this embodiment, the advantages resulting from the erection of the masonry in a vertical plane and from the casting of the masonry in the horizontal plane, connected in an ideal manner, without the masonry must be transported between the operations.

For carrying out the method, an apparatus for producing a wall element, comprising a pivotable formwork support, which can be transferred between a vertical plane and a horizontal plane, is suitable. The formwork support is used in the construction of the masonry in a vertical plane preferably as a support wall. The formwork support may also be slightly inclined in the erection of the masonry as needed, preferably deviating in the range 1 to 10 ° from the vertical, so that the bricks in the construction of the masonry be held by the force of gravity in contact with the formwork support. With mortar, the masonry can be sealed against the formwork underlay to prevent ingress of concrete between masonry and formwork underlay. The formwork support is preferably magnetizable and is transferred to pour the concrete frame in the horizontal plane and provided with a closed formwork around the masonry.

Brief description of the drawings

• Figur 1: ein nach dem erfindungsgemäßen Verfahren herstellbares Wandelement für Bauwerke aus Fertigteilen gemäß einem ersten Ausführungsbeispiel, wobei das Mauerwerk und der Betonrahmen im wesentlichen rechteckige Umrisse aufweisen und die Mauersteine am Umfang des Mauerwerks bündig angeordnet sind.
• Figur 2: ein nach dem erfindungsgemäßen Verfahren herstellbares Wandelement für Bauwerke aus Fertigteilen gemäß einem zweiten Ausführungsbeispiel, wobei das Mauerwerk und der Betonrahmen im wesentlichen rechteckige Umrisse aufweisen und die Mauersteine am Umfang des Mauerwerks unbündig angeordnet sind, so dass einzelne Mauersteine in den Betonrahmen hervorstehen.
• Figur 3: ein Wandelement für Bauwerke aus Fertigteilen,
  wobei das Wandelement eine Bewehrung und Transportanker aufweist, wobei Fig. 3a eine Seitenansicht und Fig. 3b einen Schnitt A-A aus Fig. 3a zeigt.
• Figur 4: ein Wandelement für Bauwerke aus Fertigteilen,
  wobei das Wandelement jeweils eine Türöffnung und eine Fensteröffnung aufweist, wobei Fig. 4a eine Seitenansicht und Fig. 4b einen Schnitt A-A aus Fig. 4a zeigt.
• Figur 5: ein nach dem erfindungsgemäßen Verfahren herstellbares Wandelement für Bauwerke aus Fertigteilen gemäß einer dritten Variante des ersten Ausführungsbeispiels, wobei das Wandelement jeweils eine Türöffnung und eine Fensteröffnung aufweist und eine Leerverrohrung vorgesehen ist.
• Figur 6: weitere Varianten des nach dem erfindungsgemäßen Verfahren herstellbaren Wandelements für Bauwerke aus Fertigteilen nach dem ersten Ausführungsbeispiel, wobei das Mauerwerk und das Wandelement gemäß Fig. 6a im wesentlichen dreieckige Umrisse, gemäß Fig. 6b im wesentlichen rechteckige Umrisse mit kuppelförmiger Oberseite und Fensteröffnung, gemäß Fig. 6c näherungsweise trapezförmige Umrisse und jeweils eine Türöffnung und eine Fensteröffnung, und gemäß Fig. 6d polygonale Umrisse und jeweils eine Türöffnung und eine Fensteröffnung aufweisen.

Show it:

• FIG. 1 : A producible by the novel wall element for buildings made of prefabricated parts according to a first embodiment, wherein the masonry and the concrete frame have substantially rectangular outlines and the bricks are arranged flush on the circumference of the masonry.
• FIG. 2 a wall element producible by the method according to the invention for prefabricated structures according to a second embodiment, wherein the masonry and the concrete frame have substantially rectangular outlines and the bricks are arranged on the periphery of the masonry unbound, so that individual bricks protrude into the concrete frame.
• FIG. 3 : a wall element for buildings made of prefabricated parts,
  wherein the wall element comprises a reinforcement and transport anchor, wherein Fig. 3a a side view and Fig. 3b a section AA Fig. 3a shows.
• FIG. 4 : a wall element for buildings made of prefabricated parts,
  wherein the wall member each having a door opening and a window opening, wherein Fig. 4a a side view and Fig. 4b a section AA Fig. 4a shows.
• FIG. 5 a wall element for prefabricated structures constructed by the method according to the invention, according to a third variant of the first embodiment, the wall element each having a door opening and a window opening and an empty piping being provided.
• FIG. 6 : further variants of the wall element producible by the method according to the invention for buildings made of prefabricated parts according to the first embodiment, wherein the masonry and the wall element according to Fig. 6a essentially triangular outlines, according to Fig. 6b substantially rectangular outlines with dome-shaped top and window opening, according to Fig. 6c approximately trapezoidal outlines and each a door opening and a window opening, and according to Fig. 6d polygonal outlines and each having a door opening and a window opening.

