EP3059354B1 - Structural module and method for mounting structural modules - Google Patents

Structural module and method for mounting structural modules Download PDF

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Publication number
EP3059354B1
EP3059354B1 EP16156124.6A EP16156124A EP3059354B1 EP 3059354 B1 EP3059354 B1 EP 3059354B1 EP 16156124 A EP16156124 A EP 16156124A EP 3059354 B1 EP3059354 B1 EP 3059354B1
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EP
European Patent Office
Prior art keywords
heat
layer
insulating
modules
structural
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.)
Not-in-force
Application number
EP16156124.6A
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German (de)
English (en)
French (fr)
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EP3059354A1 (en
Inventor
Vitalii V. GANZHA
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Individual
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Individual
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Priority to PL16156124T priority Critical patent/PL3059354T3/pl
Publication of EP3059354A1 publication Critical patent/EP3059354A1/en
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    • 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
    • E04B2/88—Curtain walls
    • E04B2/90—Curtain walls comprising panels directly attached to the structure
    • E04B2/94—Concrete panels
    • 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
    • E04C2/02—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials
    • E04C2/26—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups
    • E04C2/284—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups at least one of the materials being insulating
    • E04C2/288—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups at least one of the materials being insulating composed of insulating material and concrete, stone or stone-like material

