NL1029807C1 - Method for building an outer wall. - Google Patents

Description

Title: Method for building an outer wall Area

The invention relates to a method for building an outer wall of a building to be provided with one or more frames, said outer wall comprising an inner cavity leaf, a cavity and an outer cavity leaf.

Background

The façade of a home (in general: building) largely determines the price 10 (and the quality) of the home and also largely determines the construction time of the home. The partitioning walls and load-bearing front facades provide the floor-supporting function; they are part of the skeleton that is the first to be built. The longitudinal façade of terraced houses and terraced houses (the bulk of the house construction) is the most labor-intensive, construction time-determining (it is only after rainproofing and windproofing that interior construction can be started) and the expensive part of the house. The longitudinal façade also contains most frames, which in the Netherlands are mainly made of tropical hardwood. These frames are usually bricked in early as a semi-finished product and only glazed and painted late, often even after completion, due to the winter break of the painter.

20

The dominant technique of the longitudinal facade is a superstructure with a masonry outer cavity leaf, behind which an air cavity and an inner cavity leaf (against which insulation material is attached). Constructively, including when taking up the wind load, inner cavity leaf and outer cavity leaf work together. For the outer cavity leaf, mainly brick is chosen, a typical one

Dutch choice. Stony material is generally used for the inner cavity leaf (except for prefab, which has only a small market share); often 100 mm thick sand-lime blocks or elements, which is a rather expensive solution compared to the non-load-bearing inner walls (100 versus 25 Euro 30 per m2).

The building process in the Dutch tradition is that the facade is constructed from 10 2 9 R 0 7_ 2 [! inside out: the inner cavity wall is first bricked (with prefab variant hoisted and mounted with the crane). Frames are placed against the inner cavity leaf in the places provided for this purpose (in the case of prefab, the frames are sometimes already mounted in the inner cavity leaf). Transparent foil is often provided in the window openings to improve the working conditions for finishing work indoors. The placement of the window frames, viewed over time, goes hand in hand with the application of insulation material against the inner cavity leaf, the installation of the cavity anchors and the brickwork of the outer cavity leaf. The craftsmen involved are standing outside, in all weather, partly on a (masonry) jetty. The joining and painting of wooden parts near the gutter is done from the same masonry scaffolding. The scaffolding therefore stands for a relatively long time in front of the facade and hinders accessibility. All these operations on the façade are therefore weather dependent and often hinder planning.

15 Masonry in the facade is typically Dutch and has many positive qualities.

The freedom of design, the freedom of choice in form and color, the durability and the relatively low costs are the decisive arguments why brickwork is expected to be preferred by buyers and architects for decades to come. There are also limitations to traditional brickwork. The joint is the weakest link, both structurally and in terms of durability and color uniformity. Visual aging is almost entirely the result of the joint and the phenomenon of limescale is also caused by the grout.

We summarize the characteristics of the Dutch construction method of the longitudinal facade in 25 residential buildings:

Construction process from the inside out

Frame usually of masonry frame type, with direct contact between frame and masonry

Frame is a semi-finished product that is only glazed late in the finishing and painted 30 and is therefore executed in environmentally unfriendly tropical heartwood

Inner cavity leaf - especially before and during the construction of the 1029807 3 outer cavity leaf - has a wind-bearing function and must therefore be thick, heavy and expensive.

The use of an air cavity ensures accurate flood defense. The outer cavity leaf is usually made of masonry.

5

Two new technologies have been developed that have since conquered a small but steadily growing market share in residential construction: 1. Bonding bricks (see for example http://www.knb-baksteen.nl/publicaties/publicatie_35.htm) 10 As with the traditional bricklaying is also using cement as a binder. The glued joint is considerably thinner than before and lies about 8 mm back; use is made of special tools, which means that there is no need for retreat. Gluing is in fact super-bricklaying whereby the bricklayer comes to the end result in one operation.

The technology is often somewhat higher per m2 of wall due to the limited number of bricklaying companies that have a great deal of practical experience and due to the additional architectural possibilities that architects immediately use.

