WO1999042674A1

WO1999042674A1 - Set of construction members for realising a construction body and method for producing and using the same

Info

Publication number: WO1999042674A1
Application number: PCT/CH1999/000075
Authority: WO
Inventors: Balz Jenny; Ueli Rhyner
Original assignee: Jenny & Co. Ag
Priority date: 1998-02-19
Filing date: 1999-02-16
Publication date: 1999-08-26
Also published as: EP1056910A1; AU2262399A

Abstract

The present invention relates to a set of construction members comprising a plurality of construction members (1) which can be joined together for building outer walls tightly connected together as well as partitions (17) connected together by key-slot couplings in order to form outer or inner walls. The outer-wall members (1) can be used for forming wall, angle or curved sections and consist in reinforced members assembled on the spot with concrete so as to be rigidly interconnected. Their upper and lower outer edges are used as a form-work for the slab (4) to be poured using concrete as well as for the floor-covering plates (26), which eliminates the need for any wooden form-work. Other construction members for the inner walls (17) can be connected together and with the outer walls (1) using key-slot couplings. The floor-covering plates (26) are obtained by pouring concrete on finished plates (19) while the outer-wall members (1) are simultaneously filled with concrete. The plates (19) can be mounted on the already-assembled outer and inner walls (1, 17) using a reduced quantity of connectors (18).

Description

Component set for creating a structure, as well as methods for producing and using the same

This invention relates to a component set consisting of special components that can be used in general for creating a structure. The structure can be, for example, a one- or multi-storey building in solid construction. But other structures such as retaining walls, garages and similar structures can also be created with this component set. The invention further relates to the method of how the components of this component set are manufactured, and also how the component set is used in practice to create a building structure and in particular a one or more storey building.

According to the conventional design for a building, for example for a garage, a commercial building, an industrial building or a residential building, a foundation is laid after excavation, on which a first floor slab is concreted, for which an edge formwork is necessary. The first walls are then shuttered, reinforced and concreted in place, with the corresponding recesses for the windows, doors and building services having to be measured and installed in place beforehand. After concreting, the walls must be stripped and treated by removing any eyebrows and gravel nests are filled. Binding points and joints must be sealed separately. The interior walls are then built by hand from stones and mortar, whereby the doors and other openings and recesses for installations have to be made to measure and lintels have to be moved. Such limestone or brick walls are always more or less inaccurate because they are created by hand and must therefore be provided with a leveling plaster of 1 to 2 cm thick. To create the next floor-ceiling slab, a large number of sprouts are required, which must be placed individually and on which longarines are then placed, on which, in turn, squared timbers are placed as distribution timber, which ultimately carry the many formwork panels. Then the underarming of the floor-ceiling slab is created first. As soon as this is installed, the electrician, the heating engineer and the plumber must appear and install their installations, after which the upper armouring can be created over these installations. The edges of the floor-ceiling slab to be concreted must now be shuttered and finally this floor-ceiling slab can be concreted. All of this work is essentially repeated for the next floor. For the attic, usually two gable walls made of bricks are raised and after the ridge purlin has been placed, the space between the rafters and the gable walls has to be bricked up, which is quite complex.

The just described conventional construction of a building or house, which is then very solid, is complex and it has to be taken into account in many different conditions. The process over time must be coordinated between different experts, many devices must be available at all times and the individual construction steps are also very labor intensive. Because the coordination of the work on the one hand can never be perfect and other boundary conditions cannot always be met, construction progress is often delayed due to the many unavoidable work stoppages. For example, sometimes the underarming is finished a little earlier than planned and the plumber is not yet there, sometimes it is the other way around. In both cases, one construction specialist has to look at the other 3

waiting. The upper reinforcement can only be created if, for example, the water drains have been laid. Sometimes the concrete runs out, sometimes it is not yet dry, while you actually want to start shuttering. In addition, practically an entire "construction factory" has to be built on site. That means that concrete has to be prepared or constantly transported. You always need a crane, a carpenter's workshop to cut the formwork as well as the machines for its reprocessing, etc., etc.

