WO1997038181A1

WO1997038181A1 - Method for producing an element structure and an element structure

Info

Publication number: WO1997038181A1
Application number: PCT/FI1996/000188
Authority: WO
Inventors: Jarmo Pirhonen; Reino Parkkila
Original assignee: Jarmo Pirhonen; Reino Parkkila
Priority date: 1996-04-10
Filing date: 1996-04-10
Publication date: 1997-10-16
Also published as: AU5335996A

Abstract

The invention relates to a method for producing an element structure, that is meant particularly for facade repair building, such as for supplementary thermal insulation, surface repairment and/or a like of the same. The element structure is at least partly being prefabricated during the manufacturing process of the same by arranging at least an integral thermal insulation arrangement (1) and a surface polishing (3) therewith, whereby the element structure (2) may be transported, stored and furthermore installed at the site as a construction element, that forms an essentially finished facade surface (u) right away. At least the supporting structural parts (2'') of the element structure (2) are at least partly being prepared of an organic first base material (2a), for example based on wood, vegetable and/or like, and of an inorganic second base material (2b), for example based on stone, plastics, glass, rubber, metal and/or like, preferably by adapting cement as binder material (2c). The invention relates to an element structure as well.

Description

Method for producing an element structure and an element structure

The invention relates to a method for producing an element structure, that is ment particularly for facade repair building, such as for supplementary thermal insulation, surface repairment and/or a like of the same, and which is at least partly being prefabricated during the manufacturing process of the same by arranging at least an integral thermal insula¬ tion arrangement and a surface polishing therewith, whereby the element structure may be transported, stored and furthermore installed at the site as a construction element, that forms an essentially finished facade surface right away.

The method according to the invention is applicable for repairing of facades made of most heterogeneous materials and particularly well for repairing facades formed of brickwork structures or reinforced concrete structures, a particular characteristic of the latter of which, comprising usually a so called sandwich composition, is so called carbonation. Carbonation is caused by carbon dioxide that drifts inside the reinforced concrete structure, whereby the shrink steels inside the concrete get rusty, which is due to the neutralisation of the concrete surrounding the same. By influence of the internal pressure effect caused by formation of rust, it is usual, that parti- cularly the steels situated close to the outer surface of the concrete split loose concrete above the same from the wall structure, whereby certain parts of the same become totally visible.

The phenomena in question is particularly harmful in the sense of esthetics, in addition to which the phenomena is harmful considering strength of mate¬ rials, also, because corrosion of steel due to the carbonation may significantly embrittle the structure. When the steels in the concrete are uniformly surroun¬ ded by alkaline concrete, the type of phenomena due to corrosion described above may not occur. To prevent or eliminate actual carbonation it is known to use most heterogenous methods. One method to eliminate the problem due to carbonation is based on that, that the outer surface of a carbonated structure is coated with an alkalising mass. Most heterogenous chemical compo- sitions have been developed for this purpose to achive the desired effect.

On the other hand for repairing of esthetically wounded facades it is known to use covering by so called thin-shell precasts, which kind of method is represented by the facade system marketed by Partek Betonila Oy. In this case on the outer surface of the wounded surface a new casing element made of concrete is attached at a distance apart from the original wall surface. This kind of a casing element must always be rested on a supporting construction element that is for example on the inner construction element of a so called sandwich element. This is due to that, that the hairpins binding the inner and outer construction elements of the reinforced concrete together are not able to carry any additional concrete structures mounted outside the facade. The top edge of such a casing element is attached with binders, that transmit both horizontal and vertical forces to the supporting structure. The binders being adapted at the bottom edges of each element transmit horizontal forces only. Normally for example a M 16 chemical anchor is appli¬ cable as a binder to be mounted on the supporting concrete structure. Accordingly the fixing of the bottom edge may normally be carried out for example by a M12 cotter bolt. When adapting the above method thus all attachments of the casing elements are rested on the supporting construction elements. In case an original exterior structure is being left in place in a facade repairing site, necessary cuttings must be done to the same, to enable the above attachments. In addition to that the attachment of the original exterior surface must be secured for example by means of separate binders. So the method described above is very troublesome, because it requires quite a lot discharging measures directed to the facade to be covered, that is total removal of the outer construction element or making openings to the same.

The method above naturally improves the appearance of the facade, but by adapting the above method it is not possible, however, to affect in any way directly the thermal insulation of the original wall structure, that must always be done so, that the original casing structure is totally removed. This is why adapting the method above particularly at sites requiring addi¬ tional thermal insulation does not for its part offer any kind of advantage with respect to those methods and construction elements being adapted for similar purposes.