The opening of the butt joint (joint width also here about 4 to 5 mm) presents no visual objection, but it does promote the ventilation function of the air cavity (and has a favorable effect on the labor factor)

The aftermath, with all its quality limitations, is canceled 25 The strength of the glued construction increases significantly (strength is no longer limited by the joint; the stone quality is decisive)

At the sight of the glued façade, there is almost only a view of the brick, which greatly increases the color intensity.

Early color aging and limescale are a thing of the past.

Due to the thin joint, 92 bricks instead of 75 are used per m2 wall

There are now several manufacturers who have adapted the size of the 10 2 9 8 0 7 4 brick to the new technology (two heads plus joint = stretch). The additional costs due to more sawing work are thus reduced.

2. Application of ready-to-place (Kapla) frames 5 (see for example http://www.kapla.nl/):

A ready-made frame (glazed, painted and provided with sealants and fasteners) is supplied by the carpentry industry (50% added value) at a late stage of completion (5 weeks prior to completion).

10 The lifting is done with the crane, about two houses in one day

A development has been carried out that is mainly aimed at ensuring in a practical manner that the facade opening (both in the inner cavity leaf and in the outer cavity leaf) matches the frame dimensions.

An additional advantage of the method is that there is no longer contact between exterior brickwork and the wooden frame; an important source of wood rot is thus eliminated.

The most important attack on the frame (damage in the structural work phase, unpainted through the winter) is canceled. Painting and glazing takes place in the carpentry factory under optimum conditions, with for example an insured layer thickness of the paintwork.

The latter two points make it possible to use tropical hardwood instead of large risks, but European softwood, while retaining the GIW guarantee (unique).

25 In the structural work phase, a cheap and recyclable work-through window is temporarily built in; the working conditions inside are made acceptable at an early stage.

The construction process on the construction site is greatly simplified.

30 In summary, the following applies to the current state of the art: 1. The current building process works from the inside to the outside, whereby the construction of the inner cavity leaf, the placement of the window frames and the insulation are insulated: • on the criticism path • are weather dependent with consequences for working conditions • are carried out outdoors and therefore have a quality risk 5 2. Traditional bricklaying is usually chosen for the masonry process: • relatively weak constructively | • less durable joint connection • color-aging-sensitive aftermath • sensitivity and uncontrollability of the quality of masonry 10 o size of the burrs o moisture bridges to insulating material 3. Use of bricklaying frames (in the inner cavity leaf) has the disadvantages: • fragmented version with many disciplines 15 · on the critical path in the planning • little or no room for buyers' wishes (choosing early) • high-quality risk (damage in carcasses / unpainted throughout the winter) • sustainability risk due to direct contact with outside masonry • non-wind compensating air cavity, with sensitivity as a result for moisture leaks along the frame 4. The inner cavity leaf also takes care of the wind-bearing function • thick (loss of space) 25 · heavy (costs and facilities in the floor / foundation) • limited freedom of choice of materials • expensive

Summary 30 The present invention contemplates the aforementioned problems resp. to overcome disadvantages by providing a method for building an outer wall which can be provided with one or more frames, comprising an inner cavity leaf, a cavity and an outer cavity leaf, which method comprises the following steps: a. masonry around one or more work windows placed in time; 5 b. The work-through windows are removed and replaced by frames; c. Insulation (5) is applied against the inside of the outer cavity leaf, if desired with consideration of an open cavity (6); i d. The inner cavity leaf (7) is fitted.

The outer cavity leaf is preferably manufactured from mutually glued bricks, while Kapla frames are also preferably used as frames.

A few things will be discussed and explained further below.

15 Embodiment example

Figures 1 and 2 schematically show phase 1 of the method according to the invention, figure 1 the vertical section thereof, figure 2 the horizontal section.

j

Figures 1 and 2 show an outer cavity leaf 1, a door frame 2, a wooden profile 3, a Kapla frame 4, insulation 5, an open cavity 6, an inner cavity leaf 7 and a window sill / sill 8

The following construction phases are distinguished in the figures, which will be discussed below: • Phase 1: Masonry outer cavity leaf 1 around a working frame 2 (suspended from a wooden profile 3).

