WO2019221617A1 - Prefabricated construction element and the method of erecting objects made of prefabricated construction elements - Google Patents

Prefabricated construction element and the method of erecting objects made of prefabricated construction elements Download PDF

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Publication number
WO2019221617A1
WO2019221617A1 PCT/PL2018/000121 PL2018000121W WO2019221617A1 WO 2019221617 A1 WO2019221617 A1 WO 2019221617A1 PL 2018000121 W PL2018000121 W PL 2018000121W WO 2019221617 A1 WO2019221617 A1 WO 2019221617A1
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WO
WIPO (PCT)
Prior art keywords
wall
panels
panel
prefabricated construction
walls
Prior art date
Application number
PCT/PL2018/000121
Other languages
French (fr)
Inventor
Marek SZOCHNER
Original Assignee
Szochner Marek
Priority date (The priority date 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 date listed.)
Filing date
Publication date
Application filed by Szochner Marek filed Critical Szochner Marek
Publication of WO2019221617A1 publication Critical patent/WO2019221617A1/en

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Classifications

    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B2/00—Walls, e.g. partitions, for buildings; Wall construction with regard to insulation; Connections specially adapted to walls
    • E04B2/84—Walls made by casting, pouring, or tamping in situ
    • E04B2/86—Walls made by casting, pouring, or tamping in situ made in permanent forms
    • E04B2/8647—Walls made by casting, pouring, or tamping in situ made in permanent forms with ties going through the forms
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • E04B1/38—Connections for building structures in general
    • E04B1/61—Connections for building structures in general of slab-shaped building elements with each other
    • E04B1/6108—Connections for building structures in general of slab-shaped building elements with each other the frontal surfaces of the slabs connected together
    • E04B1/6116—Connections for building structures in general of slab-shaped building elements with each other the frontal surfaces of the slabs connected together by locking means on lateral surfaces
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B2/00—Walls, e.g. partitions, for buildings; Wall construction with regard to insulation; Connections specially adapted to walls
    • E04B2/84—Walls made by casting, pouring, or tamping in situ
    • E04B2/86—Walls made by casting, pouring, or tamping in situ made in permanent forms
    • E04B2002/867—Corner details
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B2/00—Walls, e.g. partitions, for buildings; Wall construction with regard to insulation; Connections specially adapted to walls
    • E04B2/84—Walls made by casting, pouring, or tamping in situ
    • E04B2/86—Walls made by casting, pouring, or tamping in situ made in permanent forms
    • E04B2002/8676—Wall end details

Definitions

  • the subject of invention is a prefabricated construction element intended for erecting walls and a method for erecting residential, commercial and industrial objects made of prefabricated construction elements.
  • the subject of the invention is a prefabricated building wall self-supporting panel intended for use in low-rise construction, implemented by an industrialized system.
  • the panel with wall elements described here characterizes in that it consists of girders: upper and lower, each of which is made of two reinforced concrete beams with a cross-section in the shape similar to the letter L, which are equipped with steel hooks, used to join reinforced concrete beams with each other as well as to fasten bolts and hooks.
  • the bracing rods are used to integrate girders and wall elements as a whole, while the gap between reinforced concrete beams is filled by the thermal insulation material.
  • the subject of the invention is prefabricated falsework-forming building unit made of expanded polystyrene, used in the construction of load-bearing and partition walls, in particular, of residential houses.
  • the falsework-forming has two side walls, to which transverse elements are attached with a height equal to the height of these walls, which form, at least, two closed chambers.
  • a glass fibre mesh coated with plastic material is glued to a surface of the side walls.
  • the subject of the invention is a prefabricated wall intended for constructing buildings for various purposes and different thermal insulation properties.
  • This wall may be intended for filling framework structures of buildings, curtain wall, a partition wall or a structural wall, especially low buildings.
  • the wall structure consists of prefabricated hollow core boards joined in vertical joint with bolts through the spacer. The spacer enables dry fastening of external finishing elements and internal finishing elements, such as dry plaster, panelling, etc.
  • Another type of known and applied solutions for building walls out of prefabricated elements include the use of relatively small building blocks.
  • the disadvantage of these solutions is time-consuming, and thus extending the construction time.
  • erection of objects made of this type of prefabricated elements is possible only with the participation of a qualified workforce.
  • Prefabricated building blocks of smaller size and methods of erecting buildings with them require carrying out time-consuming works based on combining individual prefabricates.
  • Magnesium panels called "MgO panels” are widely known from the chemical symbol magnesium Mg and oxygen O, which are manufactured as construction boards with a wide range of applications.
  • the natural raw material is magnesium oxide - a type of mineral cement.
  • Standard magnesium boards are a layer board consisting of a core of powdered pearlite surrounded on both sides with a glass fibre mesh and magnesium layer MgO or magnesium-cement often reinforced (in a dispersed way) with cellulose fibre with the addition of other derivatives of magnesium compounds such as magnesium chloride - MgCI2 or magnesium sulphates.
  • Cement-particle boards are also commonly known, the advantage of which is that they are a fully ecological material. They do not contain any harmful substances like asbestos or formaldehyde. They are resistant to solvents, oils and greases.
  • the aim of the invention is to develop prefabricated construction elements using the properties of MgO boards and cement-particle boards, which will enable poorly qualified workers to implement a simple, fast and economical method of building objects from prefabricated construction elements, significantly limiting, at the same time, necessity to use in the construction process specialized, heavy equipment.
  • a prefabricated construction element that is the subject of the invention is a panel consisting of two walls joined together, i.e. an inner wall and an outer wall, which are joined by means of at least one fastener, however between the inner wall and the outer wall there is an additional filling, which is preferably a concrete mix.
