EP3494264B1 - Method for producing prefabricated components for buildings - Google Patents

Method for producing prefabricated components for buildings Download PDF

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Publication number
EP3494264B1
EP3494264B1 EP17748761.8A EP17748761A EP3494264B1 EP 3494264 B1 EP3494264 B1 EP 3494264B1 EP 17748761 A EP17748761 A EP 17748761A EP 3494264 B1 EP3494264 B1 EP 3494264B1
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EP
European Patent Office
Prior art keywords
base element
lightweight
construction layer
plate
lightweight construction
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EP17748761.8A
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German (de)
French (fr)
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EP3494264A1 (en
Inventor
Florian REDLBERGER
Alfred Redlberger
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Reprect Holding GmbH
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Reprect Holding GmbH
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Publication of EP3494264A1 publication Critical patent/EP3494264A1/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
    • 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
    • E04B1/14—Structures consisting primarily of load-supporting, block-shaped, or slab-shaped elements the elements being composed of two or more materials
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B28—WORKING CEMENT, CLAY, OR STONE
    • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B11/00—Apparatus or processes for treating or working the shaped or preshaped articles
    • B28B11/04—Apparatus or processes for treating or working the shaped or preshaped articles for coating or applying engobing layers
    • B28B11/042—Apparatus or processes for treating or working the shaped or preshaped articles for coating or applying engobing layers with insulating material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B28—WORKING CEMENT, CLAY, OR STONE
    • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B23/00—Arrangements specially adapted for the production of shaped articles with elements wholly or partly embedded in the moulding material; Production of reinforced objects
    • B28B23/0062—Arrangements specially adapted for the production of shaped articles with elements wholly or partly embedded in the moulding material; Production of reinforced objects forcing the elements into the cast material, e.g. hooks into cast concrete
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B28—WORKING CEMENT, CLAY, OR STONE
    • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B23/00—Arrangements specially adapted for the production of shaped articles with elements wholly or partly embedded in the moulding material; Production of reinforced objects
    • B28B23/02—Arrangements specially adapted for the production of shaped articles with elements wholly or partly embedded in the moulding material; Production of reinforced objects wherein the elements are reinforcing members
    • B28B23/028—Arrangements specially adapted for the production of shaped articles with elements wholly or partly embedded in the moulding material; Production of reinforced objects wherein the elements are reinforcing members for double - wall articles
    • 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
    • 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
    • E04C2/34—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 composed of two or more spaced sheet-like parts
    • 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
    • E04B2/84—Walls made by casting, pouring, or tamping in situ
    • E04B2/842—Walls made by casting, pouring, or tamping in situ by projecting or otherwise applying hardenable masses to the exterior of a form leaf
    • E04B2/847—Walls made by casting, pouring, or tamping in situ by projecting or otherwise applying hardenable masses to the exterior of a form leaf the form leaf comprising an insulating foam panel
    • 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
    • E04B2/84—Walls made by casting, pouring, or tamping in situ
    • E04B2/86—Walls made by casting, pouring, or tamping in situ made in permanent forms
    • E04B2/8611—Walls made by casting, pouring, or tamping in situ made in permanent forms with spacers being embedded in at least one form leaf
    • E04B2/8617—Walls made by casting, pouring, or tamping in situ made in permanent forms with spacers being embedded in at least one form leaf with spacers being embedded in both form leaves
    • 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
    • E04C2/04—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of concrete or other stone-like material; of asbestos cement; of cement and other mineral fibres
    • E04C2/044—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of concrete or other stone-like material; of asbestos cement; of cement and other mineral fibres of concrete
    • E04C2002/045—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of concrete or other stone-like material; of asbestos cement; of cement and other mineral fibres of concrete with two parallel leaves connected by tie anchors
    • E04C2002/047—Pin or rod shaped anchors

