SE533326C2 - Building elements and method of building exterior walls with said elements - Google Patents

Description

20 25 30 35 40 Lightweight concrete building blocks with volume weights between 400 - 800 kg / m3 have been manufactured since 1930. The first lightweight concrete was based on alum shale. In the 1970s, however, it was pointed out that it was inappropriate to use this material as it contains uranium that emits radon, which led to the production of alum shale-based aerated concrete ceased in 1975. Since then, aerated concrete has continued to be produced by e.g. finely ground sandstone, cement and lime, which are brought to expand in an autoclave by gas evolution caused by the heating of aluminum powder in the recipe. These building blocks are usually manufactured in smaller units that are stacked and joined together at the workplace, to be compared with the construction of a wall. However, the capillary suction force is so strong in these materials that moisture absorption risks significantly reducing the insulation capacity, depending on installation and use.

A method of mixing lightweight expanded polystyrene (EPS) foam particles into the cement mixture was launched as early as the 1950s and has found some use as lightweight concrete ballast at higher bulk weights, about 1000 kg / m3 or more, which in itself is a significant weight reduction. from the normal density of the concrete of about 2,400 kg / m3. The problem has been to obtain a homogeneous mixture when the foam balls float up in the water mixture. This problem is today affordable and purpose-treated EPS particles can be purchased on the market. This development has also made possible the advent of the present invention.

Summary of the invention The object of the invention is to provide a simplified, quality-assured, cost-effective, resource-efficient, environmentally friendly, non-combustible, meadow diffusion-open building system based on cement or other mainly inorganic material but with low volume weight which thus also gives the material built-in insulation.

Another object is to achieve an "all-in-one material" in the form of manageable and collapsible building elements which also means a fast and quality-assured assembly on the construction site.

Building elements according to the invention contain highly insulating EPS particles or particles of other insulating material or medium mixed in a cement mixture or other mainly mineral-based building mass which hardens when it reacts with water. Due to their admixture in the wet building mass, the particles give the resulting cured lightweight material a bulk density after curing of about 50 - 800 kg / ms, the compressive pour strength is more than 0.5 MPa and has a thermal conductivity Ä less than 0.15. Preferably the volume weight is 300-600 kg / m3 and preferably 400-500 kg / ms, the compressive pour strength is more than 1.0 MPa and preferably more than 2.0 MPa and the thermal conductivity Ä is less than 0.12 and preferably less than 0.10 . 10 15 20 25 30 35 40 1.51 ia itu A Wi m 3 The insulation particles are moisture-tight and preferably have a bulk density of less than 50 kg / m 3, more preferably less than 30 kg / m 3. Most preferably, the particles have a bulk density of up to 15 kg / ms. The volume weight is generally inversely related to the thermal conductivity number k, ie the lower the volume weight, the higher the insulation value. The desired volume weight of the final product can be determined according to the mixture of the amount of particles. Preferably, a mixture containing at least 50% by volume of expanded polystyrene (EPS) insulating particles with closed cells or other non-moisture absorbing material or medium having a bulk density not exceeding 30 kg / ma is used. Even eg blowing agent, air or other medium can be added to the mixture. The insulating particles may have, for example, graphite or aluminum admixture for increased insulating ability. The particles can have different fractions of different sizes for improved degree of filling. Without different fractions, air spaces are created between the concrete-coated and adhering particles, which thereby gives the mixture a poorer insulation value, ie thermal conductivity. The insulation particles can have all shapes but are preferably spherical to obtain optimal strength in the concrete shell formed around each particle. adjacent scaled particles. For increased strength in the concrete shell, for example, glass particles can be added to the cement mixture.

A material mixture suitable for the invention and prepared in this way can obtain a / a thermal conductivity number (lambda value) of less than 0.15, preferably about 0.060. l 2, b / a compressive pour strength of at least 0.5 MPa, preferably at least 1.0 MPa, c / a meadow passage resistance between 100 000 - 400 000 s / m, preferably between 100 000 - 100 000 s / m, preferably between 10 000 - 30,000 s / m.