  • the essence of the developed element is that the developed panel is equipped with splines that are fixed to the panel on its walls from the inside, i.e. both to the inner wall and the outer wall. These splines are placed out of, at least, one edge of the inner wall and the outer wall of the panel.
  • - inner wall is made of magnesium board (MgO) or a cement-particle board
  • the outer wall is one-layer wall and is made of a magnesium board (MgO) or a cement-particle board or a thermal- insulating material.
  • - inner wall is made of a magnesium board (MgO) or a cement-particle board
  • the outer wall is two-layer wall and consists of either a magnesium board (MgO) or a cement-particle board and a thermal insulation material and then a magnesium board (MgO) or a cement- particle board is the outer part of the panel (1), while the insulating material is the inner part of the panel (1), between the additional filling material (8), and the magnesium board (MgO) or the cement- particle board, depending on which one was used.
  • the panel also preferably has at least one lower reinforcement, usually in the form of bracket.
  • the fastener is in the form of a tube, a rectangular plate, a sheet or a block, for example a prism, and fixed to the inner wall and the outer wall permanently by means of a binder.
  • the splines are fastened to the panel on its walls from the inside by means of a set of bolts, screws, rivets, adhesive or other bonding mass.
  • the panel has at least one side wall.
  • At least one overflow opening is made.
  • the outer wall of the panel is higher than the inner wall.
  • a prefabricated construction element which is a lintel or under window element - the panel is equipped with at least one, usually horizontal, additional wall that forms the upper or lower part of the panel, (figures 41 and 43).
  • the panel has at least one marker, preferably in the form of QR code or bar code.
  • the developed panel has at least one installation trough.
  • the walls made of panels are equipped with placed and protruding reinforcement.
  • a side wall is used to introduce the construction joint (movement joint; dilatation).
  • the construction joint movement joint; dilatation.
  • the prefabricated construction element in the form of a post are four set panels that are joined together so that they form a square in cross-section.
  • the external walls made of magnesium (MgO) or cement-particle board are the external surfaces of the post in which the reinforcement is placed.
  • the building partition i.e. a wall
  • prefabricated construction elements in the form of panels consisting of two walls joined together, i.e. the inner wall and outer wall, which is are factory-joined by means of at least one fastener.
  • the essence of this method lies in the fact that the panels are made using magnesium boards (MgO) or cement-particle boards.
  • MgO magnesium boards
  • cement-particle boards In the panel there are factory-mounted permanent splines so that they are led out of at least one edge of the inner wall and the outer wall of the panel and are fixed to both the inner wall and the outer wall in such a way that after the panels are assembled the splines of the adjacent panels adjoin.
  • the panels prepared for assembly are factory-adjusted:
  • the panels are prepared so that their outer wall is one- or two- layer, and then the single-layer outer wall is made of a magnesium board or a cement-particle board or a thermal-insulating material, whereas the outer wall in a two-layer variant consists of both a magnesium board or cement-particle board as well as thermal insulation material,
  • At least one lower reinforcement is fastened, for example in the form of a bracket,
  • the panels are equipped with installation troughs
  • the fasteners are arranged so that their greatest concentration is located at the lower part of the panel, - preferably, lintels made of panels are usually equipped with horizontal additional walls that form the upper or lower part of the panel (figures 41 and 43),
  • the panels are equipped with markings, i.e. markers, e.g. in the form of a Q.R code or bar code, preferably, the panel is equipped with a side wall that is vertical and perpendicular to the walls in the base panel, i.e. to its inner wall and outer wall and placed inside the panel, preferably so that the location of the side wall that forms the construction joint does not coincide with the edge of the panel.
  • markings i.e. markers, e.g. in the form of a Q.R code or bar code
  • the panel is equipped with a side wall that is vertical and perpendicular to the walls in the base panel, i.e. to its inner wall and outer wall and placed inside the panel, preferably so that the location of the side wall that forms the construction joint does not coincide with the edge of the panel.
  • the panels that are delivered to the construction site are placed in the arranged spot and positioned by attaching subsequent, fixed panels to adjacent panels and merging them together. Every spline is screwed - preferably by means of bolts, screws or rivets - to an adjacent panel, and then after assembly of complete, first row of panels is filled with filling material, preferably concrete mix.
  • filling material preferably concrete mix.
  • the process of laying and filling subsequent layers of panels is possibly repeated so as to reach the desired height of a given storey.
  • the ceiling is made using known methods, if it is planned to build another storey of the building, then the process described above is repeated in a similar manner.
  • next row of panels When the next row of panels is planned, their lower row is filled in such a way as not to fill the panels to their upper edge, leaving an unobstructed space for inserting splines of the next, higher row of panels. Then, after filling with additional filling material the lower row of panels, and after at least initial setting of the filling material- at least after 1 ⁇ 4 hour the next row of panels is arranged on them and fastened higher, in a similar way, which is filled with additional filling material, at the same time filling with the additional filling material also the upper part of the previous row panels.
  • the panels with at least one additional lower reinforcement are preferably used.
  • the place, where the panel is to be built is read and arranged on its basis, corresponding to the designed position, which has been recorded, usually coded at the stage of designing and making prefabricated construction elements, during the preparation of the construction process of a given object.
  • the marker is read using a suitable device, e.g. applications in a mobile phone or using BIM (Building Information Modelling) software.
  • the main advantage of the developed prefabricated construction elements and the method of erecting objects with their application is the reduction of time and a significant reduction in the cost of construction works, primarily due to their simplification and acceleration.
  • the building constructed with the developed method can be erected by a smaller number of workers than before.
  • the manufactured elements are light enough that their transport to the construction site is economical.
  • a heavy concrete that fill them (the use of which is required for currently constructed objects with a certain standard) is collected from the nearest concrete mixing plant.
