EP2167753A1 - Method of fabricating integrally insulated concrete wall or wall components - Google Patents
Method of fabricating integrally insulated concrete wall or wall componentsInfo
- Publication number
- EP2167753A1 EP2167753A1 EP08781206A EP08781206A EP2167753A1 EP 2167753 A1 EP2167753 A1 EP 2167753A1 EP 08781206 A EP08781206 A EP 08781206A EP 08781206 A EP08781206 A EP 08781206A EP 2167753 A1 EP2167753 A1 EP 2167753A1
- Authority
- EP
- European Patent Office
- Prior art keywords
- concrete
- wall
- type
- walls
- plastic
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Withdrawn
Links
Classifications
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04G—SCAFFOLDING; FORMS; SHUTTERING; BUILDING IMPLEMENTS OR AIDS, OR THEIR USE; HANDLING BUILDING MATERIALS ON THE SITE; REPAIRING, BREAKING-UP OR OTHER WORK ON EXISTING BUILDINGS
- E04G11/00—Forms, shutterings, or falsework for making walls, floors, ceilings, or roofs
- E04G11/06—Forms, shutterings, or falsework for making walls, floors, ceilings, or roofs for walls, e.g. curved end panels for wall shutterings; filler elements for wall shutterings; shutterings for vertical ducts
- E04G11/08—Forms, which are completely dismantled after setting of the concrete and re-built for next pouring
- E04G11/18—Forms, which are completely dismantled after setting of the concrete and re-built for next pouring for double walls
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B28—WORKING CEMENT, CLAY, OR STONE
- B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
- B28B13/00—Feeding the unshaped material to moulds or apparatus for producing shaped articles; Discharging shaped articles from such moulds or apparatus
- B28B13/02—Feeding the unshaped material to moulds or apparatus for producing shaped articles
- B28B13/021—Feeding the unshaped material to moulds or apparatus for producing shaped articles by fluid pressure acting directly on the material, e.g. using vacuum, air pressure
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B28—WORKING CEMENT, CLAY, OR STONE
- B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
- B28B13/00—Feeding the unshaped material to moulds or apparatus for producing shaped articles; Discharging shaped articles from such moulds or apparatus
- B28B13/02—Feeding the unshaped material to moulds or apparatus for producing shaped articles
- B28B13/0215—Feeding the moulding material in measured quantities from a container or silo
- B28B13/022—Feeding several successive layers, optionally of different materials
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B28—WORKING CEMENT, CLAY, OR STONE
- B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
- B28B23/00—Arrangements specially adapted for the production of shaped articles with elements wholly or partly embedded in the moulding material; Production of reinforced objects
- B28B23/0068—Embedding lost cores
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B28—WORKING CEMENT, CLAY, OR STONE
- B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
- B28B7/00—Moulds; Cores; Mandrels
- B28B7/0064—Moulds characterised by special surfaces for producing a desired surface of a moulded article, e.g. profiled or polished moulding surfaces
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04G—SCAFFOLDING; FORMS; SHUTTERING; BUILDING IMPLEMENTS OR AIDS, OR THEIR USE; HANDLING BUILDING MATERIALS ON THE SITE; REPAIRING, BREAKING-UP OR OTHER WORK ON EXISTING BUILDINGS
- E04G21/00—Preparing, conveying, or working-up building materials or building elements in situ; Other devices or measures for constructional work
- E04G21/02—Conveying or working-up concrete or similar masses able to be heaped or cast
- E04G21/04—Devices for both conveying and distributing
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04G—SCAFFOLDING; FORMS; SHUTTERING; BUILDING IMPLEMENTS OR AIDS, OR THEIR USE; HANDLING BUILDING MATERIALS ON THE SITE; REPAIRING, BREAKING-UP OR OTHER WORK ON EXISTING BUILDINGS
- E04G21/00—Preparing, conveying, or working-up building materials or building elements in situ; Other devices or measures for constructional work
- E04G21/02—Conveying or working-up concrete or similar masses able to be heaped or cast
- E04G21/04—Devices for both conveying and distributing
- E04G21/0418—Devices for both conveying and distributing with distribution hose
- E04G21/0472—Details of connection of the hose to the formwork, e.g. inlets
Definitions
- the invention generally relates to method of fabricating integrally insulated concrete walls or wall components. This invention is an improvement of existing methods of fabricating the integrally insulated concrete wall or wall components.
