WO2010085925A2

WO2010085925A2 - Modular system lightweight fitting element - based used for masonry units including landscaping or garden architecture

Info

Publication number: WO2010085925A2
Application number: PCT/CZ2010/000008
Authority: WO
Inventors: Jaromir Kovar
Original assignee: Kamen Kwr Kovar S.R.O.
Priority date: 2009-01-30
Filing date: 2010-01-28
Publication date: 2010-08-05
Also published as: CZ200951A3; WO2010085925A3

Abstract

Modular system for the masonry units is based on the lightweight fitting element (1) that consists of the front wall (2) and the rear wall (3) based on reinforced concrete mixture, between the front wall (2) and the rear wall (3) is located the solid filler (4) having density 8-55kg/m3 or the loose filler (4'). Solid filler (4) is attached to the front wall (2) and the rear wall (3) by binder (5) which joins together also individual fitting elements (1), while the distance from the front wall (2) of the rear wall (3) is defined using the spacers and reinforcing members (6), which connect the front wall (2) with the rear wall (3). When the loose filler (4') is used it is currently held between the front wall (2) and the rear wall (3) by sidewalls (7), firmly fastened with the front wall (2) and the rear wall (3). The front wall (2) eventually also the rear wall (3) of each lightweight fitting element (1) is fitted by facing material of different nature as stone design, architectural concrete, wood or brick, wood veneer visual imitation and materials plastic-based.˙

Description

Modular system lightweight fitting element - based used for masonry units including landscaping or garden architecture

Technical Field

The invention is related to the modular system based on the lightweight fitting element used for all masonry units - buildings but also for solid fencing and garden architecture. It is also appropriate for technically and esthetically advantageous solutions of landscaping — especially terrain height differences using retaining walls.

Background of the Art

At present different building materials are used for the construction of buildings. Their choice is mainly dependent on the type, size and purpose for which is construction determined. The building material suitable for example for industrial halls mostly designed from panels, is different from another one used for skyscrapers or that used for family houses where users experience and consumer preference is preferred over some other parameters. Classic burnt brick is often replaced by blocks of larger dimensions, which together with the required insulating properties and also thanks to their dimensions provide the possibility of faster building technologies. In terms of dimensions and related speed of the building rise panels are offered as an effective option, however on the other hand these building materials require using of the heavy equipment and due to their weight, costly and difficult transport to the construction site is disadvantage. Simultaneously panels as building materials have also other disadvantages known especially from the past, when panel building technology was much extended. Blocks as popular solution represent today to some extent optimization for small and medium-sized buildings, especially family houses. Their insulating properties related to normal wall thickness almost meet the required standards and together with its weight and dimensions are accessible to ordinary building technologies without using of heavy machinery.

The actual requirements for thermal insulating properties of buildings become more and more difficult to meet. For these reasons attention is focused to so called passive houses which are solved to minimize energy losses and obtain energy from renewable sources (solar or wind energy). However the thermal insulating properties of existing building materials do not allow the achievement of such energy balance for floor constructions. For these reasons the passive houses are partially embedded in the surrounding sloping terrain. Because such a solution is not feasible everywhere it is necessary to search building materials with better thermal insulating properties, lower weight and cost of transport while maintaining or increasing other technological and application advantages of existing building materials. On landscaping and building of the solid opaque self-supporting exterior units, as fence walls or fence boards or columns, are still used traditional materials which are created on the basis of concrete mixture. This material is strong enough especially if reinforced by steel reinforcement, having sufficient life, required shape conformability and due to many years of tradition also mastered and well known technology. When applied in larger volumes, its disadvantage is coefficient of thermal expansion which leads to solving such problems through to expansion jbints. Another disadvantage is the large weight influence on demanding transport of the concrete mixture. In individual cases, when additional changes can not be excluded or the need to rebuild already existing exterior solution, a real strength of the solid concrete external element can cause great problems with its removing especially when firmly connected to the concrete foundation.

