FR2540539A1 - Constructional system using permanent formwork elements which are in particular insulating and reinforced - Google Patents

Abstract

The invention relates to a system of permanent formwork elements which are insulating and reinforced, for the construction of thermally insulated walls. The formwork panels 1, which can be of any size, are positioned upright on a base element. They are joined together by spacer ties 21 forming stiffening ladders A. Preferably installed in an alternate fashion, the stiffening ladder-panel assembly forms solid rigid formwork.

Description

Constructive system using reinforced insulated formworks
The present invention relates to the field of building and public works and more particularly the construction of insulated walled walls against cold or hot (housing, underground cellars, cold rooms, swimming pools etc ... non-exhaustive list).

- We know of similar devices: PL! Fig. 1
I) French Patent No. 2394645 - This device comprises formwork elements woody concrete, blown or light, lined with respect to the outer member, an insulating material that is slid into vertical stripes in the form of T, forming an integral part of the formwork element.The thickness ratio in some parts of this insulation is about 2 / 5th When the double wall formwork is in place, the thickness ratio of the Breton cast between the two The wall is about 5/12, the stirrup of the construction of these formwork elements is characterized by a set of 4 H-shaped elements welded on a crossbar.This device has the following drawbacks: l - I1 can s' apply only to a construction whose plans are adapted to the dimensions of the formwork, thus reducing a wide range of use.

2 - Nothing is planned for the insulating form of the ends of walls (tables etc ..) and in this place, a "heat leakage" is possible.

 3 - Since the thickness of the insulation is not uniform in value, because of the design of the formwork, the insulation coefficient varies according to the point considered.

 4 - The thickness ratio of cast poured concrete being about S / 12, to obtain the so-called "loi de asse" effect, it takes a huge amount of concrete in some places 5 - At minus dX between very thick, the concrete wall - thus has regular points, weak points 6 - The connecting stirrup is difficult to manufacture and has no less than 12 weld points per unit. Hence a high cost price.

II) Certificate of utility No. 2349707 - PL I fig. 2
- The formwork of the walls is obtained by superimposing and crossing "shuttering shuttering blocks", made of non-reinforced insulating material, and whose large diameter connections molded into the mass every 25 cm, serve as a stiffener.

The dimensions are very precise and are multiples of 12.5 cm. Wall end plugs slip into existing mortises at each connection.

) Benefits on what existed before
1- An ease of implementation.

 2- Pne fairly good casting behavior 3- An adaptation to architectural plans at 't, 5 c. tr-.

 4- No "heat leak" resulting in a very good insulation coefficient.

B) Disadvantages
1- The wall banché is "mité" by the connections in insulating material and this every 25 cm squared. In fire, the insulation will melt and show in the concrete wall, horizontal "ducts" of large diameter that may cause air calls and transmit fire between walls.

 2- The insulating blocks, by their forced position in the corners, cut in its continuity, a row on two, the concrete wall and that on 25 cm high, every two rows and on each side of the inner corner. The angle is then considerably weakened.

 3- The effect called "Law of Mass" is not obtained and between separation of contiguous housing, a cons-partition is necessary.

4- These blocks to bancher require complicated molds so expensive and more require a different mold for each wall thickness (12.5 cm, 25 cm, 35.5 cm)
5- bulky packaging makes the transport price of these blocks prohibitive, because the volume / weight ratio is enormous. For example, a pallet of 1.5 m3 weighs only 14 kg. The usage radius relative to the place of production is therefore necessarily reduced.

The present invention aims not only to retain the advantages of these devices, but to eliminate the disadvantages. indeed, it makes it possible to obtain
l - An ease of implementation.

 2 - Very good resistance to casting {the formwork elements being armed and interconnected by rigid and rectilinear tie rods).

 3 - An adaptation-to all architectural plans to 10 cm.

4 - 100% outdoor insulation - and more
5 - The pouring without a solution of continuity of the wall banché.

 6 - The casting without a solution of continuity of the angles of walls.

 7 - The so-called "Mass Act" effect, particularly as regards the soundproofing of contiguous flats.

 8 - The impossibility of fire to pass between walls.

 9 - The manufacture of simple molds.

10 - The use of the same mold whatever the thickness of the walls (only the spacers will be different and will correspond to the thicknesses of the walls required, the corner-angles being the same whatever the width of the walls)
11 - A low investment cost.

 12 - The palletization of the formwork sheets as well as spocia- lous parts under a small volume.

 13 - A reduced cost of transport given the absence of lost volume.