  • prefabricated elements used in the developed method of erecting objects are so large that using them enables fast construction of large surfaces. These elements are also so light that it is possible and easy to set them up properly without the need to use specialized equipment for this purpose.
  • the inner wall and the outer wall are made of magnesium boards (MgO) or of cement- particle boards.
  • An important advantage of the panel made of MgO board is the improvement of technical parameters that a given partition shows, e.g. improving its fire resistance.
  • the partition made of the above mentioned boards thanks to the aesthetics of their surfaces, does not require additional plastering. For finishing, it is enough to make only a thin-layer coat on it and apply a paint coat. It also essentially affects the acceleration and reduction of the investment process costs.
  • the developed invention provides for the possibility of introducing markers placed on individual panels, which being an element of the coding system of individual elements, enable precise planning as well as determining the location of their position. As a result, their search, settlement and installation in the area of the erected building, at the construction site, is easy.
  • fig.l - shows a vertical cross-section through a wall made of three stacked sets of panels with rectangular fasteners
  • fig.2 - shows a vertical cross-section through a wall made of three stacked sets of panels with tubular fasteners
  • fig.3 - shows a vertical cross-section through a wall, also made of three stacked sets of panels with tubular fasteners, which is filled with an additional filling material
  • fig.4 - shows a cross-section through a three-layer wall, i.e. a wall understood as a building partition with: an inner wall, an outer wall (a single-layer made of a board) and an additional filling material placed between them,
  • fig.5 - shows a cross-section through a three-layer external wall, i.e. a wall understood as a building partition with: an inner wall, an outer wall (single-layer of thermal insulation) and an additional filling material placed between them
  • fig.6 - shows a cross-section through a four-layer wall, i.e. a wall understood as a building partition with: an inner wall, an outer wall (a double-layer of thermal insulation and a board) and an additional filling material placed between them
  • fig.7 - shows a section through a three-layer wall, i.e.
  • fig.8 - shows a cross-section through a three-layer outer wall, i.e. a wall understood as a building partition with: an inner wall, an outer wall (a single-layer with thermal insulation) and with an additional filling inserted between them, and also with the installation trough
  • fig.9 - shows a cross-section through a four-layer wall, i.e. a wall understood as a building partition with: an inner wall, an outer wall (a double-layer with thermal insulation and a board) and an additional filling material inserted between them, as well as installation trough,
  • fig.10 - shows, in an axonometric view, a building corner made of basic panels with rectangular fasteners joining boards,
  • fig.ll - shows, in an axonometric view, a building corner made of basic panels with tubular fasteners
  • fig.12 - shows, in an axonometric view, a building corner made of panels in a variant with an outer wall made of a thermal insulation material with tubular fasteners,
  • fig.13 - shows, in axonometric view, a building corner made of panels in a variant with a two-layer outer wall with tubular fasteners,
  • fig.14 - shows, in an axonometric view, a building corner made of panels in a variant with an outer wall made of a thermal insulation material with tubular fasteners and installation troughs,
  • fig.15 - shows, in an axonometric view, a building corner with a window opening made of panels in a variant with an outer wall made of a thermal insulation material with tubular fasteners,
  • fig.16 - shows in axonometric view a fragment of a wall arranged with basic panels with tubular fasteners
  • fig.17 - shows the lower base panel in axonometric view with lower reinforcement and rectangular fasteners adjusted for joining the walls, shown without the inner wall,
  • fig.18 - shows the lower base panel in axonometric view with lower reinforcement and with rectangular fasteners joining the walls
  • fig.19 - shows in an axonometric view the lower base panel with lower reinforcement, side wall and tubular fasteners, showed without inner wall
  • fig.20 - shows in an axonometric view the lower base panel with lower reinforcement, side wall, overflow openings in the inner wall and tubular fasteners,
  • fig.21 - shows in an axonometric view the lower panel in a variant with an outer wall made of a thermal insulation material with a lower reinforcement with two side walls on the sides and with tubular fasteners, shown without the inner wall
  • fig.22 - shows, in axonometric view, the lower panel in a variant with an outer wall made of a thermal insulation material with lower reinforcement with two side walls and with tubular fasteners
  • fig.23 - shows in axonometric view the lower panel in a variant with a two-layer outer wall with a lower reinforcement with a side wall with overflow openings made therein and with tubular fasteners, shown without an inner wall
  • fig.24 - shows in axonometric view the lower panel in a variant with a two-layer outer wall with lower reinforcement, a side wall with overflow holes made therein and with tubular fasteners
  • fig.25 - shows, in axonometric view, the middle panel in a variant with a two-layer outer wall with not only side splines, but also along the top and lower edges of the panel and with tubular fasteners, shown without the inner wall,
  • fig.26 - shows, in axonometric view, a middle panel in a variant with a two-layer outer wall with not only side splines, but also along the top and lower edges of the panel and with tubular fasteners,
  • fig.27 - shows in an axonometric view the central base panel with splines on one side and also along the top and lower edges of the panel, with a side wall and with rectangular fasteners, showed without the inner wall,
  • fig.28 - shows in an axonometric view the central basic panel with splines on one side and also along the top and lower edges of the panel, with a side wall, overflow openings in the inner wall and with rectangular fasteners
  • fig.29 - shows in an axonometric view the central basic panel with splines along the top and lower edges of the panel, with two side walls and with tubular fasteners, showed without an inner wall
  • fig.30 - shows in an axonometric view the central base panel with splines along the top and lower edges of the panel, with two side walls and with tubular fasteners,
  • fig.31 - shows in an axonometric view, the central panel in the variant with an outer wall made of thermal insulation material with splines on one side and also along the top and lower edges of the panel, with a side wall and overflow openings and tubular fasteners made in it, showed without the inner wall,
