RS51248B - PROCEDURE FOR BUILDING A BUILDING, BUILDING BY PROCEDURE AND A WALL ELEMENT FOR BUILDING SUCH A BUILDING - Google Patents

Abstract

The invention relates to a method of constructing a building, comprising the step of providing a skeleton for a building wall of the building. The skeleton includes at least upright building elements such as columns (1) or dividing walls. At least one lightweight, heat insulating and fire retarding wall element (2) is placed between each adjacent pair of said upright building elements. The upright building elements are covered to provide substantially closed wall surfaces. The wall surfaces are covered with a covering layer having properties so as to provide fire-resistance to the complete wall. The covering layer (8) on the inside wall surface may include a base layer (11) of modified resin mortar, and a top layer (12) of plaster mortar. The covering layer (7) on the outside wall surface may include a base layer (9) of modified resin mortar and a top layer (10) of mineral mortar. Lightweight, heat insulating floor elements (18) are placed and interconnected, and supported if necessary, and thereafter structural fill-material, such as concrete (22) is poured onto the floor elements to form a floor. The invention also includes a building, and wall and floor elements. <IMAGE>

Description

The subject invention relates to the process of building a building, a building that is primarily built according to this process, as well as wall and floor elements with application in the construction of such a building.

In the current state of the art, several methods of building construction are known in which light elements are used for the construction of walls. In most cases, the wall elements are formed from expanded polystyrene. Examples of these processes and buildings constructed in this way are known from documents US-A-5,353,562, US-A-4,823,534 and US 5,617,686.

EP 0 727 535 A1 describes the process of building a partition wall, which includes a number of columns, for which the basic materials for the faces of both outer sides of the columns are placed over the sound insulation material, which fix the solid gypsum sides for the outer sides of the corresponding face materials, thus forming a wall structure that has anti-earthquake properties.

US 5,765,333 describes a unique beam and panel construction system in which the beams are placed on the floor. A rigid foam panel consisting of one or more layers of rigid foam joined together by adhesive and shaped to fit the joist is placed next to the joist and connected to the joist and floor, after which the next joist is placed and connected to the same panel, etc. Thin long strips of wood or metal can be placed on the surface of the panels to allow easy placement of plasterboard on the inside of the panel wall system or laterally on the outside.

The object of the present invention is to describe an improved process of building construction.

For this reason, the present invention describes the building construction process according to Claim 1.

In this way, a building construction procedure is described that is simple and ensures high-quality construction with low construction costs, but also ensures that the building will be built in accordance with the most stringent fire protection requirements without the need for additional expensive measures. Primarily, the walls of the building according to the present invention are subject to all basic requirements in construction such as resistance to compression, resistance to wind, etc. without the need for expensive additional measures.

Primarily, the process in question uses large wall elements so that one floor-height wall element completely fills the space between two vertical building elements, such as columns or partition walls. If the adjacent elements of the wall touch at the place where the vertical element is placed, it is automatically covered by it. In the case of a column, the other, primarily internal, side of the column can be covered with a separate panel to close the space around the column. Primarily, the wall surfaces on both sides of the building wall are flat, but, for example, in the area of the columns, the flat wall surfaces may be interrupted by recessed or protruding parts of the wall. Columns can be prefabricated from wood, steel or concrete or from any combination thereof, and it is also possible to cast columns on site by closing off the space around the place where the column is to be placed and using wall elements, such as panels, as part of the mold in which the column will be formed from a material such as concrete. In the case of the construction of a row of houses where the vertical building elements at least partially contain gap walls, the walls can be formed in situ, that is, on the construction site itself, or they can consist of prefabricated walls that are erected before the wall elements are installed.

After the (external) walls of the building have been constructed, the walls can be worked, primarily with steps, to form openings and recesses in the walls that are to receive doors, windows, power lines, pipes and the like. As columns and/or partition walls take the majority of the building's load, openings in the wall elements can be created as needed without compromising the structural integrity of the building's walls. As the wall elements are very lightly loaded, they do not deform, which is why there is no need for frames around the windows that are normally needed to protect the glass from the forces acting on the wall. This further reduces the costs required for the construction of the building. Frames are only needed for windows that can be opened. As there is great freedom in the formation of openings in the walls and as these openings can only be formed after the wall is installed, the design of the building can be changed in the later stages of construction. This makes the construction concept very flexible.