If it is necessary to solve capturing the soil and fixation of the height differences of terrain this problem is almost exclusively solved with concrete walls which simultaneously form very important division and aesthetic element. In comparison with concrete fence boards or columns, fence wall applications are really one of the best use of the complex properties of concrete for exterior elements. In terms of strength it is an exposed application and on the other hand changes in concepts of exterior requiring wall removing are not often used. But during certain period comes to erosion of the surface of the concrete body and it is necessary to make a correction even mechanically stable body wall to prevent further erosion and also improve design of the wall as the aesthetic element of landscaping. These corrections are carried out again with the concrete mixture while its consumption for more damaged walls is large, demands on transport of the concrete mixture high and consistency with damaged basis may be problematic. The mechanical properties of the new concrete layer remain due to its location and other parameters practically unused.

To get rid of the disadvantages of the concrete walls or fence elements and columns for landscaping the system of planar and spatial compact exterior elements has been developed which is described in CZ utility model 20233. Each such an element consists of the facing panels under which is located polymer integral filler from the inside containing at least one carrying element. There is horizontally placed the cover part on this unit and firmly connected with it. Outer surface of facing panels and also cover part consists of mineral material nature stone or concrete. Polymer integral filler is made of the material with high adhesion to facing elements and also to the carrying element, especially by cellular polyurethane.

Carrying element of the planar element is the construction wall or terrain wall. For the planar element application is as carrying element often used renovated wall. Reinforcement or fixation profile is the carrying element of the spatial element. As a spatial element is mostly used column or fence board with the concrete cover part.

The planar element advantage according to UV 20233 is the possibility of renovation of the existing elements that can hold and fix soil mass for older walls and retaining walls, if their function and mechanical strength is still sufficient however this state is time-limited and visual characteristic are not good. On renovation, function and mechanical characteristics of the existing wall are used, its lifetime extends and the aesthetic parameters of such a renovated wall improve significantly. Technology is not burdened with preliminary preparation and transport of the large concrete mixture mass. The good consistency of new material with original concrete base is very important advantage.

The spatial exterior elements advantages according to UV 20233 are given by the different nature of used material - polymer integral filler - in comparison with the concrete, as in ready status, when material is so conformable that there is no need to solve dilation, so also on making of these exterior elements, when it is possible to prepare the polymer integral filler immediately at the place of application. Then we can avoid transportation of the large mass of concrete mixture. If we decide to do possible changes of exterior elements in future - their removing or reinstalling - elements as above mentioned UV are better compared with concrete massif.

Despite all the advantages this solution has some application restrictions and partial disadvantages. Compact exterior elements according to UV 20233 require integration of the massive carrying element whether in the form of original mechanically enough solid wall (planar element) or in the form of reinforcement for example made of steel profile (spatial element). Furthermore, it is necessary to keep in mind the fact that polymer integral filler is created just in the place of application and therefore it is important to have necessary equipment just in place.

Summary of the Invention

Modular system lightweight fitting element - based, determined for masonry units including landscaping or garden architecture, according to the invention, largely removes the disadvantages and shortcomings of known solutions. Modular system according to this invention is based on the lightweight fitting element which consists of the front and rear wall based on reinforced concrete and between the front wall and the rear wall located the solid filler having density 8-55kg/m or the loose filler; solid filler - if used - is attached to the front wall and the rear wall by binder which subsequently joins together also individual fitting elements; the distance from the front wall of the rear wall is defined using the spacers and reinforcing members, which connect the front wall with the rear wall. If the loose filler is used then it is currently held between the front wall and the rear wall also by sidewalls, firmly fastened with the front wall and the rear wall. The front wall eventually also the rear wall of each lightweight fitting element is fitted by facing material like stone design or architectural concrete, wood or brick , wood veneer visual imitation or facing materials plastic-based. The advantage of the modular system based on the lightweight fitting element according to the invention is its modular character which enables dimensional variability of the created exterior units - building walls, fence boards or walls - in multiple of the module given by dimensions of the individual fitting element. Another advantage is easy application using traditional and well- managed technology - adhesive-based brickwork - while this fitting element is light and allows easy handling. The key advantage of building walls applications are excellent thermal insulation properties. Low weight of the fitting element has also a significant impact on reducing transport costs. Moreover in terms of dispatch and transport the lightweight fitting element is good also for its smaller dimensions - is storable and cuts costs in case of possible damage during the transport. Thanks to total low weight it is not necessary for example to create classical concrete strip foundations for fence boards, easy firming spillage of gravel substrate is sufficient. Further modular system based on the lightweight fitting element also allows creating of terraced retaining walls with partial overlap of individual lines of fitting elements. Therefore the system is characterized by a higher variability of the shaping solutions. There is also an option that provides the possibility of partial or complete filling of the fitting elements with soil which results very interesting, cheap and also eco-friendly alternative of landscaping.