  • fig.32 - shows in an axonometric view, the central panel in the variant with an outer wall made of a thermal insulation material with splines on one side and also along the top and lower edges of the panel, with a side wall and overflow holes and with tubular fasteners made in it,
  • fig.33 - shows in an axonometric view, the upper base panel, with the upper outer wall and the tubular fasteners, showed without the inner wall,
  • fig.34 - shows in an axonometric view, the upper base panel, with the upper outer wall and the tubular fasteners,
  • fig.35 - shows in an axonometric view, the upper panel in a variant with an outer wall made of a thermal insulation material, with a higher outer wall, side wall and with tubular fasteners, showed without the inner wall,
  • fig.36 - shows, in an axonometric view, the upper panel in a variant with an outer wall made of a thermal insulation material, with a higher outer wall, side wall and with tubular fasteners, with overflow openings in the inner wall,
  • fig.37 - shows in an axonometric view, the top panel in a variant with a two-layer outer wall, with a higher outer wall, side wall with overflow openings and with tubular fasteners, showed without the inner wall
  • fig.38 - shows, in an axonometric view, the upper panel in a variant with a higher two-layer outer wall, and with side wall with overflow openings and with tubular fasteners
  • fig.39 - shows in an axonometric view, the upper base panel with the upper outer wall, the side wall with overflow openings and rectangular fasteners, showed without the inner wall,
  • fig.40 - shows in an axonometric view, the upper base panel, with the upper outer wall, side wall with overflow openings and with rectangular fasteners
  • fig.41 - shows in an axonometric view, the panel in the variant with the higher outer wall made of a thermal insulation material that forms a lintel, with tubular fasteners
  • fig.42 - shows in an axonometric view, the upper panel in the variant with the higher outer wall made of a thermal insulation material, with a cut-out for the panel that forms the lintel and with tubular fasteners,
  • fig.43 - shows in an axonometric view, the base panel with a higher outer wall that forms a lintel, with tubular fasteners,
  • fig.44 - shows in an axonometric view, the upper base panel with the upper outer wall, with a cut out for the panel that forms lintel and with tubular fasteners
  • fig.45 - shows a section through the lower panel with the outer wall made of a thermal insulation material, showing the location of the lower reinforcement relative to the panel layers
  • fig.46 - shows the detail of joining two panels and the position of the splines in a panel variant with a two-layer outer wall
  • fig.47 - shows a panel with a marker in an axonometric view.
  • the developed invention provides for the building partition, i.e. walls made of prefabricated construction elements, i.e. panel 1, each of which consists of two walls joined together, i.e. the inner wall 2 and the outer wall 3.
  • the developed prefabricated construction element forms therefore a panel 1, which is manufactured in the factory by combining, at least, the following elements: the inner wall 2 and the outer wall 3, which are joined by means of fasteners 4.
  • Each fastener 4 may be in the form of a tube, a rectangular plate, a sheet or a block, for example a prism, and is fixed to the inner wall 2 and the outer wall 3 permanently using binder 5.
  • binder 5 for example, a set of bolts, screws, rivets, adhesive or other bonding compound is used.
  • fastener 4 To join walls of the panel 1 must be used at least one fastener 4. If there is more than one, they are arranged so that the greatest concentration of fasteners 4 occurred in the lower part of the panel 1.
  • the fasteners 4 are preferably made of plastic material.
  • Panels 1 must be fitted with splines 7.
  • the task of the splines 7 is mutual blocking, bonding and stabilizing of adjacent panels 1 once they have been positioned at the installation site, for the time necessary to stabilize the panels 1 pre-attached with additional filling material 8 (e.g. with concrete mix), which the panels 1 are filled with immediately after positioning.
  • additional filling material 8 e.g. with concrete mix
  • the splines 7 are permanently attached to the panel 1, on its walls from the inner side also by means of a set of bolts, screws, rivets, adhesive or other bonding material. They are attached to both the inner wall 2 and the outer wall 3 in such a way that, after the panels 1 have been assembled, the splines 7 of the adjacent panels 1 will adjoin. After setting adjacent panels 1, they are joined together by screwing each spline 7 with bolts, screws or rivets to the adjacent panel 1.
  • the splines 7 are placed outside, at least, one edge of the inner wall 2 and the outer wall 3 of the panel 1.
  • the panels 1, especially corner ones, may have one or two side walls 9.
  • overflow openings 10 can be made, through which, during filling of the panels 1 with the additional filling material 8, it overflows and consolidates the masses on their both sides.
  • the height of the panels 1 generally do not exceed the height of 1.5 meters and they are designed so that the height of usually three panels 1 arranged adequately on each other corresponds to the designed height of a given storey in the building.
  • the total width of panels 1 in a given wall of an erected object is at the design and manufacturing stage of prefabricated construction elements adapted to the construction design, preferably being a multiple of 30 centimetres.
  • Additional filling material 8 can be appropriately compacted with vibrators. Then, after positioning and filling panels 1 of one row, after filling them with filling material 8 and after at least pre-setting of the filling material, possibly a further row of panels 1 is arranged on them.
  • next row of panels 1 is positioned so that the vertical joining points of the adjacent panels 1 of individual rows adjoin the vertical joining points of the adjacent panels 1 of the other rows.
  • the second row of panels 1 - after at least 15 minutes - is filled with additional filling material 8, as was the case with the first row of panels 1. At this point, also the upper part of panels 1 of the previous row, is filled with additional filling material 8.
  • the last and highest row of panels 1 on a given storey arranged and prepared earlier may have an outer wall 3 higher than the inner wall 2 by the arranged ceiling height, which will be laid over the storey. Then, filling the last, top layer of panels 1 with additional filling material 8, panel 1 is filled with filling 8 to the inner wall's 2 height. In the case of division wall, both described walls will have an equal height.