Alternatively, the wall elements can be prefabricated, with all windows, doors, pipes, ducts and/or other necessary elements installed already on the production line where the wall elements are produced. It is also conceivable to prefab the entire facade of one floor of a building or even an entire building before it is delivered to the construction site.

The subject invention also includes a building according to Claim 8.

Primarily, the covering layer also contains a reinforcing layer, such as for example a knitted mesh, reinforcement and the like, and primarily a fibrous reinforcing layer.

This reinforcing layer provides additional strength to the wall elements in order to ensure resistance to the action of external forces, such as forces resulting from the action of wind and the like. The reinforcing layer on the inside of the building can also provide additional strength for the needs of placing objects inside the house, such as for example hanging kitchen elements and the like.

The subject invention also includes wall elements according to Claim 14.

The wall element is generally flat, but if necessary it can be curved along one or more axes.

Floors in a building are primarily formed by placing and interconnecting lightweight floor elements with thermal insulation properties, supported as necessary, on which a structural fill material, such as concrete or some similar material, is then poured to form the floor. Thin steel profiles are primarily used to connect floor elements.

The invention in question will be described in the following text according to the attached figures, which show examples of the invention.

Figure 1 represents the appearance of a planar section of a part of a building wall according to the implementation of the subject invention.

Figures 1a, 1b and 1c represent the appearance of the planar section of the columns that can be used in the construction of the building from Figure 1.

Figure 2 represents the appearance of the side section of the part of the building from Figure 1.

Figure 3 is a view of the parts that make up the wall of the building from Figures 1 and 2.

Figure 4 presents a perspective view of the parts that make up the floor of the building floor.

Figures 5, 6 and 7 are front views (on a reduced scale) and sectional views along lines VI-VI and VII-VII of Figure 5 showing the building wall element of Figures 1 and 2.

Figure 8 presents a section view on an enlarged scale of a part of the wall element from Figure

5 to 7 illustrating the structure of the wall element.

Figure 9 represents a planar cross-sectional view of two elements according to another embodiment of the invention.

Figure 10 represents a cross-sectional view of the floor element of the floor from Figure 2.

Figure 11 presents a cross-sectional view of part of the steel profile used to connect the floor elements.

Figure 12 is a perspective view of the front part of the skeleton of another building together with a planar cross-sectional view of another embodiment of a wall element according to the present invention.

Figure 13 is a perspective view of the wall element for building the skeleton of the building of Figure 12, in an enlarged proportion.

Figure 14 shows the cutaway details of the wall elements from Figure 13 when incorporated into the building from Figure 12.

Figure 15 is a perspective view of the connection between the horizontal beam and the vertical support column as it is realized during the construction of the building of Figure 14.

Figure 16 represents a horizontal section of the wall of the building from Figure 12.

The figures, and in the first case Figures 1 to 3, show part of the wall of a building according to the present invention. This building can be a house, but it can also be a business building with offices or, in general, a building of any purpose. Figures 1 and 2 show that the wall of the building contains a skeleton containing upright building elements, in this case columns 1, and wall elements 2 that fill the space between two columns 1. As shown in Figures 1a, 1b and 1c, columns 1a, 1b, 1c can be made of steel (Figure 1a), wood (Figure 1b) or concrete (Figure 1c). Concrete columns can be prefabricated or they can be cast on site. The wall elements 2 are primarily of such dimensions that they completely fill the space between the columns of one floor, so that there is only one wall element 2 between every two adjacent pairs of columns 1. This avoids the need for a complicated (mechanical) connection between the wall elements.

Figures 5 to 7 show the shape of one element of 2 walls. From Figure 5 it is obvious that element 2 of the wall is rectangular in shape. In this version, the width of element 2 of the wall is 2.5 m, the height is 3.0 m, while the thickness is 0.3 m, but such dimensions are, of course, subject to measurements in accordance with the needs of the specific application. Figures 6 and 7 show that only the part of the wall element 2 to be placed on the outside of the building wall has the dimensions indicated in the text above. The rest of element 2 of the wall is smaller. Due to these reduced dimensions, an edge 3 is formed on all four edges of the wall element 2. This edge is placed along the edges of the outer surfaces of the wall element 2 and can have a thickness of approximately 60mm. The length of the edge can, for example, be approximately 90mm.

