EP3563010B1

EP3563010B1 - The large-size prefabricated construction segment, the method of its production and the method of building a building with a prefabricated segmental construction

Info

Publication number: EP3563010B1
Application number: EP17842296.0A
Authority: EP
Inventors: Czeslaw MACHELSKI
Original assignee: Individual
Current assignee: Szymanski Jerzy
Priority date: 2017-01-02
Filing date: 2017-12-29
Publication date: 2022-05-04
Anticipated expiration: 2037-12-29
Also published as: WO2018128556A1; PL420089A1; EP3563010A1

Description

The invention relates to The large-size prefabricated construction segment, the method of its production and the method of building with a prefabricated segmental construction applicable both in residential, commercial and industrial construction.
The documents of the application US2016032594 discloses construction panels and a construction system using construction panels. The wall panel system comprises at least one panel, the claddings of which is made of durable materials based on cement or gypsum, involving a foam core. A channel is conducted through the core along the panel, which is provided for inserting a rod to reinforce the connection of adjacent panels
The application WO2015/042665 discloses construction panels - system components and methods. The modular construction panel for the implementation of walls comprises an internal foam core and a frame surrounding said core. The individual panels fit into C-shaped edges of the frame.
The documents of the application US2014/0053481 disclose a modular construction building with a continuous insulating layer comprising at least one wall panel element and at least one corner panel element. Each of the panel elements comprises at least two surfaces and at least two edges and a continuous and complete polyurethane insulation between the surfaces and edges. Each of the edges comprises an exposed portion of the polyurethane insulation, and the edge of at least one of the panel elements is formed so as to adhere to the edge of at least one corner element to form a joint. The invention also relates to a double joint, one overlapping perpendicularly formed as tongue and groove, comprising an anti-strain connector embedded in the polyurethane insulation.
The application US2016/0208489 discloses a large-size prefabricated construction segment according to the preamble of claim 1.
Known panels enable quick and energetically low-cost construction of buildings, however, they require appropriate framework or local reinforcements in places subject to the greatest loads with additional reinforcing elements.
The large-size prefabricated construction construction segment comprising

separated from each other by spacing inserts, an external cladding and an internal cladding, between which there is a polyurethane foam filling, preferably a closed cell PIR one in which cable and installation trays are preferably arranged, characterised in that the claddings are cement-and-fibre or gypsum-and-fibre boards whose edges along at least one side protrude beyond the outline of the filling. Along the remaining sides, the filling protrudes beyond the outline of the cladding. The spacing inserts are provided in the form of PVC tubes, which are pressed between mounting holes in the claddings.