  • Panels 1 form a stay-in-place formwork. This is a formwork that after being filled (for example pouring concrete) - does not need to be dismantled, but remains a part of the built building partition.
  • its inner wall 2 and the outer wall 3 - are made of magnesium boards (MgO) or of cement- particle boards.
  • the outer wall 3 can be one or two-layer.
  • the single-layer outer wall 3 can be made of a magnesium board or a cement-particle board, but it can also be made of a thermal insulation material, e.g. polystyrene, styrodur or mineral wool.
  • the outer wall 3 in a two-layer variant consists of either a magnesium board or a cement-particle board as well as a thermal insulation material. Then, the magnesium board or cement-particle board forms the outer part of the panel 1, while the insulating material is the inner part of the panel 1, between the magnesium board or the cement-particle board (depending on which one was used) and the additional filling material 8.
  • the panels 1 are designed in such a way that they are adapted in advance to the window and door openings. Some of them are, among others, lintels. Such panels are equipped with regular horizontal additional walls 12 that form the upper or lower part of the panel 1 (figs. 41 and 43).
  • the panels 1 can be equipped with markings, i.e. markers 13, e.g. in the form of a QR code or a bar code. Such designation is different on each prefabricated element, i.e. on each panel 1.
  • the marker 13 is read using a suitable device, e.g. application in a mobile phone, or using the software BIM (Building Information Modelling), which is used more and more frequently in the construction industry, which supports building information about a given element. It is then possible to precisely determine the place in which a given panel 1 should be located as planned.
  • a suitable device e.g. application in a mobile phone, or using the software BIM (Building Information Modelling), which is used more and more frequently in the construction industry, which supports building information about a given element. It is then possible to precisely determine the place in which a given panel 1 should be located as planned.
  • BIM Building Information Modelling
  • the panels 1 can be additionally equipped with installation troughs 11.
  • the walls made out of panels 1 in the manner described can be additionally equipped with reinforcement placed and exposed. They are used when there is a necessity of pouring out of reinforced concrete walls, that is, using a reinforced concrete structure in the building.
  • the places are determined where the construction joint (movement joint; dilatation) should occur and the panels 1 can be appropriately prepared for the construction joint.
  • the length of the panel 1 is then set and an additional side wall 9 is placed in the planned location, which in this case is a construction joint.
  • the side wall 9 (which is always vertical and perpendicular to the base wall in the panel 1, i.e. to its inner wall 2 and the outer wall 3), because it forms construction joint element - is placed inside the panel 1.
  • the location of the side wall 9 that forms a construction joint does not coincide with the edge of the panel. Then, during the operation of the building, there will not appear visible cracks on the outside walls.
  • the solution also provides the possibility of making building posts out of developed panels 1.
  • the panels 1 are then selected so that the outer walls 3 of the post are made of and formed magnesium or cement-particle boards.
  • the height of the post depends on the planned height of the storey and starts on the upper surface of the ceiling of the lower storey, and ends on the lower surface of the ceiling of the upper storey.
  • Developed prefabricated construction elements can be used to build outer construction walls, outer insulating walls, inner construction walls, partition walls, partitions between residential rooms, and a staircase, or a corridor and lintels.

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  • Engineering & Computer Science (AREA)
  • Architecture (AREA)
  • Physics & Mathematics (AREA)
  • Electromagnetism (AREA)
  • Civil Engineering (AREA)
  • Structural Engineering (AREA)
  • Conveying And Assembling Of Building Elements In Situ (AREA)
  • Load-Bearing And Curtain Walls (AREA)

Abstract

The invention concerns prefabricated construction element and a method of erecting objects by means of this element. Developed panels (1) are made using magnesium (MgO) or cement-particles boards. The splines (7) are fastened permanently in the panel (1) so that they are placed outside at least one edge of the inner wall (2) and the outer wall (3) of the panel (1). The panels (1) can be previously prepared and adapted to the needs of the object and then: panels (1) are prepared, the outer wall (3) of which is one or two-layer, and then the outer wall (3) one-layer is made of a magnesium or a cement-particle board or of a thermal insulation material, while the outer wall (3) in a two-layer variant consists of either a magnesium or a cement-particle board as well as a thermal insulation material. Sometimes - in the inner wall (2), outer wall (3) or side wall (9) - overflow openings (10) are made, lower reinforcements (6) for example in the form of a bracket, installation troughs (11), horizontal additional walls (12) that form the upper or lower part of the panel (1), additional cut outs. The panels (1) are preferably equipped with markings, i.e. markers (13), e.g. in the form of QR code or bar code.

Description

PREFABRICATED CONSTRUCTION ELEMENT AND THE METHOD OF ERECTING OBJECTS MADE OF PREFABRICATE D
CONSTRUCTION ELEMENTS
[0001] The subject of invention is a prefabricated construction element intended for erecting walls and a method for erecting residential, commercial and industrial objects made of prefabricated construction elements.
[0002] Various prefabricated materials, i.e. construction or structural elements, are known and used, whose usage parameters are similar to those desired or which require slight processing (e.g., mechanical), and which are manufactured in the production hall. There are also different methods for erecting buildings and walls with them.
[0003] From the description of the Polish invention with the patent number PL 166533 filed for protection on November 13, 1991, the solution is known as: „Samonosna ptyta scienna prefabrykowana" („ Prefabricated building wall self- supporting panel"). The subject of the invention is a prefabricated building wall self-supporting panel intended for use in low-rise construction, implemented by an industrialized system. The panel with wall elements described here characterizes in that it consists of girders: upper and lower, each of which is made of two reinforced concrete beams with a cross-section in the shape similar to the letter L, which are equipped with steel hooks, used to join reinforced concrete beams with each other as well as to fasten bolts and hooks. The bracing rods are used to integrate girders and wall elements as a whole, while the gap between reinforced concrete beams is filled by the thermal insulation material.
