EP2780514A1 - Insulated wall module - Google Patents
Insulated wall moduleInfo
- Publication number
- EP2780514A1 EP2780514A1 EP12766324.3A EP12766324A EP2780514A1 EP 2780514 A1 EP2780514 A1 EP 2780514A1 EP 12766324 A EP12766324 A EP 12766324A EP 2780514 A1 EP2780514 A1 EP 2780514A1
- Authority
- EP
- European Patent Office
- Prior art keywords
- wall
- elements
- building
- steel
- internal
- 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- Withdrawn
Links
- 229910000831 Steel Inorganic materials 0.000 claims abstract description 38
- 239000010959 steel Substances 0.000 claims abstract description 38
- 238000009413 insulation Methods 0.000 claims abstract description 33
- 238000000034 method Methods 0.000 claims abstract description 28
- 238000009434 installation Methods 0.000 claims abstract description 19
- 125000006850 spacer group Chemical group 0.000 claims abstract description 15
- 238000010276 construction Methods 0.000 claims abstract description 7
- 230000007246 mechanism Effects 0.000 claims abstract description 5
- 229920002635 polyurethane Polymers 0.000 claims abstract description 5
- 239000004814 polyurethane Substances 0.000 claims abstract description 5
- 238000009776 industrial production Methods 0.000 claims abstract 5
- 238000004364 calculation method Methods 0.000 claims description 11
- 239000000463 material Substances 0.000 claims description 9
- 238000005192 partition Methods 0.000 claims description 6
- 230000002787 reinforcement Effects 0.000 claims description 5
- 238000002347 injection Methods 0.000 claims description 3
- 239000007924 injection Substances 0.000 claims description 3
- 238000007789 sealing Methods 0.000 claims description 3
- 230000005611 electricity Effects 0.000 claims description 2
- 238000009428 plumbing Methods 0.000 claims description 2
- 230000035515 penetration Effects 0.000 abstract description 9
- 238000004519 manufacturing process Methods 0.000 abstract description 6
- 230000003068 static effect Effects 0.000 abstract description 3
- 239000000919 ceramic Substances 0.000 abstract description 2
- 238000009408 flooring Methods 0.000 abstract description 2
- 230000005494 condensation Effects 0.000 abstract 1
- 238000009833 condensation Methods 0.000 abstract 1
- 238000010438 heat treatment Methods 0.000 description 3
- 238000009435 building construction Methods 0.000 description 2
- 230000001143 conditioned effect Effects 0.000 description 2
- 238000005516 engineering process Methods 0.000 description 2
- 229910052602 gypsum Inorganic materials 0.000 description 2
- 239000010440 gypsum Substances 0.000 description 2
- 239000008259 solid foam Substances 0.000 description 2
- 230000000712 assembly Effects 0.000 description 1
- 238000000429 assembly Methods 0.000 description 1
- 239000004794 expanded polystyrene Substances 0.000 description 1
- 239000003063 flame retardant Substances 0.000 description 1
- 239000011810 insulating material Substances 0.000 description 1
- 239000002184 metal Substances 0.000 description 1
- 239000011343 solid material Substances 0.000 description 1
- 239000000243 solution Substances 0.000 description 1
Classifications
-
- 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
- E04B1/62—Insulation or other protection; Elements or use of specified material therefor
-
- 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
- E04B1/08—Structures consisting primarily of load-supporting, block-shaped, or slab-shaped elements the elements consisting of metal
-
- 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
- E04B1/62—Insulation or other protection; Elements or use of specified material therefor
- E04B1/74—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls
- E04B1/76—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls specifically with respect to heat only
- E04B1/78—Heat insulating elements
- E04B1/80—Heat insulating elements slab-shaped
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
- E04B2/00—Walls, e.g. partitions, for buildings; Wall construction with regard to insulation; Connections specially adapted to walls
- E04B2/56—Load-bearing walls of framework or pillarwork; Walls incorporating load-bearing elongated members
- E04B2/58—Load-bearing walls of framework or pillarwork; Walls incorporating load-bearing elongated members with elongated members of metal
-
- 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
- E04C2/30—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure
- E04C2/38—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure with attached ribs, flanges, or the like, e.g. framed panels
- E04C2/384—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure with attached ribs, flanges, or the like, e.g. framed panels with a metal frame
-
- 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
- E04B1/38—Connections for building structures in general
- E04B1/61—Connections for building structures in general of slab-shaped building elements with each other
- E04B1/6108—Connections for building structures in general of slab-shaped building elements with each other the frontal surfaces of the slabs connected together
- E04B1/612—Connections for building structures in general of slab-shaped building elements with each other the frontal surfaces of the slabs connected together by means between frontal surfaces
- E04B1/6125—Connections for building structures in general of slab-shaped building elements with each other the frontal surfaces of the slabs connected together by means between frontal surfaces with protrusions on the one frontal surface co-operating with recesses in the other frontal surface
- E04B1/6137—Connections for building structures in general of slab-shaped building elements with each other the frontal surfaces of the slabs connected together by means between frontal surfaces with protrusions on the one frontal surface co-operating with recesses in the other frontal surface the connection made by formlocking
Definitions
- This invention a wall module of superior insulation properties for passive buildings, a technique of manufacture of a product provided with all needed installations, through application of the appropriate technological process, easy to install on a building site - encompasses the technological domains marked as E04B 2/58, E04C 1/00 and E04C 2/00 according to the International Patent Classification.
- the technical problem resolved in the subject invention consists of the definition of such wall structure and of the application of such materials and making and building techniques, to achieve excellent insulation properties of the wall needed for the construction of passive buildings with at the same time meeting all the requirements of the professional building practice and the regulations with respect to the strength and the statics of walls and of the entire building. It would be preferable here to make sure also that the appropriate technological process is used such that the finished wall can be made in factory complete with ceramic tiles and parquet flooring, with all needed installations, all openings including door and window openings.