Preferably, the cable and installation trays are fixed to the internal cladding from the side of the filling.
Preferably, the segment of the invention is provided with an engagement hole.
Preferably, in places where local effects occur, a reinforcement element is arranged, preferably in the form of a grid, a profile or a tape made of carbon or glass fibres at the claddings on the side of the filling.
The method for manufacturing a large-size prefabricated construction segment of the invention is characterised in that a formwork mould is formed having a shape in accordance with the requirements of the detailed design in which parallel mounting slots are provided. Next, mounting holes are made in the claddings, after which the claddings are arranged in the mounting slots so that they protrude by the width of the mounting lap connection above the side of the formwork mould on one side. Moreover, the claddings are made to protrude by the length of the assembly lap connection beyond said mould, and subsequently through spacing inserts are arranged between the claddings. Next, the formwork mould is filled with polyurethane foam, preferably closed cell PIR one.
Preferably, in places where local effects occur, a reinforcement element is arranged, preferably in the form of a grid, a profile or a tape made of carbon or glass fibres at the external cladding on the side of the filling.
Preferably, an engagement hole is additionally formed by means of a casing pipe arranged in the formwork mould.
Preferably, cable and installation trays are fixed to the internal cladding on the side of the filling.
The method for building a building having a segment structure consisting in joining said large-size prefabricated construction segments in the direction and sequence as specified in the assembly diagram, including internal partition wall modules, and then providing floors, internal joinery and installations is characterised in that in the foundation slab, along the external edges, parallel to the ridge of the building, foundation boards are made, between which endwalls are installed. Between the endwalls, side walls are successively provided alongside the boards, which are made from segments in accordance with the essence of the inventions referred to above. The individual segments are lap connected preferably using glue, after which the spaces between the side walls and the foundation board are filled with adhesive and sealing material, and then filled with polyurethane foam.
Preferably, respective segments made in accordance with the essence of the inventions referred to above, are first used to assemble internal transverse load-bearing walls, then middle segments of the external wall and of the ceiling in the middle part are assembled at the foundation boards. In multi-storey buildings, along with the assembly of load-bearing wall segments, ceiling segments are assembled, which preferably have an H-shaped cross-section. Next, segments of endwalls and partition walls of the ground floor are assembled, and then segments of the floor and roof walls are assembled.
Preferably a steel wire is provided in the engagement holes, which is anchored in the external walls of the building.
Preferably, windows are peripherally adhesively inserted in the face of the facade on the external side of the wall, and the internal surfaces of window holes are adhesively covered with properly cut cladding panels.
Preferably, the interior and exterior claddings are painted or covered with finishing materials.
The construction system according to the invention using large-size prefabricated multilayer construction segments joined by double-sided lap gluing, allows to combine structural, partition, insulation and finishing features. Buildings can be swiftly erected, adapted to individual requirements, while meeting both construction and safety requirements. Preferably, the segments can be modified and adapted to individual design solutions. It is possible to manufacture prefabricated elements with a finished façade surface.
Through spacing inserts in the segments have an additional assembly function: by inserting properly formed rods into the spacing holes, prefabricated elements can be transported, arranged and stabilised during construction.
The production process of prefabricated elements and their assembly significantly reduces the generation of waste, and also contributes to the reduction of energy consumption level (savings in terms of energy and materials in addition to the reduction of energy demand (during use).
The invention is presented in more detail in the embodiments in the drawing, where:

fig. 1 is a side view of a wall-and-roof prefabricated segment,
fig. 2 is a side axonometric view of a wall-and-roof segment,
fig. 3 is a front view of a wall-and-roof prefabricated segment,
fig. 4 is a side axonometric view of a wall-and-roof segment,
fig. 5 is vertical cross-section of a portion of a segment with spacing inserts,
fig. 6 a side axonometric view of a formwork mould for the wall-and-roof segment,
fig. 7 and fig. 8 schematically show a method for building a building made of prefabricated segments,
fig. 9 schematically shows a method for building a building with an attic made of prefabricated segments,
fig. 10 schematically shows a two-story building made of prefabricated segments in a vertical cross-section,
fig. 11 schematically shows a method for building a two-story building made of prefabricated segments in an axonometric view.

Example I

As shown in fig. 1, fig. 2, fig. 3, fig. 4 and fig. 5, the prefabricated construction segment for a segmented construction comprises claddings 3 of cement-and-fibre boards from the outside or gypsum-and-fibre boards from the inside and as a partition wall cladding. Between the claddings 3 there is a filling 6 made of PIR polyurethane foam. The edges of the cladding 3 along the two sides of the construction element protrude beyond the outline of the filling 6 by the width of the assembly lap connection. On the opposite side, the filling 6 protrudes beyond the contour of the cladding boards 3. Through spacing inserts 2 are pressed between the claddings 3 with their ends fixed between the mounting holes 3a. Cable and installation trays are glued 4 to the internal cladding 3 from the side of the filling 6. In the corners and on the contacts of the claddings 3, i.e. in places where local effects occur, reinforcing grids 5a, 5b are provided on the inside of the claddings 3.

Example II

In the ridge segment, as in the example 1, there is a through hole 7 provided.

Example III

As shown in fig. 4, fig. 5 and fig. 6, the method for producing a prefabricated construction segment consists in forming a formwork mould 1 according to the design specification for each segment type. Parallel mounting slots are provided 9 in the mould 1 from one end. Technological holes 1a are provided in the places in accordance with the design in the side boards of the formwork mould 1. mounting holes 3a are provided in the claddings 3. The claddings 3 may have factory-fmished external surfaces. Cable and installation trays 4 are glued to the interior cladding 3g from the side of the filling, and in places where local effects occur from the side of the filling 6 reinforcing grids are provided 5a, 5b made of materials such as GRP, GFK, CFK etc.. Claddings 3 with a width greater by the assembly lap connection than the height of the boards of the formwork mould 1 are placed in the mounting slots 9 and are made to protrude by the length of the assembly lap connection beyond said mould. PVC tubes 2 are pressed between the claddings 3, after which the formwork mould lis filled with PIR polyurethane foam through the technological holes 1b. Then, the mould 1 is closed and sealed, and after form stripping of the segment and safeguarding the protruding parts of the cladding 3, the segment is transported to the warehouse and subjected to the maturing process. After achieving the target strength parameters, the segment undergoes a quality control.