- Integrally insulated concrete walls also known as sandwich walls
- These walls are well known in the art and offer a number of advantages to the residential, commercial, institutional and agricultural industry building construction. These walls are typically cast at a manufacturing plant or on-site. The walls can be cast horizontally or vertically and when cast vertically; the concrete is placed from top of the forms.
- Integrally insulated concrete walls contain two outer layers or wythes of concrete sandwiching rigid insulation board. Connectors are used to tie the outer layer concrete with the inner layer concrete through the insulation.
- the connectors can be metallic or non-metallic.
- the rigid insulation board is a type of extruded polystyrene, expanded polystyrene, or polyisocyanurate or other rigid board insulation. Many types of connectors, both metallic and non-metallic, are available in the market.
- the panels are cast horizontally on the floor slab of the building.
- the fascia wythe is placed first and then the insulation and connectors are placed on top of the fascia wythe while the concrete is still plastic.
- the structural wythe reinforcing is then placed on top of the insulation after about 24 hours or after the fascia concrete has hardened sufficiently. Finally, the structural wythe concrete is placed and finished.
- the walls are formed in place with insulation and reinforcing and then the concrete is placed from the top of the form into the form with or without a tremie.
- the components of the concrete tend to segregate and also the concrete tends to entrain air.
- the concrete must be vibrated to consolidate the concrete and for concrete to flow into the large pockets typically left due to the restriction to concrete flow between the formwork due to the presence of reinforcing and door and window openings. However, this vibration process will cause the entrained air to travel towards the formwork and cause for surface blemishes.
- the method of fabrication is improved by setting up the vertical forms in a manufacturing plant or on-site and introducing the concrete from the base or near the base in both wythes simultaneously.
- the primary objective of the present invention is an improved method of fabrication of integrally insulated concrete wall that results in wall components that may have different surface finishes on the two outwardly facing surfaces.
- Another objective of the present invention is the ability of setting up the formwork anywhere with little site preparation since the formwork can be self contained with adjustable sides, base and adjustable bulkhead.
- Yet another objective of the present invention is to pump concrete from the bottom or near the base. This method eliminates the need for vibrating concrete.
- Another objective of the present invention is to be able to construct vertical cast sandwich walls with thinner interior and/or exterior wythes.
- a further objective of this invention is its ability to use different colored concrete or concrete with different properties in the fascia wythe and the structural wythe simultaneously.
- Yet another objective is to construct taller single pour walls without segregation of concrete.
- Yet another objective is to eliminate or limit insulation displacement during concrete placement.
- Still another objective is to use a vacuum and/or pressurized air, fluid or both to assist in placing the concrete in the form.
- the wall panels are fabricated by casting the walls or wall components vertically and pumping the concrete from the bottom of the form or from sides near the base.
- Walls and wall components fabricated thus can be used in commercial, industrial, residential, and agricultural buildings. These panels can be cast on-site or in a manufacturing plant.
- the formwork for the panels contains a fixed vertical form and a moveable base form.
- the bulkheads are adjustable to accommodate various thickness of wall and various lengths of the wall.
- a ball valve, gate valve, plunger valve, or other similar valve system is used on or near the bottom of the form to introduce concrete in both wythes simultaneously.
- the wall panel can be one single panel or it can be multiple panels poured parallel to each other or it can be a multiple sided module.
- Fig. 1 is a perspective view showing the formwork and panel with preferred non- metallic connectors connecting the two wythes of concrete.
- Fig. 2 is a cross sectional view of an alternative embodiment of the present invention wherein the formwork is provided with airtight seals and placement of the concrete in the form is assisted by a vacuum that communicates with the top of the form.
- Fig. 3 is a cross sectional view of an alternative embodiment of the present invention wherein a concrete hopper is charged with a pressurized air, fluid or both to force the plastic concrete into the form without the need for a concrete pump.
- Movable base 3 is an adjustable base so that different height and thickness walls can be constructed. This base 3 preferably includes a leveling mechanism to keep the base 3 level even if the ground is not level on-site.