Definitions

  • the main problem is that during the manufacture of the prefabricated part, which is mostly cast from concrete in a formwork in the factory, there are tolerances of +/- 0.5 - 0.8 cm in the dimensions and thickness of the precast part. Thermal insulation applied in the factory also has tolerances of this magnitude. When erecting the building, where the individual prefabricated components are assembled, these tolerances can hardly be equalized. However, on the outside, where the thermal insulation layer is applied, there must be a tight joint without any tolerance. Any joints that occur would have to be foamed/filled to prevent cold bridges from forming. In practice, however, this is hardly possible, since the foam filling never takes place over the entire thickness of the existing thermal insulation, which means that continuous thermal insulation is no longer guaranteed.
  • the document EP 2 123 837 A1 shows a method for producing a prefabricated part for buildings according to the preamble of claim 1.
  • the object of the present invention is therefore to create a method for producing prefabricated components which already provides a corresponding thermal insulation layer ex works, with the prefabricated components being able to be assembled later at the construction site without post-processing by specialist personnel.
  • the tolerances in the area of the solid components should be reduced to the necessary level and at the same time the joints in the thermal insulation layer at the interfaces between adjacent ones should be closed
  • Prefabricated components must be tight, and the thermal insulation layer on the outside of the building must have an even surface.
  • the manufacturing costs of the prefabricated components should be kept low.
  • an additional feature of the present invention is that the lightweight component units are provided with surface-enlarging structuring, for example in the form of elevations and/or depressions, on the side faces facing the base element in the assembled state before assembly.
  • structuring for example in the form of ribs or grooves, creates better adhesion to the base element.
  • Another feature of the method according to the invention is that additional formwork elements are inserted in the formwork for the hardenable casting compound, which formwork elements later fill in for doors or windows, for example, in the base element, and that the lightweight construction layer extends the edges of the recesses created in this way in the direction of the recesses also around surpasses at least one processing section.
  • recesses for windows, doors or other openings can be machined precisely and precisely to the final external dimensions during the manufacture of the prefabricated component, so that the installation of windows, doors, window sills, roller shutter boxes, etc. can also be carried out precisely without adjustment and rework can.
  • the machined surfaces in the recesses are preferably used to position built-in components (such as windows, doors, roller shutter systems, etc.) in an unloaded state, and starting from this position, the elements to be assembled are fastened to the base element of the prefabricated components.
  • built-in components such as windows, doors, roller shutter systems, etc.
  • the lightweight construction layer is first connected to the connecting elements and then the free ends of the connecting elements are pressed into the not yet fully cured base element, so that a gap remains between the base element and the lightweight construction layer, which can later be filled out with in-situ concrete when erecting a building at a construction site, for example.
  • a particularly light prefabricated component can be created which, on the one hand, can be seamlessly and precisely assembled without post-processing when erecting the building on the construction site and, on the other hand, serves as permanent formwork when the resulting gap is filled with in-situ concrete.
  • the basic element of the prefabricated component can be a single wall or a double wall
  • the fitting sections of the built-in parts which are made of plastic, for example, are machined after the finished part has been completed and any manufacturing tolerances are compared with a reference ex works.
  • the prefabricated components can then be assembled particularly quickly on site using the fitting sections as adjustment and connection points. If the basic element is designed as a double wall, the intermediate space is then filled with in-situ concrete.
  • the machined end faces of the lightweight construction layer are finally provided with elevations or depressions, which can be brought into engagement with corresponding elevations or depressions of adjacent prefabricated components, for example conical or longitudinally directed elevations and depressions for the formation of teeth or Tongue and groove connections are provided between the prefabricated components.
  • a possible embodiment of a prefabricated component 1 produced by the method according to the invention is shown schematically.
  • the proportions do not correspond to the real conditions, but have been enlarged for a better understanding.
  • a base element 2 is first produced for the prefabricated component 1, which is cast, for example, from concrete in a formwork.
  • formwork elements in the formwork, which are used in order to form the subsequent recesses 7 for doors or windows, for example.
  • lightweight component units for example thermal insulation panels, are inserted into the still soft base element 2 and connected to it by the complete hardening of the base element 2 .
  • connection between the corresponding side surface of the lightweight component units and the base element can be improved if the lightweight component units are provided with a structure on the relevant side surface, for example in the form of ribs and grooves.
  • Different types of connecting elements 3 can also be used, which are pressed into the base element and protrude partially or completely through the lightweight component units.
  • connecting elements 3 which protrude through the lightweight component units, while on the right side of the 1 Connecting elements 3 are shown, which end inside the lightweight component units.
  • the lightweight component units are laid close together, with the lightweight component units also being cut to size depending on the design of the basic element 2 .
  • the now densely laid lightweight component units result in a lightweight layer 4 which covers the entire base element 2 and protrudes beyond all edges of the base element 2 by at least one processing section 5 .
  • the processing sections 5 are both on all end faces 12, facing away from the base element 2 Side surface 6 and provided on the side edges 8 of the recesses 7 on the lightweight layer 4.
  • the finished component 1 After the finished component 1 has completely hardened, it is measured against a factory reference value and the deviations of the finished component from a desired tolerance range are determined. Due to the manufacturing process, there are generally deviations of 0.5 - 0.8 cm from the specified size. However, no joints should remain at the construction site in the area of the lightweight construction layer 4, so that a continuous thermal insulation layer is formed around the entire building. The side surface 6 of the lightweight construction layer 4 pointing outwards should also extend over the entire surface without steps at the seams. For this reason, in a next method step, the lightweight layer 4 of the respective prefabricated component 1 is precisely machined on the basis of the previously measured deviations, with material being removed from the lightweight layer 4 at the machining sections 5 depending on the deviation. As a result, each end face, the thickness of the prefabricated component 1 and the recesses 7 for doors or windows can be machined to the extent that the prefabricated components 1 can be assembled on site without further post-processing.
  • the finished parts can also be provided with structuring 15, such as decorative grooves or cornices or the like, on the side surface 6 pointing outwards.
  • structuring 15 such as decorative grooves or cornices or the like
  • the prefabricated components 1 can be erected on the lightweight construction layer 4 for the purpose of constructing the building on the construction site, with the solid basic elements 2 being lined as required.
  • the construction is therefore carried out completely via the end faces 12 of the lightweight construction layer 4, which is used for easier adjustment on the construction site can also be provided with corresponding tongue and groove structures or elevations 13 and depressions 14 for toothing.
  • the solid basic elements 2 can be connected to one another and sealed, and the building is erected very quickly and without a great deal of personnel.
  • a further possible embodiment is shown, in which the lightweight construction layer 4 is connected to the base element 2 via a further form of connecting elements 3 .
  • a gap 9 remains between the base element 2 and the lightweight construction layer 4. Erection on the construction site takes place, as described above, via the end faces 12 of the lightweight construction layer 4.
  • the solid base elements 2 are then sealed accordingly and the gap 9 is filled with in-situ concrete.
  • the prefabricated component 1 consequently serves as permanent formwork. Any recesses 7 for windows or doors must of course be sealed by appropriate formwork elements before the in-situ concrete is added.
  • the base element 2 is designed as a double wall.
  • built-in parts 10 are also connected to the basic element 2, which in the example shown serve as spacers between the two double wall panels.
  • machinable fitting sections 11 for example made of plastic, which after machining using the same reference as for the machining of the lightweight layer, serve as adjustment and connection points in the erection of the building.
  • the finished component 1 is also already measured here in relation to the reference for the desired tolerances in the factory and the machining sections 5 of the lightweight construction layer 4 are machined accordingly.
  • the target position of the built-in parts 10 and fitting sections 11 is represented by the dashed lines.
  • the fitting section 11 was processed in such a way that the deviation of the built-in part 10 from the desired position is compensated for in the future connection with an adjacent prefabricated component 1 .
  • deviations of Entire basic element 2 and the lightweight layer 4 from the desired final position for example regarding the total component thickness or the joint width are compensated for by editing the processing sections 5 on the lightweight layer 4.
  • a clear advantage of the method according to the invention is that all necessary processing can be carried out under controlled workshop conditions and can be largely automated, which reduces the production costs. When constructing the building, time-consuming work and the need for appropriate skilled workers are eliminated, which further reduces costs.

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  • Engineering & Computer Science (AREA)
  • Architecture (AREA)
  • Structural Engineering (AREA)
  • Civil Engineering (AREA)
  • Physics & Mathematics (AREA)
  • Electromagnetism (AREA)
  • Chemical & Material Sciences (AREA)
  • Ceramic Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Manufacturing & Machinery (AREA)
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Description

Technisches Gebiettechnical field

Die Erfindung betrifft ein Verfahren zur Herstellung von Fertigbauteilen für Gebäude umfassend die folgenden grundsätzlichen Schritte:

  • ) Einfüllen eines aushärtbaren Gießmaterials in eine Schalung zur Ausbildung eines im Wesentlichen plattenförmigen Grundelements und
  • ) Verbinden des Grundelements mit Leichtbauteileinheiten, wie beispielsweise Wärmedämmplatten, entweder durch Einlegen der Leichtbauteileinheiten in das noch nicht vollständig ausgehärtete Gießmaterial oder durch Verbindungselemente, die Grundelement und Leichtbauteileinheiten miteinander verbinden, wobei alle Leichtbauteileinheiten ohne Fugen dicht aneinandergereiht und gegebenenfalls zugeschnitten werden, um in Summe eine im Wesentlichen plattenförmige Leichtbauschichte zu ergeben.
The invention relates to a method for producing prefabricated components for buildings, comprising the following basic steps:
  • ) Filling a hardenable casting material into a formwork to form a substantially plate-shaped base element and
  • ) Connecting the basic element to lightweight component units, such as thermal insulation panels, either by inserting the lightweight component units into the casting material that has not yet fully hardened, or by connecting elements that connect the basic element and lightweight component units to one another, with all lightweight component units being lined up closely together without joints and, if necessary, cut to size in order to total one to result in essentially plate-shaped lightweight layer.