On the one hand it is further known to recover facades with for example prefabricated elements, such as by metal cassette elements coated by plastics, in which there is a built-in thermal insulation. An andvantage of such construction components is naturally the lightness of the same as well as that, that the installation of the same includes only attachment of the metal elements, that is why there is no need for actual surface polishing excluding possibly jointing. It is not too often, however, possible to adapt such metal cassette elements as described above, because building authorities do not in all circumstances approve modification of for example a rock based facade into one coated by metal. Naturally also other problems are involved when using metal cassette elements, wherein they are in principle, however, very vulnerable for impact and alike wounds, whereby the covering plastic being wounded the metal casing of the element begins to rust sooner or later depending on the circumstances.

On the other hand a covering element equipped with thermal insulation is known from previous technics for example from Finnish Patent No. 69336 or application document DE 2 134 823. The former patent includes a thermally insulated covering element that comprises advantageously for example a substance layer made of concrete, to the outer surface of which there has been arranged during the manufacturing of the same an actual surface material being advantageously built-in therewith, such as a brickwork covering or a like. The thermal insulation is connected to the inner surface of the substance layer, the specific stiffness of which decreases as a function of the distance measured from the surface of the same being against the subs¬ tance layer. On the other hand from the latter appli- cation document DE 2 134 823, that is earlier than the above, it is known to form prefabricated covering elements, that comprise for example a surface sheet made of for example gypsum, to the back surface of which there has been attached a stiff structured thermal insulation, such as a foam plastic sheet, and further a flexible thermal insulation, such as a wood¬ wool sheet, that is attached to the above. Particular¬ ly from the point of view of the facade rebuilding, the covering element according to the Finnish Patent 69336 is advantageous particularly in that respect, that it may be pre abricated at the factory to a great extent, due to which it may be installed at the site as a construction element forming a finished facade surface right away.

A disadvantage of the above solution is naturally the massiveness of the element which is due to that, that the type of covering element includes first of all a substance layer made for example of concrete and the brickwork covering attached at the outer surface of the same. That is why the type of covering elements are hard to handle in practice, particularly due to the weight of the same as well as of the vulnerability of the brickwork. The type of covering elements are further very laborious and slow to produce and ins¬ tall, because in this connection traditional attach- ment arrangements must be used.

It is the aim of the method according to this inventi¬ on to achieve a decisive improvement in the problems presented above and thus to raise substantially the level of knowledge in the field. To achieve this aim, the method according to the invention is primarily characterized in, that at least the supporting struc¬ tural parts of the element structure are at least partly being prepared of an organic first base mate- rial, for example based on wood, vegetable and/or like, and of an inorganic second base material, for example based on stone, plastics, glass, rubber, metal and/or like, preferably by adapting cement as binder material.

As the most important advantages of the method accor¬ ding to the invention simplicity and versatility may be mentioned, that is why the element structures being prepared by the method may be adapted for example in addition to the above repair building of reinforced concrete also in repairment of other types of surface structures. The advantageousness of the method accor¬ ding to the invention is based firstly on the light- ness of the element structure being produced. The method brings also significant improvements to the installation of element structures thanks to that, that during the manufacturing of the element structu- res there are arranged pref bricated mutual joint arrangement and a finished outer surface at the same, that is why no finishing stages, that is for example plastering, painting and the like are needed as is the case with usual traditional rock based element struc- tures being nowadays on the market. Thus with the method according to the invention it is possible to improve significantly the work efficiency and also to decrease significantly the costs of the facade repair¬ ment works by transfering a part of the measures, that have been previously performed at the site, in connec¬ tion with the manufacturing process. On the other hand it is also possible to rationalize the manufacturing of the element structure by arranging the surface polishing including therewith according to the princi- pies of the invention advantageously for example during the casting of the supporting structural part of the element structure.

Advantageous embodiments of the method according to the invention are represented in the dependent claims • directed to the method.

The invention relates to an element structure, also, that is represented in greater detail in the preamble of the independent claim related to the same. The primary characteristics of the element structure are represented in the characterizing part of the corres¬ ponding claim.