- the simple and fast installation of a building on a building site with a low labor cost will reduce significantly building costs per surface area unit of the building.
- the building walls prefferably be made as a light load bearing steel structure filled with light material of excellent insulation properties, polyurethane (PIR) a fire-retardant, and for the walls to be of the appropriate thickness and of appropriate rectangular dimensions (one-floor elevation): higher than 2 m and of the appropriate width.
- PIR polyurethane
- a possible reduction of the building cost depends directly on the wall structure that requires the adequate consumption of materials, and it depends in particular on the extent to which the wall can be factory-built and on the extent of the remaining work that needs to be done at the building site.
- the passive house is a result of a low-energy house development cycle (NEK).
- the passive house consumes up to 80% less energy compared to a low-energy house and up to 90% less energy compared to conventional building structures.
- the thickness of the passive house insulation should be at least 55 to 60 cm in combination with the placement of triple glazed windows and doors of appropriate thermal insulation properties.
- Wall elements are mostly made of expanded polystyrene. Examples of these techniques and their resulting structures have been published in US5,353,562, US4,823,534 and US 5,617,686.
- EP 0 727 535 A1 is the partition wall building technique that involves the use of a large number of posts and steel elements, securing the position of main surface materials on both sides of the element with the noise insulating material and hard gypsum panels as reinforcement for the principal external surfaces, making a fireproof wall structure.
- US 5,765,333 describes the system of building using posts and panels that are joined such that the post is placed on the floor, a solid foam panel, consisting of one or several glued layers of solid foam shaped to fit the post placed next to the beam and joined with the beam and the floor, thereafter the following post is placed and joined with the same panel etc.
- Prefabricated strips may be placed on the surface of panels, to join gypsum panels on the inside of the wall structure, or as a fixing element on the outside.
- bearing wall structures There are several types of bearing wall structures mostly made at the passive house building site but the quality of the wall fill, from the technical and technological aspect, is lower.
- the importance of the invention is in its technical design that resolves the indicated technical problem by defining the load-bearing steel structure of the wall with all the appertaining components and all needed installations and openings for a specific structure intended for a specific purpose, of specified dimensions and location, of the specific layout of premises, after the completion of appropriate calculations, according to well known methods, and in compliance with the principal requirements set by the building regulations, such as pressure strength, earthquake, wind resistance and fire safety properties, which in the end allows in terms of technology, the development of complete walls, factory made, simple installation of these walls on the building site with the characteristics and qualities in compliance with the criteria set to meet passive house standards.
- Such a defined steel structure consist of elements of specified shapes and dimensions, in general of C elements, horizontal 1.1 and vertical 1.2, C elements made of steel metal sheathing of the appropriate thickness and appropriately joined, according to the established work method, with in the middle additional steel elements for reinforcement 8.1. , as suitable, for additional strength, according to calculations, and in addition to horizontal 1.1 and vertical 1.2 C elements.
- the suitable wall fasteners or their elements are fixed inside horizontal 1.1 and vertical 1.2 C elements, according to calculations done in compliance with all relevant building practice requirements and regulations, to fasten walls or their segments horizontally 2.1 and vertically 2.2 with fasteners.
- Horizontal and vertical wall fasteners consist of a clamping screw, with a body 3.2 and a head 5.1 , of a fastener cylinder 3.1 with a housing for the C element and a nut 3.3 with a housing for the C element.
- the fastener cylinder 3.1 with a housing and a nut 3.3 with a housing are placed on the C element in a position, as allowed by the internal surface 4.1 at the bottom of the C element and two internal side surfaces 4.2 of the C element such that neither the fastener cylinder 3.1 nor the nut
- the fastener cylinder 3.1 with the housing and the fastener nut 3.3 with the housing are placed on the C element, as described above, laid in the direction of the axis 4.3 of the C element, and as a rule placed in the corner to lean against and be fixed on the internal surface 4.1 at the bottom of the C element and on the appropriate internal side surface 4.2 of the C element, for better and more compact joining of elements.
- Such a developed steel structure of a wall or of its segments is of a specific thickness 2.4, which in compliance with calculations is sufficient for any requirements set with respect to a specific building.
- the needed number of suitably shaped internal 1.3 and external 1.4 spacers are placed and fixed on appropriate points of horizontal 1.1 and vertical 1.2 C elements.
- the internal 8.2 and external 8.3 lining is placed on the internal 1.3 and external 1.4 spacers, in which way a space is left between the internal 8.2 and external 8.3 lining to inject insulation fill 8.4 thereby obtaining the total thickness 2.5 of the wall or of its segments of such dimensions that depend on the intended use of the building premises and the set requirements, which may be approximately 200 - 400 mm, most frequently approximately 300 mm.
- a module is the usual word used for a wall structure made according to the above specified method by using a press, either for complete walls or their segments.
- Modules in general, are of a rectangular shape usually of the total surface area of 36 m 2 , 3 x 12 m in height and width, thereby meeting practically all the requirements encountered in practice.
- all such modules i.e., all wall elements are factory-made, with all windows, doors, utility penetrations/channels and/or other additional elements installed in the production facility, one can make in advance the entire structure before it is brought to the building site, which results in a very flexible building concept with additionally reduced building costs.
- the floor module 10.3 of the wall is placed and thereafter the upper bearing module 10.2 of the wall and partition walls, upper 10.4 and lower 10.5.
- Position 1.4 External spacer
- Figure 2a Steel structure with fasteners Position 2.1 : A part of the fastener for horizontal fastening of walls or their segments;
- Position 2.2 A part of the fastener for vertical fastening of walls or their segments;
- Position 2.3 Channels for the installation of pipes and utilities
- Position 3.3 The fastener's nut with the housing to be fixed to the C element;
- Position L The total length of the C element
- Position D The distance of the fastener, the cylinder or the nut from the edge of the C element
- Position W The distance between the axes of two C elements with wall or wall segment fasteners
- Position 4.1 The internal surface of the bottom of the C element
- Position 4.3 The axis of the C element
- the subject invention has been developed such that the appropriate calculation has been done, according to the known and established method, in compliance with all the essential requirements defined in building regulations, such as pressure strength, resistance to earthquakes, wind and fire safety, relating to a specified structure intended for a specified purpose, with specified dimensions and the location, the layout of premises; a load bearing steel structure of the wall has been defined in such manner with all components and all channels and openings needed for installation of plumbing and other installation elements, allowing the application of the technology of completely factory-built walls, easy to install on the building site fulfilling all the criteria of passive house building standards.