Definitions

  • the invention relates to a modular construction sector, in particular, to structures of modular structural elements which already have bearing, heat-insulating and facing layers and are used for construction of residential and public buildings having any number of storeys without using a cement grout. Further, the invention relates to methods of mounting structural modules of the proposed design having bearing, heat-insulating and facing layers in construction of residential and public buildings.
  • a structural module having a bearing element and a heat-insulating layer made of expanded polystyrene and a facade layer made of brickwork attached thereto is known in the art.
  • the method of modules mounting comprises coupling of their butt ends with vertical and horizontal beams of a pre-formed frame construction (Patent US 3 775 916 published on 04.12.1973).
  • the disadvantage of the known module and the related mounting method is the need for using a frame structure that complicates construction of building walls, limits the number of floors in the building and restricts the scope of decorative designing of a facade layer of the building. Further, this module does not provide for means to improve waterproofing of building walls.
  • Structural modules having a bearing base, a heat-insulating layer and a facade layer as well as means enhancing convenience of coupling modules to each other when they are mounted being made as a component of the bearing element are also known in the art.
  • the heat-insulating layer is located inside the spatial bearing element or between its layers.
  • the modules further have window or door systems or decorative elements mounted on a facade surface (Patent US 5 697 189 published on 16.12.1997, Application US 2011/0252728 A1 published on 20.10.2011, Application US 2014/0260030 A1 published on 18.09.2014).
  • a structural module having a reinforced concrete bearing wall element with a heat-insulating layer fixed outside thereof, being made of a concrete mixture with plant-derived fibers, whereon a facade layer made of a plaster material is fixed is also known in the art (Application for an Invention FR 2 709 504 A1 published on 10.03.1995, IPC: E04C2/06; E04B1/90; E04B2/92; E04C2/06; E04C2/52).
  • the known structural module allows simplifying construction of residential and public buildings through the presence of heat-insulating and facade layers already mounted on a reinforced concrete bearing element.
  • the disadvantage of the known solution is relatively insufficient shear strength of the facade layer and relatively high thermal conductivity of the facade module, both due to materials used in these layers, as well as relatively insufficient hydrophobicity of both the module and buildings constructed with such modules due to insufficient waterproofing of joints both between modules and between structural elements of modules, i.e. between heat-insulating layers and facade layers and window and/or door units or hanging structures such as balconies and the like.
  • a structural module having a heat-insulating layer and a facade layer is also known in the art.
  • the heat-insulating layer is made of mineral fiber selected from fiberglass, asbestos fiber, slag wool fiber, ceramic fiber and having a multi-layer structure with the outer and inner surfaces being hydrophobic (Patent of Ukraine No. 91984 published on 27.09.2010, IPC (2009): E04B 1/80).
  • the disadvantage of the known structural module is the lack of a bearing element necessitating the use of many elements of a frame, before an outer wall of a building is constructed, followed by mounting the above modules to the frame as well as the lack of means for waterproofing when modules are mounted together.
  • a structural module comprising a reinforced concrete wall element whereon an insulating element is fixed is also known in the art.
  • the reinforced concrete wall element has shelves and ribs for fastening the insulating element.
  • the insulating element is made of layers, so that, in particular, a layer of asbestos cement that performs a bearing, fire protective and decorative functions, and a layer of expanded polystyrene performs a heat-insulating function.
  • the insulating element has elastic parts to compensate for temperature deformations as well as an elastic sealing gasket at a junction with the reinforced concrete wall element.
  • the disadvantage of the known structural module is the structural complexity and, consequently, higher manufacturability requirements due to shelves and ribs on the bearing structure required for fixing the insulating element.
  • the known module may have insufficient parameters of heat insulation due to shelves and ribs on the reinforced concrete bearing structure which are not closed with a heat-insulating material.
  • Further disadvantage is the embodiment of the insulating element that has relatively poor environmental and decorative properties due to materials used. When such building modules are mounted, further steps are required to ensure waterproofing and heat insulation of joints between adjacent modules.
  • a structural module comprising a bearing, preferably, reinforced concrete element having the form of a rectangular parallelepiped, a heat-insulating layer, a reinforcing layer and a facade layer is also known in the art.
  • the outer surface of the facade layer features volumetric decorative elements attached with a mechanical fastener, located inside the heat-insulating layer.
  • the module further features sites fit for installation of window and door systems ( Patent EP 2 140 992 B1 published by 06.01.2010, IPC (2006.01): E04C 2/04, E04F 19/02, E04C 1/40, E04F 13/08, B28B 19/00).
  • GB 603 906 A discloses a composite building unit that comprises a body portion of porous concrete provided with a surrounding metal, wood or synthetic resin frame and reinforcing crossbars, and an outer layer of heavy concrete which may be secured thereto by bitumen, rubber, etc. and/or reinforcing strips or wire netting. Wood or fibreboard members may be secured to the synthetic resin frame and/or the reinforcing crossbars to assist insulation and plasterboard, asbestos-cement, metal, etc. may be attached to one or both faces of the unit by bitumen, rubber etc..
  • US 4 702 058 A discloses a prefabricated architectural or decorative wall system that has thin slabs of decorative materials, such as marble, granite, other natural stone or aggregates thereof, or other decorative exterior finish material, as an exterior finish bonded to the exterior of a thermally insulated structural panel.
  • Such wall panels, including door and window openings are prefabricated at a plant location and assembled at the building site by use of internal fastening means. Each section or panel is itself a structural member and the system requires no frame or "superstructure" for support.
  • EP 2 418 058 A2 discloses a method that involves placing cladding panels on a production table under release of joints arranged next to each other in a formwork frame. Edges of the panels are pressed into strips on all sides to apply a concrete layer on the panels. A sealing compound present in the strips is applied on the table, where a position of the compound corresponds to a pattern of the joints. An insulating layer is applied on the concrete layer. Boreholes are attached to the insulating layer to insert an anchoring rod into each borehole after inserting the insulating layer into the frame.
