HRP960170A2 - Lightweight concrete construction system with grid-slab carriers - Google Patents

Description

The field of technology

The field of technique is well defined in accordance with MKP subgroup E04B 1/00 and E04B 2/00, which contain general constructions of walls, floors, ceilings and roofs, as well as individual elements.

Technical task

The subject of the invention is a construction system using fully reinforced lightweight concrete grill-plate supports composed of semi-prefabricated fine-ribbed grill plates, cassette plates and cassette grill supports. Ceilings, floors and roofs, one-story and multi-story frame buildings and halls, harbor piers and smaller bridges can be built.

The invention solves the task of fast, rational and safe construction of grill-plate constructions in a new way. The high adaptability of lightweight concrete grill plate supports to various shapes and monolithic semi-prefabricated or prefab design contributes to the efficiency of its application.

State of the art

A brief overview of the development of construction with reinforced lightweight concrete leads to the end of the nineteenth century. At the beginning of the twentieth century (1907), we register the use of lightweight concrete based on clinker in the construction of the British Museum. Later, in the mid-thirties of this century, the development of aerated concrete began in Europe, and especially significantly in Sweden. After the Second World War, the production and application of lightweight concrete elements from expanded clay, shale, lava, slag and similar materials expanded, all with the aim of reducing the specific weight and thereby improving the insulating properties, especially the thermal insulating properties, with slight reductions in mechanical strength. A special type of lightweight concrete - reinforced concrete made from granules of expanded polystyrene as aggregate and normal other concrete ingredients was launched in 1951 in Germany.

Existing well-known lightweight concrete systems that solve the mentioned technical task in a narrower sense are Ytong (Europe), Leca (Germany), Lytag (Britain) and systems based on expanded clays such as Aglite (Britain), Gravelite (USA) and Solite (Canada) ), and for example Liapor (Sweden), then systems based on the use of fly ash lightweight concrete.

In construction, there are no solutions similar to the subject of the invention due to the fact that all lightweight concrete systems up to now have been created with a significant proportion of lightweight concrete in the reception of internal forces. The concept used in this invention leaves the transmission of internal forces mainly or entirely to the reinforcement and leaves lightweight concrete a secondary role.

The technical task of bridging larger spans in the lightweight concrete version, but solving it in a completely different way:

(1) In Aglite technology like a multi-storey building in London, see [1].

(2) In Lytag technology, such as the 60-story Marina City Towers in Chicago and the Water Tower Plaža in Chicago as the tallest lightweight concrete buildings in the world, see [1].

(3) In Leca technology like the BMW administrative building in Munich, see [1] .

(4) Generally for tall buildings, see [2].

(5) Generally in bridge construction, see [3].

According to its conceptual concept, the invention approaches the idea used in patent applications HP-P960052A, HP-P960066A and HP-P960128A. The difference compared to the HP-P960052A, which has a small lightweight concrete rib of I profile, is that in this invention, an inverted T profile support is used as a small rib, and the semi-mounted plate ends with a thin pressure plate.

The difference compared to HP-P960066A, which contains a plate of TT section with load-bearing ribs in one direction only, while in this invention, load-bearing ribs are used in both directions.

The difference compared to HP-P960052A is that in it the panel is constructed as solid with possible reliefs by savings openings or styro blocks and inner ribs supported according to the frame principle, while in this invention it is a semi-prefabricated panel where the styro fillings are the load-bearing elements in in the manufacturing phase, and the ribs are designed on the principle of lattice construction.

Lightweight concrete for structural and insulating purposes is "known" by the regulations and norms of all developed countries. A special treatment of such constructions is given in the European regulation [4].

References

[1] Short A., W. Kinniburgh, Lightweight Concrete, Third Edition, Applied Science Publishers Ltd., 1978.

[2] Bobrovski J., Outstanding Applications of Lightweight Concrete and an appreciation of likely future developments, in Lightweight Concrete (The Concrete Society, The Construction Press Ltd, Lancaster, England, 1980) 239-260.

[3] Roberts J.E., Lightweight Concrete Bridges for California highway system, in Structural Lightweight Aggregate Concrete Performance, Holm, T.A. Vaysburd, A.M., Edt. (ACI, SP-136, Detroit, 1992) 255-271.

[4] Eurocode 2: Design of concrete structures - Part 1-4; General rules - Lightweight aggregate concrete with closed structures, ENV 1992-1-4:1994.