With the element structure according to the invention it is possible to ease and minimize the installation measures relating especially to facade repairment works in a simple and advantageous way. This is firstly based on the lightness of the prefabricated element structure, in addition to which a surface polishing arranged at the same during the prefabrica- tion process enables an outer surface that is ready right away in connection with the installation, that is why there is no need to perform those, nowadays necessary separate manual measuring stages, that is surface patterning, painting and the like. Thus the element structure, that has been transported to the site, may be installed as such by utilizing mutual joint arrangements being arranged at the same, in which case after the attachment and jointing it forms the desired facade surface immediately. Due to the above it is further possible to minimize surface mistakes in the repaired facade caused by carelessness during the installation measures or inadequate profes¬ sional skills. In addition to that, the element structure according to the invention may be produced for example during casting of the supporting structu- ral part of the element structure, when adapting profitable method techniques and manufacturing proces¬ ses so, that it is most suitable at the site for the part of both the surface pattering and the colouring of the same. In addition to that the element structure according to the invention may be equipped during the manufacturing process with a protecting layer protec¬ ting the outer surface of the same, whereby surface damages during the transportation, storage as well as installation are prevented.

Advantageous embodiments of the element structure according to the invention are represented in the dependent claims related to the same.

In the following description, the invention is illu¬ strated in detail with reference to the appended drawings. In the drawings, Fig. 1 shows as a principle some advantageous ele¬ ment structures to be produced by the method according to the invention,

Fig. 2 shows a three-dimensional cross-section of an advantageous element structure according to the invention, that is advantageously so to speak called internally insulated,

Fig. 3 shows a sectional side view of an element structure according to the invention, and

Fig. 4 shows the embodiment according to fig. 3 seen from above.

The invention relates to a method for producing an element structure, that is ment particularly for facade repair building, such as for supplementary thermal insulation, surface repairment and/or a like of the same. The element structure is at least partly being prefabricated during the manufacturing process of the same by arranging at least an integral thermal insulation arrangement 1 and a surface polishing 3 therewith, whereby the element structure 2 may be transported, stored and furthermore installed at the site as a construction element, that forms an essen¬ tially finished facade surface u right away. At least the supporting structural parts 2" of the element structure 2 are at least partly being prepared of an organic first base material 2a, for example based on wood, vegetable and/or like, and of an inorganic second base material 2b, for example based on stone, plastics, glass, rubber, metal and/or like, preferably by adapting cement as binder material 2c.

As an advantageous embodiment the element structure 2 is made of a first base material 2a for example formed of wood, pressed straws or the like and of for example a rock based other base material 2b, in which case very light elements are achieved, that do not signifi¬ cantly increase the loads directly to the wall to be repaired.

As an advantageous embodiment, the surface polishing 3, being essentially built-in with the supporting structural part 2" of the element structure 2 or being arranged in connection with the same, is being ac- hieved, on the one hand to achieve an outer surface patterning of the element structure 2, during the manufacturing of the supporting structural part 2" of the element structure 2, such as in connection with casting by using preferably a surface patterned mold or a like. On the other hand to achieve correspondin¬ gly an essentially coloured or a like appearance of the element structure 2, during the manufacturing of the supporting structural part 2" of the element structure 2, such as in connection with casting, one or several pigments are being adapted as mixture material.

Further as an advantageous embodiment of the method, the thermal insulation arrangement 1 in the element structure 2, shown for example in view lb of fig. 1, is being equipped with at least one essentially flexi¬ ble thermal insulation 1", such as with a mineral wool sheet, rock wool sheet or a like, at least to enable the installation height adjustment of the element structure 2, which embodiment is shown in view lc of fig. 1.

Otn the other hand, as an advantageous embodiment, the thermal insulation arrangement 1 is being arranged at least partly to be surrouded by one or several suppor¬ ting structural parts 2" of the element structure 2 for example as a layer structure or a like. This kind of an embodiment is shown in view Id of fig. 1. Further as an advantageous embodiment, an essentially sti f structured thermal insulation layer 1 * belonging to the thermal insulation arrangement 1 is being arranged essentially built-in with the supporting structural part 2" of the element structure 2 as a truss-like x, y, perforated sheet or a like structure being essentially uniformly surrounded by the same. The truss-like principle is shown for example in fig. 2 and the perforated sheet structure in principle correspondingly in view la of fig. 1 and in figs. 3 and 4.

Further as an advantageous embodiment of the method, whereby the element structures 2 to be produced are intended to be installed in place at least partly by adapting joint organs 4 to be settled at least partly inside one or several adjacent element structures 2, the joint organs 4 are being formed of male joint 4a and/or of female joint arrangements 4b, that are formed preferably in connection with the manufacturing of the supporting structural part 2" of the element structure 2 for example during casting of the same.

As an advantageous embodiment, the element structure is equipped during the manufacturing of the same furthermore with a protecting film, sheet an/or a like s, as shown in view lc of fig. 1, at least to protect the outer surface u of the element structure during succeeding handling of the same, such as during transportation, storing and/or the like.