  • a structural module comprising a bearing wall, preferably, reinforced concrete element having, preferably, the form of a rectangular parallelepiped, a heat-insulating layer, a reinforcing layer and a facade layer, was chosen as a prototype.
  • the module further comprises horizontal and vertical insulating inserts located along the perimeter of the module to provide additional insulation of modules upon mounting.
  • the known module allows enhancing the convenience of mounting in construction of buildings to some extent and prevents loss of heat-insulating properties or parameters of strength as may be possible when wall thus constructed are further decorated with necessary means.
  • heat-insulating and waterproof parameters, and parameters of strength may be improved, and waterproofing of joints between modules may become easier when modules are mounted.
  • the invention is based on the task to develop a building module having a bearing element, a heat-insulating layer, a reinforcing layer and a facade layer with improved thermal insulation and waterproof properties and parameters of strength and being easier-to-mount when buildings are constructed with structural modules of the claimed design and allows enhancing the convenience of waterproofing works at buildings during mounting of such blocks by redesigning the module and using mate rials with certain properties therein.
  • a further task is to improve manufacturability of the structural module with the facade layer and decorative elements fixed on its surface.
  • Thickness of the facade layer may be 50 to 150 mm, and thickness of the heat-insulating layer may be 40 to 160 mm.
  • the facade layer may be made using clinker tiles.
  • the building module may comprise window units and/or door units and/or balcony elements mounted.
  • the building module may further include protruding decorative elements fixed.
  • Decorative elements may be fixed at sites where window units and/or door units and/or balcony elements are located.
  • Decorative elements may be attached to the bearing wall element using an adhesive mixture.
  • Decorative elements may be made of reinforced expanded polystyrene.
  • the further task of the invention claimed is to simplify the method of mounting structural modules and, at the same time, to provide better hydrophobic parameters of a building, made of such modules, without affecting decorative properties of the facade of the building by waterproofing joints between modules using decorative elements of the facade.
  • Protruding architectural decorative elements may be used as insulating linings.
  • Horizontal or vertical structures of reinforced expanded polystyrene may be used as architectural decorative elements.
  • Expanded polystyrene may be used as a heat-insulating material.
  • Insulating linings may be fixed onto surfaces of adjacent modules by gluing.
  • An embodiment of the structural module comprising a bearing element, a heat-insulating layer, a reinforcing layer and a facade layer allows simplifying the construction of residential and public buildings and, consequently, reducing their costs as well as increasing their heat-insulating properties by forming the necessary heat-insulating layer and facade layer that performs protective and decorative functions, when modules are mounted.
  • Providing the structural module with the means to insulate and waterproof building walls further improves the reliability of the overall wall structure in a building so constructed since integrity of the bearing structure may be compromised when walls constructed are faced with heat-insulating and waterproof layers.
  • An embodiment comprising the heat-insulating layer, the reinforcing layer and the facade layer with an indention L from an edge of the bearing wall element along its perimeter allows providing a surface, where the module may be caught with special means.
  • the embodiment having an indention L within 100 to 250 mm from an edge of the bearing wall element and an edge of the heat-insulating layer, the reinforced layer and the facade layer allows forming a surface whereon means for sealing joints between adjacent modules, when mounted, may be fixed, which may include insulating linings, fixed on surfaces of the modules.
  • the range of indentions within 100 to 250 mm was defined by the inventor bearing in mind the convenience of mounting building blocks followed by sealing of joints between thereof.
  • the inventor further conducted a series of studies to identify optimal thickness of the heat-insulating layer made of expanded polystyrene and the facade layer to ensure the building module features the above parameters of thermal conductivity with due consideration of thermal conductivity of other elements, such as the bearing element made, preferably, of reinforced concrete.
  • Studies were carried out according to DSTU B V.2.7-105-2000 for temperate continental climate conditions.
  • the structural module as used in the studies, comprised a bearing element of reinforced concrete 160 mm thick.
  • the facade layer was made of clinker tiles and reinforced with a fiberglass grid. The results of the studies are presented in Table 1 and Table 2 below. Table 1. Thermal conductivity of the building module vs.
  • This finding may be explained by a synergistic effect of using the heat-insulating layer made of expanded polystyrene of defined thickness and the facade layer of defined thickness which, when used together with preferably reinforced concrete base, provide the required parameters of thermal conductivity of the structural module within the above range.
  • expanded polystyrene for the heat-insulating layer is preferred since it is relatively light-weighted and environmentally friendly and has excellent sound insulation due to its porous structure.
  • building items, particularly, structural modules preferably use modified expanded polystyrene with addition of flame retardants etc. providing significant reduction in fire safety when used in the structural module.
  • expanded polystyrene is resistant to various microorganisms and factors such as low temperature and high humidity. It is readily workable and deservedly considered a durable and strong material. All the above factors allow improving safety, heat resistance, durability and manufacturability of the structural module.
  • the facade layer with both the decorative and protective functions, in particular, waterproofness and resistance to thermal conductivity as well as higher parameters of strength, in particular, wear resistance and temperature stability, improves overall heat resistance of the structural module and provides hydrophobicity, so required.
  • clinker tiles as a material for the facade layer, meet the above requirements with its low thermal conductivity, high hydrophobicity and resistance to abrasion. Being environmentally friendly and having many decorative options, this material further simplifies the construction technology of the structural module. Further, clinker tiles may have a special base.