The object of the present invention is now to provide a component set for creating a structure and to specify the method for its production and use, with the use of this component set to overcome many of the above disadvantages. Building should be more efficient, faster and less labor-intensive, and several steps can be saved compared to the conventional construction method described briefly above. At the same time, however, the construction quality should not suffer and the process and the elements should enable the builder to still create a tailor-made building or house that does not suffer from the image problem of a prefabricated series house.

This object is achieved by a set of components for creating a building structure, which is characterized in that it consists of pourable components for the creation of firmly connected external walls and of walls that can be connected to one another via tongue and groove connections as external or internal walls consists.

Furthermore, the object is achieved by a method for producing such a set of components, which is characterized by the features of claim 8, and finally by a method for creating a structure with such a set of components, which is characterized by the steps according Claim 9 is distinguished. 4

In the drawings, exemplary embodiments of such components are shown that belong to such a component set. They are described below and the manner in which they are manufactured is also disclosed. The drawings also show how such components can be used to build a building, the individual steps being explained and explained.

It shows:

Figure 1: A pourable component in the form of a corner element for an outer wall shown in a perspective view;

Figure 2: A pourable component with its front connection wall elements, as well as with an inner wall built at a right angle, and a further inner wall at right angles to this inner wall, shown in the floor plan;

Figure 3 The floor plan of a basement, created with components for the outer and inner walls;

Figure 4 shows the individual stations A-D of the construction of a basement in an elevation;

Figure 5 shows the individual stations A-C of the construction of several floors and the attic in an elevation;

Figure 6 The tubes and tube segments to achieve the recesses in the pourable components.

A set of construction elements according to the invention for creating a one- or multi-storey building consists of pourable construction elements for the 5

make of firmly connected outer walls as well as inner and outer walls that can be connected to one another via tongue and groove connections. The pourable components are first described and explained in more detail. Such a pourable component 1 of the component set is shown in perspective view in FIG. It is a corner element for the basement of a building. It was cast from concrete and has recesses 2 on its inside, which were formed from overlapping cylindrical recesses 3. The remaining part of the element consists of solid material and therefore consist of concrete or reinforced concrete. The two sides which surround the recesses are connected to one another via the webs 38, so that the inherent stability of the component 1 is ensured. According to the same principle as the component 1 shown here, straight components or curved components with any radii of curvature can also be produced. At the locations of the webs 38, the inner wall 16 extends all the way to the bottom, while it is otherwise withdrawn around the ceiling of the floor slab to be created, as is indicated by dashed lines. On the upper side of the component 1, the inner side 16 is set back in the same way by the thickness of the floor slab to be created, so that the outer side 14 of the component 1 serves as edge formwork, as will be described later. So that the finished components 1 can be easily attached to one another, the end faces or joints are provided, for example, with trough-shaped cutouts 12. Two such end faces or joints can then be put together with the surfaces 1 1, after which a round recess is formed between two elements 1, which is poured in place with concrete after the placement of these pourable components 1, whereby a firm connection of the two neighboring ones Components 1 arises. The aim, which is to be achieved with the use of such components 1 as basement outer walls, is to be able to rationally carry out as much work as possible in connection with the construction of an underground floor in a stationary factory and to produce such components 1 that are as light as possible to be transported, handled and set. With the principle presented here, such components 1 can be prefabricated precisely in a factory 6

so that formwork no longer has to be created on site. In the factory, the formwork can be created more efficiently and reused. The recesses 2 shown here contribute to the fact that the building elements 1 are not heavy and can therefore be easily lifted with a mobile crane and placed precisely on site. Furthermore, the trough-shaped recesses 12 serve to connect a plurality of components 1 to one another and, like the recesses 2, are rationally filled with pumpable concrete.