- building regulations such as pressure strength, resistance to earthquakes, wind and fire safety
- Such a defined steel structure consists of elements of specified shapes and dimensions, mostly C elements, horizontal 1.1 and vertical 1.2 C elements made of steel sheathing of the appropriate thickness and joined appropriately according to the well-known method, with additional steel reinforcement elements 8.1. between them, as needed, for additional strength, according to calculations.
- suitable wall or wall segment fastening mechanisms are fixed inside horizontal 1.1 and vertical 1.2 C elements, for horizontal 2.1 and vertical 2.2 tightening and joining of walls or their segments.
- the fastener cylinder 3.1 with the housing and the fastener nut 3.3 with the housing are placed on the C element inside the space defined by the internal surface 4.1 of the bottom of the C element and two internal side surfaces 4.2 of the C element, such that neither the fastener cylinder 3.1 nor the fastener nut 3.2 ever protrude beyond the volume of the C element but they are at the distance D from the edge 3.4 of the C element whether used for vertical or horizontal tightening.
- the fastener cylinder 3.1 with the housing and the fastener nut 3.3 with the housing are placed on the C element as indicated above, laid in the direction of the axis 4.3 of the C element, located in general in the corner and fixed appropriately to the internal surface 4.1 at the bottom of the C element and the respective internal side surface 4.2 of the C element, to give more strength to the joined segment.
- Such a developed steel structure of the wall or of its segments is of the specified thickness 2.4, sufficient according to the calculation for a specific building.
- the appropriate number of suitably shaped internal 1.3 and external 1.4 spacers are placed and fixed at the specified points horizontally 1.1 and vertically 1.2 on the C elements.
- Internal 1.3 and external 1.4 spacers are made of such materials that are of appropriate thermal insulation properties to eliminate thermal bridges between external and internal surfaces of walls.
- the internal 8.2 and external 83 linings are placed and fixed onto the internal 1.3 and external 1.4 spacers, in which way the space is left between the internal 8.2 and external 8.3 lining in which the insulation fill is injected 8.4 to make up the total thickness 2.5 of the wall or its segments, whose dimensions depend on the intended use of the building and the corresponding requirements, which most frequently may be up to 300 mm.
- the steel structure of the wall or of its segment made as described above, complete with spacers, fastening mechanisms and final lining elements, of the specified outside volume and surfaces, for example of 36 m 2 , is placed in the frame of the appropriate dimensions and the appropriate, for example, 3-bar, injection press technique is applied to inject insulation fill, most frequently expanded polyurethane, which expands spontaneously while the pressure squeezes out the air hermetically sealing the space between placed final panels and ' bo daTy ⁇ surfacesnsf the steel structure of the wall or of its segments, consisting of elements, mostly, horizontal 1.1 and vertical 1.2 C elements. Because of such compact wall structure the statics of the steel structure is improved for at least 30 %.
- the module is the usual name for the wall structure obtained after the application of the press technique in the above mentioned way, both on complete walls or their segments.
- Modules in general are rectangular in shape, usually of the total surface area of 36 m 2 , 3 x 12 m in length and width, meeting practically all requirements encountered in practice.
- all such modules i.e., all wall elements are factory-made, with all windows, doors, utility channel and/or other additional elements installed in the production facility, one can make in advance the entire structure before it is brought to the building site, which results in a very flexible building concept and an additional reduction of building costs.
- the floor module 10.3 of the wall is placed and thereafter the upper bearing module 10.2 of the wall and partition walls, upper 10.4 and lower 10.5.
- the subject invention can be applied in the construction industry and achieve the highest possible flexibility of building, beyond any comparison, with the radically reduced building costs and time schedules, which is a natural result of a process in which all modules, i.e., all wall elements are factory built with all windows, doors, installation channels and/or other additional equipment installed in the production facility, which means that the entire structure can be built in advance, before it is transported to the building site.
- all modules i.e., all wall elements are factory built with all windows, doors, installation channels and/or other additional equipment installed in the production facility, which means that the entire structure can be built in advance, before it is transported to the building site.
- the subject invention allows the building of walls of excellent insulation properties of the heat penetration coefficient U not higher than 0.15 W/(m 2 K°), whereby the subject invention may be relevant in current construction achievements in the building of passive houses fulfilling the parameters and characteristics in compliance with the strictest standards.