Stand der TechnikState of the art

Derzeit ist es üblich, Fertigteil-Bauwerke aus massiven Baustoffen, getrennt von der Wärmedämmschichte anzufertigen und auf der Baustelle durch manuelles Positionieren und Einrichten zu einem Bauwerk zusammenzufügen. Anschließend wird die Wärmedämmschichte außenseitig auf die Bauteile mittels Kleber und/oder mechanischer Verbindung aufgebracht. Die Arbeiten werden ausschließlich manuell und von Fachpersonal durchgeführt. Das ist sehr zeit- und personalaufwändig und somit kostenintensiv.It is currently customary to manufacture prefabricated structures from solid building materials, separately from the thermal insulation layer, and to assemble them into a structure on the construction site by manual positioning and setting up. The thermal barrier coating is then applied to the outside of the components using an adhesive and/or mechanical connection. The work is carried out exclusively manually and by qualified personnel. This is very time-consuming and labor-intensive and therefore cost-intensive.

Um die Kosten zu reduzieren, wurden immer wieder Versuche unternommen, die Wärmedämmschichte bereits im Werk aufzubringen und die massiven Bauteile gemeinsam mit dieser Wärmedämmung auf der Baustelle zu einem Bauwerk zusammenzufügen. Die Versuche waren aber bisher nicht erfolgreich, da durch die im Rahmen der Produktion und der Montage entstehenden und vorhandenen Toleranzen keine dichten Fugen und keine ebenen Außenflächen in der Wärmedämmschichte hergestellt werden konnten.In order to reduce costs, repeated attempts have been made to apply the thermal insulation layer in the factory and to assemble the solid components together with this thermal insulation on the construction site to form a structure. The tests have not been successful so far, however, because the tolerances that arise and exist during production and assembly mean that no tight joints and no flat outer surfaces can be produced in the thermal insulation layer.

Das Hauptproblem liegt darin, dass bei der Fertigung des Fertigbauteils, welches zumeist aus Beton in einer Schalung im Werk gegossen wird, Toleranzen von +/- 0,5 - 0,8 cm in den Abmessungen bzw. in der Dicke des Fertigteils auftreten. Im Werk aufgebrachte Wärmedämmungen weisen ebenfalls Toleranzen in dieser Größenordnung auf. Beim Errichten des Gebäudes, wo die einzelnen Fertigbauteile zusammengefügt werden, lassen sich diese Toleranzen kaum egalisieren. An der Außenseite, wo die Wärmedämmschichte angebracht ist, muss jedoch eine dichte Fuge ohne jegliche Toleranz vorhanden sein. Etwaige auftretende Fugen müssten ausgeschäumt/ausgefüllt werden, damit keine Kältebrücken entstehen. Dies ist in der Praxis jedoch kaum möglich, da das Ausschäumen nie über die gesamte Dicke der vorhandenen Wärmedämmung erfolgt, wodurch eine durchgehende Wärmedämmung nicht mehr gewährleistet ist. Auch die Abweichungen in der Dicke zwischen den einzelnen Fertigteilen müssten erst an der Baustelle durch ein Abschleifen der Wärmedämmschicht erfolgen, wodurch erneut ein erhöhter Arbeitsaufwand gegeben ist. Außerdem kann auf diese Weise nicht sichergestellt werden, dass die Wärmedämmschichte an den bearbeiteten Stellen weiterhin normgerecht die notwendige Mindestdicke aufweist. Aufgrund dieser Probleme und dem damit verbundenen Arbeitsaufwand bei gleichzeitig schlechterem Endergebnis wird es bisher unterlassen, die Wärmedämmschichte bereits ab Werk zu installieren, sondern die Wärmedämmplatten, werden erst auf der Baustelle dicht an dicht auf der Außenseite der bereits errichteten Fertigbauteile aufgebracht.The main problem is that during the manufacture of the prefabricated part, which is mostly cast from concrete in a formwork in the factory, there are tolerances of +/- 0.5 - 0.8 cm in the dimensions and thickness of the precast part. Thermal insulation applied in the factory also has tolerances of this magnitude. When erecting the building, where the individual prefabricated components are assembled, these tolerances can hardly be equalized. However, on the outside, where the thermal insulation layer is applied, there must be a tight joint without any tolerance. Any joints that occur would have to be foamed/filled to prevent cold bridges from forming. In practice, however, this is hardly possible, since the foam filling never takes place over the entire thickness of the existing thermal insulation, which means that continuous thermal insulation is no longer guaranteed. The deviations in the thickness between the individual prefabricated parts would first have to be corrected at the construction site by grinding down the thermal insulation layer, which again increases the amount of work involved. In addition, it cannot be ensured in this way that the thermal barrier coating at the processed points continues to have the required minimum thickness in accordance with the standard. Due to these problems and the associated workload with a worse end result, it has so far been omitted to install the thermal insulation layer at the factory, but the thermal insulation panels are only applied tightly to the outside of the already erected prefabricated components on the construction site.

Das Dokument EP 2 123 837 A1 zeigt ein Verfahren zur Herstellung eines Fertigteils für Gebäude gemäß dem Oberbegriff des Anspruchs 1.The document EP 2 123 837 A1 shows a method for producing a prefabricated part for buildings according to the preamble of claim 1.

Darstellung der ErfindungPresentation of the invention

Es ist somit Aufgabe der vorliegenden Erfindung, ein Verfahren zur Herstellung von Fertigbauteilen zu schaffen, welches bereits eine entsprechende Wärmedämmschichte ab Werk vorsieht, wobei die Fertigbauteile bei einem späteren Zusammenbau an der Baustelle ohne Nachbearbeitung durch Fachpersonal zusammengefügt werden können. Die Toleranzen im Bereich der Massivbauteile sollen dabei auf das notwendige Maß reduziert sein und gleichzeitig sollen die Fugen in der Wärmedämmschichte an den Schnittstellen zwischen benachbarten Fertigbauteilen dicht sein, und die Wärmedämmschichte an der Außenseite des Gebäudes eine ebene Oberfläche aufweisen. Die Herstellungskosten der Fertigbauteile sollen dabei gering gehalten werden.The object of the present invention is therefore to create a method for producing prefabricated components which already provides a corresponding thermal insulation layer ex works, with the prefabricated components being able to be assembled later at the construction site without post-processing by specialist personnel. The tolerances in the area of the solid components should be reduced to the necessary level and at the same time the joints in the thermal insulation layer at the interfaces between adjacent ones should be closed Prefabricated components must be tight, and the thermal insulation layer on the outside of the building must have an even surface. The manufacturing costs of the prefabricated components should be kept low.

