FR2634238A1 - Prefabricated construction elements, and method for the economical construction of an isothermal wall - Google Patents

Abstract

The invention relates to two prefabricated construction elements: an element 1 made of insulating material of the expanded polystyrene type, of a considerable length and self-supporting, and a facework element 2 made of a conventional hard material (concrete, clay, stone) of short length. The height of the two elements 1, 2 is substantially equal to the slab thickness. The facework elements 2 are arranged on both sides of the insulating element 1 and are thus stacked, row by row, in the dry state, with lapped and tightened joints. These facework elements 2 are sealed simultanteously on several superimposed rows; when the slab is put into use, the vertical concrete cores are filled so as to form connection and reinforcement columns on the two sides of the insulating wall and over the entire height of the said wall, for private or public housing.

Description

 Prefabricated building elements and process for the economic realization of insulated wall.

 The present invention relates to prefabricated building elements, insulating elements and parliamentary elements, and extends to a new industrial process of building construction from such elements; it applies in all cases where it is desired to obtain economic constructions with excellent thermal and sound insulation.

The principle of insulating banister blocks for the realization of walls is well known. However, these insulating bancher elements with facing modules on both sides have disadvantages
a relatively high cost of manufacturing these elements due to the combination of two different processing materials.

 - Delicate transport and handling from the fragility of these elements due to the two materials of different density and strength.

 a resistance of the walls obtained low because the mechanical supports are distributed in three ranges over the width of the wall.

 the cohesion of the facing modules on both sides is low or very expensive in terms of manpower.

the two insulating walls produced have numerous detrimental connections for a good quality of insulation.
- Several different elements are needed to make the angles and the door and window frames.

 - The connection with prefabricated elements to make the door and window frames is difficult, because of the small width of the facing module.

 - The insulation without thermal bridge and the implementation of the wall at the slabs and door and window frames is not solved.

Also, the present invention proposes to provide two improved structural elements of great structural simplicity, which combine the essential qualities:
- very economical construction because the process uses only two basic elements with a reduced manpower in hours and specialization,
- quality of thermal and sound insulation that can satisfy the highest requirements, total absence of thermal bridge, even at the level of slabs and frames of doors and windows,
- Easy installation with automatic positioning and very precise alignment of the elements as well as excellent flatness of the walls obtained,
- outstanding qualities of strength and cohesion of the walls obtained,
- traditional type construction with a finished appearance similar to that of traditional block walls and extremely resistant hanging of external plaster,
the possibility of obtaining an insulation either from the inside, or from the outside or mixed with walls that breathe through well-formed cells in the facing elements located on either side of the insulating wall,
- reduction of wall thicknesses without losing the characteristics of resistance and insulation,
- ease of connection at slabs and door and window frames,
- possibility of self-construction, to realize all the architectures and forms of construction, to use also the same elements for the buried walls, for individual and collective houses.

(For ease of understanding, the terms used later, whether it is a direction or an orientation, assume each element in the position it is when it is laid to make a wall.)
The method, object of the invention is characterized in that the construction method requires:
a central insulating element (1) molded in one piece of polystyrene foam having a density of 30 kgs / m3, of a height corresponding to the thickness of the slab, for example 200 mm, and of great length, ie 2.50. meters for example.

 - An element (2) said facing element is shown in a preferred form by a concrete honeycomb block, of height substantially less than that of the insulating member (1) wall thickness 50 mm and standard length 500 mm. .

According to the present invention, these elements have, in combination, the following characteristics
a) their substantially identical height corresponds to the thickness of the slab,
b) the profiled shape of their respective faces in contact,
c) their mechanical connection is of the type: tenons and mortises, formed on their respective faces in contact; in the example, these engagement structures are of trapezoidal section projecting or hollow in rectilinear form or in broken line for the connection between the insulating elements (1), and for the connection insulating elements (1) and facing elements ( 2), these interlocking structures are double grooves and tenons that are. on their geometrically truncated pyramid-shaped sectional length. "
d) their weights are low and make the implementation easy and without means of handling.