Adjacent to the opposite surface, in order to form the inner surface of the building wall, a recess 4 is formed, which has mostly the same dimensions as the edge 3. This recess 4 is also formed on all four sides of the wall element 2. In this way, the edges of the wall elements 2 have a stepped shape, such that the middle step is of a height that primarily corresponds to the thickness of the pillars 1, with the depth of the first and last step primarily corresponding to half the width of the protruding pillars 1.

If two elements 2 of the wall are placed next to each other so that they touch, a recess is formed that has three sides measuring 200 mm, which has the role of containing a column, as shown in Figure 1. As the steel or wooden columns 1 will not have exactly these dimensions, inserts 5 are placed on them, which are placed on certain columns 1 in order to mostly fill the space between the elements 2 of the wall. The covering panel 6 can be placed in the recess 4 along the two adjacent edges of the wall elements 2 in order to close the recess between the two wall elements so that, not only on the outside of the building wall but also on the inside, a closed and continuous wall surface is formed. These closed and flat wall surfaces can be covered with covering layers 7 and 8 from the outside and inside of the building wall.

If columns of larger dimensions, especially of greater thickness, are used, several different situations can occur: first, wall elements of greater thickness are used so that walls with flat surfaces can be obtained again, and also the column and/or the covering surface placed on it can be extended towards the interior and/or exterior of the wall so that the wall surface has breaks in the places where the columns are located.

Figure 8 shows a more detailed section of the building wall at the location of element 2 of the wall. This element 2 of the wall forms the core of the building's wall and is made of light materials with primarily pronounced fire-fighting and thermal insulation properties that are non-compressible and stable so that the building's wall has the necessary qualities. This material can for example be a modified pressed cardboard (as described in document EP-A-1 180 564) or some other expanded polymer such as for example EPS (expanded polystyrene), for example the one sold by the company Unidek under the name Unidek EPS, which is modified according to NEN 6065/6066 in order to obtain anti-fire properties.

The covering layer 7 on the outside of the building wall contains the first, basic or base layer 9 primarily formed from a modified epoxy mortar known in the state of the art. This base layer 9 is an adhesive layer whose role is to correctly accept another, i.e. surface layer 10, which can be a layer of mineral plaster for example, which has resistance to weather influences as well as to other influences that may exist from the outside of the building. Such a mineral mortar is also known in the prior art.

On the inside of the building wall, the covering layer 8 contains the first or base layer, primarily made of modified epoxy plaster 11, and the second surface layer 12, formed for example of gypsum plaster. The total thickness of the covering layers 7 and 8 can be in the range from 20 to 30 mm, and primarily in the range between 22 and 25 mm. Within these covering layers 7 and 8 there are reinforcing layers 13 and 14 which can be made in the form of a woven mesh, for example a mesh of reinforced glass or carbon fibers. Primarily, at least one of the reinforcing layers 13, 14, and in this case the reinforcing layer 14 on the inner side, is positioned against the surface of the covering layer 8 so as to be at the maximum distance from the neutral line of curvature of the wall element 2 in order to achieve maximum resistance to bending, for example when the wind exerts a force on the building wall. Another advantage of this position of the reinforcing layer 14 is that it gives strength to the layer 8 so that the wall can be used to accept fixing means such as nails, screws and the like, and to enable the installation of objects on the wall.

Expanded polystyrene can be produced in different qualities, and in this version the element 2 of the wall can be formed so that it is of standard quality, while the inserts 5 and the covering panel 6 can be produced from material obtained by compression or pressing in order to obtain additional thermal insulation as well as strength around the pillars 1, and so that the quality of thermal insulation is mostly uniform along the entire surface of the wall.

Figure 9 shows a variation of the building wall of Figures 1 and 2, where the wall elements 2 are curved along the vertical axis to form a circular wall.