Landscapes
- Engineering & Computer Science (AREA)
- Architecture (AREA)
- Physics & Mathematics (AREA)
- Civil Engineering (AREA)
- Structural Engineering (AREA)
- Electromagnetism (AREA)
- Acoustics & Sound (AREA)
- Building Environments (AREA)
- Finishing Walls (AREA)
Abstract
The construction of a wall module of superior insulation properties required for passive buildings, the method of its industrial production for easy to install at erection site as technical design of the load bearing steel truss of the defined height, width and thickness, made of appropriate shaped steel elements, of appropriate dimensions, positioned appropriately to form the structure and fixed in compliance with all relevant requirements of the professional building practice and regulations. Steel elements are mostly C elements, horizontal (1.1) and vertical (1.2) C elements with fastening mechanisms fastened on the outside horizontally (2.1) and vertically (2.2) with internal (1.3) and external (1.4) spacers positioned on their sides of low thermal conductivity, on which internal (6.2) and external (6.3) lining panels are placed of the appropriate thickness defining in such manner the total thickness of the wall. The complete wall is factory-built so that the developed steel structure with all needed installation channels built in and with placed lining panels is placed in the appropriate press to inject expanded polyurethane in the space between the lining and the outside line of the steel structure that forms the wall, at approximately 3-bar pressure, which then expands and squeezes out the air from within the structure thereby creating a compact fill mass eliminating any risk of damp and condensation in the wall, at the same time improving for at least 30 % the statics of the steel structure. In this way a full compact wall of precise dimensions is built in a factory to the full completion with all ceramic tiles and parquet flooring, with all needed installation channels built in, with all openings including window and door openings of excellent insulation properties with the heat penetration coefficient U of approximately 0.14 W/(m2K°) which is less than 0.15 W/(m2K°) as the limit value for the compliance with passive house characteristics. Walls produced in entirety or in segments according to the described invention are transported to the site and installed, all the walls or their segments are joined, with fastening mechanisms vertically and horizontally, to make complete building structures. Because this invention allows the precise building of walls, in entirety or in segments, their installation after the transport on site is easy, based on precisely defined figures and methods, with the minimum labor and in a short time period, with only a few tools and equipment needed for the job. If all such modules, i.e., all wall elements are factory-made, with all windows, doors, utility channels and/or other additional elements installed in the production facility, one can make in advance the entire structure before it is brought to the building site, which results in a very flexible building concept with additionally reduced building costs.
Description
INSULATED WALL MODULE
DESCRIPTION OF THE INVENTION
1. Technical Field
This invention: a wall module of superior insulation properties for passive buildings, a technique of manufacture of a product provided with all needed installations, through application of the appropriate technological process, easy to install on a building site - encompasses the technological domains marked as E04B 2/58, E04C 1/00 and E04C 2/00 according to the International Patent Classification.
2. Technical Problem
Professionals continuously endeavor to achieve as minimum as possible consumption of material and time and as low as possible building costs per surface area unit of structures in combination with the optimum characteristics of structures and this has been a constant technical challenge in the technological field in question.
It is a well known fact that the price, quality and characteristics of a structure are mostly conditioned by the technical design of walls, therefore by their structure, therefore, methods have been developed to produce walls as finished structures, to the maximum possible extent and to find options for their as economical as possible installation at the building site. Naturally, the success of finding the above indicated technical solution is predominantly conditioned by the successful technical design of the wall and the manufacturing technique as well as installation methods-used-in-the-building-eonstruction-opeFations,
The technical problem resolved in the subject invention consists of the definition of such wall structure and of the application of such materials and making and building techniques, to achieve excellent insulation properties of the wall needed for the construction of passive buildings with at the same time meeting all the requirements of the professional building practice and the regulations with respect to the strength and the statics of walls and of the entire building. It would be preferable here to make sure also that the appropriate technological process is used such that the finished wall can be made in factory complete with ceramic tiles and parquet flooring, with all needed installations, all openings including door and window openings. The simple and fast
installation of a building on a building site with a low labor cost will reduce significantly building costs per surface area unit of the building.
In order to make sure that passive house standards are fulfilled, this has been confirmed with the "Blower - Door - Test", all external elements of the building except glazed surfaces should have such thermal insulation for the heat penetration coefficient U not to exceed 0.15 W/(m2K), whereby the needed thermal energy does not exceed 15 kWh/m2.
The prerequisite for the completion of a passive house is the technical design of the entire envelope of the building with thermal insulation of the appropriate quality, fully compact, i.e., almost hermetically closed building envelope. This means that edges, angles, joining points and openings must be designed in such manner that as consequence all thermal bridges are eliminated to prevent the loss of valuable heat through joints and various openings.
This means that high and demanding standards will be set for the technical design of walls as structure components that have a prevailing impact on the resulting excellent insulation properties of individual sections or the building in entirety, achieved thanks to the quality of used materials, which, accompanied by adequate performance, allow the achievement of characteristics specific to passive houses.
It is preferable for the building walls to be made as a light load bearing steel structure filled with light material of excellent insulation properties, polyurethane (PIR) a fire-retardant, and for the walls to be of the appropriate thickness and of appropriate rectangular dimensions (one-floor elevation): higher than 2 m and of the appropriate width.
3. State of the Art
Historically, people have continuously endeavored to achieve as low as possible consumption of materials and time in combination with as low as possible building cost per surface area unit of a structure, with the optimum characteristics of the structure, mostly with respect to insulation properties which guarantee the lowest possible consumption of heating sources per square meter of residential surface, which includes: solid materials, gas, heating oil or electricity.
A possible reduction of the building cost depends directly on the wall structure that requires the adequate consumption of materials, and it depends in particular on the extent to which the wall can be factory-built and on the extent of the remaining work that needs to be done at the building site.
Lately, the focus has been put on efforts to achieve such insulation properties of a building for the needed heating energy value not to exceed 15 kWh/m2 per year, which is a vital feature of
structures called passive houses. Studies and works have been done for over two decades now in the area of passive houses and it is clear that in order for the passive house to be completed some high and demanding standards need to be met in terms of the quality of components of the house. Therefore, all external elements of the house, except glazed surfaces, need to have such thermal insulation for the heat penetration coefficient U not to be higher than 0.15 W/(m2K).
The passive house is a result of a low-energy house development cycle (NEK). The passive house consumes up to 80% less energy compared to a low-energy house and up to 90% less energy compared to conventional building structures.
The uncontrolled exchange of the external and internal air must be prevented in passive houses, which can be achieved through excellent thermal insulation and a compact structure of individual components and of the entire structure.
This means that outside surfaces of a building must allow the full sealing of its insulation envelope for them to form jointly a sort of a wind-tight surface. In addition, joining points of all structural elements and utility channels must be made carefully to ensure the needed wind tight property is achieved. Edges, angles, joints and openings must be done properly to avoid thermal bridges.
Structures performed according to such quality standards not only prevent draught and the loss of energy, but the reduced penetration of damp into structures reduces substantially the risk of damage on the building's structural elements.