As shown in figs. 1, 2, 3 and 4 in principle, the element structure 2, that is ment particularly for facade repair building, includes at least one suppor- ting structural part 2", that is at least partly made of an organic first base material 2a, for example based on wood, vegetable and/or like, and of an inorganic second base material 2b, for example based on stone, plastics, glass, rubber, metal and/or like, preferably by adapting cement as binder material 2c. According to the invention the element structure 2 is arranged preferably as a totally prefabricated entire- ty, that may be transported, stored and further installed at the site as a construction element, that forms an essentially finished facade surface u right away, in which case to the outer surface of the supporting structural part 2 " there has been esta- blished a desired external relief of surface for example by utilizing a surface patterned mold in connection with casting of the same. It is also possible to arrange the colouring of the element structure as desired by utilizing suitable pigments during the casting of the supporting structural part 2".

As shown in view lc of fig. 1, the thermal insulation arrangement 1 in the element structure 2 comprises as an advantageous embodiment at least one essentially flexible thermal insulation 1", such as a mineral wool sheet, rock wool sheet or a like, which enables the installation height adjustment of the element structu¬ re 2.

Further as an advantageous embodiment, the thermal insulation arrangement 1 of the element structure 2 is arranged to be surrounded by one or several supporting structural parts 2" of the element structure 2 for example as a layer structure, which kind of a solution is represented in view Id of fig. 1, or as a lattice structure x, y being placed totally inside the struc¬ tural part 2", which embodiment is shown in Fig. 2, or as a perforated sheet structure as shown in view la of fig. 1, that is essentially built-in with the suppor¬ ting structural part 2". The aim of the type of thermal insulation arrangements is naturally to eminate cold spots of the structures and on the other hand to enable adequate natural metabolism of the element structure as well as anchoring of the opposite walls of the same to each other.

Further as an advantageous embodiment with reference to Fig. 2 the element structure is intended to be installed in place at least partly by adapting joint organs 4 to be settled at least partly inside one or several adjacent element structures 2, whereby the joint organs 4 are arranged as an advantageous embodi¬ ment at least partly by male joint 4a and/or female joint arrangements 4b existing built-in with the supporting structural part 2" of the element structure 2, that are formed in connection with the manufactu¬ ring of the same for example during casting of the same.

Futher with reference to figs. 3 and 4, the element structure 2 being represented therewith comprises futhermore as an advantageous embodiment male couplers 4a belonging to the joint organs 4, such as guiding flanges, that are formed of thermal insulation sheets 6a' being attached to the recess arrangements 4b, that have been formed during the manufacturing of the supporting structural part 2", whereby correspondingly the recess arrangements at two sides of the element structure act as female couplers 4b, when connecting the element structures to each other.

Further particularly with reference to fig. 3, the attachment point 8 of an element structure 2, that is to be installed in place by adpting at least partly a mechanic attachment arrangement, such as by means of attachment bolts or the like, is arranged advanta¬ geously essentially in connection with the joint organs 4, that is in the guiding flanges 4a. Further as an advantageous embodiment particularly with reference to fig. 3, to the back surface of the element structure 2, there has been arranged as an advantageous embodiment binding means 9, such as recesses, grips and/or like, to secure the attachment of the element structure to the original wall particu- larly when adapting glueing or solidifying attachment mass.

As shown in view lc of fig. 1, the element structure 2 represented therewith is equipped with a protecting film s to protect the outer surface u of the same during transportation, storage as well as installation of the element structure 2. Particularly a protecting film s being used while installation makes the istal- lation measures significantly easier, because the protecting film may be removed not until as a final stage, whereby no traces of the intallation measures will be left to the repaired facade.

It is obvious, that the invention is not limited to the embodiments presented or described above, but it can be modified within the basic idea even to a great extent. This is firstly due to that, that the method and element structure according to the invention may be adapted technically in very many ways, in most heterogeneous circumstances and by adapting most heterogeneous manufacturing techniques. Thus the directive drawings represent general principles, only, however in maybe most general contexts.

Claims

1. Method for producing an element structure, that is ment particularly for facade repair building, such as for supplementary thermal insulation, surface repairment and/or a like of the same, and which at least partly is being prefabricated during the manu¬ facturing process of the same by arranging at least an integral thermal insulation arrangement ( 1) and a surface polishing (3) therewith, whereby the element structure (2) may be transported, stored and further¬ more installed at the site as a construction element, that forms an essentially finished facade surface (u) right away, characterized in, that at least the supporting structural parts {2") of the element structure (2) are at least partly being prepared of an organic first base material (2a), for example based on wood, vegetable and/or like, and of an inorganic second base material (2b), for example based on stone, plastics, glass, rubber, metal and/or like, preferably by adapting cement as binder material (2c) .

