DE29805829U1 - Thermally insulated, hollow-walled component - Google Patents

Description

-1 Thermally insulated hollow-walled component

The innovation concerns a thermally insulated, hollow-walled component for the Low Energy Standard and/or the Passive House Standard, in particular for building construction with the features according to the generic term of claim 1.

Such a component is prefabricated in the workshop, with an outer wall section made of rigid foam, from which spacer elements protrude, which are connected to a second, inner wall section made of concrete. Such a component can be manufactured efficiently and economically in series. It should be ensured that the reinforcement mats on the spacer elements can be easily placed and fastened in the grid-like reinforcement support slots and that the support slots have the required minimum cover in the concrete structure and at the same time ensure that the two shells are parallel. This component can be constructed using prefabricated slab construction as well as on-site construction. Furthermore, it should be ensured that these components can be manufactured simply, efficiently and economically using insulating blocks with web formation.

External wall structures using formwork construction, with the formwork remaining on the building, are known (DE 29 603 330 111; DE-OS 22 00 156; DE-OS 53 516 576; DE-GM 851 316).

Such formwork blocks have an outer and an inner insulation layer.

A disadvantage of this solution is that the formwork has to be assembled on site, and then the formwork blocks are filled with concrete before the ceiling is laid. This means that no static monolithic bond is created.

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Double-shell cavity wall elements are known that consist of two factory-made 5 - 7 cm thick concrete shells that are connected to each other by cast-in lattice girders.

A disadvantage of this solution is the technically complex production of the two shells using plate turning devices. Only after the first plate has hardened for 6 to 8 hours is it placed into the freshly concreted second plate. The heavy concrete plate must be turned 180 degrees.

Another disadvantage is that the outer shell is not thermally insulated at the factory, but has to be installed on site in several steps (applying adhesive; pressing panels onto the wall; making around 8 anchor holes; inserting panel dowels), whereby the force-fit connection is only achieved with great effort.

DE 43 31 698 A1 and DE 296 05 098 U1 describe hollow-walled shell components.

The disadvantage of these components is that the outer shell is made of concrete and the inner shell is made of cement-bonded wood construction panels, which, however, cannot bear any load when the walls are erected on site, e.g. by laying a ceiling on top. Another disadvantage is the complex manufacturing process, because many individual parts have to be screwed, glued or connected together. The disadvantage is that the concrete wall lacks external insulation, which is absolutely necessary in accordance with the high requirements of the thermal insulation regulations.

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The innovation is based on the task of creating a component of the type mentioned at the beginning, in which the floor-to-ceiling prefabrication in the workshop, the walls insulated on the outer formwork side and concreted on the inner formwork side, can be manufactured simply and time-savingly without technically complicated devices.

This object is achieved by the features specified in the characterizing part of claim 1.

In a first embodiment of the component according to the invention, industrially prefabricated rigid foam insulation blocks are used, which are made with a web made of any material and in any shape. The individual insulation blocks are put together to the height of one storey and connected to one another in a force-locking manner. The insulation blocks are usually several meters long or more. Grid-shaped, storey-high components can be formed by arranging them next to one another.

Steel reinforcements are bolted to the webs, which serve as spacers. These are then fitted with commercially available spacers so that the parallelism of the two shells is guaranteed during production.

Such an element is light and therefore easy to handle in the production of the two-sided formwork parts and can be rotated very flexibly. Complicated devices for rotating the upper formwork side are not required.

-A-

In a second embodiment, the innovation is based on the idea that spacer elements according to the invention are placed in the insulation panels in a grid-like manner, so that steel mats are placed in the space between the spacer elements and locked into the reinforcement support slots and thus anchored. It is important to ensure that the spacer elements ensure the necessary coverage of the reinforcement in the concrete structure and that the parallelism of the two shells is maintained.