The essence of invention

The essence of the invention is in the application of the principle of complete reinforcement to lightweight concrete grill plate supports. Full reinforcement was applied to semi-prefabricated light concrete fine-ribbed grill full panels, cassette panels and cassette supports. The construction of frame buildings and halls, wharves and smaller bridges were created by combining supports and slabs. With complete reinforcement, the transfer of compressive, tensile and shear stresses is almost completely left to the reinforcement. In a new way, the lightweight concrete body is entrusted with the role of secondary load-bearing material for local and global stabilization, as well as the role of anti-corrosion, thermal, acoustic, fire protection and moisture protection. The lightweight concrete body has properties of low density, which implies a reduction of forces in the elements and later in the construction, and thus the use of a smaller amount of reinforcement, as well as excellent insulating properties. Grid-plate supports are made as prefabricated, monolithic or mixed.

Description of the drawing

The drawings show a new system of load-bearing fully reinforced lightweight concrete grill plate supports. The drawings show one of the possible ways of applying the elements and in no way restrict the rights granted by the patent claims.

drawing 1 shows the longitudinal and cross-section of the lightweight concrete semi-prefabricated fine-ribbed grill plate construction,

drawing 2 shows a longitudinal and transverse section through a lightweight concrete cassette panel supported at full height,

drawing 3 shows a longitudinal and transverse section through a lightweight concrete cassette panel supported at a reduced height,

drawing 4 shows a longitudinal and transverse section through a lightweight concrete cassette panel prepared for continuation by monolithication,

drawing 5 shows a section past the transverse rib and a section through the rib of the cassette support intended for the construction of the jetty,

drawing 6 shows cross-sections through the transverse rib of cassette supports intended for ceiling and roof structures of buildings and halls,

drawing 7 shows a section of the cassette support intended for the construction of the bridge,

drawing 8 shows a section through a building constructed using a ceiling and roof structure made of cassette supports and cassette panels,

drawing 9 shows a section through one field of a frame building next to a column,

drawing 10 shows a section through one field of a frame building in the middle of the field,

drawing 11 shows the floor plan of the field ceiling of the frame building composed of four cassette supports and a cassette panel,

drawing 12 shows the floor plan of the field ceiling of the frame building composed of two cassette supports and

cassette tapes,

drawing 13 shows the floor plan of the field ceiling of the frame building composed of cassette panels,

drawing 14 shows a view of the bearing structure of the pier of the harbor,

drawing 15 shows the details of connecting pier supports above supports,

drawing 16 shows a cross-section through the structure of the jetty of the port,

drawing 17 shows a view of a single-span bridge with a load-bearing structure made of cassette girders,

drawing 18 shows a view of a two-span bridge with a load-bearing structure made of cassette girders,

drawing 19 shows a cross section through the bridge structure.

Detailed description of one of the ways of realizing the invention

The new construction system with fully reinforced lightweight concrete grill-plate supports shown in drawings 1-19, consists of: semi-prefabricated lightweight concrete fine-ribbed grill plate (1), prefabricated or monolithic cassette panels (2, 2A, 2B, 2C), prefabricated or monolithic cassette supports (3, 3A, 3B, 3C, 3D), and procedures for the execution of frame buildings, or halls (4), quays (5) and smaller bridges (6).

Drawing 1 shows the longitudinal and cross-section of a semi-prefabricated lightweight concrete grill plate (1), the thickness and spans of which are chosen according to the load-bearing requirements, protection against moisture, noise and fire. The recommended dimensions are h=0.1 -0.3 m, l < 12.0 m. The components of the slab are the main prefabricated lightweight concrete ribs (1.1), monolithic transverse ribs (1.2), ceiling infill (1.3) and pressure plate (1.4). Recommended spacing of the main ribs d=40 - 80 cm, width b=8 - 15 cm, plaster thickness z=1-2 cm, pressure plate thickness 3.5 -6 cm.

The prefabricated lightweight concrete rib is made of a reinforcing skeleton and lightweight concrete body of the lower belt (1.1). The lightweight concrete body has a bulk mass of less than 1500 kg/m3, a compressive strength of more than 2 MPa. The reinforcing skeleton of the main rib is selected in such a way that at least one bar is placed in the upper belt (1.4), at least two bars in the lower belt (1.5), and the connecting reinforcement (1.6) is placed in such a way that it forms a complete lattice support with the upper and lower belt with filling in V, X or N-shaped parts. Grid filling is placed in at least one plane. It is recommended to have one bar in the upper belt, in the lower two, then to have two V-shaped lattice fillings. If the lightweight concrete body of the main rib or pressure plate and infill is made of lightweight concrete that does not provide anticorrosive protection of the reinforcement, then the reinforcing skeleton is coated with an anticorrosive coating after welding.