The means used to obtain these results are as follows and are represented in the accompanying drawings in which
- Figure 3 shows in plan, two formwork insulating plates, armed, positioned opposite.

 - Figure 4 shows an insulating formwork plate, armed, in perspective.

 - Figure 5 shows a wall tip seen in plan.

 - Figure 6 shows a scale of stiffening.

 - Figure 7 shows a corner bracket.

 FIG. 8 represents the upper orifice of stiffening tube.

 - Figure 9 shows a junction stiffening tube.

 - Figure 10 shows the lower tube stiffener orifice.

 - Figure 11 shows a longitudinal section of a pulling scale spreader stiffening.

 - Figure 12 shows a basic spacer scale in perspective.

 - Figure 13 shows an isolated wall cut isolated on floor slab.

 - Figure 14 shows a section of formwork lintels plate.

 - Figure 15 shows a plan view of the construction of an angle.

 - Figure 16 shows a perspective of the variant - vertically positioned stiffening scales.

 The shuttering plates (1), of insulating material, which can be armored (depending on the destination of the structure or the part of the structure, one of the walls of the formwork may consist of non-insulating plates made of various materials , capable of being reinforced or arranged in order to withstand the effects of the material poured between plates, which may bear on their edge assembling devices allowing their positioning on the various scales used in the same conditions as the insulating plates and on one of their face, comprising the finished coating or support of the desired finished coating), one of whose faces may comprise a finished coating or coating support, are made of materials of resistance appropriate to the nature of the cast material. This material preferably of high density, may be expanded polystyrene, extruded polystyrene foam, polyurethane foam, non-limiting enumeration. These plates (1) can be of any size.

The first row of plates (15 used can be positioned and erected on a base spacer (B) .The plates constituting the other rows are connected to the first row and the others by grouped spacers or spacer rods (21) forming a stiffening scale (A) without a solution of continuity along its length, variable according to the work or part of the structure to be built by a preferably alternating and alternating positioning, these stiffening scales (A) constitute a particularly effective connection of plates (1) between them, and make it possible to produce strong and homogeneous walls, even though they consist of separate elements.It is an important characteristic of the invention, even if the formwork, mounted at a floor height waiting casting, is subject to the wind, it resists.

 The plate reinforcement which comprises uncle is formed by a core or resistant zone (4) which can marry different profiles acting as stiffeners. This can be done in a plane of the thickness, by increasing the molecular density of the insulating material, or by the interposition of a solid or clear sheet or weft (eg plywood or compressed wood, hard plastic, fiberglass, wire mesh, welded mesh, synthetic fabrics etc ...). Vertical stiffeners (3) can be connected to this resistant core (4) or can be an integral part thereof. These may be tubes (3) or profiled, for example metal, molded plastics or fiberglass, through the formwork plate over its entire height.These stiffeners (3) can be assembled at their ends, or by modifying their end caps , obtained for example by mechanical pinching, or by the interposition of a junction (17-18 -19) of resistant material. They subject at this level the plates and all the elements constituting the basic scales (B), stiffening (A) and the ancillary parts such as angle squares (11). Thus is achieved the narrow, rigid and homogeneous connection of the entire formwork.

 The plates having no reinforcement may carry on their edge, an assembly device for positioning on the various scales used in the same conditions as the insulating plates, armed or not. This assembly device may comprise projections (13) hollow or notches exactly corresponding to those practiced symmetrically but inversely in the stringers of ladders (12 and 8). A similar assembly can also be made at the junctions between plates by interlocking adapted to the nature of the material used in the manufacture of these plates wood, compressed wood, gypsum tile, brick or other resistant material.

 The base spreader (B1 consists of a rigid ladder whose horizontal members (12) (the spars designate the sides of the ladder-shaped devices whose "bars" are the spreading rods) may be constituted by profiles of various shapes and types, the "wings" of which are interconnected by spreading rods (14) .These spacer rods (14) may carry perforation (27) or hollow allowing the fixing of the base spacer (B) by any known means (spaying, nailing, mortar coating, etc.) on the horizontal plane of use (base plate, floor slab, etc.). This scale (B) of variable length according to use may be made in long length compatible with its easy transport, stamped or folded, molded hard plastic or any other similar material eg (polyurethane foam reinforced or not with a synthetic fabric) It is cut length on site. The longitudinal members (12) of 1 base spacer (B) can for example be made by metal profiles or molded hard plastic, U-shaped reversed.Ce profiled may have on its upper horizontal surface projections (13) or hollow corresponding to those exiles both on the lower slice of the plates, device that allows the immobilization of the plates. The profile may also include a raised wing housed in a groove made in the lower edge of the plates.