Building elements have a unfolding shape, ie it is intended to be mounted in the open space between erected vertical elements, such as inner walls or girder beams, and subfloors to form the outer wall. The unfolding element has at least one form fit fitting in the space formed by subfloor layers and vertical elements and has a circumferential projection for abutment against subfloor layers and vertical elements. In this way, vertical elements and subfloors are insulated from weather and wind on the outside of the outer wall formed by unfolding elements.

Preferably, the unpacking element has at least one excess lip extending beyond the circumferential projection along one or two adjacent sides for overlapping joints between adjacent unfolding elements in mounted position. In this way, heat leakage is minimized and cooled in the joint between the unfolding elements. Preferably, both protrusions and lip are integrally molded from the same material as the remaining portion of the unfolding element. In order to minimize the heat leakage and the cold slide even more, a seal can be arranged on the mold fits, for example a sealant.

In addition, the unfolding element preferably has a fitting or device for solution against bee layers and vertical elements, respectively, for fixing in its mounted base.

Devices can be poured into the building element according to the invention. It can be, for example, reinforcements, fastening devices so that screws can fasten well in the building elements, frames for windows or doors, whole windows or doors, electrical or water mains, etc. The reinforcement can be one-, two- or three-dimensional adapted for each construction shaped reinforcement structure, of e.g. metal nut, embedded in the element to be able to withstand very high load requirements both vertically and horizontally. The reinforcement constructions can also be cast angled, trapezoidal or in another shape. In addition to reinforcing the building element in its use in the building construction, e.g. a double reinforcement, ie two reinforcement structures in the same building element, be an advantage in connection with the manufacture of the building element in order to prevent the building element from twisting in connection with the drying after casting.

The unfolding elements are produced in a factory for later assembly on future buildings.

The method according to the invention for building exterior walls by means of building elements according to the invention comprises the step of fitting prefabricated molded unfolding elements in the spaces formed by secondary layers and vertical elements in a building frame.

The building frame is erected by joining steel beams and / or load-bearing inner walls and beehive layers to the desired height and finishing by fitting the roof beehive layer. Then mounting elements are formed which form the outer walls.

For the outer wall of the building, a plaster layer of mineral thick plaster is preferably applied with a capillary suction force that is greater than the capillary suction force of the building mass, which guarantees that the element is always dry while maintaining insulating ability.

The external mineral wall plaster layer serves partly as reinforcement, de-icing, pre-decoration layer and moisture absorber / moisture regulator, which guarantees that the insulation value of the wall is maintained by the pores of the wall element always being dry. The plaster layer of mineral plaster can be applied prefabricated in the factory or on site at the construction site. Alternatively, a panel wall of e.g. trö is mounted on the outside of the wall element with an air gap in between.

With this building system based on solid weight building elements according to the invention, a number of advantages are achieved in relation to previous technology: 10 15 20 25 30 40 išt ul! w t ... \.,. t t GT * 5 l / A uniform material concept for unpacking elements, which consist of the same type of material with the same insulation value, so that no cold drafts occur in the connections between the adjacent unfolding elements. 2 / The building elements are non-combustible. 3 / The building elements are load-bearing. 4 / The building elements are vapor diffusion open (breathable). 5 / The building elements are insulating. 6 / Because the building elements are prefabricated in a controlled factory environment, the environmental problems that otherwise apply at a construction site are avoided, which is why production efficiency and quality become significantly higher and smoother.

Brief Description of the Drawings The present invention will now be described in more detail with reference to the accompanying drawings, in which: Fig. 1 shows a building element according to the present invention having unfolded shape in cross section, Fig. 2 shows the unfolding element in Fig. 1 from the inside, Figs. Fig. 3 shows a variant of the unpacking element in Fig. 1 in cross section, Fig. 4 shows the unfolding element in Fig. 3 from the inside, Fig. 5 shows a unfolding element according to the present invention provided with reinforcement in cross section.

Fig. 6 shows an outer wall under construction from the outside of a future building, and Fig. 7 shows a mounted unfolding element from the inside of a future building.