Figures

Design solution of the modular lightweight fitting element - based system according to the invention is clear from the attached drawings, where fig. IA - the lightweight fitting element with the solid filler and binder based on the concrete mixture - in space sectional view fig. IB - the lightweight fitting element with the solid filler and binder based on the polymer adhesive - in space sectional view fig. 2A - modular system application with the binder based on the concrete mixture on making building wall - straight section - in front and sectional view fig. 2B - modular system application with the binder based on the polymer adhesive on making building wall - straight section - in front and sectional view fig. 3A - modular system application with the binder based on the concrete mixture on making building wall - corner section - in front and sectional view fig. 3B - modular system application with the binder based on the polymer adhesive on making building wall - corner section - in front and sectional view fig. 4A - modular system application with the binder based on the concrete mixture on making beam element - in front and sectional view fig. 4B - modular system application with the binder based on the polymer adhesive on making beam element - in front and sectional view fig. 5A - the lightweight fitting element for the window frame placing - technology for the binder based on the concrete mixture fig. 5B - the lightweight fitting element for the window frame placing - binder based on the polymer adhesive fig. 6A/B - front view of the unit rear wall made of the lightweight fitting elements - view on the part of the inner building wall, fig.6A for binder based on the concrete mixture, fig. 6B - for binder based on the polymer adhesive fig. 7A/B - modular system application on making fence wall and columns of the garden architecture - in front and sectional view (7A - concrete mixture option, 7B - polymer adhesive option), fig. 8B - modular system application with the binder based on the polymer adhesive on making ceiling structure - in sectional front view fig. 9B - modular system application with the binder based on the polymer adhesive on making floor structure - in sectional front view fig. 1OB - modular system application with the binder based on the polymer adhesive on making staircase structure - in space view and side sectional view fig. HA - modular system application based on the lightweight fitting element with loose filler - circular platform, front view fig. 12A - modular system application based on the lightweight fitting element with loose filler - modified circular platform, front view fig. 13A - modular system application based on the lightweight fitting element with loose filler - hexagonal platform, front view fig. 14A - modular system application based on the lightweight fitting element with loose filler - type "shoe" - platform, front view fig. 15A/B - modular system application based on the lightweight fitting element with solid and loose filler - type "flower wall" - front view, sectional view: 15A - with binder concrete mixture- based, 15B - with binder polymer adhesive-based.

Examples

Following examples are given for better understanding of the invention. They show the particular applications based on using of the lightweight fitting elements and modular systems. Example 1

From fig. IA the lightweight fitting element I can be seen which is formed by the front wall 2 and the rear wall 3 that are made on the basis of the reinforced concrete mixture and between them is located the solid filler 4 of expanded polystyrene, surrounded from both sides by binder 5 based on concrete mixture. Between the front wall 2 and the rear wall 3_ are diagonally located spacer and reinforcing members 6, seen in sectional view in the front part of the fitting element L The front wall 2 and the rear wall 1 are provided by the facing nature-brick material and their side pointed lines going the same direction oblique upwards follow the outline of this brick design. So the result is the lightweight fitting element I of the cascade nature as well shown in the figure. The lightweight fitting element 1 is on its base provided at least by one guide groove 9 for location of the coupling element JK). In the rear wall 1 of the lightweight fitting element 1 is created installation groove H for electricity, water and heating medium.

Fig. IB shows the lightweight fitting element 1 formed by the front wall 2 and the rear wall 3. that are made of the reinforced concrete mixture and the solid filler 4 of expanded polystyrene is located between them, surrounded from both sides by binder 5 based on polyurethane adhesive. The front wall 2 and the rear wall 3_ are provided by the facing nature-brick material and their side pointed lines again follow the outlines of this brick design. So as in the previous case, the result is the lightweight fitting element 1 of the cascade nature as well shown in the figure. The lightweight fitting element 1 is on its base provided at least by one guide groove 9. In the rear wall 3 of the lightweight fitting element 1 is created installation groove 11 for electricity, water and heating medium.