Diese Aufgabe wird durch das erfindungsgemäße Verfahren dadurch gelöst, dass die geschaffene Wärmedämm- bzw. Leichtbauschichte an allen Seitenkanten um zumindest einen Bearbeitungsabschnitt größer ausgebildet ist als das Grundelement und dieses daher überragt, und dass folgende weiteren Schritte durchgeführt werden:

  • ) Werkseitiges Vermessen des fertig ausgehärteten Fertigbauteils gegenüber einer werkseitig vorhandenen Referenz zur Feststellung der herstellungsbedingten Abweichungen der Messwerte von durch die werkseitige Referenz vorgegebenen Toleranzbereich für den späteren Aufbau am Aufstellungsort und
  • ) Werkseitiges maßgenaues Bearbeiten der randseitigen Bearbeitungsabschnitte sowie der dem Grundelement abgewandten Seitenfläche der Leichtbauschichte durch Entfernen von Material der Leichtbauschichte im Ausmaß der im vorigen Schritt festgestellten Abweichungen vom Toleranzbereich. Das erfindungsgemäße Verfahren beruht darauf, die Leichtbauschichte, welche die Wärmedämmung bildet, werksmäßig mit dem massiven Grundelement zu verbinden, die Leichtbauschichte aber, nachdem das Grundelement ausgehärtet ist, allseitig maßgenau zu bearbeiten. Dabei wird die Leichtbauschichte um einen Bearbeitungsabschnitt größer als das Grundelement ausgeführt, sodass nur die Leichtbauschichte bearbeitet werden muss. Aufgrund der heute üblichen Wärmedämmstärken ist es dann auch möglich, die bearbeiteten Stirnflächen der Leichtbauschichten der Fertigbauteile als Aufstell- und Passflächen für eine aufgrund der Bearbeitungsgenauigkeit ganz präzise Montage zu verwenden. Um eventuell die Belastung der Leichtbauschichten durch das Gewicht des massiven Grundelements beim Aufstellen gering zu halten, können die Fertigbauteile gegebenenfalls im Zuge der Montage im Bereich des Grundelements unterfüttert werden. Erfindungsgemäß ist die Leichtbauschichte um zumindest einen dem Fugen- und Toleranzbereich entsprechenden Bearbeitungsabschnitt größer als das Grundelement ausgebildet, sodass bei der Bearbeitung immer die Leichtbauschichte die äußerste Abmessung des Fertigbauteils darstellt. Die Bearbeitung der Fertigbauteildicke erfolgt ausgehend von der massiven Innenseite des Grundelements. Mit diesen Maßnahmen ist sichergestellt, dass sowohl die Außenabmessungen als auch die Gesamtbauteildicke präzise ausgeführt werden kann. Das Dämmmaterial, welches die Leichtbauschichte bildet, lässt sich sehr leicht und mit hoher Geschwindigkeit kostengünstig bearbeiten.
This object is achieved by the method according to the invention in that the thermal insulation or lightweight construction layer created is designed larger on all side edges by at least one processing section than the base element and therefore projects beyond it, and that the following further steps are carried out:
  • ) Factory measurement of the fully cured prefabricated component against a factory reference to determine the manufacturing-related deviations of the measured values from the tolerance range specified by the factory reference for later assembly at the installation site and
  • ) Exact machining of the peripheral machining sections and the side surface of the lightweight layer facing away from the base element by removing material from the lightweight layer to the extent of the deviations from the tolerance range determined in the previous step. The method according to the invention is based on connecting the lightweight layer, which forms the thermal insulation, to the solid base element at the factory, but machining the lightweight layer on all sides with dimensional accuracy after the base element has hardened. The lightweight layer is designed to be one machining section larger than the basic element, so that only the lightweight layer has to be processed. Due to the thermal insulation thicknesses that are usual today, it is then also possible to use the machined end faces of the lightweight construction layers of the prefabricated components as installation and fitting surfaces for very precise assembly due to the machining accuracy. In order to keep the load on the lightweight construction layers low due to the weight of the solid basic element when erecting, the prefabricated components can be padded if necessary in the course of assembly in the area of the basic element. According to the invention, the lightweight construction layer is around at least one of the joint and tolerance areas corresponding processing section is designed to be larger than the basic element, so that the lightweight construction layer always represents the outermost dimension of the prefabricated component during processing. The thickness of the finished component is processed starting from the solid inside of the basic element. These measures ensure that both the external dimensions and the overall component thickness can be carried out precisely. The insulation material, which forms the lightweight construction layer, can be processed very easily and inexpensively at high speed.

Dabei ist es ein weiteres Merkmal der vorliegenden Erfindung, dass anschließend an den letzten Schritt des maßgenauen Bearbeitens der Leichtbauschichte an der vom Grundelement abgewandten Seitenfläche weitere Strukturierungen, wie Ziernuten, Gesimse oder dergleichen, in der Leichtbauschichte vorgesehen werden. Die Fassadengestaltung kann somit auch bereits ab Werk an der Leichtbauschichte vorgesehen werden, wobei etwaige 3D-Strukturen, wie Gesimse, Ziernuten oder andere Ausgestaltungen in das leicht zu bearbeitende Leichtbaumaterial eingearbeitet, beispielsweise eingefräst, werden können.It is a further feature of the present invention that subsequent to the last step of dimensionally accurate processing of the lightweight layer, further structuring, such as decorative grooves, cornices or the like, is provided in the lightweight layer on the side surface facing away from the base element. The façade design can thus also be provided ex works on the lightweight construction layer, with any 3D structures such as cornices, decorative grooves or other configurations being incorporated, for example milled, into the lightweight construction material, which is easy to process.

Ein zusätzliches Merkmal der vorliegenden Erfindung besteht darin, dass die Leichtbauteileinheiten an der im montierten Zustand dem Grundelement zugewandten Seitenflächen vor dem Zusammenfügen mit einer oberflächenvergrößernden Strukturierung, beispielsweise in Form von Erhöhungen und/oder Vertiefungen, versehen werden. Insbesondere bei einer Ausführungsform, in welcher die Leichtbauteileinheiten direkt in das noch nicht ausgehärtete Grundelement eingelegt werden, schafft eine Strukturierung beispielsweise in Form von Rippen bzw. Nuten eine bessere Haftung am Grundelement.An additional feature of the present invention is that the lightweight component units are provided with surface-enlarging structuring, for example in the form of elevations and/or depressions, on the side faces facing the base element in the assembled state before assembly. Particularly in an embodiment in which the lightweight component units are placed directly into the base element that has not yet hardened, structuring, for example in the form of ribs or grooves, creates better adhesion to the base element.