When the joining pieces (17-18-19) between plates are used for their assembly, they also constitute projections, recesses or notches intended for their casing. The essential feature of the basic spacer is its rigidity and straight nature. Once positioned on the desired location, the wall alignment is perfect.

 The stiffening ladders (A) of rigid constitution are formed of longitudinal members 13) in profiles of various shapes and of various nature, interconnected by spreading rods (21) oriented vertically or not at or after the emushion, or at the molding. Each of these ladders, as basic spreader (B), manufactured in long length compatible with easy transport, is cut on the ship in lengths according to the use. They can be made of stamped or folded sheet metal, molded hard plastic or any other similar material (eg polyurethane foam with or without synthetic fabric). The longitudinal members (8) perforated (9) or not, or with or without male / male junction protrusions, drilled, serEesX welded or secured by any other known means, can be inserted into the male or female devices used, in an inverse manner, in the lower and upper slices of the formwork plates (I), or inner face (ie side cast material) such as for example the tips of vertical edgers (3). The spacer rods (21) connecting the longitudinal members (8) may comprise notches (22) intended for the possible positioning of reinforcement bars for reinforcement of the hip wall. The stiffening ladders (A) thus realize, as the basic retractor (B) at each row of plates, a rigid and rectilinear arrangement which is, again, the essential characteristic of this formwork process.

 To ensure the perfect assembly of plates <1) - advantage for perfect insulation - the shuttering plates may have on their upper or lower edge, a burr (15) in the material, insulating or not, of dimension adapted to the constituent elements ladders and or their accessories. Thus, a complete embedding of the ladders in the constituent material of the shuttering plates is realized.

 If the profile used to make the ladder rails has a lower or lateral vertical wing, or if the fold at 900 of a side member is required, a groove (5) of the appropriate size is used for its housing, in the upper edge of the plate or the inner side side cast material.

 The inner side - material side sinks - plates, can be grooved (2) vertically to ensure the positioning, in the necessary locations, endings (6) wall, and or raidisseh.ent scales (A).

 The outer face, as opposed to the previous one - insulating plates (1) may include a relief (16) molded in the mass, allowing the "hooking" of the desired coating.

 The wall ends (6) of variable profile can carry on their side edge of the tenons (7) corresponding to the grooves (2) of the inner faces - side cast material - shuttering plates. These tips (6) are slid vertically in these grooves (2) or can be nested by a device of inverted profiles. On their lower and upper edges, the end caps may include reliefs and recesses for nesting. On their outer face, opposite to that in contact with the cast material - they may comprise, besides a molded relief (16) in the mass, identical to that of the formwork plates, a special profile for the establishment of pre-framing or fastening device for various frames, closures etc ...

 The lintel formwork plates (C) are made of the same insulating material as the other formwork sheets. They can be armed with the base spacer (B) positioned in the insulating material (10) so that the longitudinal members (12) comprising the assembly device of the shuttering plates, level the surface of the insulation (10) on the face intended to be in contact with the cast material. On this face can be arranged a burr (28) in the insulator, revealing under the spreading rods (19) a recess allowing the passage of a connecting means, or with the stiffening scale used for the establishment upper formwork plates, either with the rebar reinforcement of the lintel, or with the stiffening ladder of the upper row of the shuttering plates.This connecting means is constituted by any other known means, such as wire son , various hooks, fasteners etc ...

 The end caps (6) and lintel formwork plates (C) - and their armatures, spacers, stiffening scales implemented in their constitution - have variable dimensions, established depending on the thickness of the walls.

 The angle brackets (11) for connecting, in their corners, the walls of shuttering plates (1) at the level of the stiffening ladders (A) are made of resistant material of various kinds, such as stamped or folded sheet metal molded hard plastic, fiberglass, etc ... For reasons of economy, they can be made in the material used for the manufacture of stiffening scales, by possible use of falls.

They may be perforated (9) or comprise male / male junction protrusions, molded, crimped welded or secured by any other known means. These junctions can be engaged in male or female devices performed in an inverse manner in the lower and upper edge of the shuttering plates such as for example the ends 24-25) of the vertical stiffeners (3).

These angle brackets can be independent. But they can also, to give even more rigidity to the angle, be assembled two by two by any known means. They can also be replaced by a piece of stiffening scale forming an angle at 900.