The insulation blocks/insulation panels with steel reinforcement are placed in the formwork table filled with a 5 - 8 cm thick layer of concrete, with the reinforcement and the spacers pointing downwards. The vibration process causes the reinforcement with the upper formwork side to move downwards until the spacers stop this movement. After the concrete has set, the insulation layer is firmly connected to the concrete shell.

This creates a double-shell cavity wall that is concreted in one step, with the special feature that one side is immediately thermally insulated.

The quick adjustment of the reinforcement mats is an advantage. The cumbersome and time-consuming threading of steel rods is no longer necessary.

The advantage of this component is the fast, uncomplicated production process with few work steps, whereby the second shell does not have to be manufactured a day later.

During the drying process, 50% of the energy normally required is saved because only one concrete slab needs to be dried.

Another advantage is that the outer shell is made of rigid foam insulation, which means that excellent thermal insulation can be achieved in the area of the basement's outer walls. This leads to a significant improvement in the low-energy standard values of a house.
Thermal bridges in the ceiling area are avoided.

A further advantage is that the elements to be transported to the construction site are relatively light in terms of their weight and can be moved using simple mechanical aids, e.g. construction cranes.

Another advantage is that work can continue on site during assembly without any loss of time, as the ceiling can be installed immediately. The inner concrete wall forms the support. The cavity is poured on site with in-situ concrete or flowing concrete, thus forming a monolithic component.

This method enables more cost-effective construction because the production process and the drying process are significantly shortened, because transport costs are reduced due to lower weight, because no heavy cranes have to be used to erect the walls on site and because the labor required for the subsequent installation of external insulation is eliminated.

A preferred embodiment of the method according to the innovation is illustrated below with reference to the drawings.

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The drawing shows

Fig. 1 in a sectional view, schematically, an embodiment of a component according to the invention with insulating blocks with web formation

Fig. 2 in a partial section, schematically, an embodiment of a component according to the invention with insulation panels with grid-like spacer elements, into which steel mats can be easily attached as reinforcement

Fig. 2 a Interior view of an insulation board with grid-shaped

Spacer elements with suspended steel mat

Fig. 3 Side view of a spacer element with grid slots for the steel reinforcement

Fig. 4 in a schematic representation, which is freshly

Concrete inner shell of the component into which the outer insulation shell is placed

Fig. 5 Front side of a corner formwork part on the concreting table

Fig. 6 in plan view an embodiment of a corner formation

Fig. 7; Fig. + 7/1 + Fig. 7/2 Precast grid options

Fig. 8 a component according to the invention with applied

Ceiling panel

Figure 1 shows a schematic sectional view of an embodiment of a component according to the invention with insulating blocks (2) on the outer side, with a web (6) for the force-fitting connection of the inner and outer shells before the gap is filled with concrete. The inner shell (3) is a layer of 5-8 cm of concrete. A reinforcement mat (7) is attached to the webs (6). Commercially available spacers (8) are clipped onto this steel reinforcement (7). This ensures the parallel distance (5) when the component is concreted.

In Figure 2, spacer elements (20) provided with grid slots (16 + 17) are inserted into the insulation panel (2), in which the steel reinforcement (7) can be easily anchored. (18) shows the overlap distance for the inner steel mat. Due to the grid arrangement of the spacer elements in the insulation panel, steel mats (7) are used in the cavity (14) between the two shells (2 + 3).

Fig. 2 a shows the inside view of an insulation panel (2) with a grid-like arrangement (21) of the spacer elements (20). Grid slots (16; 17) are made in these spacer elements. The grid-like reinforcement mats (7) can be easily placed in this grid before concreting.

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The spacer elements arranged in this way allow the lattice-shaped steel reinforcement to be anchored cost-effectively in the production plant.

Figure 3 shows the spacer element (20), which is designed with anchors on both sides (16 + 17) for locking the steel reinforcement. The respective anchor hole is made in such a way that the steel mat is firmly in place after locking in place and therefore no further wiring work needs to be carried out. The steel mesh mats must have a certain concrete cover according to DIN. This is ensured by the cover distances (18).