 The central insulating element (1), rigid, of great length of insulating material, for example expanded polystyrene foam serves as a guide, support and ancraye to the facing elements (2) that are available on both sides. other of the central insulating element (i), ranned per row.

The central insulating element (1) comprises
- on one of the vertical side edges a tenon, on the other a groove, both rectilinear and trapezoidal section,
- On the horizontal side edge, lower and upper respectively a groove and a trapezoidal section of the tenon, in the form of broken line so as to ensure the plumb with the cells in the superposition of the rows of elements i, 2).

- on both sides a shape profiled in the vertical direction which serves as anchoring to the laces of facing and formwork for the columns
(1,2) concrete, cast once the elements / set up on a height of strut.

 The cladding elements (2) of small dimensions preferably consist of cellular concrete formwork blocks and / or terracotta honeycomb briquettes.

The elements of facing include
- a flat face
- A formally shaped face in the vertical direction which serves as anchoring to the central insulating element (l) and formwork for the reinforcing columns.

 - A vertical recess on the vertical side edges and a vertical recess located midway of the element (2).

Other features, objects and advantages of the invention will emerge from the description which follows with reference to the accompanying drawings, which show by way of non-limiting example an embodiment; sure
These drawings are an integral part of this description ::
FIG. 1 is a perspective view of the two standard elements in accordance with the invention;
FIG. 2 is a diagrammatic perspective view illustrating the mounting of the elements (1, 2),
FIG. 3 is a diagrammatic perspective view of a variant of the element 1 and the assembly of the elements (1, 2),
FIG. 4 is a partial cross-section illustrating the connection of the finished wall with the slab, by a vertical plane;
FIG. 5 is a partial cross-section illustrating the connection of the finished wall and the door or window post by a horizontal plane;
FIG. 6 is a partial cross-section illustrating the connection of the finished wall and of the tops and bottoms of windows or door, by a horizontal plane,
FIG. 7 is a schematic partial sectional view illustrating an angle of said wall, being mounted by a horizontal plane,
FIG. 8 is a view from above, illustrating in detail an interlocking structure of the two elements,
FIG. 9 is a schematic front view illustrating the interlocking structures of the two elements,
FIG. 10 is a diagrammatic side view of the two elements, in a vertical plane, illustrating the structures of the two elements,
FIG. 11 is a view from above, illustrating the standard facing element,
FIG. 12 is a view from above, illustrating a variant of the facing element for outside wall angle,
- Figure 13 is a top view, illustrating a variant of standard facing element.

The central insulating element (1) represented by way of example in FIGS. 7, 8, 9 and 10, is part of a rectangular parallelepiped, the dimensions given for illustrative purposes being approximately as follows:
Length 2.50 meters, height 215 mm, thickness 200 mm overall with center wall 100 mm.

 This element (1) is made in one piece by molding expanded polystyrene foam density of between 25 and 40 kg / m3, in particular equal to 30 kg / m3 and has a male interlocking structure such that (lg ) extending along its upper edge, a female nesting structure such as (lh) extending along its lower edge, a male nesting structure such that (lk) extending along one of the vertical edges and a female embroidering structure such as- (lj) extending along its other vertical edge.

 For example, these structures are of rectilinear shape on the vertical edges and in the form of a broken line on the horizontal edges so as to automatically ensure the plumb and the alignment of the cells and the facing elements (2) in the superposition of the rows of elements (1, 2); all these structures are trapezoidal section, projecting or recessed, so as to ensure automatic positioning and accurate end nesting.

This insulating element (1) represented by way of example in FIG. 7, has on both vertical faces a profiled shape which comprises
1) vertical grooves and tenons (la, lb, lc, Id) to achieve the mechanical connection with the facing elements (2), these grooves and tenons arranged in opposition go in pairs and are on their length, trunk section of pyramid with geometric base "
2) vertical grooves (1c) which, with the superposition of the elements, form shuttering parts for the realization of reinforcing columns (5).