The transverse rib (1.2) is placed within the height of the main rib. Its reinforcement is chosen arbitrarily, from just one bar in the lower belt to a complete lattice support. Transverse ribs are placed at a distance a, recommended a=1.5 -2.0 m.

The ceiling infill (1.3) is made of a polystyrene block or material of similar mass and a protective layer on the bottom side. The recommended length of the filling is 1.0 m. The protective layer, see mark z on drawing l, together with the plaster must have the necessary thickness for fire protection. It is recommended to make it from light concrete 2-4 cm thick.

The pressure plate (1.4) is made of reinforcing mesh and a concrete or lightweight concrete body. The type of concrete is chosen so that the entire slab meets the conditions of deformability.

The sequence of semi-prefabricated construction is as follows: First, prefabricated main supports and light ceiling infill are made. Then prefabricated ribs are placed on the prepared walls or similar construction. A light filling is inserted between the ribs, which has channels on the edges for inserting the transverse ribs. Then the reinforcement of the transverse ribs and the mesh reinforcement of the pressure plate are inserted. Then comes the concreting of the pressure plate. At the end, if necessary, plaster is applied on the underside of the panel.

The longitudinal and transverse section of the cassette panel (2) is shown in drawing 2. It consists of at least two longitudinal ribs (2.1), at least two transverse ribs (2.2) and a pressure plate (2.3). The recommended spacing of the longitudinal ribs is a=1.0-2.5 m. The recommended spacing of the transverse ribs is the same. The inner field is square or rectangular. The thickness of the ribs in the lower belt is recommended b=6-30 cm. The height of the ribs is coordinated with the main spans of the slab, and is h=0.15-2.5 m. The spans of the slab are recommended l =4-25 m. The thickness of the pressure slab is adopted according to the requirements of the load-bearing capacity and physics of the building, recommended t=4-20 cm.

Lightweight concrete with longitudinal and transverse ribs has a bulk density of less than 1500 kg/m3, a compressive strength of more than 2 MPa, a tensile strength of more than 1 MPa and a shear strength of more than 0.1 MPa. The reinforcing skeleton of the longitudinal ribs forms a complete grid support whose upper belt (2.5) and lower belt (2.4) consist of at least one bar, preferably two, and the lattice filling (2.6) of at least one bar. The grid has the shape of a V, X or N filling in parts.

The reinforcing skeleton of the transverse ribs forms a complete grid support whose upper belt (2.8) and lower belt (2.7) consist of at least one bar, preferably two, and the grid filling (2.9) of at least one bar. The grid has the shape of a V, X or N filling in parts.

The reinforcement of the transverse and longitudinal ribs is joined and continued by welding. In the event that the lightweight concrete body of the rib or pressure plate does not sufficiently protect the armature from corrosion, after welding the armature frame is coated with an anti-corrosion coating.

The pressure plate (2.3) is reinforced with reinforcing mesh. It is made of light or normal concrete. In the case of using lightweight concrete of low strength, the pressure zone (2.10) is also covered with reinforcement.

The longitudinal and cross-section of a cassette panel supported in the height part, version (2A), is shown in drawing 3. In this case, the last field of the reinforcing grid disappears, and the support takes place using metal plates (2.12) to which the rods of the upper belt and fillings are welded.

In the event that the cassette panel continues continuously into other supports or supports, variant (2B), then this is achieved by welding the reinforcement of the lower and upper belt as shown in drawing 4 or by anchoring it in constructions made of normal concrete.

Kassetrian supports (3, 3A, 3B, 3C) are types of grill-plate supports where one span dominates the other. The ribs themselves and the pressure plate are constructed in the same way as with cassette plates.

The cross-sections of cassette girders (3) intended for harbor piers and similar buildings are shown in drawing 5. They have two main ribs at an axial distance d, recommended d = 1.0-3.0 m, recommended range l = 10-30 m.

The cross-sections of cassette supports intended for supporting other structures on one side (3A) or on both sides (3B) are shown in drawing 6. The supports are realized on a special tooth held by a special armature (2.14) connected to the transverse ribs. This reinforcement with the reinforcement of the transverse rib forms a complete lattice girder.

The cross-section of a cassette girder intended for the construction of smaller bridges (3C) is shown in drawing 7. The special feature of this type of girder is that its pressure plate (2.3) becomes a cantilever girder with reinforcement in the upper and lower zones. The span of the cantilever overhang k and its thickness must be coordinated with the axial distance d and the height of the support h.