Example IV

The segment is made as in example II, wherein a casing tube is mounted at the ridge top parallel to the ridge to form a trough engagement hole 7.

Example V

As shown in figs. 7 to 11, foundation boards 11 are provided along the external walls of the building in the foundation slab 10. Between them, the first endwall or segments of the endwall are arranged, and then in succession towards the second endwall, parallel to the ridge, along the foundation board 1, span-and-segment side walls 12 are added adjusted to the cross-section of the building. Inside the building, known polyurethane foam segments 17 are arranged on the foundation slab 10 for the purposes of thermal insulation and stabilisation of the assembly of the wall segments. The walls 12 are made of prefabricated building segments, as in example I and example II, which are lap connected by means of glue. The spaces between the side walls 12 and the foundation tray 11 are filled with adhesive and sealing material and then filled with polyurethane foam. Then, the last segment wall is connected to the second endwall. A steel wire is pulled through the ridge engagement holes 7, which is anchored in the endwalls of the building.
In the face of the facade on the outside of the wall windows 23 are peripherally mounted, using specialist assembly and sealing foam 24, and the internal surfaces of window holes are glue-covered with fragments of properly cut cladding 3g. Gluing the boards into the internal surfaces of the window holes further stabilises the window assembly. The interior and exterior claddings 3 are painted or covered with finishing materials. At the production stage, it is possible to make segments with a finished external surface. The so-called dry screed made of cement-and-fibre or gypsum-and-fibre boards is glued onto the flooring prefabricates. Partition walls are made of segments made according to the invention, wherein they are characterised by a smaller thickness (by approx. 1/3 of that of the external walls), and gypsum-and-fibre boards, also waterproof, are used as the cladding. Segments of partition walls are assembled by gluing. The installation spaces at the interface between the external segments are filled with insulation and assembly foam, and then sealed with cladding boards.

Building a one-storey building

The following types of prefabricated segments are prepared:
side walls 12 with their forms in accordance with a detailed design including various forms, roof walls 13, endwalls 14, internal load-bearing walls 15, internal partition walls 16, floor segments 17 on the foundation slab.
The foundation slab 10 is made together with the boards along the side walls 11 for embedding the wall prefabricates 12. Then, the first endwall is mounted between the boards 11. Then, step by step, wall, roof and floor prefabricated elements are mounted towards the second endwall, partition walls and the second endwall are mounted. The individual segments are joined using glue. A steel wire is conducted through the engagement hole 7 in the ridge and anchored in the endwalls. PVC foil 20 is glued on the roof, gutters and downpipes 21 are mounted. Windows 22 is glued into the window holes, and the inner surfaces of the window holes are glue-covered with properly cut cladding panels 3g. The surfaces of walls and ceilings are finished, finishing works are implemented (floors, internal joinery, the so-called sanitary fixtures etc.)

Erecting a two-storey building

The following types of prefabricated segments are prepared in accordance with the detailed design: side walls 12 having various forms, endwalls 14, segments of roof 13, ceiling 18, H-shaped ceiling-and-wall 19, which enables additional reinforcing of the ceiling-wall joints, internal load-bearing 15, internal partition walls 16, floor segments 17 on the foundation slab, ridge segments 20. The foundation slab 10 is made together with the boards along the side walls 11 for embedding the wall segments 12. Transverse internal load-bearing walls, segments of external walls and ceiling segments are mounted in the middle part. Step by step, segments of wall, ceiling, ceiling-and-wall and floor segments are mounted towards the endwalls. Then, endwalls are mounted on the ground floor level, ground floor partition walls. Prefabricated walls, roof and dormers are mounted in the middle part. Step by step, segments of prefabricated walls and roof are mounted, endwalls at the floor level, floor partition walls, prefabricated ridges are mounted. The individual segments are joined using glue. A steel wire is conducted through the engagement holes 7 and anchored in the external endwalls and side walls. Subsequently, the procedure is identical as for one-story building.