 3) vertical grooves (lof) which, with the superposition of the elements, form formwork parts for the realization of securing columns (6).

 This insulating element (1) shown by way of example in FIGS. 7, 8, 9 and 10 is assembled with tight, crossed joints and the high dimensional accuracy thereof combined with the presence of nesting structures (the , lb, lc, ld) ensures precise and automatic positioning and self-alignment of the facing elements (2); in this way we obtain walls with two perfectly flat and vertical faces.

As illustrated in FIG. 7, the vertical faces (ie ', the ") of the cells (1c) on the profiled faces serve
a) shuttering for a filling material,
b) guide for making the cuts (11, 1R ')
c) contact faces to achieve a 90 degree angle in the former example.

 The facing elements (2) represented by way of example in FIGS. 7, 8, 9 and 10 are inscribed in a rectangular parallelepiped whose dimensions given for illustrative purposes are approximately as follows: width 500 mm, height 200 nm , thickness 100 mm except all with external wall of 50 mn.

These elements (2) are, in the example, constituted by cellular honeycomb wafers of agglomerated concrete which comprise
a vertical face with a profiled shape comprising, vertical grooves and tenons (2a, 2b, 2c, 2d) for making the mechanical connection with the insulating elements (1), these grooves and tenons arranged oppo-sition go in pairs and are on their length, of section "pyramid trunk with geometric base"
a flat vertical face.

 - two smooth horizontal edges.

 - two vertical side edges with groove.

These facing elements (2) shown by way of example in FIGS. 11, 12 and 13, have
- a recess (2s) vertical, through, located at mid-length to facilitate the cutting of a half-element and to achieve the vertical sealing columns (4) with a pose of the elements (2) with cross joints,
vertical grooves (2r) on the flat face which serve to facilitate the cutting of the half-elements or elements to make a wall with an angle,
vertical grooves (2p) serving as a recess for limiting the contact with the insulating element (1) and for facilitating the cutting of the half-facing elements (2),
a groove (2m) of trapezoidal section on each of the two vertical lateral edges,
vertical chamfers (2n) to prevent cutting defects on a half-element facing each other,
vertical grooves (2q, in particular 6 in number) which serve:
a) increasing the width and strength of the reinforcing (5) and securing columns (6)
b) increasing the cohesion of the columns (5, 6) with the facing elements (2),
c) to facilitate the cutting of these elements (2) to make a wall with an angle.

As illustrated in Figures 10, 11 and 12, these facing elements (2, 3) manufactured by molding, have several blind cells (2t, in particular 8 in number) which open on the lower edges of said elements and serve
- to identify the direction of assembly of these elements,
- to lighten these elements and to make two healthy walls, with "vacuum of air",
- To facilitate the cutting of these elements to make a wall with an angle.

The example of Figure 5; represents the connection of a prefabricated door or window jamb with the facing elements (2); fixing said amount is achieved by the sealing column (4). The example of Figure 6, shows the conventional masonry connection of a top or underside of window or door with the facing elements (2).

The example of Figure 4, shows the connection of the elements (1, 2) with the conventional masonry slab called "to hourdis".

According to the example shown in FIG. 12, the corner facing element (3) is a variant of the standard element (2), made in the same mold on an impression whereas the other nine impressions are for standard elements (2).

This corner element (3) can be used to realize the outside corners of walls as illustrated in Figure 7 as well as the tables of openings in the absence of pre-framing, as shown in Figure 5.

As illustrated in FIG. 12, this corner facing element (3) comprises
a plane vertical side edge (2w),
vertical chamfers (2n) to avoid cutting defects on the element opposite,
- A vertical recess (2v) to achieve a possible sealing of this element (3) with its opposite.

These facing elements (2, 3) may be formed by honeycomb briquettes or by stone facings of comparable dimensions.

The example of Figure 13, shows a variant of solid concrete facing elements.