In Figure 2, a variant of such a pourable component 1 is shown in plan, with another pourable component 1 being attached to the end faces thereof. The trough-shaped recesses 12 of the adjacent elements 1, together with the end-side trough-shaped recesses 12 on the intermediate element 1, each form a cylindrical recess. Between these cylindrical recesses 12 and the recesses 2, a web 38 extends over the height of the component 1 to ensure the intrinsic stability of the component 1. In the example shown, the intermediate component also has a vertically extending groove 5 on its inside, which is used for mounting an inner wall 17 is used. These inner walls are also prefabricated building elements 17. They advantageously consist of expanded clay, for example of Lecca concrete, which is lighter than conventional concrete and which has a lower strength, but is excellently suitable for inner walls as well as for outer walls. In the example shown, an inner wall 17 is attached to the pourable component 1 at a right angle and a further inner wall 17 is in turn attached to this inner wall 17 at a right angle. The groove 5 for the connections is formed by a steel profile 6, which in the example shown includes a trapezoidal cross section. So that the steel profile 6 is well anchored to the component, it has wings 7 which protrude on both sides and which were cast in during the production of the component 1 or the wall element 17. As far as the mass of such a component 1 is concerned, it can vary widely. The wall thickness can be, for example, a total of 20cm, then 7

the diameter of the round recesses 2 is, for example, 12 cm. If these are nicely averaged over the wall thickness, as shown here, 4cm solid material or concrete remain on both sides. This 4 cm thick concrete wall can accommodate the groove profile 6.

The counterpart to the groove 5 is the spring 8. This consists of a profile 9 running on the end face of the inner wall 17, trapezoidal in cross section. On its side facing the component 1, this steel profile 9 has a wing 10 with a Y-shaped end that is poured into the concrete or expanded clay. Because the groove and associated tongue are made of a steel profile, they can be made to fit perfectly. In addition, these steel profiles are very strong and therefore the grooves and tongues are protected from damage when the construction elements are handled. The assembly of the elements is very simple and safe, simply by pushing one element with a light crane from top to bottom into the groove or over the tongue of the element already installed - done. It goes without saying that the cross-sectional shape of the tongue and groove does not necessarily have to be trapezoidal, but can just as well be circular. In both cases, the connection can absorb tensile force and thus immovably connect the two elements. However, it is not absolutely necessary that the connection can absorb traction at all. In most cases, such a tongue and groove is sufficient, which, when put together, result in a connection which holds the elements which are joined together in the element plane. The tongue can also be just a metal bar that fits into a corresponding groove on the next element.

Figure 3 shows the floor plan of the basement of a building, the outer walls with the pourable components 1 and the inner walls 17 were created with expanded clay walls. The outer walls here consist of nine pre-fabricated elements 1 lined up, which can of course be installed very quickly, since they can only be placed one by one with the crane and are simply placed. There is no need to create formwork, which means that a great deal of effort is avoided. 8th

Otherwise, a carpenter's workshop must be used to create the formwork on the construction site, which custom-made this formwork with all the required recesses, then set it up and dismantled it after concreting. In addition, post-processing on the basement walls is no longer necessary, because these are perfectly prefabricated. The cutouts 12 in the outer walls are filled with pumpable concrete after the construction elements 1 have been placed, after which the individual elements 1 are fixed and are also firmly connected to one another. These areas 12 poured with pumpable concrete are shown hatched here. After a box has been created in this way, the base plate 4 is concreted. For this purpose, a reinforcement is laid and then concrete is poured into the box and this is then distributed, as will be described later. After completion of the base plate 4, the inner walls 17 are attached to each other and placed one above the other by means of a crane by means of the grooves and tongues provided, the tongues in the corresponding grooves ensuring an accurate and, if necessary, tensile connection. Then the next floor slab can be created, as will be described for Figure 4. The recesses 2 in the components 1 are then concreted together with the floor slab to be created, which comes to rest on the components 1.