Es ist ein weiteres Merkmal des erfindungsgemäßen Verfahrens, dass in der Schalung für die aushärtbare Gießmasse zusätzliche Schalungselemente eingelegt werden, welche die späteren Ausnehmungen für beispielsweise Türen oder Fenster im Grundelement ausfüllen, und dass die Leichtbauschichte die Ränder der so geschaffenen Ausnehmungen in Richtung der Ausnehmungen hin ebenfalls um zumindest einen Bearbeitungsabschnitt überragt. Es können folglich bereits bei der Herstellung des Fertigbauteils Aussparungen für Fenster, Türen oder sonstige Öffnungen präzise und exakt zu den endgültigen Außenabmessungen hin bearbeitet werden, sodass auch der Einbau von Fenstern, Türen, Fensterbrettern, Rolllädenkästen, etc. ohne Justier- und Nacharbeit präzise erfolgen kann. Vorzugsweise werden beim Einbau an der Baustelle die bearbeiteten Flächen in den Ausnehmungen zur Positionierung von Einbauten (wie Fenster, Türen, Rollladensysteme, etc.) in unbelastetem Zustand verwendet, und ausgehend von dieser Lage eine Befestigung der zu montierenden Elemente am Grundelement der Fertigbauteile vorgenommen.Another feature of the method according to the invention is that additional formwork elements are inserted in the formwork for the hardenable casting compound, which formwork elements later fill in for doors or windows, for example, in the base element, and that the lightweight construction layer extends the edges of the recesses created in this way in the direction of the recesses also around surpasses at least one processing section. As a result, recesses for windows, doors or other openings can be machined precisely and precisely to the final external dimensions during the manufacture of the prefabricated component, so that the installation of windows, doors, window sills, roller shutter boxes, etc. can also be carried out precisely without adjustment and rework can. During installation at the construction site, the machined surfaces in the recesses are preferably used to position built-in components (such as windows, doors, roller shutter systems, etc.) in an unloaded state, and starting from this position, the elements to be assembled are fastened to the base element of the prefabricated components.

Gemäß einer möglichen Ausführungsform der Erfindung ist es ferner ein Merkmal des erfindungsgemäßen Verfahrens, dass die Leichtbauschichte zuerst mit den Verbindungselementen verbunden wird und anschließend die freien Enden der Verbindungselemente in das noch nicht vollständig ausgehärtete Grundelement eingedrückt werden, sodass zwischen Grundelement und Leichtbauschichte ein Spalt verbleibt, welcher später beim Errichten eines Gebäudes an einer Baustelle beispielsweise mit Ortbeton ausfüllbar ist. Auf diese Weise kann ein besonders leichtes Fertigbauteil geschaffen werden, welches beim Errichten des Gebäudes auf der Baustelle einerseits nahtlos und präzise ohne Nachbearbeitung zusammengefügt werden kann und andererseits als verlorene Schalung dient, wenn der entstandene Spalt mit Ortbeton ausgegossen wird.According to a possible embodiment of the invention, it is also a feature of the method according to the invention that the lightweight construction layer is first connected to the connecting elements and then the free ends of the connecting elements are pressed into the not yet fully cured base element, so that a gap remains between the base element and the lightweight construction layer, which can later be filled out with in-situ concrete when erecting a building at a construction site, for example. In this way, a particularly light prefabricated component can be created which, on the one hand, can be seamlessly and precisely assembled without post-processing when erecting the building on the construction site and, on the other hand, serves as permanent formwork when the resulting gap is filled with in-situ concrete.

Es ist ferner ein weiteres Merkmal der vorliegenden Erfindung, dass mit dem Grundelement weitere Einbauteile verbunden werden, welche über Passabschnitte verfügen, welche ebenfalls nach dem vollständigen Aushärten und Vermessen des Fertigbauteils bearbeitbar sind, um einen Toleranzausgleich gegenüber einer werkseitig vorhandenen Referenz herzustellen, und welche bei einem späteren Errichten eines Gebäudes an einer Baustelle als zusätzliche Justier- und Verbindungsstellen zwischen den Fertigbauteilen dienen. Derartige Einbauteile mit Passabschnitten sind beispielsweise in der EP 2601358 A1 beschrieben. Das Grundelement des Fertigbauteils kann dabei als Einzelwand oder auch als Doppelwand ausgebildet werden, zusätzlich zu den präzise passgenau bearbeiteten Bearbeitungsabschnitten der Leichtbauschichte werden in dieser Ausführung auch die Passabschnitte der Einbauteile, welche beispielsweise aus Kunststoff gefertigt sind nach der Fertigstellung des Fertigbauteils bearbeitet und etwaige Herstellungstoleranzen werden ab Werk gegenüber einer Referenz abgeglichen. Die Fertigbauteile können dann auf der Baustelle über die Passabschnitte als Justier- und Verbindungspunkte besonders schnell zusammengesetzt werden. Bei einer Ausgestaltung des Grundelements als Doppelwand, wird der Zwischenraum anschließend mittels Ortbeton ausgegossen.It is also a further feature of the present invention that further built-in parts are connected to the base element, which have fitting sections which can also be machined after the finished part has completely hardened and been measured in order to compensate for tolerances compared to a factory reference, and which at a later erection of a building at a construction site serve as additional adjustment and connection points between the prefabricated components. Such built-in parts with fitting sections are, for example, in EP 2601358 A1 described. The basic element of the prefabricated component can be a single wall or a double wall In addition to the precisely machined machining sections of the lightweight construction layer, in this embodiment the fitting sections of the built-in parts, which are made of plastic, for example, are machined after the finished part has been completed and any manufacturing tolerances are compared with a reference ex works. The prefabricated components can then be assembled particularly quickly on site using the fitting sections as adjustment and connection points. If the basic element is designed as a double wall, the intermediate space is then filled with in-situ concrete.

Schließlich ist es ein weiteres Merkmal der vorliegenden Erfindung, dass die bearbeiteten Stirnseiten der Leichtbauschichte abschließend mit Erhebungen oder Vertiefungen versehen werden, welche mit entsprechenden Erhebungen oder Vertiefungen benachbarter Fertigbauteile in Eingriff bringbar sind, wobei beispielsweise konusförmige oder längsgerichtete Erhebungen und Vertiefungen zur Ausbildung von Verzahnungen oder Nut-Feder-Verbindungen zwischen den Fertigbauteilen vorgesehen werden. Durch die Ausbildung von Nut- und Feder-Verbindungen oder anderwärtiger Verzahnungen zwischen den Fertigbauteilen kann die lagegenaue Positionierung der Einzelelemente untereinander im Zuge der Montage unterstützt und sichergestellt werden.Finally, it is another feature of the present invention that the machined end faces of the lightweight construction layer are finally provided with elevations or depressions, which can be brought into engagement with corresponding elevations or depressions of adjacent prefabricated components, for example conical or longitudinally directed elevations and depressions for the formation of teeth or Tongue and groove connections are provided between the prefabricated components. Through the formation of tongue and groove connections or other types of gearing between the prefabricated components, the precise positioning of the individual elements among one another can be supported and ensured during assembly.