According to the example shown in FIG. 8, 9 and 10, the conjugation of the grooves (1a, 1c, 2b, 2d) and tenons (1b, 1d, 2a, 2c) in the shape of their length of truncated pyramid geometric section'1 ensures during its establishment, a clearance of the facing element (2, 3) relative to the central insulating element (i) and compared to facing elements already placettout guaranteeing an automatic and precise positioning at the end of nesting.The facing elements (2, 3) bear against the insulating elements (1) which therefore act as temporary support means for the facing elements (2, 3). by contact of mutual interlocking structures; the current dimensional accuracy of the height of the facing elements (2, 3) of concrete make a clearance of 2 mm, at most between the rows of said elements (2, 3).

Of course, the invention is not limited to the terms of the description which precedes, but on the contrary includes all the variants; thus the cladding elements can be made of another known carrier material: stone, plaster-based material, terracotta ....

The implementation is as simple as that of traditional blocks.

 It is enough to put the first insulating element (1) as well as the first elements of facing (2, 3) on a bed of mortar sufficiently consistent and of level in order to be able to regulate the good alignment on the set, the following rows are posed Dry, cross-seamed and tight.

The cutting of the insulation, if it is necessary, is done with a saw; that of facing elements is done as traditionally by hammer or with a tool, like "aligator clamp".

The same standard elements, insulating (1) and facing (2, 3), make it possible to realize the incoming and outgoing angles as well as the openings of bays. The cut-out on the inner wall top to support the prefabricated slab elements is no longer necessary, possibly one can stall on the last row to ensure a perfect leveling of the slab.

The siding elements are sealed by filling the cavities provided for this purpose with a sufficiently fluid mortar over a height of floor or in three heights.

The doors and windows can be made by traditional method, reinforced concrete, with central insulation. The pipes or sheaths can be placed in the still empty vertical cells.

Then, it performs the filling of cells provided for this purpose with a sufficiently plastic mortar on a floor height to achieve the securing columns, outer wall side and the reinforcing columns, inner wall side; this is done at the same time as the implementation of the slab respecting the rules of the art, particularly in terms of reinforcement.

elements 1, 2 and 3 according to the invention can be made industrially without particular difficulty.

 The central insulating element (1) is prefabricated by po-lystyrene foam molding and production can be centralized, given the low transport costs due to the specific weight of this product.

The cladding elements (2, 3) can be made of precast cast concrete and their production can be regional or departmental. The facing elements (2, 3) have a decorative plane vertical fdce such as pebbles, relief, natural stone look etc.

Claims (7)

 cladding elements (2) of small dimensions, in traditional material on both sides of an insulating self-insulating (1) self-supporting, kind expanded polystyrene of great length.

 characterized by the fact that they  REENDI CATIONS -1. Prefabricated building elements, 2. Prefabricated building elements according to Claim 1, characterized in that a) The insulating element (1) is molded in one piece of polystyrene foam having a density of between 25 Kg / m 3 and 40 Kg / m 3. m, has a height corresponding to the slab thickness of 200 mm or more and a lenght of 2.50 meters or more, t) This insulating element (I) is made to have a suitable mechanical strength to be able to serve as temporary support during the superposition of the building elements, c) This insulating element (1) has on its two vertical edges a groove (1j) or a tenon (1k) extending over the height, and trapezoidal section d) The cladding elements (2) consist of concrete honeycomb blocks and / or terracotta honeycomb briquettes, have a height of

 two flat horizontal songs.  e) These cladding elements (2) comprise a plane vertical face and  standard length is 500 mm,  substantially lower than that of the insulating element (1) and a  filling.  the other faces to form formwork for a material of  on one of the faces and vertical recesses (1f) on  its mechanics with facing elements (2) and worm recesses  several interlocking structures (1a, 1b, 1c, 1d) to ensure a connection  their two vertical faces: a vertical profiled form composed of  characterized in that the insulating elements (1) comprise on ~ 3. Prefabricated building elements according to claim 1 or 2  sweat, in the form of a broken line with a trapezoidal section.  upper horizontal one tenon (ig) which spread over their whole length  on their lower horizontal song a groove (1h> and on their song  Or 3, characterized by the fact that the insulating elements (1) comprise  4. Prefabricated building elements according to claims 1, 2 ~ 5. Prefabricated building elements according to claims 1, 2 or 3, characterized in that the planes (1e ") of the vertical cells (1c) on the profiled faces serve as a) formwork for a filling material, b) guide for making the cuts (1); Il); c) contact faces for making an angle.