[0004] However, from the description of the Polish invention with application number P.295375 of July 21, 1992 - the solution is known as «Prefabrykowana szalunkowa ksztattka budowlana" („ Prefabricated falsework-forming building unit"). The subject of the invention is prefabricated falsework-forming building unit made of expanded polystyrene, used in the construction of load-bearing and partition walls, in particular, of residential houses. The falsework-forming has two side walls, to which transverse elements are attached with a height equal to the height of these walls, which form, at least, two closed chambers. A glass fibre mesh coated with plastic material is glued to a surface of the side walls.
[0005] Whereas, from the description of the Polish invention with the application number P.298831 dated May 4, 1993 - the solution is known as„Sciana prefabrykowana budynkow" („ Prefabricated wall of buildings”). The subject of the invention is a prefabricated wall intended for constructing buildings for various purposes and different thermal insulation properties. This wall may be intended for filling framework structures of buildings, curtain wall, a partition wall or a structural wall, especially low buildings. The wall structure consists of prefabricated hollow core boards joined in vertical joint with bolts through the spacer. The spacer enables dry fastening of external finishing elements and internal finishing elements, such as dry plaster, panelling, etc.
[0006] However, from the description of the Polish invention with the patent number PL 194292 filed for protection on October 15, 1997, the solution is known as „Sposob budowania cztonow sdennych, podfogowych lub sufitowych na miejscu i czton scienny, podtogowy lub sufitowy" („Wall, floor or ceiling segment and method of erecting the same in situ"). The process of building wall, floor or ceiling in situ includes the stages of assembling a generally rigid frame and fixing fibre-reinforced cement panels to the front and rear surfaces of the frame to form a niche between these sides. This niche is then filled with cement mortar with light aggregate and left for maturation. The boards are adapted to absorb moisture from mortar with light aggregate, sufficient to ensure the natural adherence of cement mortar to the panels without significantly losing its structural integrity during bonding and maturing of concrete.
[0007] However, from the description of the US invention with the publication number US2018044914 with the date of priority of April 16, 2016 - the solution is known as„Modu†owy zaz^biajgcy si¾ blok (oparty na BIM) System do budowania struktur architektonicznych" („Block-lnterlocking Module-based (BIM-based) System to build architectural structures"). The system includes units of the system, modular construction units, their method of manufacturing as well as details for the construction of simple structures, such as single and double walls, Whyte's single arch shape walls, one-bit columns, corner walls, windows and door openings, etc. The system also includes construction units that facilitate the installation of electrical sockets, switches and other components.
[0008] So far, prefabricated elements for building walls known and applied in construction industry were based on heavy elements that were manufactured in a factory and then transported to the construction site. Large elements (usually manufactured at a height of at least 2.5 m and similar width) are inconvenient in transport. Their weight and size limit the possibility of free movement of such elements and increase their cost, and thus the cost of investment. Additionally, in order to build a given object from such prefabricated elements, there is a necessity of introducing heavy equipment and qualified employees to the construction site, who are authorized to operate this type of equipment, because the assemblers would not be able to lift and position the next elements in a proper place.
[0009] In the Polish invention, the application no. P.295375, two parallel walls, joined with fasteners, were shown. However, in this solution, as shown in the figure, all the elements presented were made of a thermal insulation material. What's more, fasteners in the above mentioned invention are of the same height as the two parallel walls and form separate closed chambers. Therefore, when such a prefabricate is filled, for example with concrete, the space between the walls is not monolithic, but the filling mass is interrupted by other materials.
[0010] Another type of known and applied solutions for building walls out of prefabricated elements include the use of relatively small building blocks. The disadvantage of these solutions is time-consuming, and thus extending the construction time. In addition, erection of objects made of this type of prefabricated elements is possible only with the participation of a qualified workforce.
[0011] Prefabricated building blocks of smaller size and methods of erecting buildings with them require carrying out time-consuming works based on combining individual prefabricates.
[0012] The known, smaller prefabricated elements for the construction of walls, which consist of three layers (concrete-thermal insulation-concrete or reinforced- concrete-thermal insulation-reinforced concrete) are unfortunately very heavy, which makes it difficult to transport them and the construction process.
[0013] Also, it is often necessary to use cranes, lifts, etc. for lifting and positioning such a type of prefabricated elements, because the strength of construction workers is not sufficient to lift a given element.
[0014] This is especially so when it is necessary to bring a given element to a higher storey or when employees have to move on the scaffolding.
[0015] In addition, in the place where the prefabricates meet, especially when the building is exposed to uneven movement of the structure during its settlement, undesirable phenomena appear, such as, e.g., the formation of gaps, cracks.
[0016] Magnesium panels called "MgO panels" are widely known from the chemical symbol magnesium Mg and oxygen O, which are manufactured as construction boards with a wide range of applications. The natural raw material is magnesium oxide - a type of mineral cement.
[0017] Standard magnesium boards are a layer board consisting of a core of powdered pearlite surrounded on both sides with a glass fibre mesh and magnesium layer MgO or magnesium-cement often reinforced (in a dispersed way) with cellulose fibre with the addition of other derivatives of magnesium compounds such as magnesium chloride - MgCI2 or magnesium sulphates.
[0018] Cement-particle boards are also commonly known, the advantage of which is that they are a fully ecological material. They do not contain any harmful substances like asbestos or formaldehyde. They are resistant to solvents, oils and greases.
[0019] The aim of the invention is to develop prefabricated construction elements using the properties of MgO boards and cement-particle boards, which will enable poorly qualified workers to implement a simple, fast and economical method of building objects from prefabricated construction elements, significantly limiting, at the same time, necessity to use in the construction process specialized, heavy equipment.