Example 2

From fig. 2A we can see the preparation of the lightweight fitting element 1 from the semifinished product right on the application site. Semi-finished products made of reinforced concrete mixture are formed by the front wall 2 and the rear wall 3, between them are given spacer and reinforcing members 6 as shown in sectional view 1 - 1' according to fig. 2A Described semifinished products are fit together into the unit. Two lines of the unit are illustrated in this figure. The solid filler 4 of expanded polystyrene (in fig. IA) is pushed into the free space from above, which is then poured by binder 5, based on the concrete mixture. The result of this process is the first and second line of lightweight fitting elements 1.

From fig. 2B can be seen different alternative of the lightweight fitting elements 1, when binder 5 based on polyurethane adhesive is used. In this case the binder 5 surrounds the solid filler 4 of expanded polystyrene and connects it with the front wall 2 and the rear wall 3_, which are concrete reinforced mixture - based. Each such a lightweight fitting element 1 is produced in the matrix in the plant and then is assembled into the unit on the application site according to fig.2B. Connections of individual lightweight fitting elements 1 to each other are made again by polyurethane adhesive.

Example 3

Fig. 3A shows again the semi-finished product intended for the manufacture of the lightweight fitting element I, in this example shaped as a corner part. As it is shown in sectional view 1 - 1 ' spacer and reinforcing members 6 are again located between the front wall 2 and the rear wall 3. of reinforced concrete mixture, used to shape stability of the semi-finished product during transportation, assembling and following technological steps, that are the same here as in the previous example.

Fig. 3B shows the analogy to figure 3A, when the lightweight fitting element I is in the shape of the corner part, however it is in contrast to the figure 5, connected inside with other elements of modular system by the binder 5 based on polyurethane adhesive. As can be seen in sectional view 1 — 1' the parts of solid filler 4 of expanded polystyrene are placed between the front wall 2 and the rear wall 3_ of reinforced concrete mixture, surrounded by layer made of binder 5_^ - here of polyurethane adhesive. These units are produced in matrix in the plant and transport to the application site, where are assembled with other elements of modular system using binder 5 - polyurethane adhesive-based.

Example 4

Fig. 4A shows a beam part as another series of lightweight fitting elements I constructed as a beam part, again in the form of a semi-finished product consisting of the front wall 2 and the rear wall 3 of reinforced concrete mixture, again connected with spacer and reinforcing members 6. This lightweight fitting element 1 is also of the cascade nature following the outline of the brick design and is intended to be filled with the solid filler 4 of expanded polystyrene surrounded by binder 5, concrete mixture-based. Moreover due to high load requirements the armature 12 of the beam part - see sectional view 1 - Y- is placed here.

Fig. 4B shows a beam part as another series of lightweight fitting elements 1, again in the form of a semi-finished product consisting of the front wall 2 and the rear wall 3 of reinforced concrete mixture. This lightweight fitting element 1_ is also of the cascade nature following the outline of the brick design and is intended to be filled with the solid filler 4 of expanded polystyrene also surrounded by binder 5 but polyurethane adhesive-based. Due to high load requirements the armature 12 of the beam part - see sectional view 1 - Y- is again placed here. In fig. 4B' is this beam part seen in the front view. As with previous variant 4A there is also here placed the armature 12 of the beam part due to high load requirements - see sectional view 1 - 1 ' according to fig. 4B\ Whereas this beam part is bonded by binder 5 polyurethane adhesive-based and not concrete mixture-based, it also includes reinforcement plate JJ_. as shown in sectional view 1 - 1 ' according to fig. 4B.

Example 5

Fig. 5A shows the lightweight fitting elements I, determined for window frame placing. It is constructed in such a way that on cascade structure (in figure left) follows vertical end of the lightweight fitting element I on the opposite side while the inner space is closed by a beam 25. Then a groove remains in side wall which enables to install the window frame. So window is built into modular system together with lightweight fitting elements I and after placing of the beam part over the window frame according to fig.4A the construction is continued using the basic types of the lightweight fitting elements 1 according to fig. IA. At such a described system is used the binder 5, concrete mixture-based.