Therefore, the design and work on a passive house for builders is a much more complex task than the design and work on, in terms of dimensions and functions, an equivalent traditional building.
The thickness of the passive house insulation should be at least 55 to 60 cm in combination with the placement of triple glazed windows and doors of appropriate thermal insulation properties.
-The-'Blower^Door^-Test— is-used-to-check-whether-a-structure-meets-the-passive-house- building standards. All external elements of the building, except glazed surfaces need to have such thermal insulation for the heat penetration coefficient U not to exceed 0.15 W/(m2K).
The state of the art, in terms of achieving excellent insulation properties of buildings, has given some building techniques that use light wall elements.
Wall elements are mostly made of expanded polystyrene. Examples of these techniques and their resulting structures have been published in US5,353,562, US4,823,534 and US 5,617,686.
EP 0 727 535 A1 is the partition wall building technique that involves the use of a large number of posts and steel elements, securing the position of main surface materials on both sides of the element with the noise insulating material and hard gypsum panels as reinforcement for the principal external surfaces, making a fireproof wall structure.
US 5,765,333 describes the system of building using posts and panels that are joined such that the post is placed on the floor, a solid foam panel, consisting of one or several glued layers of solid foam shaped to fit the post placed next to the beam and joined with the beam and the floor, thereafter the following post is placed and joined with the same panel etc. Prefabricated strips may be placed on the surface of panels, to join gypsum panels on the inside of the wall structure, or as a fixing element on the outside.
There are several types of bearing wall structures mostly made at the passive house building site but the quality of the wall fill, from the technical and technological aspect, is lower.
There are also modules, US2010242394(A1) and WO20101 11945 (A1), that are somewhat similar to the subject invention but different in terms of several essential properties.
4. Essence of the invention
The importance of the invention is in its technical design that resolves the indicated technical problem by defining the load-bearing steel structure of the wall with all the appertaining components and all needed installations and openings for a specific structure intended for a specific purpose, of specified dimensions and location, of the specific layout of premises, after the completion of appropriate calculations, according to well known methods, and in compliance with the principal requirements set by the building regulations, such as pressure strength, earthquake, wind resistance and fire safety properties, which in the end allows in terms of technology, the development of complete walls, factory made, simple installation of these walls on the building site with the characteristics and qualities in compliance with the criteria set to meet passive house standards.
Such a defined steel structure consist of elements of specified shapes and dimensions, in general of C elements, horizontal 1.1 and vertical 1.2, C elements made of steel metal sheathing of the appropriate thickness and appropriately joined, according to the established work method, with in the middle additional steel elements for reinforcement 8.1. , as suitable, for additional strength, according to calculations, and in addition to horizontal 1.1 and vertical 1.2 C elements.
The suitable wall fasteners or their elements are fixed inside horizontal 1.1 and vertical 1.2 C elements, according to calculations done in compliance with all relevant building practice requirements and regulations, to fasten walls or their segments horizontally 2.1 and vertically 2.2 with fasteners.
Horizontal and vertical wall fasteners consist of a clamping screw, with a body 3.2 and a head 5.1 , of a fastener cylinder 3.1 with a housing for the C element and a nut 3.3 with a housing for the C element.
The fastener cylinder 3.1 with a housing and a nut 3.3 with a housing are placed on the C element in a position, as allowed by the internal surface 4.1 at the bottom of the C element and two internal side surfaces 4.2 of the C element such that neither the fastener cylinder 3.1 nor the nut
3.2 ever protrude beyond the volume of the C element and so that they are always at a distance D from the edge 3.4 of the C element -fastening the wall either horizontally or vertically.
The fastener cylinder 3.1 with the housing and the fastener nut 3.3 with the housing, are placed on the C element, as described above, laid in the direction of the axis 4.3 of the C element, and as a rule placed in the corner to lean against and be fixed on the internal surface 4.1 at the bottom of the C element and on the appropriate internal side surface 4.2 of the C element, for better and more compact joining of elements.
Such a developed steel structure of a wall or of its segments is of a specific thickness 2.4, which in compliance with calculations is sufficient for any requirements set with respect to a specific building. The needed number of suitably shaped internal 1.3 and external 1.4 spacers are placed and fixed on appropriate points of horizontal 1.1 and vertical 1.2 C elements.
properties to eliminate thermal bridges between the outside and inside wall surface.
The internal 8.2 and external 8.3 lining is placed on the internal 1.3 and external 1.4 spacers, in which way a space is left between the internal 8.2 and external 8.3 lining to inject insulation fill 8.4 thereby obtaining the total thickness 2.5 of the wall or of its segments of such dimensions that depend on the intended use of the building premises and the set requirements, which may be approximately 200 - 400 mm, most frequently approximately 300 mm.
Holes are drilled on the internal 8.2 and external 8.3 lining at such position to match the internal
1.3 and external 1.4 spacers.
The wall or segment steel structure made in the above mentioned way, complete with spacers, fasteners and final lining, of the specified external volume, dimensions and the surface, for example of 36 m2, is placed in the frame of the matching dimensions and the appropriate pressurized (for example 3 bar) injection press is used to inject the suitable insulation fill, most frequently expanding polyurethane, which expands spontaneously and squeezes the air out hermetically filling every inch of the space between two end panels and between boundary surfaces of the steel wall structure or of the wall segment, formed by appropriate elements, mostly horizontal 1.1 and vertical 1.2 C elements.
In this way the structure of the wall is completely compact ensuring excellent insulation properties with the heat penetration coefficient U not higher than 0.15 W/(m2K°).
A module is the usual word used for a wall structure made according to the above specified method by using a press, either for complete walls or their segments. Modules, in general, are of a rectangular shape usually of the total surface area of 36 m2, 3 x 12 m in height and width, thereby meeting practically all the requirements encountered in practice.
If all such modules, i.e., all wall elements are factory-made, with all windows, doors, utility penetrations/channels and/or other additional elements installed in the production facility, one can make in advance the entire structure before it is brought to the building site, which results in a very flexible building concept with additionally reduced building costs.