[0020] A prefabricated construction element that is the subject of the invention is a panel consisting of two walls joined together, i.e. an inner wall and an outer wall, which are joined by means of at least one fastener, however between the inner wall and the outer wall there is an additional filling, which is preferably a concrete mix.
[0021] The essence of the developed element is that the developed panel is equipped with splines that are fixed to the panel on its walls from the inside, i.e. both to the inner wall and the outer wall. These splines are placed out of, at least, one edge of the inner wall and the outer wall of the panel.
[0022] At the same time in the panel its:
- inner wall is made of magnesium board (MgO) or a cement-particle board, while the outer wall is one-layer wall and is made of a magnesium board (MgO) or a cement-particle board or a thermal- insulating material.
However, in the next variant of the panel's structure its:
- inner wall is made of a magnesium board (MgO) or a cement-particle board, while the outer wall is two-layer wall and consists of either a magnesium board (MgO) or a cement-particle board and a thermal insulation material and then a magnesium board (MgO) or a cement- particle board is the outer part of the panel (1), while the insulating material is the inner part of the panel (1), between the additional filling material (8), and the magnesium board (MgO) or the cement- particle board, depending on which one was used.
[0023] The panels' splines are fixed so that after the panels are assembled, the splines of adjacent panels adjoin each other.
[0024] The panel also preferably has at least one lower reinforcement, usually in the form of bracket.
[0025] However, the fastener is in the form of a tube, a rectangular plate, a sheet or a block, for example a prism, and fixed to the inner wall and the outer wall permanently by means of a binder.
[0026] The splines are fastened to the panel on its walls from the inside by means of a set of bolts, screws, rivets, adhesive or other bonding mass.
[0027] If the construction of the object requires - the panel has at least one side wall.
[0028] Preferably in the inner wall of the panel or in its outer wall or side wall at least one overflow opening is made.
[0029] In the panels located at the top part of the storey, the outer wall of the panel is higher than the inner wall.
[0030] In a prefabricated construction element, which is a lintel or under window element - the panel is equipped with at least one, usually horizontal, additional wall that forms the upper or lower part of the panel, (figures 41 and 43).
[0031] But, prefabricated construction element, which is adjacent to the lintel panel being a lintel, the panel has an additional cut out. (figures 42 and 44).
[0032] Typically, the panel has at least one marker, preferably in the form of QR code or bar code.
[0033] Preferably, the developed panel has at least one installation trough.
[0034] When it is necessary to use reinforced elements, the walls made of panels are equipped with placed and protruding reinforcement. [0035] However, a side wall is used to introduce the construction joint (movement joint; dilatation). Vertical and perpendicular to the base walls panel - i.e. to its inner wall and the outer wall - the side wall is arranged inside the panel, where, preferably, the location of the side wall that forms the construction joint does not coincide with the edge of the panel.
[0036] The prefabricated construction element in the form of a post are four set panels that are joined together so that they form a square in cross-section. The external walls made of magnesium (MgO) or cement-particle board are the external surfaces of the post in which the reinforcement is placed.
[0037] In the developed manner of erecting objects from prefabricated construction elements of the previously planned shape, the building partition, i.e. a wall, is made of prefabricated construction elements in the form of panels consisting of two walls joined together, i.e. the inner wall and outer wall, which is are factory-joined by means of at least one fastener.
[0038] The essence of this method lies in the fact that the panels are made using magnesium boards (MgO) or cement-particle boards. In the panel there are factory-mounted permanent splines so that they are led out of at least one edge of the inner wall and the outer wall of the panel and are fixed to both the inner wall and the outer wall in such a way that after the panels are assembled the splines of the adjacent panels adjoin.
[0039] In addition, the panels prepared for assembly are factory-adjusted:
- preferably, the panels are prepared so that their outer wall is one- or two- layer, and then the single-layer outer wall is made of a magnesium board or a cement-particle board or a thermal-insulating material, whereas the outer wall in a two-layer variant consists of both a magnesium board or cement-particle board as well as thermal insulation material,
- preferably in the panel - in the inner wall, outer wall or side wall - overflow openings are made,
- preferably in the panel, at least one lower reinforcement is fastened, for example in the form of a bracket,
- preferably, the panels are equipped with installation troughs,
- preferably the fasteners are arranged so that their greatest concentration is located at the lower part of the panel, - preferably, lintels made of panels are usually equipped with horizontal additional walls that form the upper or lower part of the panel (figures 41 and 43),
- preferably, in the basic panels adjacent to the panel, which forms the lintel, additional cut outs are made (figures 42 and 44),
- preferably, the panels are equipped with markings, i.e. markers, e.g. in the form of a Q.R code or bar code, preferably, the panel is equipped with a side wall that is vertical and perpendicular to the walls in the base panel, i.e. to its inner wall and outer wall and placed inside the panel, preferably so that the location of the side wall that forms the construction joint does not coincide with the edge of the panel.
The panels that are delivered to the construction site are placed in the arranged spot and positioned by attaching subsequent, fixed panels to adjacent panels and merging them together. Every spline is screwed - preferably by means of bolts, screws or rivets - to an adjacent panel, and then after assembly of complete, first row of panels is filled with filling material, preferably concrete mix. The process of laying and filling subsequent layers of panels is possibly repeated so as to reach the desired height of a given storey. In the constructed object, after the ceiling is made using known methods, if it is planned to build another storey of the building, then the process described above is repeated in a similar manner.
[0040] When the next row of panels is planned, their lower row is filled in such a way as not to fill the panels to their upper edge, leaving an unobstructed space for inserting splines of the next, higher row of panels. Then, after filling with additional filling material the lower row of panels, and after at least initial setting of the filling material- at least after ¼ hour the next row of panels is arranged on them and fastened higher, in a similar way, which is filled with additional filling material, at the same time filling with the additional filling material also the upper part of the previous row panels.