2. Method according to claim 1, characterized in, that the surface polishing (3), being essentially built-in with the supporting structural part (2") of the element structure (2) or being arranged in connec¬ tion with the same, is being achieved, on the one hand to achieve an outer surface patterning of the element structure (2) , during the manufacturing of the suppor- ting structural part (2") of the element structure (2), such as in connection with casting by using preferably a surface patterned mold or a like, and/or, on the other hand to achieve an essentially coloured or a like appearance of the element structure (2) , during the manufacturing of the supporting structural part (2") of the element structure (2), such as in connection with casting by adapting one or several pigments as mixture material.

3. Method according to claim 1 or 2, characteri¬ zed in, that the thermal insulation arrangement (1) in the element structure (2) is being equipped with at least one essentially flexible thermal insulation (1"), such as with a mineral wool sheet, rock wool sheet or a like, at least to enable the installation height adjustment of the element structure (2).

4. Method according to any of the above claims 1 - 3, characterized in, that the thermal insulation arrangement (1) is being arranged at least partly to be surrouded by one or several supporting structural parts (2") of the element structure (2) for example as a layer structure or a like.

5. Method according to any of the above claims 1 - 4, characterized in, that an essentially stiff structured thermal insulation layer ( 1 ' ) belonging to the thermal insulation arrangement (1) is being arranged essentially built-in with the supporting structural part (2") of the element structure (2) as a truss-like (x, y) , perforated or a like structure being essentially uniformly surrounded by the same.

6. Method according to any of the above claims 1 - 5, whereby the element structures (2) to be produced are intended to be installed in place at least partly by adapting joint organs (4) to be settled at least partly inside one or several adjacent element structures (2), characterized in, that the joint organs (4) are being formed at least partly of male joint (4a) and/or of female joint arrangements (4b), that are formed in connection with the manufac¬ turing of the supporting structural part (2") of the element structure (2) for example during casting of the same.

7. An element structure, that is ment particu¬ larly for facade repair building, such as for supple¬ mentary thermal insulation, surface repairment and/or a like of the same, and which at least partly is prefabricated during the manufacturing process of the same by arranging at least an integral thermal insula¬ tion arrangement (1) and a surface polishing (3) therewith, whereby the element structure (2) may be transported, stored and furthermore installed at the site as a construction element, that forms an essen¬ tially finished facade surface (u) right away, charac¬ terized in, that at least the supporting structural parts (2") of the element structure (2) are at least partly made of an organic first base material (2a), for example based on wood, vegetable and/or like, and of an inorganic second base material (2b), for example based on stone, plastics, glass, rubber, metal and/or like, preferably by adapting cement as binder material (2c).

8. An element structure according to claim 7, characterized in, that the element structure (2) comprises a surface polishing (3), being essentially built-in with the supporting structural part (2") of the element structure (2) or being arranged in connec¬ tion with the same, that is prepared during the manu¬ facturing of the supporting structural part (2") of the element structure (2), such as in connection with casting on the one hand by using preferably a surface patterned mold or a like to achieve an outer surface patterning of the element structure (2), and/or by mixing one or several pigments to the raw material of the supporting structural part (2") to achieve an essentially coloured or a like appearance of the element structure (2).

9. An element structure according to claim 7 or 8, characterized in, that the thermal insulation arrangement (1) in the element structure (2) comprises at least one essentially flexible thermal insulation (1"), such as a mineral wool sheet, rock wool sheet or a like, at least to enable the installation height adjustment of the element structure (2).

10. An element structure according to claim 8 or 9, characterized in, that a thermal insulation arran¬ gement ( 1) of the element structure (2) is arranged to be surrounded by one or several supporting structural parts (2" ) of the element structure (2) or example as a layer structure and/or to be essentially built-in with the supporting structural part (2") of the ele¬ ment structure (2) as a truss-like (x, y), perforated or a like structure being uniformly surrounded by the same.

11. An element structure according to any of the above claims 8 - 10, whereby the element structures (2) to be produced are intended to be installed in place at least partly by adapting joint organs (4) to be settled at least partly inside one or several adjacent element structures (2), characterized in, that the joint organs (4) are arranged at least partly by male joint (4a) and/or of female joint arrangements (4b), that are formed in connection with the manufac¬ turing of the supporting structural part (2") of the element structure (2) for example during casting of the same.