These wall modules, completely factory-made in the described manner, are then installed within the building construction process, on the building site such that they are joined horizontally and vertically with fasteners.
After the placement of the lower bearing module 10.1 of the wall on the foundations prepared in advance, the floor module 10.3 of the wall is placed and thereafter the upper bearing module 10.2 of the wall and partition walls, upper 10.4 and lower 10.5.
5. Brief description of the drawings
Figure 1a Essential Steel Structures
Position 1.1 : Horizontal C element;
Position 1.2: Vertical C element;
Position 1.3: Internal spacer;
Position 1.4: External spacer;
Figure 1 b Examples of parts of the made steel structure segment
Figure 2a Steel structure with fasteners
Position 2.1 : A part of the fastener for horizontal fastening of walls or their segments;
Position 2.2: A part of the fastener for vertical fastening of walls or their segments;
Position 2.3: Channels for the installation of pipes and utilities;
Position 2.4: Thickness of the steel wall structure;
Position 2.5: Total thickness of the finished wall
Position 2.6: Channels for clamping screws;
Figure 2b Examples of developed steel structures with fasteners
Figure 3. Wall or wall segment fastener assemblies
Position 3.1 : The fastener cylinder with the housing to be fixed to the C element;
Position 3.2: Clamping screw;
Position 3.3: The fastener's nut with the housing to be fixed to the C element;
Position 3.4: The edge of the C element;
Position L: The total length of the C element;
Position D: The distance of the fastener, the cylinder or the nut from the edge of the C element;
Position W: The distance between the axes of two C elements with wall or wall segment fasteners;
Figure 4. The position of wall fasteners fixed to the C element
Position 4.1 : The internal surface of the bottom of the C element;
Position 4.2: Internal side surfaces of C elements;
Position 4.3: The axis of the C element;
Figure 5. The assembly of the clamping screw and the fastener cylinder with the housing to be fixed to be C element
Position 5.1 : The head of the clamping screw;
Figure 6. The assembly of the clamping screw and the fastener nut with the housing to be fixed to the~C~element
Figure 7. Examples of installed fasteners for vertical and horizontal fastening of walls or their segments
Figure 8. Essential wall components
Position 8.1 : Steel structure elements, C elements and reinforcements;
Position 8.2: Internal lining;
Position 8.3: External lining;
Position 8.4: Insulation fill;
Figure 9. Cross section of the wall
Position 9.1 : Internal support of the facade;
Position 9.2: External support of the facade;
Figure 10. Examples of joined wall segments
Position 10.1 : Lower load-bearing module of the wall;
Position 10.2: Upper load bearing module of the wall;
Position 10.3: Floor module of the wall;
Position 10.4: Upper partition wall;
Position 10.5: Lower partition wall;
6. Description of one mode for carrying out of the invention
The subject invention has been developed such that the appropriate calculation has been done, according to the known and established method, in compliance with all the essential requirements defined in building regulations, such as pressure strength, resistance to earthquakes, wind and fire safety, relating to a specified structure intended for a specified purpose, with specified dimensions and the location, the layout of premises; a load bearing steel structure of the wall has been defined in such manner with all components and all channels and openings needed for installation of plumbing and other installation elements, allowing the application of the technology of completely factory-built walls, easy to install on the building site fulfilling all the criteria of passive house building standards.
Such a defined steel structure consists of elements of specified shapes and dimensions, mostly C elements, horizontal 1.1 and vertical 1.2 C elements made of steel sheathing of the appropriate thickness and joined appropriately according to the well-known method, with additional steel reinforcement elements 8.1. between them, as needed, for additional strength, according to calculations.
In accordance with calculations made in compliance with all relevant rules of the building practice requirements and regulations, suitable wall or wall segment fastening mechanisms are fixed inside horizontal 1.1 and vertical 1.2 C elements, for horizontal 2.1 and vertical 2.2 tightening and joining of walls or their segments.
The fastener cylinder 3.1 with the housing and the fastener nut 3.3 with the housing are placed on the C element inside the space defined by the internal surface 4.1 of the bottom of the C element and two internal side surfaces 4.2 of the C element, such that neither the fastener cylinder 3.1 nor the fastener nut 3.2 ever protrude beyond the volume of the C element but they are at the distance D from the edge 3.4 of the C element whether used for vertical or horizontal tightening.
The fastener cylinder 3.1 with the housing and the fastener nut 3.3 with the housing are placed on the C element as indicated above, laid in the direction of the axis 4.3 of the C element, located in
general in the corner and fixed appropriately to the internal surface 4.1 at the bottom of the C element and the respective internal side surface 4.2 of the C element, to give more strength to the joined segment.
Such a developed steel structure of the wall or of its segments is of the specified thickness 2.4, sufficient according to the calculation for a specific building. The appropriate number of suitably shaped internal 1.3 and external 1.4 spacers are placed and fixed at the specified points horizontally 1.1 and vertically 1.2 on the C elements.
Internal 1.3 and external 1.4 spacers are made of such materials that are of appropriate thermal insulation properties to eliminate thermal bridges between external and internal surfaces of walls.
The internal 8.2 and external 83 linings are placed and fixed onto the internal 1.3 and external 1.4 spacers, in which way the space is left between the internal 8.2 and external 8.3 lining in which the insulation fill is injected 8.4 to make up the total thickness 2.5 of the wall or its segments, whose dimensions depend on the intended use of the building and the corresponding requirements, which most frequently may be up to 300 mm.
Holes are bored on the internal 8.2 and external 8.3 lining to match the location of the internal 1.3 and external 1.4 spacers.