• Phase 2: Remove work-through window 2 and place Kapla frame 4.

• Phase 3: Applying insulation 5 incl. Open cavity 6.

30 · Phase 4: Installing inner cavity leaf 7 and window sill / sill 8.

1029807 7

Phase 1: Masonry outer cavity leaf around a continuous work frame With the new building sequence, after the completion of the load-bearing structure (skeleton), consisting of dwelling separating floor-bearing walls and the floor-bearing bearing inner cavity sheets of the end wall, the outer masonry is immediately made.

The outer brickwork is carried out according to the adhesive technique, so that the outer leaf has sufficient strength to provide the wind-bearing function on its own. It is even possible to use gluing work with open butt joints (faster construction, price advantage and better ventilation of the later air cavity).

Openings are saved in the exterior brickwork in which later, shortly before delivery, the then ready-made frames (glazed and painted) fit. This façade opening is obtained by bricking in a working frame, with dimensions around 6 mm larger than the later frame. This working-through window has the following function: - ensuring the correct dimensions - ensuring the correct size of the frame opening 20 - providing a stop for the bricklayer who masters it in the way in which it traditionally handles a masonry frame.

- taking care of an indoor environment in the home at an early stage, so that the work can be carried out under good working conditions conditions.

25

The work-through window is relatively cheap and, if desired, it can be made from recyclable materials.

The work-through window can be fitted in several ways. It can be set in advance by the person making the measurements or during the bricklaying process (at the moment that the bricklayer is aware of the bottom of the work-through window). The first method seems obvious. Perhaps it is decided, especially with very spacious 10 2 9 8 0 7 8 window openings, for a wooden profile that transfers the wind force on the window frame, also definitively, to upper and lower floors. See the wooden profile in figure 2.

5 The placement of this profile and the work-through window is the task of the scraper. The bricklayer only bricks in and bears no responsibility for the correct location of the later frame in the façade (and he and the jointer no longer mess with it).

10 The bricklayer stands, just like traditional, on the outside of the house, partly on a brick scaffolding. The glued version, which is essential here, is not adhered to. As soon as the bricklayer is at height with his work, the masonry scaffolding can go away, unless the contractor also wants to use the masonry scaffolding for trimming the gutter and wants to use it as fall protection for the roofer. So there will no longer be a single person at work. The bricklayer delivers the end product in a single pass.

Like the traditional masonry, the gluing work is on the critical path and runs the risk of delay due to rain and wind. The gluing work starts earlier than traditional 20 because it is not necessary to wait for: - building inner cavity leaf - insulating (also from outside on the scaffolding, in all weather conditions) - dimensions for frame and hoisting of the frame.

25 The gluing work has a shorter lead time than traditional bricklaying because: - the gluing has no limitations due to "floating" - the jointing is canceled

Phase 2: Remove work-through window and install Kapla frame.

30 The frame is placed at the end of the completion of the dwelling. Usually, the work-through window is removed first. The steel connecting shoes are detached from the inside. The work-through window is pulled in 10 2 9 80 7 9 and is then released. It is completely removed to be dismantled and possibly recycled. The frame opening is now ready to place the frame in it.

The frames, which are made by the same carpentry factory as the working windows 5 (prevents dimensional errors from creeping in), are supplied ready-made. They are glazed, painted, fitted with hinges and locks, possible ventilation facilities, sealing tapes for air sealing against the later inner leaf and water barriers at the location of the future air cavity. It is even possible to integrate the leak sill function (usually a separate leak sill 10 of baked material, which is subsequently mounted under the wooden sill) into the frame. The sill of the frame is then made of plastic concrete, provided with a draining edge on the front and with a neutral for the connection to the frame wood of the uprights of the windows (because of the neut the connection is above the sill and becomes so much less 15 exposed to dripping rainwater). In other words, the durability and quality of the frames are a category better than the quality of traditional bricklaying frames.