Claims

A large-size prefabricated construction segment comprising - separated from each other by spacing inserts (2), an external cladding (3) and an internal cladding (3) parallel to each other, between which there is a polyurethane foam filling (6), preferably a closed cell PIR one, in which cable and installation trays are preferably arranged, whereby the claddings (3) are cement-and-fibre or gypsum- and-fibre boards whose edges along at least one side protrude beyond the outline of the filling (6), wherein the filling (6) is integrally connected with each of the claddings and protrudes beyond the outline of the claddings (3) along the other sides, characterized in that the spacing inserts (2) are provided in the form of PVC tubes, which are located perpendicularly to the claddings and pressed between mounting holes (3a) in the claddings (3).
The segment according to claim 1, characterised in that the cable and installation trays (4) are fixed to the internal cladding (3) from the side of the filling (6).
The segment according to claim 1, characterised in that it is provided with an engagement hole (7).
The segment according to claim 1 or 2 or 3, characterised in that in places where local effects occur, a reinforcement element (5) is arranged, preferably in the form of a grid, a profile or a tape made of carbon or glass fibres at the claddings (3) on the side of the filling (6).
A method for manufacturing a large-size prefabricated construction segment according to claim 1, consisting in placing two claddings (3) parallel to each other with spacing inserts (2) located between the claddings and filling the resulting space between the claddings with an insulation characterised in that a formwork mould (1) is formed having a shape in accordance with the detailed design requirements, in which parallel mounting slots (9) are provided, then mounting holes (3a) are provided in the claddings (3), after which the claddings (3) are arranged in the mounting slots (9) so that they protrude by the width of the assembly lap connection beyond the boards of the formwork mould (1) on one side, while on the other side the claddings (3) are made to protrude by the length of the assembly lap connection beyond said mould, after which spacing inserts (2) are fixed between the claddings (3), and then the formwork mould (1) is filled with polyurethane foam, preferably with closed cell PIR foam.
The method according to claim 5, characterised in that in places where local effects occur, a reinforcement element (5) is arranged, preferably in the form of a grid, a profile or a tape made of carbon or glass fibres at the external cladding (3) on the side of the filling (6).
The method according to claim 5 or 6, characterised in that an engagement hole (7) is additionally formed by means of a casing pipe arranged in the formwork mould (1).
The method according to claim 5 or 6 or 7, characterised in that the cable and installation trays (4) are fixed to the internal cladding (3) on the side of the filling (6).
A method for erecting a building with a segment structure consisting in joining large-size prefabricated construction segments according to claim 1 in the direction and sequence specified in an assembly diagram, including internal partition wall modules, and then providing floors, internal joinery and installations, characterised in that in a foundation slab (10), along the external edges, parallel to the ridge of the building, foundation boards (11) are made, between which endwalls are mounted, between which, along the foundation boards (11), side walls (12) are successively arranged made of segments according to any of the claims 1 to 4, wherein the individual segments are lap connected preferably using glue, after which the spaces between the side walls (12) and the foundation board (11) are filled with adhesive and sealing material and then filled with polyurethane foam.
The method according to claim 9, characterised in that respective segments according to any of the claims 1 to 4 are first used to assemble internal transverse load-bearing walls, then middle segments of the external wall and of the ceiling in the middle part are assembled at the foundation boards, wherein in multi-storey buildings, along with the assembly of load-bearing wall segments, ceiling segments are assembled, which preferably have an H- shaped cross-section, after which segments of endwalls and partition walls of the ground floor are assembled, and then segments of the floor and roof walls are assembled.
The method according to claim 9, characterised in that a steel wire is provided in the engagement holes (7), which is anchored in the external walls of the building.
The method according to claim 9 or 10 or 11, characterised in that windows (23) are peripherally adhesively inserted in the face of the facade on the external side of the wall, and the internal surfaces of window holes are adhesively covered with properly cut cladding panels (3g).
The method according to any of the claims 9 to 12, characterised in that the interior (3g) and exterior (3c) claddings are painted or covered with finishing materials.