- the base 3 contains one or more openings 4 with ball valve, a gate valve or a plunger valve or similar valve (not shown) to pump concrete from the bottom.
- Adjustable bulkheads 5 are set on top of the movable base 3 with help of magnets or other means to keep it in place. With adjustable and interchangeable bulkheads 5, the length and thickness of the wall can be adjusted.
- the reinforcing 9 for the wythe adjacent to the fixed form is placed.
- insulation 6 and the connectors 7 are placed in the form 2.
- the insulation 6 is extruded polystyrene board insulation with fiber composite connectors 7.
- the reinforcing 9 for the other wythe is placed and the movable form 10 is placed at the correct location.
- another set of one or more openings 4 with a ball valve, a gate valve or a plunger valve or similar valve are located in the base closer to the movable form 10.
- the whole assembly may be braced with braces 11 on both sides of the form 2.
- Concrete is then pumped from the bottom through opening 4 either with one pump or more pumps.
- each type of concrete is pumped with different pump.
- the rate of pumping concrete is adjusted such that the concrete in both wythes fills up to substantially the same height simultaneously.
- the concrete can be pumped from the sides near the base through the openings 12 on either or both sides or from the end of the form 2.
- the pumping is continued until the concrete raises to the top of the form 2 or to the required height of the wall.
- lifting devices (not shown) are placed near the top of the forms using magnets or tied to the reinforcing 9.
- the multiple openings 4 allow plastic concrete to enter the form from both sides of the insulation 6.
- concrete can be provided from different sources to the different wythes on opposite sides of the insulation 6.
- different types of concrete can be used for the different wythes simultaneously.
- one of the wythes may be formed of a concrete that is a different color that the concrete that forms the other wythe.
- concrete of different physical properties can be used to form the different wythes as may be advantageous if one of the wythes is an outside wall exposed to the elements and the other is a protected inside wall.
- Haring openings 4 and 12 are particularly applicable if the form 2 is divided into regions that are not common at the bottom of the form 2, as is the case if a door opening was being formed. Without multiple openings 4 and 12, the plastic concrete would need to fill up the form on one side of the door opening until it exceeded the height of the door opening and then would pour down the height of the door opening into the other chamber of the form 2.
- Some of the alternate embodiments are to cast another wall on the other side of fixed form, which becomes the common form for both walls or wall components, to add another section of wall, perpendicular or at an angle to one or both ends of the wall. Another embodiment is to fabricate more than two walls or wall components side by side.
- An advantage of the present invention is that introducing plastic concrete into the bottom of the form 2, rather than pouring it in from the top as is done in the prior art, assists in forcing air out of the plastic concrete in the from 2, thus reducing the need for vibration or other methods for removing air and reducing the occurrence of voids in the formed concrete due to air pockets.
- Introducing the plastic concrete into the bottom of the form 2 is also advantageous in that it reduces the hydraulic pressure that is imposed on the form 2 and insulation 6 by the plastic concrete compared to the conventional method wherein the plastic concrete is poured into the top of the form.
- a form 16 is constructed so that it is air tight, including, for example, a top cover 18 (Fig. 2).
- the interior of the form 16 is placed in communication with a vacuum chamber 20 or other source of a vacuum.
- Plastic concrete is provided in a hopper 22 that is connected to a pair of openings 24 and 26 on either side of the form 16.
- Valves 28 and 30 control the flow of plastic concrete 36 into the form 16.
- concrete is placed in the form 16 by opening of the valves 28 and 30 and connecting the vacuum source.
- an alternative concrete hopper 32, 38 is provided with a bladder 40 or similar system for applying a positive pressure to the concrete to assist in forcing the plastic concrete 36 from the hopper 32 into the form 44 (Fig. 3).
- Pressurized fluid 34 such as air, another gas, or a liquid, is introduced above the bladder 40 through a supply line 42.
- pressurized concrete is provided without the need for expensive and high maintenance concrete pumps. It is of course possible to combine the systems of Fig. 2 and Fig. 3 wherein both a vacuum is created on the top of the form and pressurized fluid assists in introducing the plastic concrete into the form. If the plastic concrete has sufficiently low viscosity, such as some so called self consolidating concretes, gravity alone would be sufficient to force the plastic concrete into the form.