 It is recommended in most cases; to facilitate the implementation of the method described, to cast the material used for the construction of walls, midway up the first row of formwork plates.

 A variant of the method described resides in the position of the stiffening ladders and their subjection to the shuttering plates. The stiffening ladders, positioned vertically from the base course (FIG. 16), and no longer horizontally, comprise sections fitting into vertical grooves or vertical reliefs, arranged in the face of the cast material, or projecting from shuttering plates. These vertical grooves or relief may be an integral part of the frame that can be incorporated into the formwork plates. The latter, superimposed or crossed, may include hollows or reliefs permitting a perfect interlocking. They are thus linked together by scaling height scales compatible - with easy implementation.

 The described method - type or variant - allows 1 - easy construction and a particularly effective connection of the walls of the partition and any partition.

2 - any cutting of the formwork wall such as pignonslarases floors, various reservations etc ... cut easily made using any known sawing means adapted to the materials used. Thus is avoided the often delicate establishment of particular forms, a high cost.

 The invention described is a definite progress, in all respects, compared to conventional forms of formwork and insulation currently existing.

 By a simple "construction game", in a single operation - where multiple interventions of different trades were necessary the invention allows an easy, fast, economic and high quality construction of walls of any kind.

By way of non-limiting example, an embodiment of the invention will be described here.
- On the perfectly horizontal arase (25), a foundation or floor slab (26), is positioned e nailing them to the setting of previously drawn walls, the base spacers (B) in such stamped 15 / 10th of mm and whose spacing measured at the axis of the longitudinal members (12) is 20 cm.Ces longitudinal members (12) inverted U-shaped whose sides have 1 cm and the bottom 2 cm, are connected by tie rods (14) of 2 cm wide and spaced 30 cm, pierced with holes (27) of 0.5 cm to allow nailing on the foundation or the slab of planher- The spars (12) are bristling with stubborn (13) tapered 1 cm high and whose base has an outer diameter of 0.08 cm - On this base spacer (B) are embedded the first row of plates (1) of insulating material and armed, 4 cm thick, 30 cm of height and 100 cm of length.These plates (1) comprise
a) on their upper face and in their middle, a burr (15) 0.02 cm thick and 0.25 cm wide, turning 90 towards the inner face in the axis of the tubes (3) whose internal diameter is 0,10 cm, incorporated vertically and longitudinally before molding in the plate and in its middle, and positioned respectively the 1 to 2 cm of one end of the plate (1) the 2nd to 8 cm further , the 3rd, 4th, 5th, 6th, 7th, 8th, 9th, 10th 10 cm apart, the 11th to 8 cm of the 10th.These tubes are leveled at the lower level of the smashed (15) - Against these tubes (3) one has, on the internal side of the plate (1), a fine mesh (4) of 1 cm2 - A groove (5) of 0.14 cm thick and 0.10 cm deep is positioned at 1 cm of the axis of the tubes (3) on the outside face of the plate (1) and this throughout the length of the plate. This groove (5) allows the embedding of the 1 cm back folded at 900 of the spars (8) of the spacer (A)
b) on the inner face of the plates (1) vertical grooves (2), slightly conical to allow demolding, 1 cm deep and 2 cm wide, positioned in the axis between two tubes (3) vertical , except at the ends of the plates (1) where the axis of the groove is at 5 cm from the end of the plates.These grooves (2) make it possible to position their inserts (6), whose external face, with their lugs (7). may itself be coated with a molded relief (16) of the same material as the tip, with 2 cm2 mesh projecting 0.2 cm for hanging the coating - The tip (6) has 7 cm d thickness, 16 cm wide (excluding studs) and 30 cm high.

 c) on the underside of the plates (1) the tubes (3) are leveled.

 - d) on the outer face of the plate is molded the same relief (16) as that mentioned above.

 The first row of plates being thus laid, it is poured at half height with concrete, then is incorporated in the top hole (24) tubes (3) junctions (17) of hard plastic, a slightly smaller diameter. at the internal dianeter of the tubes (3) so that this junction (17) is slightly forced in, a rim (18) having a diameter equal to the outer diameter of the tubes (3) and having a thickness of 0.2 cm thickness of the broken (15) -sert base cone (19) whose diameter of its base to 1 cm outside and 5 cm high.

 These gonctons (17) being positioned in the upper orifices (24) of the tubes (39), the spacers (A) are placed in. These spacers (A) are made of pressed sheet metal 5 / 10th of a millimeter thick, of which the axes of the spars (8) are 20 cm apart (for a 16 cm concrete wall) Their length is 200 cm.