-6. Prefabricated building elements according to claims 1, 2 or 3, characterized in that the facing elements (2) comprise on a vertical face: a profiled shape composed of several interlocking structures (2a, 2b, 2c, 2d) to ensure the mechanical connection with the insulating elements (1) and vertical recesses (2q) serving as a coffraye and also pre-cut for these elements.  according to # of claims 1, 2, 3> 3, 6, 7 or 8, characterized in that the facing elements (2, 3) bear on the insulating elements (1) by contact with the interlocking structures ( 2a / 1a, 1b / 2b, 2c / 1c, 1d / 2d).

 according to preceding claims, characterized in that the insulating elements (i) and the facing elements (2, 3) form by their assembly vertical cells (1e, 1f) which, with the superimposed rows of the elements (1, 2) form forms for a filling material and thus form reinforcing columns (5) and securing (6). ~ 13. Prefabricated building elements

 according to claims 1, 2, 6, 7 or 8, characterized by the fact that the facing elements (2) comprise vertical recesses (2n) making it possible to absorb the squareness defects originating from the cut of the facing elements ( 2, 3) in screws 0 screws. ~ 12.Fabricated building elements

 according to claims 1, 2,6, 7 or 8, characterized in that the facing elements (2) have grooves (2p, 2r) vertical on both sides to facilitate their cutting to achieve a cross-seamed poo and angles. ~ 11. Prefabricated building elements

 9. Prefabricated building elements according to claims 1, 2, 6, 7 or 8, characterized in that the facing elements (2) have recesses (2m, 2v) on their two vertical edges and a recess (2s). vertically extending intermediate the length of the element (2) which form superposed form vertical recesses for formwork to achieve, with a filling material of the sealing columns making said solidarity elements (2) poses b dry and to cross joints, ~ 10.Fabricated building elements

 b. prefabricated building elements according to claims 1,, 6 or 7, characterized in that the facing element (2) comprises two pairs of pins (2a, 2c) and grooves (2b, 2d) to ensure the integrity of a facing element half (2, 3) and perform a cross-joint pose.

-7. Prefabricated building elements according to claims 1, 2, 3 @ E, characterized in that the mechanical connection between the insulating elements (1) and the facing members (2) is provided by interlocking structures formed by a pair of tenons (1b, 1d / element 1; 2a, 2c / element 2) and grooves (la, lc / element 1; 2b, 2c / element 2) shaped in the direction of their lonyueur, truncated pyramid of geometric section ", corresponding structures formed on the opposite faces of the insulating elements (1) and facing elements (2),

 -14. prefabricated building elements  faded lets, relief, natural stone look etc .....  facing (2, 3) have a decorative flat vertical face such that  according to claims 1, 2, 6, e, B> 9, 10, 11 or 14, characterized in that the elements of

<tb> SelOnpgS <SEP> claims 1, 2, 6, 8, 9, 10 or 11, characterized in that the standard facing elements (2) are manufactured on nine mold cavities and the facing elements angle (3) are manufactured on an impression of the same mold. ~ 15. Prefabricated building elements <tb> <SEP> IiL <SEP> CUCllrL \ .L  side of the insulating wall and the entire height of said wall.  reinforcing columns (5) and securing columns (6) of the two  - b fill the vertical cells to make  (2, 3) superimposed by producing sealing columns (4),  - to seal several rows of facing elements  insulating elements (1) and this, dry, and row by row,  arranging the facing elements (2, 3) on both sides of the  tes, characterized by a consistent implementation  prefabricated elements according to one of the preceding claims. ~ 16. Method of constructing an isothermal wall of building from