Figure 4 shows a formwork table (4) on which the fresh concrete (3) is poured into a mold. The component with the outer insulation layer (2), web (6) with steel reinforcement (7) and spacers (8) attached to the steel mat (7) is let into the fresh concrete. The vibrating process causes the steel reinforcement with the outer insulation layer to move downwards until this process is stopped by the spacers (8). The side edges (13) attached to the mold ensure that the dimensions of the lower concrete slab (3) match those of the upper insulation slab (2).

In Figure 5, a corner part is shown on a formwork table (4) at the front. The insulation board (2) is placed in the fresh concrete (3) as described in Figure 4. The right side edge of the insulation board protrudes over the concrete slab.

In Figure 6, two corner pieces are set up (10).

Figures 7, 7.1 and 7.2 show possible grid shapes (11/1; 11/2; 11/3). The width of the insulation board determines the respective production size. By lining them up next to each other, a grid-shaped (11) size is created that can be multiplied as required. Series production is possible by using grids.

Figure 8 shows the component (1) according to the invention, which is placed on a floor slab. The insulation layer (2) faces outwards, the concrete shell (3) inwards. The ceiling panels or prefabricated ceiling elements (15) are placed on this shell. The ceiling and hollow wall are concreted on site (19) so that a monolithic bond is created. Depending on the static requirements, steel reinforcements must be anchored in the hollow wall area at the factory. The sealing tape (22) anchored in the floor slab serves as a moisture barrier.

-10 markings:

1 component with outer insulation layer and inner concrete slab

2 rigid foam insulation blocks or panels of any thickness

3 Concrete slab

4 Switchboard side

5 parallel distance

6 Bridge for force-locking connection

7 Steel reinforcement

8 spacers

9 Corner formation

10 set up corner

11 Grid shapes

12 openings

13 Adjustment angle

14 Cavity for filling with concrete

15 Ceiling element with lattice girder

16 outer grid slot for reinforcement

17 inner grid slot for reinforcement

18 Cover spacing for reinforcement

19 Fill concrete or ceiling concrete

20 spacers

21 Grid arrangement of the spacer elements

22 Sealing tape

23 Cove

Claims (7)

-11 Protection claims: 1. Thermally insulated, hollow-walled component, which is double-shelled, prefabricated in the workshop, on the outer side with rigid foam insulation blocks or insulation boards of any thickness (2), on the inner wall side with a 5-8 cm thick concrete slab (3), characterized in that that the lighter upper insulation side (2) is placed in the freshly concreted concrete slab (3), the parallel distance (5) is ensured by a web (6) located in the insulation layer side (2), which is reinforced with a steel reinforcement (7) on the side edge and to which further spacers (8) are attached. 2. Thermally insulated, hollow-walled component according to claim 1, characterized in that reinforcement mats (7) are already anchored in the inner and outer grid slots (16 + 17) of the spacer elements (20) at the factory by means of a grid-like arrangement of the spacer elements (20; 21). 3. Thermally insulated, hollow-walled component according to claim 1 to 2, characterized in that the spacer elements are made of sheet steel, aluminium, stainless steel, plastic, concrete, fiber concrete, recyclable plastic materials or the like, and their slot openings are square, round, oval, X-shaped or V-shaped openings. -12- 4. Thermally insulated, hollow-walled component according to claims 1 to 3, characterized in that corner formations (9) are prefabricated by moving the upper insulation layer (2) to the left or to the right during the production process and are later erected on site (10). 5. Thermally insulated, hollow-walled component according to claims 1 to 4, characterized in that a grid-shaped dimension (11) which can be multiplied as required can be formed by the respective width of the insulating blocks and by arranging them next to one another, and thus a high degree of prefabrication is achieved through series production. 6. Thermally insulated, hollow-walled component according to claims 1 to 5, characterized in that the grid dimensions are supplemented by fitting pieces. 7. Thermally insulated, hollow-walled component according to claims 1 to 6, characterized in that any opening (12) is installed in the workshop.