FR2575503A1 - Method for building constructions, and constructions created by its implementation - Google Patents

Abstract

The invention relates to the construction of buildings. It relates to a method according to which a frame of a metal framework is embedded in concrete, but fixing members 14 protrude from the upper face of the frame and thus from the composite base 18 and enable a metal framing 22 to be mounted. The walls are then built by spraying concrete onto formwork sheets interacting directly and fixed to the framing. Application to the construction of residences.

Description

 The present invention relates to a method of manufacturing constructions, in particular dwellings, as well as the constructions produced by its implementation.

 Numerous construction techniques are already known, and those which most closely resemble the technique according to the invention are, on the one hand, conventional construction in masonry and, on the other hand, construction in metal frame.

 The masonry construction process is the most used for the realization of dwellings. It is not described in detail because it is well known. It should however be noted that this technique has a certain number of drawbacks which are in particular its cost, because of the large workforce which is necessary, the long duration of realization of the construction, and the fact that the construction carried out n is not rigid, especially in the event of an earthquake or landslide, unless it is made almost entirely of reinforced concrete.

 The other aforementioned technique uses a metal frame which generally delimits walls and a roof. The structure made by mounting metal elements must be fixed to the ground. In general, it is anchored by its corners. In some embodiments, it is placed and then fixed on a slab formed of concrete. This construction has the advantage of being very rigid and able to be established in a short time.

However, it has drawbacks because the structure obtained is much lighter than a conventional masonry construction. The openings between the structural elements must be closed by elements which must be suitable for cooperation with a metal framework. For example, spaces between posts can be closed by walls formed of conventional masonry.

Closing these spaces for the delimitation of a closed volume presents difficulties given the difference between the materials used. The constructions carried out generally have poor thermal insulation, because the metal frame elements facilitate the heat exchanges between the interior and the exterior of the construction carried out. In fact, because of these drawbacks, this construction technique is very little used for dwellings.

The invention relates to a construction method which combines the advantages of good insulation of conventional masonry constructions and the advantages of rigidity and low assembly time of steel-frame constructions, while allowing construction to be carried out at costs much lower than those of classical constructions
More specifically, the invention relates to a combination of the advantages of prefabrication in the workshop (for the production of the metal framework) with those of conventional construction (insulation with concrete and special materials), in particular through the use of a modern technique of spraying concrete or mortar.

More specifically, the invention relates to a method of manufacturing constructions which comprises
- the production, in separate elements, of a metal frame comprising a support frame intended to be arranged horizontally, and a framework,
- the preparation of a horizontal base, of dimensions at least equal to those of the frame,
- the arrangement of the frame on the seat,
- casting. mortar or concrete on the base and around at least part of the. frame so that the frame and the mortar or concrete, after setting, form a rigid and heavy base in one piece,
- mounting the framework on the frame secured to the base, and
- the finish of the construction.

 Thus, according to a characteristic of the invention, the mortar or concrete of the base is poured after the installation of the frame mounted on the seat but before the assembly of the rest of the framework.

 According to an advantageous characteristic of the invention, the framework comprises posts, a chaining frame intended to be placed at a certain distance above the base, for example at the level of the floor of a floor, and trusses. In a variant, the framework may only include trusses, for example in the form of a semicircle or a semi-parabola, when the construction carried out must be in the form of a tunnel.

 It is advantageous that the seat is simply formed of a bed of stones simply having sufficient strength so that the weight of the construction, distributed by the base, does not cause it to collapse. However, the seat can also be formed of a real slab if necessary.

 It is advantageous if the frame is mounted directly on the seat using elements prepared in the workshop. However, the frame can also be mounted separately and then placed on the seat, especially in the case of constructions of relatively moderate size.

 -It is desirable that the frame comprises, before the pouring of the mortar or concrete, devices for fixing the framework.

 It is desirable that the mortar or concrete poured up to the upper face of the frame or slightly above it, cover the entire base. However, when the spaces delimited by the frame are large, the mortar or concrete may be poured only around the irons of the frame, free spaces remaining in the parts without iron.