Detailed Description of the Preferred Embodiments

FIG. 1 shows a producible by the novel wall element 1 according to a first embodiment, comprising a masonry 2, which is joined from a plurality of individual bricks 21, wherein the masonry 2 is circumferentially surrounded by a concrete frame 3.

The wall element 1 extends substantially in one plane and is intended for buildings made of prefabricated parts, wherein the masonry 2 and the concrete frame 3 and the wall element 1 have substantially rectangular contours 20, 30. The length of the wall element 1 is, for example, 6,000 mm, and the height of the wall element 1 is, for example, 3,800 mm, the concrete frame 3 having a thickness of, for example, 200 mm. The width or thickness of the wall element 1 and the concrete frame 3 are measured according to the invention according to the width of the bricks 21, wherein each brick 21 of the masonry 2 can be visible on both sides of the wall element 1. The wall element 1 can also be plastered at the factory on the inside and / or outside if necessary.

The masonry 2 is constructed of substantially identical bricks 21, which are connected with mortar as a joining means, wherein the bricks 21 in adjacent rows (flocks) 22, 23 are each offset by half brick length. The bricks 21 on the circumference 20 of the masonry 2 are flush, with the final, peripheral bricks 21 of each second row 23 have only half the brick length. For this purpose, a brick 21 is divided into two halves. As a result, the adjacent rows 22, 23 coincide in length. As bricks 21 identical, rectangular brick with a longitudinal edge length of about 400 mm and a height of about 200 mm are used in the present case. The masonry 2 may also comprise more than one brick width. For this purpose, the bricks 21 are preferably laid one row at a time (per group) longitudinally and once transversely mixed in order to prevent splitting of the wall.

FIG. 2 shows a producible by the process according to the invention wall element 1 for buildings of precast parts according to a second embodiment. In contrast to the first embodiment, the final, peripheral (half) bricks 21 are missing in every second row 23, so that the bricks 21 of each second row 22 are arranged on the periphery 20 of the masonry 2 unbounded and protrude into the concrete frame 3. As a result, the rows 22 are longer by one brick length than the adjacent rows 23. Otherwise, the wall panel 1 according to the second embodiment corresponds to the wall panel 1 according to the first embodiment. To avoid repetition, reference is made to the above description and the same reference numerals are used.

FIG. 3 shows a wall element 1 for buildings made of precast. FIG. 3a shows a side view and FIG. 3b shows a section AA Fig. 3a , In addition to the first embodiment, the wall element 1 has an embedded in the concrete frame 3, circumferentially closed steel grid reinforcement 4 and two transport anchors 5. Threaded sleeves 51 made of steel, in which the transport anchors 5 are screwed, are positively and / or materially connected to the reinforcement 4, preferably welded. The bricks of the masonry 2 comprise hollow chambers which lie one above the other in the rows of masonry 2 ( Fig. 3b ), wherein the lifting anchors 5 extend through the entire masonry 2 and on opposite sides of the masonry 2 form and / or materially connected to the reinforcement 4. In the finished state, after pouring the masonry 2 with concrete to form the concrete frame 3, the loops 52 of the lifting anchor 5 are out of the concrete frame 3 and can be taken with a lift-off in engagement. The weight of the wall element 1 is transmitted to the concrete frame 3 via the threaded sleeves 51 and via the connection points of the transport anchor 5 with the reinforcement 4.

FIG. 4 shows a wall element 1 for buildings made of precast. FIG. 4a shows a side view and FIG. 4b shows a section AA Fig. 4a , In addition to the first variant of the first embodiment, the wall element 1 in each case has a door opening 6 and a window opening 7. The encircling concrete frame 3 and the circumferential reinforcement 4 extend also on the inside of the door opening 6 contiguous along the entire circumference of the masonry 2, so that a stable and compact composite is ensured. In addition, a concrete frame 3b with embedded reinforcement 4b extends over three of the four sides of the window opening 7. About the door opening 6 extends a reinforcement bridge 41, which is positively and / or materially connected to the steel grid of the reinforcement 4. To avoid repetition, reference is made to the above description and the same reference numerals are used.

FIG. 5 shows a producible by the novel wall element 1 for buildings of prefabricated parts according to a variant of the first embodiment. According to this variant, the wall element 1 in each case has a door opening 6 and a window opening 7. To avoid repetition, reference is made to the above description and the same reference numerals are used. A reinforcement and transport anchor are not shown, but can be provided as needed in the same way as in the second variant. In this variant, an empty piping for electrical lines 81, air conditioning and / or ventilation systems 82 and / or heating systems 83 is formed. For empty piping bores are preferably introduced substantially in the plane of the wall element 1 through the concrete frame 3 in the masonry 2 and / or transversely to the plane of the wall element 1 in the masonry 2 and / or the concrete frame 3, wherein the holes / openings preferably on the Inside, if necessary, on the outside of the wall element 1 ends. Through these holes / openings flexible conduits can be performed, which later receive the corresponding electrical, sanitary, heating, ventilation, air conditioning lines or pipes.

FIG. 6 shows further variants of the producible by the process according to the invention wall element 1 for buildings of precast parts according to the first embodiment.