Detailed description of preferred embodiments of the invention The building elements according to the invention are prefabricated in a factory and molded from a building mass, based on e.g. cement or other substantially inorganic material incorporating in an aqueous mixture, with admixture of expanded polystyrene (EPS) particles with closed cells or other insulating material or medium. Preferably, the prefabricated elements have a size of up to 3 x 14 m, a thickness of 100 - 400 mm and a volume weight between 300 - 600 kg / m3. The compressive strength of the building element is preferably at least 0.5 MPa and the thermal conductivity Ä is less than 0.15. The insulation particles are moisture-tight and preferably have a bulk density of less than 50 kg / ms, more preferably less than 30 kg / ms. Most preferably, the particles have a bulk density of up to 15 kg / ma. The bulk density is generally inversely related to the thermal conductivity number k, ie the lower the bulk density the higher the insulation value. The desired volume weight of the final product can be determined according to the mixture of the amount of particles. Preferably, a mixture containing at least 50 10 15 20 25 30 40 μl is used. : _43 to t DJ F-J fi ”6% by volume of expanded polystyrene (EPS) insulation particles with closed cells or other non-moisture-absorbing material or medium with a bulk density not exceeding 30 kg / m3. Even eg blowing agent, air or other medium can be added to the mixture. The insulating particles may have, for example, graphite or aluminum admixture for increased insulating ability. The particles can have different fractions of different sizes for improved degree of filling. Without different fractions, air spaces are created between the concrete-coated and adhering particles, which thereby gives the mixture a lower insulation value, ie thermal conductivity. The insulation particles can have all shapes but are preferably spherical to obtain optimal strength in the concrete shell formed around each particle against adjacent scaled particles. For example, two fractions can be mixed where preferably the first fraction of particles has a size up to 1.5 mm and the second fraction preferably has a size between 1.5 mm and 3 mm. The first fraction may constitute 20% and the second fraction may constitute 80% as an example. For increased strength in the concrete shell, for example, glass particles can be added to the cement mixture. Figs. 1 and 2 show a building element according to the invention with embodiment 7.

If a building is erected by first erecting vertical elements, such as steel beams or load-bearing inner walls 3, and subfloor 4 to the desired height and finished by fitting the subfloor 5, the outer walls shall be provided thereafter. This can be done by mounting unfolding elements 7 in the spaces formed between the sub-ceiling elements 4 and the vertical elements, such as the inner wall elements 3. The inside 8 of the unfolding element 7 fills the space between wall elements 3 and sub-complaint elements 4 The projection 9 preferably covers half the width of the wall elements 3 and the sub-floor elements 4. In this way the sub-floor 4 and vertical elements 3 are insulated so that they do not come into contact with the outside and prevailing weather of the formed outer wall.

Figs. 3 and 4 show a variant of a unfolding element 10 which creates an overlap of the joints between the adjacent unfolding elements 10 in that one or two sides are provided with a lip 11 which covers the joints along the lip-provided sides and abuts against the sides 12 of the projections 9 of the adjacent unpacking elements 10 Preferably, both projections 9 and lip 11 are integrally molded of the same material as the remaining part of the unfolding element 7, 10. In this way the joints between the unfolding elements 10 are also insulated. For example, a seal can be arranged between lip 1 1 and the surface 12 of the projection 9, for example a sealing compound (not shown). Fig. 6 shows a start of the construction of an outer wall by means of unfolding elements 10 which are fitted between vertical elements 3 and floors 4 and overlap over the joints between adjacent unfolding element 10 with at least one lip l l.

In addition, the unfolding element 7, 10 preferably has a fitting or device for solution 17 against the floor layer 4 and vertical elements 3, respectively, to be fixed in their mounted position, a possible example is shown in Fig. 7.

It is possible to cast reinforcements, window and door frames as well as electrical and water mains, anchors and other preparations already during the manufacture of the building elements. In order to simplify later installation of, for example, suspension devices in the finished building, boards of wood or traction metal can, for example, be cast into the building elements in which, for example, screws fasten in a secure manner.