Figure 4 shows the stations A to D in the construction of a basement of a building created with such a set of components based on an elevation. First, as shown in Figure A, a foundation 13 is created in a conventional manner. The pourable component 1 for the outer wall of the floor is then placed on the foundation 13. The inner wall 16 of this component 1 extends with its webs 38 as far as the outer wall 14 so that the component 1 itself can stand. Over most of the length of the component, however, the lower edge 15 of the inner wall 16 only extends down to the level of the base plate still to be created. Thus, the outer wall 14 of the component 1 simultaneously forms the floor slab formwork, as will be described later. On the top, the inner wall 16 of the 9

Component 1 equally only up to the level of the underside of the floor slab to be created, so that the outside 14 can serve as edge formwork for the floor slab, as will also be described.

As soon as all the components 1 for the outer walls of the floor have been placed and, if necessary, stabilized with aids, the front recesses 12 in these components 1 can be filled with pumpable concrete, as a result of which these storey outer walls form a stable box after these concrete fillings have hardened. The base plate 4 can then be created. As shown in Figure B, the base plate 4 has a reinforcement on which the concrete is then heaped up and distributed up to the level of the lower edge 15 of the inner walls 16 of the components 1. The outer sides 14 of the components 1 form the permanent formwork of the floor slab 4 when the floor slab 4 is concreted. After hardening, the floor slab 4 is detached and roughened in the conventional manner.

In the next step, which is shown in Figure C, the inner walls 17 are placed from above, in such a way that their end faces consistently by tongue and groove either with a component 1 for the outer wall or with another inner wall element 17 are connected. There is therefore no longer any need for masonry work. The inner walls 17 already have all the desired recesses and lintels 37, which can be created much more efficiently in the factory. As soon as you are ready, next, if necessary, sprouts 18 are placed for the first floor-ceiling element panel 19 and then the prefabricated floor-ceiling element panel 19 with possibly already installed lower reinforcement and all necessary recesses on the upper edge 20 of the Inside 16 of the outer wall components 1 and placed on the upper edges 21 of the inner walls 17. Of course, several such floor-ceiling element panels 19 in handy sizes are used for an entire floor and are attached to one another. These element plates 19 then form the ceiling of the floor below and at the same time the lower formwork for the floor-ceiling plate to be concreted. The individual are advantageous 10

Floor-ceiling element panels 19 are already equipped with the reinforcement and the electrical and sanitary installations as well as the heating elements can already be permanently installed on them. If necessary, they can even have the upper reinforcement. In this case, the concreting of the floor-ceiling slab and the simultaneous concreting of the recesses 2 in the building elements 1 can begin immediately, which then leads to the situation shown in the picture D. Otherwise, the underarming 22 must first be created on the floor-ceiling element panels 19, or if it already exists, the electrical 24 and sanitary and heating lines 25 may also have to be built up, and then the upper armoring 23 must be created above it. With great advantage, however, the floor-ceiling element panels 19 have all of these devices 22-25 already from the factory. There, these reinforcements 22, 23 and building services installations 24, 25 can be set up more efficiently. You then do not have to wait for the relevant experts on the construction site until you can continue with the concreting and building. For the actual concreting of the floor-ceiling slab 26, concrete is poured onto these laid floor-ceiling element slabs 19 and distributed, the upper edge of the outer sides 14 of the surrounding outer walls 1 forming the formwork. At the same time, the concrete falls into the recesses 2 in the outer walls 1, so that they are thus concreted. The concrete then only has to be filled and leveled up to the level of the upper edge 27 of the outer sides 14 of these outer walls 1. So that the floor slab 26 is completely concreted. It is still detached and roughened and then the first basement is completed. The next basement, if there are several basements to create, is created in exactly the same way as the first.

As soon as above-ground storeys are to be built, components made of expanded clay are sufficient in most cases and therefore no further pourable components 1 are required. The construction of two floors on a basement is shown in Figure 5. The expanded clay components 17 are consistently for the entire floor like the inner walls 17 of the basement floors 1 1

created, that is, by simply lining them up, each of which is inserted with its end-side spring into the groove on the end side of the one previously laid. The inner walls 17 can also be connected to one another at a right angle, for which purpose one component has a tongue or groove in its side, as has already been described for FIG. 2. A floor with prefabricated windows, doors and other recesses on elements 17 can thus be set up in a very short time. The outer walls advantageously have a stepped upper edge 33, so that the upper edge of the outer side of the outer wall element 17 can serve as formwork for the next floor slab 26, as shown in Figure B. For the top floor, components 28 with bevels 29 for purlins 30 are placed at the top to place a gable roof, as shown in Figure C. This eliminates the time-consuming task of creating a gable masonry, which is otherwise first pulled to a raw height and can only be bricked up after the roof truss has been put on. With these components 28 which can be assembled into a gable, on the other hand, the upper edge 31 can be adapted exactly to the course of the gable rafters 32, so that there is no need for lining. The roof structure can then be created in a conventional manner.