The steel structure of the wall or of its segment made as described above, complete with spacers, fastening mechanisms and final lining elements, of the specified outside volume and surfaces, for example of 36 m2, is placed in the frame of the appropriate dimensions and the appropriate, for example, 3-bar, injection press technique is applied to inject insulation fill, most frequently expanded polyurethane, which expands spontaneously while the pressure squeezes out the air hermetically sealing the space between placed final panels and'bo daTy^surfacesnsf the steel structure of the wall or of its segments, consisting of elements, mostly, horizontal 1.1 and vertical 1.2 C elements. Because of such compact wall structure the statics of the steel structure is improved for at least 30 %.
In such way a fully compact wall structure is achieved of excellent insulation properties such that the heat penetration coefficient U of the wall does not exceed 0.15 W/(m2K°).
The module is the usual name for the wall structure obtained after the application of the press technique in the above mentioned way, both on complete walls or their segments. Modules, in
general are rectangular in shape, usually of the total surface area of 36 m2, 3 x 12 m in length and width, meeting practically all requirements encountered in practice.
If all such modules, i.e., all wall elements are factory-made, with all windows, doors, utility channel and/or other additional elements installed in the production facility, one can make in advance the entire structure before it is brought to the building site, which results in a very flexible building concept and an additional reduction of building costs.
These wall modules, completely factory-made in the described manner, are then installed within the building construction process, on the building site such that they are joined horizontally 7.1 and vertically 7.2 with fasteners.
After the placement of the lower bearing module 10.1 of the wall on the foundations prepared in advance, the floor module 10.3 of the wall is placed and thereafter the upper bearing module 10.2 of the wall and partition walls, upper 10.4 and lower 10.5.
Internal facade supports are then fixed onto the steel structure, as necessary, followed by the installation of external facade supports (9.2) lying-on the external-lining (8.2).-
7. Industrial applicability of the invention
The subject invention can be applied in the construction industry and achieve the highest possible flexibility of building, beyond any comparison, with the radically reduced building costs and time schedules, which is a natural result of a process in which all modules, i.e., all wall elements are factory built with all windows, doors, installation channels and/or other additional equipment installed in the production facility, which means that the entire structure can be built in advance, before it is transported to the building site.
In addition, the subject invention allows the building of walls of excellent insulation properties of the heat penetration coefficient U not higher than 0.15 W/(m2K°), whereby the subject invention may be relevant in current construction achievements in the building of passive houses fulfilling the parameters and characteristics in compliance with the strictest standards.
Claims
1. The construction of a wall module of superior insulation properties required for passive buildings, the method of its industrial production for easy to install at erection site includes the technical design of the load bearing steel truss for a specific structure intended for a specific purpose, of specified dimensions, the location and the layout of premises, based on the appropriate calculations done according to the established method, in compliance with all essential requirements set in the building regulations, such as pressure strength, resistance to earthquake and wind , fire safety, defining the load bearing steel structure of the wall with all appertaining components and all needed door and window openings, but also with channels for all needed installations, for example electricity and telecommunications with installed plumbing and sewer installations, whereby such defined steel structure consists of elements of the determined shape and dimensions, mostly C elements, horizontal (1 .1 ) and vertical
(1.2) C elements, made of steel sheathing of the appropriate thickness and appropriately joined according to the established method , and between them, as necessary, to provide additional strength, according to calculations, additional steel reinforcement elements (8.1 ) are built, in addition to horizontal (1.1 ) and vertical (1.2) C elements, characterized in that suitable wall fasteners are fixed inside specified horizontal (1.1 ) and vertical (1.2) C elements of the steel structure, in accordance with calculations made according to all relevant requirements of the building profession and the regulations, in walls or their segments to fasten/tighten the walls horizontally (2.1 ) and vertically (2.2) with fasteners, whereby the fastener cylinder (3.1 ) with the housing and the fastener nut (3.3) with the housing are placed in the C element inside the space defined by the internal surface (4.1 ) at the bottom of the C element with two internal side surfaces (4.2) of the C element such that neither the fastener cylinder (3.1 ) nor the fastener nut (3.2) protrude in any way beyond the volume of the C element but they are at the distance (D) from the edge (3.4) of the C element, when fastened hOTizon ta 11 y~0T" vert rca tl y^
(3.3) with the housing , are laid in the direction of the axis (4.3) of the C element, placed, in general, in the corner to lean against and be fixed appropriately to the internal surface (4.1 ) at the bottom of the C element and the corresponding internal side surface (4.2) of the C element, in which way they are joined more firmly.
2. The construction of a wall module of superior insulation properties required for passive buildings, the method of its industrial production for easy to install at erection site according to patent claim 1 , characterized in that at the specified points of horizontal (1.1 ) and vertical (1.2) C elements, the needed number of suitably shaped internal (1.3) and external (1.4) spacers are placed and fixed, which are of such design and material properties that may serve for good thermal insulation.
3. The construction of a wall module of superior insulation properties required for passive buildings, the method of its industrial production for easy to install at erection site according to patent claims 1 and 2, characterized in that the internal (8.2) and external (8.3) lining placed on internal (1 .3) and external (1.4) spacers, with suitable holes bored to match the location of internal (1.3) and external (1 .4) spacers.
4. The method of industrial production of wall modules of superior insulation properties for passive houses, of the specified outside volume and surface of the steel wall structure, of for example 36 m2, made according to patent claims no. 1 , 2 and 3, characterized in that the structure is placed in the frame of the matching dimensions, in the appropriate pressurized, for example 3-bar, injection press, with corresponding insulation fill, most frequently expanding polyurethane (PIR), which expands spontaneously and squeezes out the air under pressure, thereby sealing every inch of the space defined by final panels and boundary surfaces of a steel wall structure or its segment, consisting^of the corresponding elements, mostly horizontal . (1 .1 ) and vertical (1.2) C elements.
5. The procedure of installation of wall modules of superior insulation properties, factory built according to patent claims 1 , 2, 3 and 4, for building development on site on the foundation prepared in advance characterized in that installation done with modules joined with horizontal and vertical fastening mechanisms such that the lower bearing module (10.1 ) of the wall is placed on the foundations prepared in advance, followed by the floor module (10.3) of the wall and the upper bearing module (10.2) of the wall with partition walls, upper (10.4) and lower (10.5).