Landscapes
- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Architecture (AREA)
- Manufacturing & Machinery (AREA)
- Chemical & Material Sciences (AREA)
- Ceramic Engineering (AREA)
- Civil Engineering (AREA)
- Structural Engineering (AREA)
- Physics & Mathematics (AREA)
- Fluid Mechanics (AREA)
- On-Site Construction Work That Accompanies The Preparation And Application Of Concrete (AREA)
Abstract
Description
Claims
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US93751907P | 2007-06-28 | 2007-06-28 | |
PCT/US2008/068846 WO2009006440A1 (en) | 2007-06-28 | 2008-06-30 | Method of fabricating integrally insulated concrete wall or wall components |
Publications (2)
Publication Number | Publication Date |
---|---|
EP2167753A1 true EP2167753A1 (en) | 2010-03-31 |
EP2167753A4 EP2167753A4 (en) | 2012-01-04 |
Family
ID=40158794
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
EP08781206A Withdrawn EP2167753A4 (en) | 2007-06-28 | 2008-06-30 | Method of fabricating integrally insulated concrete wall or wall components |
Country Status (3)
Country | Link |
---|---|
US (1) | US20090000241A1 (en) |
EP (1) | EP2167753A4 (en) |
WO (1) | WO2009006440A1 (en) |
Families Citing this family (15)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
ES2374123B1 (en) * | 2009-04-22 | 2012-12-21 | Carmelo Vázquez del Campo | IMPROVEMENTS INTRODUCED IN THE INVENTION PATENT NUMBER 200602721, BY "CONSTRUCTION SYSTEM FOR FAÇADES". |
FR2952098B1 (en) * | 2009-10-30 | 2012-05-04 | Entpr Generale Leon Grosse | METHOD AND DEVICE FOR MAKING A DOUBLE-WALL WALL AND PROVIDED WITH INSULATION |
WO2012075071A1 (en) | 2010-12-02 | 2012-06-07 | Cemex Research Group Ag | Reinforced wall system and method |
US8555584B2 (en) | 2011-09-28 | 2013-10-15 | Romeo Ilarian Ciuperca | Precast concrete structures, precast tilt-up concrete structures and methods of making same |
CA2853766C (en) | 2011-11-11 | 2016-06-21 | Romeo Ilarian Ciuperca | Concrete mix composition, mortar mix composition and method of making and curing concrete or mortar and concrete or mortar objects and structures |
KR101454276B1 (en) * | 2012-01-17 | 2014-10-23 | 정문형 | method for constructing soil structure |
US8636941B1 (en) | 2012-09-25 | 2014-01-28 | Romeo Ilarian Ciuperca | Methods of making concrete runways, roads, highways and slabs on grade |
US8877329B2 (en) | 2012-09-25 | 2014-11-04 | Romeo Ilarian Ciuperca | High performance, highly energy efficient precast composite insulated concrete panels |
US8532815B1 (en) | 2012-09-25 | 2013-09-10 | Romeo Ilarian Ciuperca | Method for electronic temperature controlled curing of concrete and accelerating concrete maturity or equivalent age of concrete structures and objects |
US9458637B2 (en) | 2012-09-25 | 2016-10-04 | Romeo Ilarian Ciuperca | Composite insulated plywood, insulated plywood concrete form and method of curing concrete using same |
WO2014186299A1 (en) | 2013-05-13 | 2014-11-20 | Ciuperca Romeo Llarian | Insulated concrete battery mold, insulated passive concrete curing system, accelerated concrete curing apparatus and method of using same |
US10065339B2 (en) | 2013-05-13 | 2018-09-04 | Romeo Ilarian Ciuperca | Removable composite insulated concrete form, insulated precast concrete table and method of accelerating concrete curing using same |
EP3043971A4 (en) | 2013-09-09 | 2017-01-18 | Romeo Ilarian Ciuperca | Insulated concrete slip form and method of accelerating concrete curing using same |
US10280622B2 (en) | 2016-01-31 | 2019-05-07 | Romeo Ilarian Ciuperca | Self-annealing concrete forms and method of making and using same |
GR1009639B (en) * | 2018-08-06 | 2019-11-08 | Θεοδωρος Ιωαννη Αναγνωστοπουλος | Void space confinement for the building of concrete houses |
Citations (6)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