In this case, these free spaces can then be filled at least in part with stones or other materials and are finally covered with a thin layer of mortar or concrete. The assembly obtained in any case forms a heavy and rigid base to which the frame can be directly attached.

 The frame has posts or trusses delimiting spaces, when it has been mounted on the base. These spaces are advantageously closed according to the invention by a cooperating formwork sheet disposed in a substantially vertical direction; concrete or mortar is then sprayed onto the cooperating formwork so that one face of this cooperating formwork and at least part of the framework are coated in the mortar or shotcrete These openings can be delimited entirely by the structure or by that -this in combination with frames fixed to the frame and intended to delimit the openings made in the construction.

 It is desirable that, before projection of the mortar or concrete, the method comprises the fixing of a mesh on the cooperating formwork or the framework, so that the holding of the mortar or concrete on vertical or substantially vertical surfaces is facilitated.

 It is advantageous that. leaf. of coo beading formwork is a sheet of a ferrous metal preferably having asperities, for example formed by undulations of the sheet.

 We already know the use of such formwork sheets cooperating for the production of floors, known methods comprising the support by scaffolding of a horizontal formwork sheet cooperating and then pouring concrete. The invention differs from this process in that the cooperating formwork sheet is placed vertically and is practically not supported over its entire extent, the concrete or mortar being sprayed successively over the entire surface and not exerting very high pressure. high.

Only a mortar or concrete spraying technique allows the use of such. cooperating formwork sheet supported almost only at its edges since the use of a recoverable frying cof for the realization of the other face of a wall would require the support of the cooperating formwork sheet over its entire extent. Although the invention also relates to such a method, the use of the projection technique greatly reduces the time necessary for the realization of the walls.

 The invention also relates to a construction carried out by implementing the method of the invention.

More specifically, it relates to a construction of the type which comprises elements of metal framework and mortar or concrete, the construction comprising in particular a base comprising a metal frame embedded in mortar or concrete and walls comprising a metal framework fixed to the frame of the base.

 Preferably, this construction has walls comprising mortar or concrete partially coating one.

structure formed by the framework and a cooperating formwork fi xed to the framework, the mortar or concrete possibly containing a mesh.

 The construction thus carried out can be supplemented by finishing operations, such as the incorporation of insulation sheets, the production of interior partitions, etc.

Other characteristics and advantages of the invention will emerge more clearly from the detailed description which follows, given with reference to the appended drawings in which
Figure 1 is a perspective showing a frame of metal frame, placed on a seat, at the beginning of the implementation of the method according to the invention
Figure 2 shows the frame of Figure 1 after its coating in mortar or concrete, during a next step of the method of the invention
Figure 3 is a perspective illustrating the next step of the construction method according to the invention, that is to say the mounting of a metal frame on the base made
Figure 4 is a section of part of the ground of a finished constructipn made according to the invention; and
Figure 5 is a section of a wall made by the method according to the invention.

 Figure 1 is a perspective which shows a base 10 of rubble on which is placed a frame 12 of a metal frame. The seat 10 must have dimensions at least equal to those of the frame 12, and it is preferable that it protrude outside the frame sufficiently so that the stresses exerted on the seat later cannot be excessive on one edge. construction. Although a seat formed of stones has been shown, any relatively compact, well horizontal soil is suitable for the construction of the invention.

 It is noted in FIG. 1 that the upper face of the frame 12 comprises fixing members 14, for example in the form of screwed or welded brackets - or simply in the form of holes, intended to allow the subsequent fixing of the framework. According to an advantageous characteristic of the invention, construction can be carried out easily with an attitude determined with precision.

Indeed, the whole of the metal frame, produced in the workshop, has excellent rigidity and perpendicularity properties. When the frame 12 has been placed well horizontally on the seat 10, for example by wedging as shown by way of illustration by reference 16, the entire construction is disposed well horizontally and vertically.

 The frame 12 shown in Figure 1 may have been removed directly, for example by a crane, but it may also have been mounted directly on site, from separate elements prepared in the workshop.

 Once the frame is placed horizontally on the seat as shown in Figure 1, mortar or preferably concrete is poured around the frame irons, as shown in Figure 2. The assembly formed by the frame and the concrete then constitutes a base 18.