On the day of assembly, the frames are supplied on special racks, with the assembly side outwards. This saves a storage operation and prevents storage damage (and vandalism). In preparation, suction cups are placed on the glass of the frame below. There are steel shoes on the floor-to-floor stands that provide vertical support. These shoes also served to position the work-through window. With high frames without parapet, a fall-out protection is installed to protect the fitter.

The frames are hoisted into the window opening with a crane and special (existing) hoisting equipment. The frame is held with the crane in a vertical position in front of the frame opening. The fitter stands in front of the frame on the inside of the house and can guide the frame on the suction cups during lifting. The wooden uprights from floor to floor provide the stop and the temporary vertical support is provided by previously described shoes on the vertical uprights.

10 2 9 80/10

The fitter checks the positioning and secures the frame. He loosens the hoisting tool so that the crane can go and get the next frame. The frame is then finely positioned and fixed against the outside brickwork with stainless steel brackets from the inside (the brackets are first placed on the frame with wood screws and then with tap bolts on the outside brickwork). For the record: no dimensioner is involved anymore, because the dimensions are already | determined by the frame opening. j! 10 Installation is fast (about 10 minutes per frame). The work order goes! probably from home to home. Two houses (with 30 to 40 frames) can be placed per day. With bricklaying frames it is not possible to mount the entire house in one go, because the frame installation takes place from the masonry scaffolding. Masonry frames are therefore placed on the construction site for a long time and are placed 15 bit by bit. Dimensioning is also fragmented. Dimensioning and the traditional frame locations cost about 60 man minutes per frame, a considerable saving.

After this assembly action, the home is wind and rainproof.

20

Phase 3: Installing insulation 5 incl. Open cavity 6.

The building order depends on the type of inner wall that is selected and in particular on whether that inner wall is placed before or after the application of the cement screed: 25 - plaster blocks inside walls (and also plasterboard inside walls) come onto the cement screed - gas concrete panels come up the rough floor for the cement screed

The most used inner wall is the plaster block wall. In this context, preference is given to a building sequence in which the screed is already applied for the frames (prevents stain). In that case, the insulation starts immediately after the frame assembly.

1029807 11

Cavity anchors are drilled in the inside of the brickwork exactly at the height of the seam in the insulation boards (sheet material or mineral wool). Where necessary, spacers are provided on the insulation material to ensure a continuous air cavity. The insulation boards run alongside the floors and are tightly connected to the frame. There is now, in contrast to the traditional method (the bricklayer applies insulation and brick it in immediately, which makes control difficult and only possible for a short time) to have sufficient time to check it; thermal bridges can be corrected and air leaks remedied.

10

There is now an air cavity that has an open connection to the outside air along the window frames and there is no contact between frame wood and brick. In short, a sustainable frame connection has been realized and a well-ventilated air cavity that is accurately and fully insulated on the inside.

15

The insulation is now installed from the inside. The vulnerable insulation boards do not blow and can no longer get wet during the construction phase (and therefore cannot sag under this moisture weight). The contractor is free to choose who will install the insulation. Under no circumstances is this the bricklayer. The work can be carried out by the plaster block adjuster, but also by a carpenter or a trained specialist.

Phase 4: Installing inner cavity leaf and window sill / sill.

The architect and the contractor are free to choose the inner cavity leaf. The wind-bearing function has been canceled. The function is therefore no different from that of the normal non-bearing inner walls, only the inner cavity leaf only has to be finished on one side. The choice therefore generally falls on the same product that is used for those inner walls. After all, the work can then be carried out by the same people and in the same course of work as the non-load-bearing inner walls.

10 2 9 80 7 12

Instead of the traditional wind-bearing inner cavity sheets of stone-like material with a thickness of 100 mm or more, the following can now be chosen: - plaster blocks thickness 70 mm, the most commonly used non-bearing inner wall - gas-concrete floor-high panels of 70 or 100 mm thickness 5 - dry-mounting walls of Fermacell or Metal Stud. These non-bearing inner walls are 70 mm thick (two plates with 50 mm of insulation material between them), but if they are used for the inner cavity leaf, the thickness is reduced to the single plate thickness of approximately 10 mm. In this case the insulation is only applied after placing the extremely thin steel or thin wooden posts on which the plates are screwed later.