According to Fig. 6a The masonry 2 and the concrete frame 3 have substantially triangular outlines 20, 30.

According to Fig. 6b The brickwork 2 and the concrete frame 3 have substantially rectangular contours 20, 30 with a dome-shaped upper side. The masonry 2 comprises a substantially rectangular recess, which is surrounded on the inner circumference with a concrete frame 3b to form a circular window opening 7.

According to Fig. 6c the masonry 2 and the concrete frame 3 approximately trapezoidal outlines 20, 30 on. The wall element 1 comprises a door opening 6 and a circular window opening 7.

According to Fig. 6d the masonry 2 and the concrete frame 3 polygonal outlines 20, 30 on. The wall element 1 comprises a door opening 6 and a circular window opening 7.

The illustrated variants and exemplary embodiments are to be understood merely as examples, wherein the features of the variants and exemplary embodiments can be combined in any manner within the scope of the invention, which is defined by the claims appended hereto.

1. a) Errichten eines Mauerwerks 2 durch Fügen einer Vielzahl einzelner Mauersteine 21,
2. b) Umgießen des Mauerwerks 2 mit Beton, so dass das Mauerwerk 2 umfangsseitig zumindest abschnittsweise von einem Betonrahmen 3 umgeben ist.

A method for producing a wall element 1 comprises the steps:

1. a) erecting a masonry 2 by joining a plurality of individual bricks 21,
2. b) pouring the masonry 2 with concrete, so that the masonry 2 is peripherally surrounded at least in sections by a concrete frame 3.

In step a), the masonry 2 is erected in a vertical plane. Using a pivotal formwork pad, which is convertible between a vertical plane and a horizontal plane, the masonry 2 is transferred from the vertical plane to the horizontal plane. If necessary, the masonry 2 is provided with a reinforcement 4 or a transport device 5. In step b) the masonry 2 is then cast in a horizontal orientation with concrete. After curing of the concrete, the wall element 1 is provided with an empty piping 81, 82, 83 as required.

With the wall element, a high degree of prefabrication can be achieved since necessary conduits, e.g. Electric pipes for electric cables, Heizungsrohe, air conditioning and plumbing pipes, and sockets and switches but also door and window lintels, roller shutter boxes, air conditioning, etc. can be installed in the factory and the wall is additionally plastered. Thus, only a few work on the site are necessary. Further advantages result from the fact that this wall element can accommodate loads, for example in multi-storey buildings (load-bearing system), and that the shape of the wall element can be designed freely according to customer requirements.

Claims (10)

1. Wall element (1) manufactured according to the method of claim 10 and comprising a brickwork (2) which is joined together from a plurality of individual bricks (21), wherein the brickwork (2) is circumferentially surrounded by a concrete frame (3) which is closed along the entire circumference (20) of the brickwork (2), so that the wall element (1) forms a self-supporting and transportable unit and wherein the width of the concrete frame (3) perpendicular to the plane of the wall element (1) measures according to the width of the bricks (21) perpendicular to the plane of the wall element (1).
2. Wall element (1) according to claim 1, characterized in that the bricks (21) are connected positively and/or by means of a joining agent, preferably mortar.
3. Wall element (1) according to one of the preceding claims, characterized in that the wall element (1) extends substantially in one plane.
4. Wall element (1) according to one of the preceding claims, characterized in that the wall element (1) comprises at least one of the following equipments: a reinforcement (4), a transport device (5), an empty tubing (81, 82, 83), preferably for electric, sanitary, heating, ventilating or air conditioning devices, a connection for electric, sanitary, heating, ventilating or air conditioning devices, a switch, preferably for operating electric, sanitary, heating, ventilating or air conditioning devices, a door or window lintel, a roller shutter casing, an exterior plaster on one or both sides.
5. Wall element (1) according to one of the preceding claims, characterized in that the brickwork (2) is built up of substantially identically constructed bricks (21).
6. Wall element (1) according to one of the preceding claims, characterized in that the bricks (21) are arranged flush with the circumference (20) of the brickwork (2).
7. Wall element (1) according to one of the preceding claims, characterized in that the brickwork (2) and/or the wall element (1) have a substantially rectangular contour.
8. Wall element (1) according to one of the preceding claims, characterized in that the bricks (21) are arranged not flush with the circumference (20) of the brickwork (2), so that individual bricks (21) project into the concrete frame (3).
9. Wall element (1) according to one of the preceding claims, characterized in that the wall element (1) comprises at least one door and/or window opening (4, 5).
10. Method for producing a wall element (1), using a pivotable casing base which can be transferred between a vertical plane and a horizontal plane comprising the steps of:

    a) building up a brickwork (2) in a vertical plane by joining together a plurality of individual bricks (21), wherein, the casing base serves as a supporting wall when building up the brickwork,

    b) transferring of the brickwork from the vertical plane into the horizontal plane, using the pivotable casing base, and

    c) casting concrete around the brickwork (2) in the horizontal plane, so that the brickwork (2) is circumferentially surrounded by a concrete frame (3) which is closed along the entire circumference (20) of the brickwork (2).

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