Kurze Beschreibung der ZeichnungenBrief description of the drawings

Die Erfindung wird nun näher anhand der beiliegenden Figuren beschrieben, wobei

  • Fig. 1 eine schematische Schnittansicht durch eine mögliche Ausführungsform eines mittels des erfindungsgemäßen Verfahrens hergestellten Fertigbauteils zeigt,
  • Fig. 2 eine schematische Schnittansicht durch eine alternative Ausführungsform eines mittels des erfindungsgemäßen Verfahrens hergestellten Fertigbauteils zeigt und
  • Fig. 3 eine schematische Schnittansicht durch eine weitere mögliche Ausführungsform eines mittels des erfindungsgemäßen Verfahrens hergestellten Fertigbauteils zeigt.
The invention will now be described in more detail with reference to the accompanying figures, where
  • 1 shows a schematic sectional view through a possible embodiment of a prefabricated component produced by means of the method according to the invention,
  • 2 shows a schematic sectional view through an alternative embodiment of a prefabricated component produced by means of the method according to the invention and
  • 3 shows a schematic sectional view through a further possible embodiment of a prefabricated component produced by means of the method according to the invention.

Weg(e) zur Ausführung der ErfindungWay(s) for carrying out the invention

In Fig. 1 ist eine mögliche Ausführungsform eines nach dem erfindungsgemäßen Verfahren hergestellten Fertigbauteils 1 schematisch dargestellt. Die Größenverhältnisse entsprechen dabei nicht den realen Verhältnissen, sondern wurden für ein besseres Verständnis vergrößert dargestellt. Für das Fertigbauteil 1 wird gemäß dem erfindungsgemäßen Verfahren zuerst ein Grundelement 2 hergestellt, welches beispielsweise aus Beton in einer Schalung gegossen wird. In der Schalung befinden sich auch weitere Schalungselemente, welche eingesetzt werden, um die späteren Ausnehmungen 7 für beispielsweise Türen oder Fenster auszubilden. Nachdem das Grundelement 2 gegossen wurde und bevor es vollständig ausgehärtet ist, werden Leichtbauteileinheiten, beispielsweise Wärmedämmplatten in das noch weiche Grundelement 2 eingelegt und mit diesem durch das vollständige Aushärten des Grundelements 2 verbunden. Die Verbindung zwischen der entsprechenden Seitenfläche der Leichtbauteileinheiten und dem Grundelement kann verbessert werden, wenn die Leichtbauteileinheiten an der betreffenden Seitenfläche mit einer Strukturierung, beispielsweise in Form von Rippen und Nuten, versehen wird. Auch können unterschiedliche Arten von Verbindungselementen 3 zum Einsatz kommen, welche in das Grundelement eingedrückt werden und die Leichtbauteileinheiten teilweise oder ganz durchragen. Im linken Teil der Fig. 1 sind Verbindungselemente 3 dargestellt, welche die Leichtbauteileinheiten ganz durchragen, während auf der rechten Seite der Fig. 1 Verbindungselemente 3 dargestellt sind, welche im Inneren der Leichtbauteileinheiten enden. Die Leichtbauteileinheiten, werden dabei dicht an dicht verlegt, wobei je nach Ausgestaltung des Grundelements 2 die Leichtbauteileinheiten auch entsprechend zugeschnitten werden. Insgesamt ergeben die nunmehr dicht verlegten Leichtbauteileinheiten eine Leichtbauschichte 4, welche das gesamte Grundelement 2 bedeckt und alle Ränder des Grundelements 2 um zumindest einen Bearbeitungsabschnitt 5 überragt. Die Bearbeitungsabschnitte 5 werden sowohl an allen Stirnseiten 12, an der vom Grundelement 2 abgewandten Seitenfläche 6 und an den Seitenrändern 8 der Ausnehmungen 7 an der Leichtbauschichte 4 vorgesehen.In 1 a possible embodiment of a prefabricated component 1 produced by the method according to the invention is shown schematically. The proportions do not correspond to the real conditions, but have been enlarged for a better understanding. According to the method according to the invention, a base element 2 is first produced for the prefabricated component 1, which is cast, for example, from concrete in a formwork. There are also further formwork elements in the formwork, which are used in order to form the subsequent recesses 7 for doors or windows, for example. After the base element 2 has been cast and before it has completely hardened, lightweight component units, for example thermal insulation panels, are inserted into the still soft base element 2 and connected to it by the complete hardening of the base element 2 . The connection between the corresponding side surface of the lightweight component units and the base element can be improved if the lightweight component units are provided with a structure on the relevant side surface, for example in the form of ribs and grooves. Different types of connecting elements 3 can also be used, which are pressed into the base element and protrude partially or completely through the lightweight component units. In the left part of 1 are shown connecting elements 3, which protrude through the lightweight component units, while on the right side of the 1 Connecting elements 3 are shown, which end inside the lightweight component units. The lightweight component units are laid close together, with the lightweight component units also being cut to size depending on the design of the basic element 2 . Overall, the now densely laid lightweight component units result in a lightweight layer 4 which covers the entire base element 2 and protrudes beyond all edges of the base element 2 by at least one processing section 5 . The processing sections 5 are both on all end faces 12, facing away from the base element 2 Side surface 6 and provided on the side edges 8 of the recesses 7 on the lightweight layer 4.

Nach dem vollständigen Aushärten des Fertigbauteils 1 wird dieses gegenüber einem werkseitig vorhandenen Referenzwert vermessen und die Abweichungen des Fertigbauteils von einem gewünschten Toleranzbereich bestimmt. Herstellungsbedingt kommt es im Allgemeinen zu Abweichungen von 0,5 - 0,8 cm gegenüber dem vorgegeben Maß. An der Baustelle sollen jedoch im Bereich der Leichtbauschichte 4 gar keine Fugen verbleiben, sodass rund um das gesamte Gebäude eine durchgehende Wärmedämmschicht ausgebildet ist. Auch soll die nach außen weisende Seitenfläche 6 der Leichtbauschichte 4 über die gesamte Fläche eben ohne Stufen an den Nahtstellen verlaufen. Aus diesem Grund wird in einem nächsten Verfahrensschritt die Leichtbauschichte 4 des jeweiligen Fertigbauteils 1 aufgrund der zuvor vermessenen Abweichungen genau bearbeitet, wobei je nach Abweichung entsprechend Material von der Leichtbauschichte 4 an den Bearbeitungsabschnitten 5 abgetragen wird. Dadurch können jede Stirnseite, die Dicke des Fertigbauteils 1 und die Ausnehmungen 7 für Türen oder Fenster soweit maßgenau bearbeitet werden, dass die Fertigbauteile 1 auf der Baustelle ohne weitere Nachbearbeitung zusammengefügt werden können.After the finished component 1 has completely hardened, it is measured against a factory reference value and the deviations of the finished component from a desired tolerance range are determined. Due to the manufacturing process, there are generally deviations of 0.5 - 0.8 cm from the specified size. However, no joints should remain at the construction site in the area of the lightweight construction layer 4, so that a continuous thermal insulation layer is formed around the entire building. The side surface 6 of the lightweight construction layer 4 pointing outwards should also extend over the entire surface without steps at the seams. For this reason, in a next method step, the lightweight layer 4 of the respective prefabricated component 1 is precisely machined on the basis of the previously measured deviations, with material being removed from the lightweight layer 4 at the machining sections 5 depending on the deviation. As a result, each end face, the thickness of the prefabricated component 1 and the recesses 7 for doors or windows can be machined to the extent that the prefabricated components 1 can be assembled on site without further post-processing.