Fig. 5B shows the lightweight fitting elements i, determined for window frame placing, difference from fig. 5A is only in used binder 5 - polyurethane adhesive-based.

Example 6

Fig. 6A/B shows the outline of the rear wall 3_. of the unit made of the lightweight fitting elements 1 - view of the part of the inner building wall equipped with installation grooves H and guide groove 9. Fig. 6 A then shows sectional view 1 - 1' according to fig. 6A/B, when binder 5_., concrete mixture-based is used. Fig. 6B shows the same case with the binder 5 polyurethane adhesive-based.

Example 7

Fig. 7A/B shows exterior wall based on the lightweight fitting elements i according to the invention. Between the columns 22 is made wall of the lightweight fitting elements 1 that is established on the soil board 24 under which is gravel sub-base JjS located on the soil 23. Columns 22 and body- wall are fitted by the cover part 26. Construction of the lightweight fitting elements I is evident from sectional view 1 - 1' according to fig. 7 'AfB. Fig. 7A shows the lightweight fitting element 1 reinforced by spacer and reinforcing members 6 and determined to link with solid filler 4 using binder concrete mixture-based. This unit is located on the soil board 24 lying on the gravel sub-base 1_8. On the same foundation is also located the lightweight fitting element 1 as shown in sectional view in fig. 7B, that has not any transverse reinforcement and its binder _.5 is polyurethane adhesive-based.

Example 8 Fig. 8B shows top wall construction for the modular system based on lightweight fitting elements 1 according to the invention. On the assembly supports 16 is acoustic tile 14, ferroconcrete slab 15. on it, layer of binder £ polyurethane adhesive-based on it and solid filler 4 expanded polystyrene-based on it.

Example 9

Fig. 9B shows floor construction for the modular system according to the invention. This construction, located on the gravel sub-base 18, is created by the soil board 24 on which is placed polyethylene foil 20, the solid filler 4 formed by expanded polystyrene on it and on the top is a floor heating-equipped board 2L Under the gravel sub-base 18 is then soil 23.

Example 10

Fig. 1 OB shows the staircase structure made of the lightweight fitting elements according to the invention. As it is shown from sectional view 1 - 1' according to fig. 1OB, every step of the staircase has the solid filler 4, formed by expanded polystyrene between the front wall 2 and the rear wall 3_. This core is surrounded from all sides by binder 5. polyurethane adhesive-based.

Example 11

Fig. HA shows the lightweight fitting elements designed to fill with loose material - soil. Arrangement of the circular platform elements 27 shows also series of the coupling elements 10. In sectional view 1 - 1' according to fig. HA is possible to see height arrangement of the system and underlay formed by soil 23, gravel sub-base 18 and soil board 24.

Example 12

Fig. 12A also shows the system of the lightweight fitting elements designed to fill with soil which are characterized by modified circular layout 28. Arrangement on the substrate and height schema visible in sectional view 1 - 1' are by analogy solved as in fig. HA including the coupling elements K).

Example 13

Fig. 13A shows another solution of the lightweight fitting elements having hexagonal platform 29. These lightweight fitting elements are also designed to fill with loose material - soil. Outline arrangement is again analogous to two previous examples.

Example 14 Fig. 14A shows system of the lightweight fitting elements having shoe-type plan 30. These lightweight fitting elements differ from the previous ones by their base 8, which is provided by the solid bottom and their front wall 2 has raised edge. In sectional view 1 - 1' according to fig. 14A is possible to see height structure of the system which is again analogous.