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
HRP20110582AA HRP20110582A2 (en) | 2011-08-04 | 2011-08-04 | Wall mounting structure for passive building, implementation and process of production |
PCT/HR2012/000017 WO2013017900A1 (en) | 2011-08-04 | 2012-07-31 | Insulated wall module |
Publications (1)
Publication Number | Publication Date |
---|---|
EP2780514A1 true EP2780514A1 (en) | 2014-09-24 |
Family
ID=46939722
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
EP12766324.3A Withdrawn EP2780514A1 (en) | 2011-08-04 | 2012-07-31 | Insulated wall module |
Country Status (8)
Country | Link |
---|---|
US (1) | US20140202100A1 (en) |
EP (1) | EP2780514A1 (en) |
JP (1) | JP2014525001A (en) |
CN (1) | CN103998694A (en) |
CA (1) | CA2844029A1 (en) |
EA (1) | EA201490414A1 (en) |
HR (1) | HRP20110582A2 (en) |
WO (1) | WO2013017900A1 (en) |
Families Citing this family (2)
Publication number | Priority date | Publication date | Assignee | Title |
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CN112127518B (en) * | 2020-09-24 | 2021-10-01 | 广东新宏富建设有限公司 | Prefabricated light steel construction wall body of building |
CN115434446B (en) * | 2021-06-03 | 2024-09-06 | 新疆建筑设计研究院股份有限公司 | External wall sandwich heat-insulating and earthquake-resistant integrated structure |
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US3193060A (en) * | 1962-05-29 | 1965-07-06 | Park Wallace Sidney | Structural bracing member |
NL7607151A (en) * | 1975-07-01 | 1977-01-04 | Becker Otto Alfred Dr | BUILDING ELEMENT, PARTICULARLY BEARING BUILDING ELEMENT SUCH AS FOR CONSTRUCTION WORKS, SUPPORTS, BRIDGES, VEHICLES ETC. |
US4823534A (en) * | 1988-02-17 | 1989-04-25 | Hebinck Carl L | Method for constructing insulated foam homes |
US5255489A (en) * | 1990-08-09 | 1993-10-26 | Mitsubishi Jukogyo Kabushiki Kaisha | Construction apparatus for buildings and constructing method therewith |
US5353562A (en) | 1991-07-03 | 1994-10-11 | Decker Wendell T | Foam panel for construction |
JPH06182639A (en) * | 1992-12-17 | 1994-07-05 | Daiwa House Ind Co Ltd | Unit house and its execution method |
JPH0874358A (en) | 1994-09-02 | 1996-03-19 | Yoshino Sekko Kk | Partition wall |
US5617686A (en) | 1995-06-07 | 1997-04-08 | Gallagher, Jr.; Daniel P. | Insulating polymer wall panels |
US5765333A (en) | 1996-04-03 | 1998-06-16 | Cunningham; Dale W. | Unitized post and panel building system |
US6125608A (en) * | 1997-04-07 | 2000-10-03 | United States Building Technology, Inc. | Composite insulated framing members and envelope extension system for buildings |
US7958690B2 (en) * | 2003-10-24 | 2011-06-14 | Simpson Strong-Tie Co., Inc. | Stitching system hold-down |
GB0412796D0 (en) | 2004-06-09 | 2004-07-14 | Price Philip A | Supawall system |
JP4364177B2 (en) * | 2004-11-25 | 2009-11-11 | 新日本製鐵株式会社 | Joining metal fittings between members, upper and lower floor vertical frame material joining structure, and joining method |
JP4369859B2 (en) * | 2004-11-25 | 2009-11-25 | 新日本製鐵株式会社 | Joining metal fittings between members, upper and lower floor vertical frame material joining structure, and joining method |
US20070107352A1 (en) * | 2005-07-21 | 2007-05-17 | Yoshimichi Kawai | Construction of wall opening in steel house |
WO2008109139A2 (en) * | 2007-03-06 | 2008-09-12 | Simpson Strong-Tie Company, Inc. | Continuity tie for prefabricated shearwall |
DE102008048800A1 (en) * | 2008-09-24 | 2010-04-01 | Hein, Viktoria | Tabular component |
CN101525915B (en) * | 2009-04-03 | 2011-11-09 | 广州拜尔冷链聚氨酯科技有限公司 | Wall structure of large cold storage and construction method thereof |
JP2010242394A (en) * | 2009-04-07 | 2010-10-28 | Shimizu Corp | Structure for installing steel plate in concrete structure |
US8820034B1 (en) * | 2012-02-28 | 2014-09-02 | Thermal Framing, LLC. | Low thermal bridge building components |
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2011
- 2011-08-04 HR HRP20110582AA patent/HRP20110582A2/en not_active Application Discontinuation
-
2012
- 2012-07-31 CN CN201280048524.7A patent/CN103998694A/en active Pending
- 2012-07-31 WO PCT/HR2012/000017 patent/WO2013017900A1/en active Application Filing
- 2012-07-31 JP JP2014523406A patent/JP2014525001A/en active Pending
- 2012-07-31 EA EA201490414A patent/EA201490414A1/en unknown
- 2012-07-31 US US14/237,070 patent/US20140202100A1/en not_active Abandoned
- 2012-07-31 EP EP12766324.3A patent/EP2780514A1/en not_active Withdrawn
- 2012-07-31 CA CA2844029A patent/CA2844029A1/en not_active Abandoned
Non-Patent Citations (1)
Title |
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See references of WO2013017900A1 * |
Also Published As
Publication number | Publication date |
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JP2014525001A (en) | 2014-09-25 |
HRP20110582A2 (en) | 2013-04-30 |
WO2013017900A1 (en) | 2013-02-07 |
EA201490414A1 (en) | 2014-07-30 |
US20140202100A1 (en) | 2014-07-24 |
CA2844029A1 (en) | 2013-02-07 |
CN103998694A (en) | 2014-08-20 |
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