  • An embodiment of the reinforcing layer having shear strength of at least 0,8 MPa when coupled with the facade layer allows improving reliability of the facade layer, so formed over the entire plane, especially when the facade layer features sufficiently high thickness and loads onto the outer surface of the facade layer are possible due to extreme weather conditions (snow, etc.) and thus increasing the life of the structural module.
  • Providing window units and/or door units and/or balconies and/or hanged elements on the facade module allows simplifying construction of building structures using such modules.
  • protruding decorative elements located on the outer surface of the facade layer further simplifies construction of building structures and, at the same time, increases aesthetic requirements to the exterior of buildings that is of prime importance residential housing.
  • Fixing decorative elements onto the bearing wall element using an adhesive mixture may improve manufacturability of the structural module, enhance reliability of its fastening and further improve waterproofing of joints between window units and/or door units and/or balcony and/or hanged elements and elements of the structural module.
  • the heat-insulating layer, the reinforcing layer and the facade layer are made, so that there is an indention from an edge of the bearing wall element with width of indention L from the edge of the bearing wall element and the edge of the heat-insulating layer, the reinforced layer and the facade layer within 100 to 250 mm.
  • This forms a space between heat-insulating layers of adjacent modules to ensure access to coupling elements to fasten modules to each other during mounting and to provide an option of applying a protective coating on coupling elements and sealing joints between bearing elements of adjacent structural modules.
  • steps are followed by filling a gap between heat-insulating layers of adjacent modules with a heat-insulating material, so to form continuous heat-insulating surface for a wall of a building comprising heat-insulating layers and linings of the heat-insulating material between them. Further sealing of joints between heat-insulating layers of modules and inserts of heat-insulating material may improve waterproof properties of the building. Further use of insulating linings allows forming the facade coupled with the facade layer of structural modules. Coupling of insulating linings with the surface of modules, in particular by gluing, provides durability of the facade, so formed and improves its hydrophobic properties. Further mechanical fastening of insulating linings onto the bearing wall element of the module allows improving the strength of fastening.
  • insulating linings play the role of a protective element for joints between modules, so the requirements to waterproofing of joints become simpler, and the role of a decorative element forming the facade of the building. This simplifies mounting of modules during construction of buildings and improves heat-insulating and hydrophobic properties of walls in the building thus constructed.
  • An embodiment of insulating linings being at least 5% wider the gap between heat-insulating layers of adjacent modules allows an insulating lining to overlap the surface of the heat-insulating insertion, and achieves better protection of joints between modules and easier mounting.
  • protruding architectural decorative elements as insulating linings allows improving aesthetic requirements to the facade of the building.
  • An embodiment of architectural decorative elements in the form of horizontal or vertical structures made of reinforced expanded polystyrene allow enhancing strength of insulating linings and, consequently, reliability of protection of joints between modules and, at the same time, reducing weight of the module and simplifying the technology of its manufacture. It also allows combining these additional decorative elements with protruding decorative elements, fixed at sites, where window units and/or door units and/or balcony and/or hanged elements are located on the structural module and increasing decorative properties of the facade of the building.
  • the structural module having the heat-insulating, the reinforcing and the facade layer made so that there is an indention from an edge of the bearing wall element allows ensuring mounting of bearing elements together and forming a single heat-insulating and facade layer in the building, indicating an association of a group of inventions, specifically, the structural module and the method of mounting of such building modules by a single inventive concept.
  • the structural module comprises a bearing wall element 1, a heat-insulating layer 2, a reinforcing layer 3 and a facade layer 4.
  • the bearing wall element 1 is made preferably of reinforced concrete in a form of a rectangular parallelepiped.
  • the heat-insulating layer 2, the reinforcing layer 3 and the facade layer 4 are made, so that there is an indention L from an edge of the bearing wall element 1. Width of the indention L from an edge of the bearing wall element 1 and an edge of the heat-insulating layer 2, the reinforcing layer 3 and the facade layer 4 is within 100 to 250 mm. Thickness of the heat-insulating layer 2 may be within 40 to 160 mm, e.g. 100 mm. When coupled with the facade layer 4, the reinforcing layer 3 has shear strength of at least 0,8 MPa. Thickness of the facade layer 4 is within 50 to 150 mm, e.g. 50 mm.
  • the facade layer may be made using clinker tiles fixed on its external surface.
  • the external surface of the facade layer of the module may be equipped with both clinker facing tiles and natural stone, decorative mixtures etc.
  • the structural module comprises window units and door units 5 mounted and protruding decorative elements 6 fixed thereon.
  • Decorative elements 6 are fixed at sites where window units and door units 5 are located along their perimeter.
  • Decorative elements 6 are made of reinforced expanded polystyrene and fastened to the bearing wall element 1 using an adhesive mixture.
  • the internal surface of the bearing element (not shown) may be decorated with a primer and have openings, made to locate electric elements, and inner slopes along windows or doors.
  • the structural module may be produced by forming the bearing element by making a spatial reinforced frame and placing it into a form together with coupling elements to mount modules followed by pouring concrete to obtain a reinforced concrete bearing element after hardening.
  • the bearing element, so formed is then cleaned and primed, and window and/or door units are then mounted.
  • the heat-insulating and reinforcing layers are then formed on the bearing element by adding an adhesive mixture and a fiber grid to expanded polystyrene to reinforce the structure with a fiberglass grid.
  • the facade layer is formed, e.g., using clinker tiles to be glued to the heat-insulating layer.
  • this invention provides the structural module comprising the bearing element, the heat-insulating layer, the reinforced layer and the facade layer having improved heat-insulating, hydrophobic and strength parameters and easier mounting in the construction of buildings with structural modules of the design claimed above and increases hydrophobic properties of the entire building.