Example 15

Fig. 15A/B shows combinations of all basic types of the lightweight fitting elements I forming the flower wall - in outline and top view. The whole system is created by the front walls 2 and the rear walls 3_ which are alternatively enclosing the lightweight fitting elements 1 with the solid filler 4 formed by expanded polystyrene and the loose filler 4^ formed by soil. The unit is placed between columns 22 and the wall section is provided by the cover parts 26. Following figures 15A and 15B show sectional view 1 - 1' and 2 - 2' according to fig. 15A/B. Fig. 15A shows the lightweight fitting element 1 concrete mixture-based, fig.l5B shows the lightweight fitting element I with binder 5. polyurethane adhesive-based. For the front wall 2 and the rear wall 3. was used facing material of brick nature as shown in figures. It may be also solved for example on the basis of artificial stone having split design, crushed design, nature design and other.

Industrial Utilization

Primarily, modular lightweight fitting element-based systems are used well mainly on creating of traditional masonry units - buildings with good insulation properties. Simultaneously they are also well used in garden architecture, particularly on creating of basic parts - fence bodies. According to the invention modular fitting elements find wide use also on landscaping as alternative of classic walls and retaining walls. This way formed walls protect the soil erosion and undesirable terrain changes. They also improve the whole appearance and stability of new performed landscaping. For all the modular system variants according to technical solution is used traditional and popular, trust raising appearance of facing design with modern, light and easy manufacturing technology.

List of Numbered Parts:

1 - lightweight fitting element

2 - front wall

3 - rear wall

4 - solid filler 4'- loose filler

5 - binder

6 - spacer and reinforcing member

7 - side wall

8 - base

9 - guide groove

10- coupling element

11- installation groove

12 - armature of the beam element

13 - reinforcement plate

14 - acoustic board

15 - ferroconcrete slab

16 - assembly support

17 - concrete pier

18 - gravel sub-base

19 - screed floor cover

20 - polyethylene foil

21 - board with floor heating

22 - cast concrete column

23 - soil

24 - soil board

25 - beam

26 - cover board

27 - circular layout

28 - modified circular layout

29 - hexagonal plan

30 - shoe-type plan

Claims

1. Modular system lightweight fitting element-based used for the masonry units including also landscaping or garden architecture, characterized by that the lightweight fitting element (1) consists of the front wall (2) and the rear wall (3) based on reinforced concrete mixture. Between the front wall (2) and the rear wall (3) is located the solid filler (4) having density 8-55kg/m³ or the loose filler (4¹). Solid filler (4) is attached to the front wall (2) and the rear wall (3) by binder (5) which joins together also individual fitting elements (1), while the distance from the front wall (2) of the rear wall (3) is defined using the spacers and reinforcing members (6), which connect the front wall (2) with the rear wall (3). While the loose filler (4') between the front wall (2) and the rear wall (3) is currently held by sidewalls (7), firmly fastened with the front wall (2) and the rear wall (3). The front wall (2) eventually also the rear wall (3) of each lightweight fitting element (1) is fitted by facing material of different nature as stone design, architectural concrete, wood or brick, wood veneer visual imitation and materials plastic-based.

2. Modular system lightweight fitting element-based according to the claim 1 , c h a r a c terized by that the geometric shape of the front wall (2) and the rear wall (3) is

^• given by two horizontal edges of equal length lying above them with affirmative offset and related side pointed lines copying facing design.

3. Modular system lightweight fitting element-based according to the claim 1, c h a r a c terized by that the solid filler (4) consists of lightweight polymeric material, particularly lightweight polystyrene.

4. Modular system lightweight fitting element-based according to the claim 1, charac terized by that the loose filler (4') is formed by soil.

5. Modular system lightweight fitting element-based according to the claim 1 , charac terized by that the binder (5) used is polymer adhesive with high adhesion to the front wall (2) and the rear wall (3), particularly polymer polyurethane-based adhesive.

6. Modular system lightweight fitting element-based according to the claim 1, c h a r a c terized by that the binder (5) used is concrete mixture.

7. Modular system lightweight fitting element-based according to the claim 1 , c h a r a c terized by that the lightweight fitting element (1) is at its base (8) fitted at least by one horizontal groove (9) for the location of coupler element (10) as other component of the modular system or it is provided on its rear wall (3) by the installation groove (11) for the location of electricity, water and heating medium.

8. Modular system lightweight fitting element-based according to the claim 1 , charac terized by that the front wall (2) and the rear wall (3) of the lightweight fitting element (1) together with side walls (7) form closed platform of characteristic shape.