The construction system of buildings and halls with a load-bearing frame construction (4) is shown in drawing 8. The system consists of foundations (4.1), columns (4.2), capitals (4.3) and casteria supports (3) and casteria plates (2). Wall panels with the necessary openings are placed on the outside of the columns, see mark z in drawing 8, which close the entire building. Buildings can be up to ten stories high with floor plan dimensions of 60x60 m. The recommended floor height h=3.0-4.0 m and the recommended dimension of the inner field L= 5.0-15.0 m.

The execution procedure which is the subject of the invention has a sequence. It begins with the creation of the foundation of the columns (4.1), the columns, prefabricated or monolithic, are placed in the foundations. In the case of prefabricated columns, their height can be more than one floor. At the height of the slabs, the columns have only reinforcement. A metal formwork is placed on the column under the slab, in which a part of the slab called the capital will be concreted. At the same time, this formwork serves as a scaffold on which cassette supports (3A.3B) or directly cassette panels (2) are placed. Then the reinforcement of the capital is placed, which is attached to the reinforcement of the cassette supports and panels by welding or anchoring in concrete. After that, concreting is done. With these operations, the slab of one floor is completed. The procedure is repeated for the other floors. Installation of wall panels is done after the completion of the entire construction. The details of the installation of the panel structure can be seen in drawings 9 and 10.

There are several ways in which cassette supports and cassette panels can be arranged in one field. One way is the one in which the cassette supports are supported on the capitals on all four sides, and the cassette panels are placed on them, see drawing 11.

The second way is the one in which the cassette supports are placed on two opposite sides and the cassette panels rest partly on the supports and partly on the capital, see drawing 12. The third way is the one in which the slabs rest directly on the capital, see drawing 13.

The jetty of the port made using cassette supports (5) is shown in drawing 14. The construction process consists in the preliminary production of cassette support bearings as pile heads or connecting beams of landings, walls and abutments. In the case of using ready-made cassette supports, ready-made supports are placed on the prepared bearings and monolithization is carried out. The reinforcing bars (5.7) are connected to each other and to the anchors left from the bearings (5.9), by welding or anchoring through normal concrete (5.8), see drawing 15. In the case of a monolithic design, the formwork for concreting the supports, which was previously placed, rests on the bearings armature. Connecting the supports is done at the same time as their concreting.

After the construction of the supports and their monolithicization is completed, the protective layer of the jetty (5.1) and other equipment (5.2), (5.3) and (5.4) are installed, see drawing 16.

Smaller bridges made using cassette girders (6) are shown in drawings 17 and 13. The construction process consists of abutments and columns with bearings for the construction of the bridge. In the variant of the prefabricated version of the bridge structure, the cassette supports are made beforehand and the sinkers are placed on the prepared bearings (6.3). If necessary, with a larger width of the bridge, they can be continued transversely to each other, in the thickness of the pressure plate and in the place of the transverse ribs. In the case of multi-span bridges, the girders can be constructively continued and monolithic over the supports.

In the version of the monolithic design, the formwork of the supports is placed next to the bridge beds, if necessary, it can be done in parts, in which the reinforcing skeleton is placed. Then the support is concreted. After the completion of the construction of the supports and their joining, the final layer is placed, see (6.1), which has the role of an insulating and wearing layer. The fence (6.2) and other bridge equipment are installed later.

One of the possible types for making a lightweight concrete body is lightweight concrete based on expanded polystyrene (styrobeton). If the lightweight concrete body is made as lightweight reinforced concrete, then in case it serves as anti-corrosion protection or is exposed to any type of fire load, the density of lightweight concrete must be greater than 800 kg/m3.

Method of industrial application

The way of industrial application of the invention in the broadest sense is obvious. The proposed lightweight concrete grill plate construction system is adaptable and adaptable in practice for a new way of building various constructions that are based on individual load-bearing lightweight concrete elements from this invention.

Claims (10)