FR2073670A5 (en) * | 1969-12-12 | 1971-10-01 | Deutsche Bauakademie | |
GB1516806A (en) * | 1975-05-17 | 1978-07-05 | Reimers H | Method and apparatus for producing prefabricated structural members |
FR2722526A1 (en) * | 1994-07-12 | 1996-01-19 | La Meridionale De Travaux | Device for manufacturing vertical or diagonal concrete components on site |
WO1997009495A1 (en) * | 1995-09-01 | 1997-03-13 | Lättklinkerbetong Ab | Prefabricated facade element for buildings |
WO2001043930A2 (en) * | 1999-12-15 | 2001-06-21 | Hollandsche Beton Groep N.V. | Method and installation for forming a concrete element |
US20040011943A1 (en) * | 2000-09-22 | 2004-01-22 | Long Sr Robert T. | Connector assembly for insulated concrete walls |
Family Cites Families (8)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
GB1248614A (en) * | 1968-10-02 | 1971-10-06 | Nat Res Dev | Apparatus for the conveyance of cohesive particulate material |
IL59332A (en) * | 1980-02-07 | 1981-09-13 | Dan Shoham | Method of contructing in-situ cast concrete internally insulated walls |
US4329821A (en) * | 1980-04-30 | 1982-05-18 | Long Robert T | Composite insulated wall |
US6086349A (en) * | 1992-05-26 | 2000-07-11 | Del Monte; Ernest J. | Variable wall concrete molding machine |
US5882540A (en) * | 1996-11-12 | 1999-03-16 | Farrington; Albert J. | Wall construction apparatus and methodology |
GB0009521D0 (en) * | 2000-04-18 | 2000-06-07 | Abersham Technologies Limited | Improvements to modular buildings and material used in their construction |
CA2400122A1 (en) * | 2002-08-28 | 2004-02-28 | Paul Baillargeon | Prefabricated thin wall concrete panel |
US20060080923A1 (en) * | 2004-10-14 | 2006-04-20 | Peter Fleischhacker | Insulation sheet structure and concrete sandwich wall panel assembly constructed therewith |
-
2008
- 2008-06-30 EP EP08781206A patent/EP2167753A4/en not_active Withdrawn
- 2008-06-30 WO PCT/US2008/068846 patent/WO2009006440A1/en active Search and Examination
- 2008-06-30 US US12/165,233 patent/US20090000241A1/en not_active Abandoned
Patent Citations (6)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
FR2073670A5 (en) * | 1969-12-12 | 1971-10-01 | Deutsche Bauakademie | |
GB1516806A (en) * | 1975-05-17 | 1978-07-05 | Reimers H | Method and apparatus for producing prefabricated structural members |
FR2722526A1 (en) * | 1994-07-12 | 1996-01-19 | La Meridionale De Travaux | Device for manufacturing vertical or diagonal concrete components on site |
WO1997009495A1 (en) * | 1995-09-01 | 1997-03-13 | Lättklinkerbetong Ab | Prefabricated facade element for buildings |
WO2001043930A2 (en) * | 1999-12-15 | 2001-06-21 | Hollandsche Beton Groep N.V. | Method and installation for forming a concrete element |
US20040011943A1 (en) * | 2000-09-22 | 2004-01-22 | Long Sr Robert T. | Connector assembly for insulated concrete walls |
Non-Patent Citations (1)
Title |
---|
See also references of WO2009006440A1 * |
Also Published As
Publication number | Publication date |
---|---|
US20090000241A1 (en) | 2009-01-01 |
EP2167753A4 (en) | 2012-01-04 |
WO2009006440A1 (en) | 2009-01-08 |
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Legal Events
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DAX | Request for extension of the european patent (deleted) | ||
A4 | Supplementary search report drawn up and despatched |
Effective date: 20111206 |
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RIC1 | Information provided on ipc code assigned before grant |
Ipc: E04G 21/04 20060101ALI20111130BHEP Ipc: E04G 11/18 20060101ALI20111130BHEP Ipc: B28B 23/00 20060101ALI20111130BHEP Ipc: B28B 13/02 20060101ALI20111130BHEP Ipc: B28B 7/00 20060101AFI20111130BHEP |
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