Anschließend an die maßgenaue Bearbeitung können die Fertigteile an der nach außen weisenden Seitenfläche 6 auch mit Strukturierungen 15, wie Ziernuten oder Gesimsen oder dergleichen versehen werden. Dies ermöglicht es auch komplizierte Außenfassaden bereits ab Werk durch die leicht zu bearbeitende Leichtbauschichte 4 weitgehend fertigzustellen, wonach bei der Endmontage auf der Baustelle nur mehr eine dünne Schicht Außenputz aufgebracht werden muss.Subsequent to the dimensionally accurate machining, the finished parts can also be provided with structuring 15, such as decorative grooves or cornices or the like, on the side surface 6 pointing outwards. This also makes it possible to largely complete complicated external facades ex works thanks to the easy-to-process lightweight layer 4, after which only a thin layer of external plaster has to be applied during final assembly on the construction site.

Bei den heute üblichen Dicken der Wärmedämmungen können zum Zwecke des Aufbaus des Gebäudes auf der Baustelle, die Fertigbauteile 1 auf der Leichtbauschichte 4 errichtet werden, wobei die massiven Grundelemente 2 je nach Notwendigkeit unterfüttert werden. Der Aufbau erfolgt somit im einfachsten Fall vollständig über die Stirnseiten 12 der Leichtbauschichte 4, welche zum einfacheren Justieren auf der Baustelle auch mit entsprechenden Nut-Feder Strukturen oder Erhebungen 13 und Vertiefungen 14 für eine Verzahnung versehen sein können. Anschließend an das passgenaue Errichten der Fertigbauteile können die massiven Grundelemente 2 miteinander verbunden und abgedichtet werden und das Gebäude ist sehr rasch und ohne großen Personalaufwand errichtet.With the thicknesses of thermal insulation that are usual today, the prefabricated components 1 can be erected on the lightweight construction layer 4 for the purpose of constructing the building on the construction site, with the solid basic elements 2 being lined as required. In the simplest case, the construction is therefore carried out completely via the end faces 12 of the lightweight construction layer 4, which is used for easier adjustment on the construction site can also be provided with corresponding tongue and groove structures or elevations 13 and depressions 14 for toothing. Subsequent to the custom-fit erection of the prefabricated components, the solid basic elements 2 can be connected to one another and sealed, and the building is erected very quickly and without a great deal of personnel.

In Fig. 2 ist eine weitere mögliche Ausführungsform dargestellt, bei der die Leichtbauschichte 4 über eine weitere Form von Verbindungselementen 3 mit dem Grundelement 2 verbunden ist. Dabei verbleibt ein Spalt 9 zwischen dem Grundelement 2 und der Leichtbauschichte 4. Das Errichten auf der Baustelle erfolgt, wie oben beschrieben über die Stirnseiten 12 der Leichtbauschichte 4. Anschließend werden die massiven Grundelemente 2 entsprechend abgedichtet und der Spalt 9 wird mit Ortbeton ausgefüllt. Das Fertigbauteil 1 dient in diesem Beispiel folglich als verlorene Schalung. Etwaige Ausnehmungen 7 für Fenster oder Türen, müssen vor dem Zuführen des Ortbetons selbstverständlich durch entsprechende Schalungselemente abgedichtet werden.In 2 a further possible embodiment is shown, in which the lightweight construction layer 4 is connected to the base element 2 via a further form of connecting elements 3 . A gap 9 remains between the base element 2 and the lightweight construction layer 4. Erection on the construction site takes place, as described above, via the end faces 12 of the lightweight construction layer 4. The solid base elements 2 are then sealed accordingly and the gap 9 is filled with in-situ concrete. In this example, the prefabricated component 1 consequently serves as permanent formwork. Any recesses 7 for windows or doors must of course be sealed by appropriate formwork elements before the in-situ concrete is added.

In Fig. 3 ist eine weitere Ausführungsform dargestellt, bei welcher das Grundelement 2 als Doppelwand ausgebildet ist. Mit dem Grundelement 2 sind neben der Leichtbauschichte 4 auch Einbauteile 10 verbunden, welche im gezeigten Beispiel als Abstandshalter zwischen den beiden Doppelwandplatten dienen. An den Einbauteilen 10 befinden sich bearbeitbare Passabschnitte 11, beispielsweise aus Kunststoff, welche nach einer Bearbeitung unter Verwendung der gleichen Referenz wie für die Bearbeitung der Leichtbauschichte, als Justier- und Verbindungspunkte bei der Errichtung des Gebäudes dienen. Das Fertigbauteil 1 wird hier ebenfalls gegenüber der Referenz für die gewünschten Toleranzen im Werk bereits vermessen und die Bearbeitungsabschnitte 5 der Leichtbauschichte 4 entsprechend bearbeitet. In der Fig. 3 ist durch die strichlierten Linien die Sollposition der Einbauteile 10 und Passabschnitte 11 dargestellt. Der Passabschnitt 11 wurde im gezeigten Beispiel derart bearbeitet, dass für die zukünftige Verbindung mit einem benachbarten Fertigbauteil 1 die Abweichung des Einbauteils 10 von der Sollposition ausgeglichen wird. Abweichungen des gesamten Grundelements 2 und der Leichtbauschichte 4 von der gewünschten endgültigen Position, beispielsweise betreffend die Gesamtbauteildicke oder die Fugenbreite werden durch Bearbeiten der Bearbeitungsabschnitte 5 an der Leichtbauschichte 4 ausgeglichen.In 3 a further embodiment is shown, in which the base element 2 is designed as a double wall. In addition to the lightweight construction layer 4, built-in parts 10 are also connected to the basic element 2, which in the example shown serve as spacers between the two double wall panels. On the built-in parts 10 there are machinable fitting sections 11, for example made of plastic, which after machining using the same reference as for the machining of the lightweight layer, serve as adjustment and connection points in the erection of the building. The finished component 1 is also already measured here in relation to the reference for the desired tolerances in the factory and the machining sections 5 of the lightweight construction layer 4 are machined accordingly. In the 3 the target position of the built-in parts 10 and fitting sections 11 is represented by the dashed lines. In the example shown, the fitting section 11 was processed in such a way that the deviation of the built-in part 10 from the desired position is compensated for in the future connection with an adjacent prefabricated component 1 . deviations of Entire basic element 2 and the lightweight layer 4 from the desired final position, for example regarding the total component thickness or the joint width are compensated for by editing the processing sections 5 on the lightweight layer 4.