These spars (8) whose developed width is 3 cm are folded on the outside 900 to 1 cm wide, and have every 10 cm on their outer side, a square of 2 cm sides (20) starting point a tie rod (21) 2 cm wide and fretted at the time of stamping in the vertical direction.

 On these vertical tie rods (21) spaced from each other by 10 cm, are positioned notches (22) V 1.5 cm side 4.5 cm longitudinal axes of the longitudinal members (8). These notches (22) make it possible to lay concrete reinforcing bars 6, 8, 10, 12, 14, 16mm in diameter to obtain a walled wall acting as a support.

 On these two side members (8) and in the middle thereof, in the axis of each tie rod (21) is drilled a hole <o) of 16 mm in diameter. On either side of the axis of this hole, two identical holes (9) are drilled whose axes are 2 cm from the axis of the central hole.

 When one has embedded this spacer (A) in the cones (19) of the junctions (17), it encases the new plate (1) over and so on, we mount the shuttering of the walls.

 To stiffen and bind the angles, we position the angle brackets (11).

In 15 / 10th of a mm stamped head, these brackets (can be cut at the same time as the stamping of the base spacers (B) in the sheet "falls" recovered between two tie rods (14). 12 cm, with a large outer side of 14 cm, they are 2 cm wide, with holes (9) identical to those located on the longitudinal members (8) of the stiffening ladders (A) and whose axes of these holes (9 ) are spaced 4 cm apart, except at the ends (23) of the brackets (11) where the axes of the first holes are 1 cm from these ends.

 For the concrete lintel formwork, an insulating plate (C) 6 cm thick, 24 cm wide and 200 cm long, is armed with the basic spacer (B) which only the nipples (13). ) protrude from the insulating material (10) in the upper part. The lower face of this plate (C) is coated with the same relief (16) of insulating material for accorching the coating.

 All the preceding provisions make it possible to form at one time the walls of walls of a building with high thermal insulation and to pour it to the concrete pump in a record time.

 The tubes and various technical ducts (electricity - telephone sanitary plumbing etc ...) can be installed before pouring the concrete.

Only then remain to perform the siding or external coatings, the inner ones that can already be part of the inner plates of formwork

Claims (8)

 1) Lost formwork device for slab walls, characterized in that it comprises insulating shuttering plates (1) or not, reinforced  (3-4) or not, interconnected by base spacers (B) of the horizontally and vertically positioned stiffening ladders (A), connecting brackets (11) or angle stiffening ladders, junctions ( 17-18-19) or assembly devices, wall ends, (6) insulators, lintel shuttering plates (C) reinforced and insulating constituting a "set of construction" rigid and homogeneous, allowing the construction of thermally wrapped banched walls.  2) plate reinforcing device (I) characterized in that it consists of a core or resistant zone (4) which can marry different profiles playing the role of stiffener, achieved either by the augamn tation of molecular density of the insulating material in a plane of the thickness, either through a feuilie or trame full or clear path, connected to vertical stiffeners (3) or by playing the role by a special profile.  3) Device according to claim 1, characterized in that the base spacer (B), the stiffening scales (A) whose longitudinal members are connected by spacer rods forming rigid and rectilinear assembly elements, positioned in the horizontal or vertical directions.  4) Device according to any one of the preceding claims, characterized in that the base spacer (B), the stiffening ladders (A), the corner brackets (11) can be made of various materials (metal, hard plastic) but also expanded or extruded polystyrene foam, or polyurethane reinforced with all known materials.  5) Device according to claim 1 characterized in that  the inner faces (side cast material) and slices of the plates  shuttering (1-C) or end caps (6) may have grooves,  cés or reliefs allowing a perfect assembly despite the interposition  between the shuttering plates, intermediate connecting pieces,  (stiffening scales - junctions) thus ensuring insulation  without a solution of continuity.  6) -Dispositif according to claim 1 characterized in that the lintel formwork plate (C) is armed with the base spacer ().  7) Device according to claim 1 characterized in that the spreading rods (21) of the stiffening scales, comprise notches (22) for positioning of reinforcing bars of different diameters, so that these reinforcing bars are always found at the same distance from the outer faces of the wall of the wall.  8) Device according to claim 1 characterized in that the configuration of the ends of the vertical stiffeners can, via junction pieces or not, the subjection of the plates together with the stiffening scales, in case they are positioned horizontally.