 It should be noted that the concrete is poured so that it coats as much as possible all the metallic elements, except on the upper face where the fixing members 14 remain accessible for the subsequent mounting of the framework.

 Concrete can be poured over the entire surface of the frame or, alternatively, it can be poured only around the metal elements, as shown in FIG. 2. There therefore remain spaces 20 not containing concrete.

This realization allows an additional saving because these spaces can then be simply filled with rubble, possibly covered with a thin layer of concrete.

 At this stage of construction, when the concrete has set, the base 18 is arranged well horizontally and already has a significant weight which ensures the stability of the construction-outskirts.

 FIG. 3 represents the next phase of the method according to the invention, in which a framework 22 has been mounted on the base, more precisely on the fixing members 14 This framework of conventional type comprises for example corner posts 24, posts intermediaries 26, trusses 28, ridge 30, etc.

Only the end trusses have been shown, but of course a roof usually has more of them.

 The state of the construction shown in FIG. 3 corresponds to the essential characteristic of the invention, the construction being able to be completed for example in a conventional manner. We can better understand, in Figure 4, how the construction shown in Figure 3 is made. More specifically, in Figure 4 the reference 10 designates the seat on which the caJ-re is arranged, an intermediate iron of which is I by preference 12. The base is formed by pouring concrete 32 around the bars and it is noted that the upper face of the concrete arrives at the level of the upper face of the iron, lorisol 14 for fixing, a bracket in the case shown, protruding above the base. There is shown an inner post fix8 to this member 14, purely for illustrative purposes.

 It is also noted in FIG. 4 that, as shown in FIGS. 2 and 3, spaces have been made in the free spaces of the frame and have then been filled with gravel 34 and then with a thin layer 36 of concrete.

The floor was then produced by a conventional finish comprising the installation of insulation 38, the provision of slabs 40, themselves covered with concrete. then laying a floor covering 42.

 We note on there figure 4 that the iron of the frame is surrounded by concrete and that the whole forms a rigid structure.

 According to a very advantageous characteristic of the invention, walls are produced on the framework 22 by spraying concrete. Construction however normally includes, before the walls are made, the installation of frames which delimit the openings (doors, windows, etc.) by fixing to the framework. -Fastening bodies 14 may also have been provided for fixing these chassis. Then, the framework, comprising these frames is used for the production of the walls by spraying concrete or mortar onto a cooperating formwork.

 Figure 5 shows how these walls are made.

 In Figure 5 which is a section through a horizontal plane, the reference 44 designates a cooperating formwork sheet fixed at 48 on an intermediate post 46. The cooperating formwork sheet is advantageously a sheet of corrugated ferrous metal, preferably a sheet whose corrugations have a specially formed profile so that the concrete clings easily to it. Such cooperating formwork sheets are already known for forming pianchers. However, contrary to the usual practice, these shuttering sheets 44 are placed vertically in the implementation of the invention. The fixing of the sheet 44 on the post 46 can be carried out in any convenient manner, for example by localized welding, by screwing, by stapling, etc.

 Then, a grid, preferably having meshes of a few centimeters, is disposed in front of the sheet 44 of cooperating formwork and this grid 50 is fixed at 52 to the sheet 44, by any suitable method.

For example, stapling is suitable since the connection between the mesh and the sheet 44 does not have to undergo significant effort.

 Then, concrete or mortar is sprayed from outside the construction to the formwork sheet 44. The technique of spraying concrete, which is relatively uncommon, allows the application in a reliable and regular manner of a layer of concrete a few centimeters thick, to the cpntact of the sheet 44 of cof -frage cooperating and all around the mesh 50. The exterior finish may be that which is usually obtained with concrete, that is to say that it may be relatively.

smooth or very rough.

 After setting the concrete, the structure produced is integral with the frame but is also integral with the base since the walls are formed from the ground, that is to say from the base.

 It is noted in FIG. 5 that there remains, over the entire length of the post 46, a space which can advantageously be filled with a thick plate 56 of insulation, advantageously formed from a foam of plastic material, having for example one side coated with aluminum foil.

Then, during the finishing of the construction, an interior partition or a facing face 58 can be formed inside the dwelling, for example in the form of a brick wall, plaster tiles, etc.