The reinforcement can be a one-, two- or three-dimensional * shaped reinforcement construction adapted for each construction, of e.g. metal mesh, embedded in the element to be able to withstand even very high load requirements both vertically and horizontally. The reinforcement constructions can also be cast at an angled, trapezoidal shape or in another shape. Fig. 5 shows a building element seeds end in cross section with a zigzag-shaped reinforcement construction ló. As an example, metal wood with a diameter of 6-8 mm can be joined to a net with, for example, square decimetre-sized gaps. The nets can be shaped or pressed to the desired shape.

In addition to strengthening the building element in its use in the building construction, e.g. a double reinforcement, ie two reinforcement structures ló in the same building element, be an advantage in connection with the manufacture of the building element in order to prevent the building element from twisting in connection with the drying out after casting. The cast reinforcement constructions ló can also serve as anchors for, e.g. in combination with cast-in and in the reinforcement construction pre-welded metal sheet, fastening devices included in the building elements.

When using anchoring reinforcement, a heel can be drilled in the building element, floor and vertical elements during mounting on e.g. pre-marked place after which, for example, so-called chemical anchors can be applied. These anchors can be used to advantage when reading the unfolding elements 7, 10 after assembly. preferably, metal sheets are arranged in the reinforcing mesh along the projections 9 or the lips 11 so that a chemical anchor can be attached to floors or vertical elements and the jib element 7, 10, respectively.

The building elements can be manufactured in any design according to the geometry of a molding tool, taking into account practical limitations such as pour strength, 10 15 m m in in wn: m 8 transport constraints, etc. The building elements can for example be cast both in any diameter or living wall surface. The casting towers for the element production can be made in e.g. metal, fiberglass-reinforced plastic or other suitable material.

According to the thawing method, prefabricated lorm-cast leaching elements 7, 10 are fitted in the spaces formed by beehive layers and vertical elements in a building frame. Preferably, they are then locked with the aid of one or more fittings or a device for locking 17 against beehive layers and vertical elements 3, respectively, see Fig. 7.

On the outer side of the unpacking element, a plaster layer of mineral thick plaster is preferably applied with a capillary suction rake which is larger than the capillary suction ratchet of the unloading element, which guarantees that the element is always dry while maintaining insulating dryness. The mineral wall plaster layer serves as a drying reinforcement, de-icing, dry decoration layer and odor absorbent / discipline regulator, which guarantees that the insulation value of the wall is maintained by always keeping the pores of the wall element dry. The plaster layer of mineral plaster can be applied prefabricated in the factory or on site during construction. Alternatively, a panel wall of e.g. trö is mounted on the outside of the wall element with a sloping gap in between.

Claims (1)

1. 533 325 O) Pate ntkrav i. Building elements of the prefabricated type, which are molded from building material, based on cement or other substantially inorganic material hardened in a water mixture and ingesting admixture of particles of expanded polystyrene or other insulating material, characterized in that the building mass contains at least 50% by volume of expanded polystyrene (EPS) insulation particles with closed cells or other non-odor-absorbing material with a bulk density not exceeding SOkg / rna so that a bulk density between SO - 800 kg / m3, a compressive strength greater than 0,5 lVlPa and heat conduction number Å of less than 0, 15 is obtained, and that the building element has a leaching storm (7, 10), which building element is steam dilution open and comprises a plaster layer of mineral thick plaster with a capillary suction bead which is larger than the building element's capillary suction groove is applicable on its outside . Building element according to claim 1, in which the leaching element (7, 10) has vertical elements having a circumferential projection (Q) for abutment against subfloor layers (4) and vertical elements. . Building element according to claim 2, in which the knock-out element (10) has at least one excess lip (ll) which extends beyond the circumferential projection (9 along one or two adjacent sides for overlapping joints between adjacent leaching elements (10) in mounted position. according to one of the preceding claims, in which devices can be poured in. Building element according to claim 4, in which the pourable device is a reinforcing structure (Sat). method of providing external walls by means of building elements according to any one of the preceding claims, wherein prefabricated lormgiuttacting extraction elements (7, 10) are fitted in the spaces formed by subfloor (4) and vertical elements in a building frame.