The components for the outer walls, the inner walls and the floor-ceiling panels are prefabricated in a factory ready for installation. In the case of the components for the outer walls, formwork walls that run parallel to one another are first constructed to the desired wall thickness, spaced apart from one another in the length and height of the desired element, and the length of the component is determined with formwork walls on the end face. These formwork walls are connected to a fixed box and can be used several times, so that a rationalization effect sets in. In the enclosed space, pipes are then placed alternately, running parallel to one another and closely adjacent to one another, and fixed on the one hand and pipe circumference segments connected to one another via a web. 12

As shown in Figure 6, the tube circumference segments 36 are formed from two mutually connected via a web 35, opposite shells 36, the shells 36 each forming a tube wall segment which extends for example by a circumference of 90 °. These tube segments 36 are then, as shown, put together with the tubes 34 to form a continuous recess. The outside of the tubes 34 and tube segments 36 are treated with a setting retarder before being inserted into the formwork box. In the next step, the spaces that remain free between the pipes 34 and pipe segments 36 on the one hand and the formwork walls on the other hand are reinforced. For this purpose, prefabricated reinforcement grids can be placed in these rooms. The free space is now poured with concrete. After the concrete has solidified, but before it has fully hardened, the pipes 34 and pipe circumference segments 36 are pulled out. When the cast element is completely hardened, it is switched off all around and is then ready for transport to the construction site.

The components, which consist of solid material and are not reinforced, such as those used for the inner walls or the outer walls of above-ground floors, are manufactured in a similar manner. The end faces between the two longitudinal formwork walls are then closed, including the space between them, with one formwork wall each, which carries a steel profile that runs along the front side of the enclosed space and engages in this space, with a trapezoidal cross section, for example, on its outer sides Has wings that extend into the pouring space. In this case, a steel groove with a trapezoidal cross-section is created on the end of the finished structural element 17.28. Conversely, a steel profile can also be cast in, from the inner side of which a wing with, for example, a Y-shaped end extends into the space to be poured out, so that finally a spring with a trapezoidal cross-section protruding from the end face of the component 17.28 is formed. Such components can thus be connected to one another by inserting the tongue of one into the groove on the other. However, it is not absolutely necessary that 13

this tongue and groove connection must be able to absorb tensile force. A tongue and groove connection that only absorbs lateral forces may also suffice. The components for the outer walls of the basement can also have such grooves or tongues on their sides, so that the inner walls can be attached, for example, at right angles to the outer walls or other inner walls.

Claims

14 Patent claims

1. Set of components for creating a building structure, characterized in that it consists of pourable components (1) for the creation of firmly connected outer walls and of walls (17.28) that can be connected to one another via tongue and groove connections as outer or inner walls .

2. Component set according to claim 1, characterized in that each pourable component (1) forms a wall or arch or corner section (1) of a building to be constructed from the desired wall thickness of reinforced concrete, with at least one inside There is a recess (2) which extends in the vertical direction over the entire height of the element (1) and has the shape of cylinders (3) which are arranged parallel to one another and partially overlap one another. ^~

3. Component set according to one of the preceding claims, characterized in that the pourable construction elements (1) on at least one end face (11) have a trough-shaped recess (12) running along the same and in the middle thereof.

4. The component set according to one of the preceding claims, characterized in that the side of the pourable components (1) to be used as the outer wall (14) has a height at the top and / or bottom to act as the inner wall (16) exceeds the thickness of a floor (4) or floor cover plate (26).