 Note that the concrete spraying technique described with reference to FIG. 5, can be implemented on all of the walls of the construction, all around it and practically without interruption, so that the walls form, Throughout the thickness of the concrete, a one-piece structure that cracks.

In addition, this risk is further reduced given the rigidity given by the metal frame.

 The construction carried out according to the invention combines the advantages of the high rigidity, dimensional precision and speed of assembly of the metal frame construction, with the advantages of weight and insulation of conventional constructions based on mineral binders.

Thus, the construction carried out is relatively heavy and does not risk being carried away, even in the most severe hurricanes. In addition, it has a very high rigidity so that, even in the event of an earthquake, it is not likely to collapse. In the event of a landslide (insufficiently stable seat), it simply moves, without cracking or collapsing. It is therefore particularly suitable for regions in which natural cataclysms such as hurricanes and earthquakes are to be feared.

 As the metal frame is prefabricated in the workshop, the dimensional precision obtained is very high, and the assembly of the frame and the framework is very fast. Given the speed of application of concrete by spraying, a construction can be carried out in a time three to four times less than that which is necessary for a construction of equivalent size by a conventional process, while the external and internal aspect of a completed construction is exactly the same as that of a -conventional construction since all the elements of the metal frame are advantageously enclosed preferably in concrete which protects them against rust.

 As prefabrication only concerns the steel structure, it does not constitute a significant financial burden, as in the case of the prefabrication of concrete elements (expensive molds, rigidity of the models, etc.). Indeed, the metal frame can be adapted to each particular case, possibly to specific forms of a single construction (rounded, etc.).

 All the advantages indicated for the construction according to the invention ultimately allow a very significant reduction in the cost of construction, especially because the manpower necessary for its realization is considerably reduced compared to the conventional technique.

Thus, the constructions produced according to the invention not only have very clear advantages compared to conventional constructions, but their cost is also significantly reduced.

Claims (10)

 1. Method for manufacturing constructions, characterized in that it comprises  the production, in separate elements, of a metal frame comprising a support frame (12) intended to be arranged horizontally, and a framework (22),  - the preparation of a horizontal base (10) of dimensions at least equal to those of the frame,  - the arrangement of the frame on the seat,  - pouring a mortar or concrete onto the seat, around at least part of the frame so that the frame and the mortar or concrete after setting form a rigid and heavy base in a single piece (18) ,  - mounting the framework on the frame secured to the base, and  - the finish of the construction.  2. Method according to claim t, characterized in that the framework (221 comprises posts, a thatched frame, intended to be placed at a distance from the frame of the base, and trusses.  3. Method according to one of claims 1 and 2, characterized in that the seat is a bed of materials without binder.  4. Method according to any one of the preceding claims, characterized in that the frame comprises, on its upper face, devices (14) for fixing the frame.  5. Method according to any one of the preceding claims, characterized in that the pouring of the mortar or concrete is carried out up to the level of the upper face of the frame (12), so that the possible fixing devices remain accessible.  6. Method according to any one of the preceding claims, characterized in that the framework 122) comprises posts delimiting spaces for the formation of walls, and the finishing of the construction comprises the construction of walls by closing at least one space by a cooperating formwork sheet (44), disposed in a substantially vertical direction, and the projection of a mortar or concrete onto the cooperating formwork, so that at least one part of the pole of this formwork (44) is coated.  7. Method according to claim 6, characterized in that it comprises, before the projection of a mortar or concrete, the fixing of a grid (50) on the coo farting formwork or on frame (22).  8. Method according to one of claims 6 ct 7, characterized in that the cooperating formwork (44) is formed of a sheet of a ferrous metal, preferably comprising asperities.  9. Construction, of the type which comprises elements of metal frame and mortar or concrete, characterized in that it comprises  - a base (18) comprising a metal frame (12) coated with mortar or concrete, and  - walls comprising a metal frame (22) fixed to the frame of the base.  10. Method according to claim 9, characterized in that the walls comprise mortar or concrete partially coating a structure formed by the frame (22) and a cooperating formwork (44) fixed on the frame.