Figure 2 shows a side section of the building of Figure 1 illustrating not only the wall structure of the building but also the building floors. The floor structure is also shown in Figure 4.

In this case, floor 15 of the ground floor, floor 16 of the first floor and floor 17 of the roof are shown. The structure of floors 15 to 17 is similar, except for some differences in the finishes. Each floor contains elements of 18 floors that are mutually connected and formed from a similar material from which the elements of 2 walls are formed, i.e. made of light material with pronounced fire-fighting and thermal insulation properties. The elements 18 of the floor are connected to each other by steel profiles 19 which can be formed from a sheet of steel, for example 1 mm thick. Indentations 20 are formed on the sides of the floor elements 18 in order to ensure the mutual coupling of the elongated parts of the steel profiles 19 in order to achieve the correct connection of the profiles for the floor elements. The floor elements 18 have lower edges 21 and these edges 21 of adjacent floor elements 18 are arranged to touch each other to form a closed and continuous lower floor surface. The upper part of the floor element 18 is smaller and has a trapezoidal cross-section. To form the floor, the floor members 18 are connected and supported by struts to resist the weight of structural fill material, such as concrete 22, fiber-reinforced epoxy, and the like, which is poured onto the floor members 18. Before the filling material 22 is poured, steel reinforcements 23 are placed on the floor elements 18. If necessary, the inserts 25 placed in the recesses can remain visible after the completion of the construction of the floors 15 to 17. The floor finish 26, the ceiling finish 27 and the covering layer 8 on the walls are installed, primarily in the last stage of construction.

The execution of the building construction procedure is described below.

First, the foundation is formed below the ground level, if it is necessary at all. This foundation can be relatively light considering that the building will be much lighter than traditional structures. If the skeleton of the building is formed by steel or wooden columns, the steel or wooden columns 1 are placed on their own foundations in the correct positions. Inserts 5 are placed around the corresponding columns to create column dimensions that will match the wall elements.

The wall elements 2 are then placed on the pillars 1, so that the edges 3 of the wall elements 2 are placed on the outside of the pillar 1 and positioned in such a way that they touch the next wall element 2. Glue can be used to fix the wall elements 2 to the columns 1 as well as to connect them to each other, and the use of other fixing means is also conceivable. A cover panel 6 is placed in the recesses 4 of the wall elements 2 to cover the last side of the column 1. Inserts 28 are placed in the corners of the building to fill any remaining gaps. After that, the inserts 25 are placed and the floor elements 18 are positioned on the lower inserts 25. Adjacent floor elements 18 are connected to each other by means of profiles 19 and are supported by means of temporary supports. After placing the reinforcement 23, the filling material 22 is poured on the floor elements 18, on the profiles 19, on the upper side of the wall elements 2 and the pillars placed below.

If concrete columns are used in the concrete construction process, which are poured on the construction site itself, the elements 2 of the wall are placed before the columns 1 are formed. The only reinforcement for the concrete columns 1 is placed inside the depressions formed by the adjacent elements 2 of the wall. Covering panels 6 are placed to form a mold for concrete which is then poured into the closed cavity to form a concrete column or a column made of some other structural infill material, which is formed between the elements 2 of the wall.

It will be clear from the following text that the subject invention describes both a building construction process and a building that is efficient from the point of view of construction costs. The resulting building can be so light that it can be transported in its entirety, or even entire floors can be raised on the ground and then later placed in position on the building. The maintenance costs as well as the cost for the energy used are also efficient from an economic point of view due to the quality thermal insulation and the reduced need for maintenance.

The building's flexibility is great due to its light construction, which makes it easy to renovate or expand parts of the building. To this end, openings can be formed after the building is completed. The building can later be dismantled and the building material itself can be reused so that, therefore, the masonry process also meets high environmental standards. Wall elements can also be used to implement an anti-burglary alarm as its elements can be integrated into the wall elements themselves, for example thin conductive fibers or electrically conductive wires.

As an alternative to a floor composed of floor elements and cast concrete, for example, it is possible to make a floor from steel parts, wooden beams, a layer of insulation and a cement finish layer.