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  • Engineering & Computer Science (AREA)
  • Architecture (AREA)
  • Civil Engineering (AREA)
  • Structural Engineering (AREA)
  • Physics & Mathematics (AREA)
  • Electromagnetism (AREA)
  • Building Environments (AREA)
  • Finishing Walls (AREA)
EP16156124.6A 2015-02-18 2016-02-17 Structural module and method for mounting structural modules Not-in-force EP3059354B1 (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
PL16156124T PL3059354T3 (pl) 2015-02-18 2016-02-17 Moduł budowlany i sposób montażu modułów budowlanych

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
UAA201501380A UA116106C2 (uk) 2015-02-18 2015-02-18 Будівельний модуль та спосіб монтажу будівельних модулів

Publications (2)

Publication Number Publication Date
EP3059354A1 EP3059354A1 (en) 2016-08-24
EP3059354B1 true EP3059354B1 (en) 2018-04-18

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Family Applications (1)

Application Number Title Priority Date Filing Date
EP16156124.6A Not-in-force EP3059354B1 (en) 2015-02-18 2016-02-17 Structural module and method for mounting structural modules

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EP (1) EP3059354B1 (uk)
HU (1) HUE038338T2 (uk)
PL (1) PL3059354T3 (uk)
UA (1) UA116106C2 (uk)

Families Citing this family (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
UA121080C2 (uk) * 2018-09-06 2020-03-25 Віталій Вікторович Ганжа Багатошаровий конструкційний модуль для будівництва

Family Cites Families (11)

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Publication number Priority date Publication date Assignee Title
GB603906A (en) * 1945-11-05 1948-06-24 Alexander Goldberg Improvements relating to structural panels
US3775916A (en) 1972-03-20 1973-12-04 Dev Co America Prefabricated wall panel
US4702058A (en) * 1986-11-17 1987-10-27 Bennett Douglas E Thermal structural wall panel
FR2709504A1 (fr) 1993-07-28 1995-03-10 Villibord Maurice Marcel Mur complexe iso-ciment, mur et paroi préfabriqués multicouches isophoniques et isothermiques.
US5697189A (en) 1995-06-30 1997-12-16 Miller; John F. Lightweight insulated concrete wall
US20060019568A1 (en) 2004-07-26 2006-01-26 Toas Murray S Insulation board with air/rain barrier covering and water-repellent covering
US8635824B2 (en) 2007-01-17 2014-01-28 Edward G. Scherrer Insulation panel system
DE102008031355A1 (de) 2008-07-04 2010-01-14 Prometheus Projektgesellschaft für rationelles 3D formen mbH Herstellung von Bauelementen, insbesondere von Wand- oder Fassadenelementen
US7984594B1 (en) 2010-01-20 2011-07-26 Propst Family Limited Partnership, Llc Composite building and panel systems
DE102010036958B4 (de) * 2010-08-12 2012-03-01 Sommer Anlagentechnik Gmbh Verfahren zur Herstellung mehrschichtiger Betonelemente
UA78799U (uk) 2013-01-30 2013-03-25 Віталій Вікторович Ганжа Будівельний блок

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Publication number Publication date
EP3059354A1 (en) 2016-08-24
HUE038338T2 (hu) 2018-10-29
UA116106C2 (uk) 2018-02-12
PL3059354T3 (pl) 2018-09-28

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