5. A component set according to one of the preceding claims, characterized in that the sides (16) of the pourable components (1) to be used as the inner wall have grooves (5) or springs (8) made of inserted steel profiles (6, 9 ) exist, the steel profiles (6,9) 15

have wings (7, 10) on their side facing the element material, which are cast in the element material.

6. The component set according to one of the preceding claims, characterized in that the inner walls (17) or outer walls (17.28) which can be connected to one another via tongue and groove connections have a groove (5) or tongue (8) along their end faces , each of which is formed by an inserted steel profile (6,9), the steel profile (6,9) on its side facing the element material having a longitudinally extending profile (6,9) wing (7,10) in the element material is poured.

7. Set of components according to one of claims 5 to 6, characterized in that the grooves (5) and springs (7) have a trapezoidal or circular cross section and consist of inserted steel profiles (6,9) which include such cross sections, wherein the steel profiles (6, 9) have wings (7, 10) on their side facing the element material, which are cast in the element material.

8. A method for producing a set of components for creating a building structure, characterized in that on the one hand for the pourable construction elements (1) a) formwork walls running parallel to one another to the extent of the desired wall thickness spaced apart from one another in the length and height of the desired element ( 1) be built up; b) in the enclosed space from above alternately, running parallel to one another and closely adjoining on the one hand tubes (34) and on the other hand connected to each other via a web (35) connected tube circumference segments (36), these tubes (34) and Segments (36) were previously treated with setting retarder; c) the free space is reinforced with reinforcing steel; d) the remaining space is poured with concrete; 16

e) the tubes (34) and tube circumference segments (36) are pulled out before curing is complete; f) the cast element (1) is completely switched off after curing; and, on the other hand, for the inner walls (17) or outer walls (17.28) a) which can be connected to one another by means of tongue and groove connections, formwork walls which run parallel to one another to the extent of the desired wall thickness and are spaced apart in the length and height of the desired element (17.28) become; b) the end faces between the two formwork walls, including the space between them, are each closed with a formwork wall which has a steel profile (6, 9) running along the end face of the enclosed space, which has a groove or a recessed in the enclosed space Spring protruding from the enclosed space, whereby wings protrude from this steel profile (6,9) into the enclosed space; c) the remaining space is filled with expanded clay or concrete; d) the cast element is completely switched off after curing.

9. A method for creating a building body with a plurality of building elements of a building element set according to one of claims 1 to 7, characterized in that a) on the foundation (13) for a first floor or basement, adjacent building elements (1) are made, which form the floor plan, the end-side recesses (12) of these structural elements (1) being poured with pumpable concrete, so that their outer wall (14) then rests consistently on the foundation (13), while the lower edge (15) most of the inner wall (16) is set back upwards by the thickness of the base plate (4) still to be created and only rests on the foundation (13) on the webs (38); 17

b) the reinforcement of the base plate (4) is created and then the concrete for the same up to the set back lower edge (15) of the inside (16) of the construction element (1) is introduced, the outer wall (14) of the construction element (1 ) forms the edge formwork for the floor slab (4), and this is then detached or roughened; c) the construction elements for the inner walls (17) are attached to one another from above by means of the springs (8) and grooves (5); d) sprouts (18) for the next floor-ceiling element plate (19) and then a prefabricated floor-ceiling element plate (19) with built-in lower reinforcement and all the necessary recesses is set; e) if necessary, an upper reinforcement is created on the floor-ceiling element plate (19) and then concrete is introduced up to the upper edge (27) of the outer sides (14) of the components (1) until the recesses (2) in the components (1 ) are filled and the floor-ceiling element plate (26) is created, the upper edge of the outer wall (14) of the construction element (1) forming the edge formwork for the floor-ceiling plate (26), and afterwards it is detached or roughened; f) for each floor, in turn, placing components (1, 17) for the outer and inner walls, and, if necessary, pouring the outer walls, then steps c) to e); g) in the case of a gable roof, setting gable-shaped components (28) with recesses (29) for the purlins (30).