Figures 12 to 16 show further embodiments of the building and process according to the invention. Figure 12 shows the skeleton of the building, which includes partition walls 29 and floors 30. Partition walls 29 function as a lightweight building element and in this case separate individual homes that are built in a row. The ends of partition walls that are placed on the outside of the building, to a greater or lesser extent, have the function of columns for external walls. In this embodiment, the wall element 2 forms a complete facade, i.e. the outer wall between two adjacent partition walls 29 and the floor 30. Between the adjacent partition walls 29 there are one or more auxiliary columns 31, in this case in the form of steel parts, which are connected to the floor and ceiling 30. These auxiliary columns 31 can be integrated into the wall elements 2 or can be placed in the skeleton of the building before the wall elements 2 are placed on the skeleton buildings.

Figures 13 to 16 show an embodiment of a wall element 2 that fits between two adjacent partition walls 29. Therefore, such a wall element can be adapted to have a length of 5 or 6 meters, or even more. In the embodiment shown, this wall element 2 has a laminate structure which includes layers 32, 33 and 34 which are joined together, for example by means of glue. The relative thickness of each of the layers can be changed according to specific needs. Primarily, the layers are individually formed from different parts and the parts of the different layers are placed to overlap to mutually reinforce each other. In the central layer 33, two horizontal beams 35, 36 made of wood or some other suitable material such as plastic or some similar suitable material are integrated. These horizontal beams are integrated into the 2 wall elements during the lamination process. The beams 35 and 36 provide rigidity to the large wall elements 2 and in addition allow the wall element 2 to be attached to the support column 31 as well as to place any window on the wall element 2. Figure 14 shows that the opening 37 is already formed in the layers 32 and 34, so that after placing the wall element 2, it is only necessary to process the layer 33 in order to form the opening 37 on the wall for the installation of the window. The window or window frame can be placed on both beams 35 and 36.

As previously mentioned, the beams 35 and 36 can also be used to place the wall element 2 on one or more support posts 31. In Fig. 13 it is shown that the inner wall layer 34 is retracted at the point where the support post 31 is to be connected to the wall element 2. Beams 35 and 36 are visible in this recess 38 and the auxiliary post 31 can be placed on the beams 35, 36 by means of self-tapping screws or some other suitable means inserted through the hole in the auxiliary post 31. Other ways of connection are also possible.

If it is necessary to form a door opening in element 2 of the wall, the lower horizontal beam 36 must be cut at the required place. The door frame needs to be attached to the upper horizontal beam 35. In general, a support post 31 will be placed up to the door opening to provide additional reinforcement to the wall element in the door area. The door frame can also be attached to the adjacent support post 31. Covering layers 7 and 8 from the outside or inside of the building can be placed on the wall elements 2 before the windows and/or doors are placed in the corresponding openings in the wall elements 2. This is particularly desirable because windows and doors are primarily placed in the 2 wall elements as late as possible in the construction process to avoid possible damage to them. These covering layers 7 and 8 will be placed inside the opening 37 next to where the window frame will be placed.

Fig. 16 shows that the recessed part 38 is filled with an insert 39 to cover the auxiliary column 31 and the recessed part 38 itself, and to form a flat inner wall that will be covered by a continuous covering layer 8.

The joint 40 between two adjacent wall elements 2 is filled with a filling material, primarily a PUR adhesive which not only fills the joint but also helps to connect the two adjacent wall elements 2 securely.

The large joint 41 between the wall element 2 and the partition wall 29 (or between the wall element 2 and the floor 30 as shown in Fig. 13) is filled with a sound insulation material that is a barrier to the transmission of sound around the separating walls 29 or the floor 30.

From the foregoing description it is clear that the present invention describes a wall element, particularly an exterior wall element, which is durable, light, fire resistant and easy to handle so that buildings can be constructed in a simple and fast manner. No large scaffolding is required, a light mobile device is sufficient to place the wall elements above the ground floor.

The subject invention is not limited only to the embodiments shown in the pictures and described in the preceding text, but different variations are also possible that do not go beyond the scope of the subject invention in the way it is defined in the Claims. For example, wall elements can have curvilinear recesses in order to accommodate e.g. pipes of underfloor or central heating systems and the like.