1. A fully reinforced lightweight concrete construction system using grill plate supports, characterized by the fact that it consists of a semi-assembled lightweight concrete grill plate (1), prefabricated or monolithic cassette panels (2, 2A, 2B), prefabricated or monolithic cassette supports (3, 3A, 3B ) and the entire system is used for the construction of ceilings, roofs, buildings (4), quays (5) and smaller bridges (6). 2. Semi-prefabricated lightweight concrete grill plate (1) according to requirement l with thickness and spans selected in accordance with calculations of load-bearing capacity, protection against moisture, noise and fire, characterized by the fact that it consists of main prefabricated lightweight concrete ribs (1.1) made of reinforcing skeleton and lightweight concrete with a volumetric mass of less of 1500 kg/m3 and compressive strength greater than 2 MPa, transverse ribs (1.2) made of light or normal concrete, prefabricated filling (1.3) made of blocks of polystyrene or similar light material coated with a layer of light concrete or plaster on the lower side, and compressive slabs (1.4) made of light or normal concrete. 3. The main prefabricated lightweight concrete rib according to claim 2, whose length, width and height are determined in accordance with load capacity calculations, whose reinforcement is welded and, if necessary, coated with a protective layer, indicated by the fact that it is self-supporting in all stages of the construction of the semi-prefabricated panel and what the reinforcing skeleton does to it in the upper belt (1.4) at least one bar, in the lower belt (1.5) at least two bars and the connecting armature of the infill (1.6), which together with the belts forms a grid support with infill in V, X or N-shaped parts, whereby the grid infill is placed in at least one plane. 4. Cassette panels (2,2A,2B) and cassette supports (3,3A,3B,3C) according to requirement l, the length, height and thickness of the ribs and the thickness of the inner panel are chosen in accordance with load capacity calculations and requirements for protection against moisture, noise and of fire, the reinforcement of which is coated with anti-corrosive coatings if necessary, indicated by the fact that their rib belts are approximately parallel, then that they have at least two longitudinal (2.1) and at least one transverse rib (2.2) made of a reinforcing skeleton and a lightweight concrete body with a volumetric mass of less than 1500 kg /m3, compressive strength greater than 2 MPa, tensile strength greater than l MPa and shear strength greater than 0.1 MPa, then to have a thin pressure plate above the ribs (2.3) reinforced with nets in one or two zones, made of light or normal of concrete. 5. Longitudinal ribs (2.1) according to claim 4, the reinforcement of which is continued by welding, characterized by the fact that the reinforcement forms a complete lattice support whose upper belt (2.5) and lower belt (2.4) consist of at least one bar each and the diagonal of the lattice (2.6) in parts they have the shape of the letter V, X or N, where the filling of the grid is placed in at least one plane. 6. Transverse ribs (2.2) according to claim 4, the reinforcement of which is continued by welding, characterized by the fact that the reinforcement is placed within the height of the longitudinal ribs and forms a complete lattice support whose upper belt (2.8) and lower belt (2.7) consist of at least one bar each and the diagonals of the grid (2.9) have the shape of the letter V, X or N in parts, whereby the filling of the grid is placed in at least one plane. 7. The process of building buildings and halls (4) using cassette supports according to claim 1, characterized by the fact that it consists of the production of prefabricated or monolithic foundation cups (4.1), monolithic columns (4.2) floor by floor or prefabricated columns placed to a height of one or more floors at once with openings at the height of the floor slabs, on which the capital formwork (4.3) is placed under the floor or roof slab that is to be installed, which as a temporary support accepts prefabricated cassette supports with a support edge (3A,3b) or cassette slabs (2) which are connected to a single unit with the capital and column by monolithication. 8. The process of building a ceiling according to claim 7 characterized by the fact that the cassette panels (2) are stacked directly on the scaffolding of the capital (4.3) or that the cassette panel (2) is stacked on two cassette supports (3A, 3B) along two parallel sides or that cassette plate (2) stacks on four cassette supports (3A,3B) placed along all four sides of it. 9. The procedure for the construction of quays (5) using cassette supports according to requirements 1, 4 and 5, whose load-bearing structure is placed on already pre-made headers, abutments and landings, characterized by the fact that it is achieved by installing monolithic or prefabricated cassette supports (2), sinks by anchoring or welding the reinforcement of the ends (5.7) to each other and to the anchors (5.9) and by monolithicing the connection with a lightweight concrete or concrete body (5.8) and an edge body (5.6), with the subsequent execution of the protective layer (5.1) and the installation of cleats (5.4), supply cabinets ( 5.3) and installation devices (5.5) into the predetermined openings in the transverse ribs. 10. The procedure for building smaller bridges (6) using cassette supports according to patent claims 1, 4 and 5, whose load-bearing structure is placed on classically designed abutments and landings and is covered with a protective and wearing layer (6.1) with a bridge fence (6.2) installed, indicated by the fact that is achieved by building a load-bearing structure over one or more spans using cassette supports (2) that have two or more longitudinal ribs (2.1), which can be performed on site or prefabricated, which can be monolithic in the longitudinal direction in the case of several spans, and in the transverse direction, in the case of three or more ribs, they can be connected to each other by monolithization, placed on metal or similar bearings (6.3).