Provisions for the technical installation can now easily be incorporated in the inner cavity leaves, at the same time as the other walls, as is proposed, for example, by patent NL1026944. The time of installation of the technical installation has been strongly shifted to the delivery in the reverse order of construction. This is of great importance because buyers often only know at a late stage of construction where the Electra installation is exactly desired.

20 The above-mentioned inner cavity leaves are not only thinner (gain of space more square meters on the same plot or a slightly smaller house on the outside with savings on the floors, the roof and foundation).

The cost saving on the inner cavity leaf is considerable. The wind-bearing 25 inner cavity leaves cost around 100 Euros (in-situ bricklaying) to 120-150 (prefab concrete and timber frame) Euros per square meter, while the new choice is between products between 20 and 30 Euros per square meter. (Terraced house has approximately 30 m2 inner cavity leaf).

30 If an inner cavity leaf is chosen in the same material as the non-bearing inner walls and is built in the same working run as the inner walls, which is very obvious, a whole working run will be canceled in the planning and the construction time of the house shortened (from a few days to a few weeks) and thus also reduces construction site costs.

Application of the present invention thus makes it possible to combine the favorable aspects of two recently introduced innovations. The use of a reverse building sequence, as described above, is added to this favorable combination. As a result: Shorter construction time due to the use of ready-made frames that fall outside of the critical path of the separate working run for the inner cavity leaf the disappearance of the critical path from insulating joints is canceled Higher quality due to application of Kapla frame due to choice of adhesives as a masonry technique because it is insulated from the inside, independent of the masonry in the version and can be inspected for a longer period of time because the inside cavity wall is fitted from the inside with optimum choices of water-retaining (especially the top of frame) air seals around the frame and execution in conditioned conditions Other place the moment of the Kapla frame 25 places before installing the cavity leaf and insulation (and not as traditional Kapla after placing the inside cavity leaf) the dimensions of the inside cavity leaf are no longer required; the dimensions are taken from the frame '30 - Cheaper.

10 2 9 80 7 14

Although gluing still costs more than traditional bricklaying (despite the fact that the aftermath has lapsed), this is more than compensated for by: shorter construction time 5 transition from expensive heavy and considerably cheap inner cavity leaf

Kapla is itself cost neutral; now the dimensions of the inner cavity leaf are no longer required

Two costly parts of the Kapla method are eliminated 10 - the Kapla strip that is necessary for the dimensions of the inner cavity leaf - the Kapla mounting bushes, which are necessary for the positioning of the frame and the connection of the frame with the outside leaf 15 - depending on the design space gain the inner cavity leaf is traditionally 100 mm thick.

Smaller air cavity due to adhesives and work from the inside (expected gain 20 mm)

With metal-stud inner cavity leaf, the space gain is greatest 20 (70 mm per façade), but also with bicycle blocks there is also a space gain of 30 mm per façade. Design freedom of choice with regard to interior walls, more possibilities for placing technical installation, 25 integrated end of drainage phase leak sill function 10 2 9 80 7

Claims (6)

Method for building an outer wall to be provided with one or more frames, comprising an inner cavity leaf, a cavity and an outer cavity leaf, characterized by the following steps: 5. the outer cavity leaf (1) is bricked around one or more timed work windows ( 2); • the one or more work-through windows are removed and replaced by frames (4); • insulation (5) is provided against the inside of the outer cavity leaf, optionally with the intervention of an open cavity (6); • the inner cavity leaf (7) is fitted from the inside. Method according to claim 1, wherein the outer cavity leaf is made of mutually glued bricks. 3. Method according to claim 1, wherein the frames are Kapla frames, which are hoisted in from outside and mounted from inside. Method according to claim 1, wherein the installation of the inner cavity leaf is postponed to the completion phase of the building in question. 5. Method as claimed in claim 1, wherein the inner cavity leaf is arranged in the same working course as in which non-bearing inner walls of the building in question are arranged. Outer wall, manufactured according to the method according to one or more of the preceding claims. 25 10 2 9 8 0 7