Claims (14)

1. A building construction process consisting of the following steps: erecting a building skeleton where the described building skeleton contains at least vertical building elements (1, 29) such as for example columns or partition walls, placing at least one light wall element (2) with fireproof and thermal insulation characteristics between an adjacent pair of vertical building elements that are placed before the wall elements are placed, in such a way that the wall elements completely cover the space between the vertical elements, placing a covering layer (7, 8) from the inner and outer side of the wall elements (2) and at least from the outer side of the vertical building elements (1, 29), whose role is to provide at least a large part of the covering of the wall surfaces, where the described covering layer must provide the entire wall with at least fireproof characteristics. 2. The method according to claim 1, where the vertical building elements are prefabricated, such as for example steel, wooden or precast concrete columns (1) which are installed before the installation of the wall elements, where the adjacent wall elements are primarily installed so as to touch each other to form a closed wall surface, especially from the outside of the building. 3. A method according to Claim 2, where the inserts (5) are placed directly next to the columns (1') to fill any gap between the columns and the wall elements. 4. The procedure according to one of the previous Claims, where the light elements (18) of the floor with heat-insulating and anti-fire characteristics are placed, interconnected and, if necessary, supported, after which the structural filling material, such as concrete, is poured onto the floor elements, in order to form the floor. 5. The procedure according to one of the previous Claims, where after the construction of the external walls, the walls are processed to form openings and recesses in the walls that will receive windows, doors, pipes and the like. 6. The method according to Claim 1, where the vertical building elements are partition walls (29) between adjacent building spaces, and where light wall elements (2) are located in the space between the partition walls. 7. The method according to Claim 6, where the auxiliary columns (31) are connected to the skeleton of the building and integrated into the elements (2) of the wall. 8. A building, which consists of: the skeleton of the outer wall of the building where the described skeleton contains at least vertical building elements (1, 29), at least one lightweight wall element (2) with thermal insulation and anti-fire characteristics between each adjacent pair of vertical building elements that completely fills the space between the vertical building elements, a covering layer (7, 8) placed on each side of the described wall element and at least on the outside of the vertical building elements in order to provide the most closed wall surfaces, where the described covering layers possess such properties as to at least provide fire resistance properties for the entire wall, where the covering layer on the surface of the inner wall contains a base layer of modified epoxy plaster and primarily a surface layer of gypsum plaster, where the covering layer on the surface of the outer wall contains a base layer of modified epoxy plaster and primarily a surface layer of mineral plaster. 9. Building according to Claim 8, where the covering layer contains a reinforcing layer, such as for example a woven mesh and the like, and primarily a fibrous reinforcing layer. 10. Building according to Claims 8 or 9, where the covering layer on the surface of the inner wall contains a base layer of modified epoxy mortar and primarily a surface layer of modified gypsum plaster, while the covering layer on the surface of the outer wall may contain a base layer of modified epoxy plaster and primarily a surface layer of mineral plaster. 11. Building according to Claims 9 and 10, where the reinforcing layer on the surface of the inner wall is placed in the surface layer, while the reinforcing layer on the surface of the outer wall is placed in the base layer. 12. The building according to one of Claims 8 to 11, contains openings between vertical building elements, where described openings are closed by doors, windows or some other similar building elements. 13. The building according to one of Claims 8 to 12, contains a floor formed by interconnected lightweight floor elements with thermal insulation and fireproof characteristics, and structural filling material, such as concrete, poured onto the floor elements, and where the mutual connection between the floor elements is primarily formed by means of parts of thin steel profiles. 14. Building wall elements according to any of Claims 8 to 13, where the wall elements are constructed of light material with thermal insulation and fireproof properties, such as for example modified polystyrene or cardboard, where the wall elements have a thickness of approximately 200 to 400mm, and preferably of approximately 300mm, and where the elements are mostly rectangular with a height and width greater than 2m, and preferably 3 x 2.5m to 3 x 6m, where on all the edges of the elements there is an edge that extends laterally from the element and which is aligned with one side of the element, where the edges of the wall element have a stepped shape that is composed of at least two steps where on all the edges of the elements there is an edge that expands laterally from the element and which is aligned with one side of the element, where the edges of the wall element have a stepped shape that is composed of at least two steps.