Ein deutlicher Vorteil des erfindungsgemäßen Verfahrens besteht darin, dass alle notwendigen Bearbeitungen unter kontrollierten Werkstattbedingungen und weitgehend automatisierbar durchführbar sind, was die Herstellungskosten senkt. Beim Errichten des Gebäudes entfallen dann zeitaufwändige Arbeiten sowie die Notwendigkeit, entsprechende Fachkräfte beim Aufbau einzusetzen, wodurch die Kosten weiter gesenkt werden.A clear advantage of the method according to the invention is that all necessary processing can be carried out under controlled workshop conditions and can be largely automated, which reduces the production costs. When constructing the building, time-consuming work and the need for appropriate skilled workers are eliminated, which further reduces costs.

Claims (8)

  1. A method of producing a prefabricated component (1) for buildings comprising the following steps:
    - ) filling a curable casting material into a formwork for forming a substantially plate-shaped base element (2),
    - ) connecting the base element (2) to a plurality of lightweight component units such as thermal insulation panels, either by inserting the lightweight component units into the casting material not yet completely cured or by means of connecting elements (3) which connect the base element (2) and lightweight component units to one another,
    wherein the method is characterised by the following steps:
    - ) seamlessly lining up of the lightweight component units, whereby a plate-shaped lightweight construction layer (4) is created which projects beyond the base element (2) at all lateral edges by at least one machining section (5),
    - ) measuring at the factory of the finished cured prefabricated component (1) comprising the base element (2) and the lightweight construction layer (4) with respect to a reference provided at the factory for determining the production-related deviations of the measured values from a tolerance range predetermined by the factory reference for the subsequent assembly at the construction site, and
    - ) dimensionally accurate machining at the factory of the machining sections (5) at the edge as well as the side surface (6) of the lightweight construction layer (4) facing away from the base element (2) by removing material of the lightweight construction layer (4) to the extent of the deviations from the tolerance range determined in the previous step.
  2. The method according to claim 1, characterised in that the lightweight component units are cut to size accordingly before the step of joining together the plate-shaped lightweight construction layer (4).
  3. The method according to claim 1 or 2, characterised in that subsequent to the last step of the dimensionally accurate machining of the plate-shaped lightweight construction layer (4), on the side surface (6) facing away from the base element (2) further structuring (15) such as decorative grooves, cornices or the like is provided at the factory in the plate-shaped lightweight construction layer (4).
  4. The method according to any of claims 1 to 3, characterised in that the lightweight component units are provided on the side surfaces facing the base element (2) in the assembled state, before they are joined together, with a surface-enlarging structuring, for example in the form of elevations and/or depressions.
  5. The method according to any of claims 1 to 4, characterised in that in the formwork for the curable casting compound additional formwork elements are inserted, which fill the later recesses (7) for, for example, doors or windows in the base element (2), and in that the plate-shaped lightweight construction layer (4) projects beyond the edges (8) of the recesses (7) thus created in the direction of the recesses (7) by at least one machining section (5), too.
  6. The method according to any of claims 1 to 5, characterised in that the plate-shaped lightweight construction layer (4) is first connected to the connecting elements (3), and then the free ends of the connecting elements (3) are pushed into the base element (2) not yet cured completely, such that between the base element (2) and the plate-shaped lightweight construction layer (4) a gap (9) remains, which can be filled later during constructing a building at a construction site, for example with in-situ concrete.
  7. The method according to any of the claims 1 to 6, characterised in that further installation parts (10) are connected to the base element (2), which parts have fitting sections (11) which can also be machined after the complete curing and measuring at the factory of the prefabricated component (1) in order to make a tolerance compensation with respect to a predetermined reference, and which serve during a later construction of a building at a construction site as additional adjustment and connection points between the prefabricated components (1).
  8. The method according to any of the claims 1 to 6, characterised in that the machined end faces (12) of the plate-shaped lightweight construction layer (4) are finally provided with elevations (13) or depressions (14) which are engageable with corresponding elevations (13) or depressions (14) of adjacent prefabricated components (1) wherein, for example, conical or longitudinally directed elevations (13) and depressions (14) are provided for forming interlocking or tongue-and-groove connections between the prefabricated components (1).
EP17748761.8A 2016-08-04 2017-08-04 Method for producing prefabricated components for buildings Active EP3494264B1 (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
ATA50713/2016A AT518959B1 (en) 2016-08-04 2016-08-04 Process for the manufacture of prefabricated building components
PCT/EP2017/069766 WO2018024874A1 (en) 2016-08-04 2017-08-04 Method for producing prefabricated components for buildings

Publications (2)

Publication Number Publication Date
EP3494264A1 EP3494264A1 (en) 2019-06-12
EP3494264B1 true EP3494264B1 (en) 2022-09-14

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Application Number Title Priority Date Filing Date
EP17748761.8A Active EP3494264B1 (en) 2016-08-04 2017-08-04 Method for producing prefabricated components for buildings

Country Status (3)

Country Link
EP (1) EP3494264B1 (en)
AT (1) AT518959B1 (en)
WO (1) WO2018024874A1 (en)

Families Citing this family (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US11248383B2 (en) 2018-09-21 2022-02-15 Cooper E. Stewart Insulating concrete form apparatus

Family Cites Families (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4829733A (en) * 1987-12-31 1989-05-16 Thermomass Technology, Inc. Connecting rod mechanism for an insulated wall construction
FR2697858B1 (en) * 1992-11-10 1995-01-27 Alain Guenee Method for manufacturing a three-layer sandwich type construction panel and panel obtained by implementing this method.
US5519973A (en) * 1993-08-17 1996-05-28 H.K. Composites, Inc. Highly insulative connector rods and methods for their manufacture and use in highly insulated composite walls
FR2931494A1 (en) * 2008-05-22 2009-11-27 Spurgin Sarl INTEGRATED FORMWORK WALL
DE202009004195U1 (en) * 2009-03-25 2010-08-19 Kastner, Erich Reinforcement device for producing a prefabricated component
DE102011052736A1 (en) * 2011-08-16 2013-02-21 Fischerwerke Gmbh & Co. Kg Anchor for use with anchor assembly for anchoring layer of multilayered finished component for distance fixing with another layer of multilayered finished component, has anchor element moved for anchoring of layer to certain side

Also Published As

Publication number Publication date
AT518959A1 (en) 2018-02-15
WO2018024874A1 (en) 2018-02-08
AT518959B1 (en) 2018-12-15
EP3494264A1 (en) 2019-06-12

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