[0041] For the assembly of the highest row of panels in a given storey, panels are used, whose outer wall is higher than the inner wall, and then filling the highest layer of panels with additional filling material, the panel is filled with the filling material to the height of the inner wall.
[0042] Sometimes, for the panels - during assembly on the construction site - additional splines are attached.
[0043] Similarly, if it is necessary for panels - during assembly on the construction site - additional overflow openings are made.
[0044] For the assembly of the lowest row of panels in a given storey, which is placed directly on the foundation or on the ceiling of a given storey, the panels with at least one additional lower reinforcement are preferably used.
[0045] The construction of a given storey usually uses rows of panels whose total height corresponds to the designed height of a given storey in the building.
[0046] After delivery of the panels to the construction site with a marker, the place, where the panel is to be built, is read and arranged on its basis, corresponding to the designed position, which has been recorded, usually coded at the stage of designing and making prefabricated construction elements, during the preparation of the construction process of a given object. The marker is read using a suitable device, e.g. applications in a mobile phone or using BIM (Building Information Modelling) software.
[0047] Sometimes, in panels, before filling with additional filling material, reinforcement is placed.
[0048] The main advantage of the developed prefabricated construction elements and the method of erecting objects with their application is the reduction of time and a significant reduction in the cost of construction works, primarily due to their simplification and acceleration. The building constructed with the developed method can be erected by a smaller number of workers than before.
[0049] In the developed technology, situations that involved a human error were practically eliminated. [0050] The basic stage of manufacturing of the developed construction elements is carried out at the factory.
[0051] However, the manufactured elements are light enough that their transport to the construction site is economical. Whereas, a heavy concrete that fill them (the use of which is required for currently constructed objects with a certain standard) is collected from the nearest concrete mixing plant.
[0052] As a result, it is unnecessary to transport the heaviest building material over long distances, which also greatly simplifies, speeds up and reduces the cost of the investment process.
[0053] Then, prefabricated elements used in the developed method of erecting objects are so large that using them enables fast construction of large surfaces. These elements are also so light that it is possible and easy to set them up properly without the need to use specialized equipment for this purpose.
[0054] Prefabricated elements, despite their lightness obtained thanks to the raw materials used to make them - are also very durable.
[0055] In the basic variant of the prefabricated construction element, the inner wall and the outer wall are made of magnesium boards (MgO) or of cement- particle boards.
[0056] An important advantage of the panel made of MgO board is the improvement of technical parameters that a given partition shows, e.g. improving its fire resistance.
[0057] In addition, the partition made of the above mentioned boards, thanks to the aesthetics of their surfaces, does not require additional plastering. For finishing, it is enough to make only a thin-layer coat on it and apply a paint coat. It also essentially affects the acceleration and reduction of the investment process costs.
[0058] The developed invention provides for the possibility of introducing markers placed on individual panels, which being an element of the coding system of individual elements, enable precise planning as well as determining the location of their position. As a result, their search, settlement and installation in the area of the erected building, at the construction site, is easy.
[0059] The designer, while designing the building, uses a catalogue of typical elements, nevertheless a large part of the elements must be made individually for each building and hence their marking at the production stage, i.e. the implementation of prefabricated elements - is very helpful and reduces the cost of construction.
[0060] The invention is described in more detail in the accompanying examples in the drawings, in which
fig.l - shows a vertical cross-section through a wall made of three stacked sets of panels with rectangular fasteners,
fig.2 - shows a vertical cross-section through a wall made of three stacked sets of panels with tubular fasteners,
fig.3 - shows a vertical cross-section through a wall, also made of three stacked sets of panels with tubular fasteners, which is filled with an additional filling material,
fig.4 - shows a cross-section through a three-layer wall, i.e. a wall understood as a building partition with: an inner wall, an outer wall (a single-layer made of a board) and an additional filling material placed between them,
fig.5 - shows a cross-section through a three-layer external wall, i.e. a wall understood as a building partition with: an inner wall, an outer wall (single-layer of thermal insulation) and an additional filling material placed between them, fig.6 - shows a cross-section through a four-layer wall, i.e. a wall understood as a building partition with: an inner wall, an outer wall (a double-layer of thermal insulation and a board) and an additional filling material placed between them, fig.7 - shows a section through a three-layer wall, i.e. a wall understood as a building partition with: an inner wall, an outer wall (a single-layer made of board) and an additional filling inserted between them as well as with the installation trough, fig.8 - shows a cross-section through a three-layer outer wall, i.e. a wall understood as a building partition with: an inner wall, an outer wall (a single-layer with thermal insulation) and with an additional filling inserted between them, and also with the installation trough,
fig.9 - shows a cross-section through a four-layer wall, i.e. a wall understood as a building partition with: an inner wall, an outer wall (a double-layer with thermal insulation and a board) and an additional filling material inserted between them, as well as installation trough,
fig.10 - shows, in an axonometric view, a building corner made of basic panels with rectangular fasteners joining boards,
fig.ll - shows, in an axonometric view, a building corner made of basic panels with tubular fasteners,
fig.12 - shows, in an axonometric view, a building corner made of panels in a variant with an outer wall made of a thermal insulation material with tubular fasteners,
fig.13 - shows, in axonometric view, a building corner made of panels in a variant with a two-layer outer wall with tubular fasteners,
fig.14 - shows, in an axonometric view, a building corner made of panels in a variant with an outer wall made of a thermal insulation material with tubular fasteners and installation troughs,
fig.15 - shows, in an axonometric view, a building corner with a window opening made of panels in a variant with an outer wall made of a thermal insulation material with tubular fasteners,
fig.16 - shows in axonometric view a fragment of a wall arranged with basic panels with tubular fasteners,
fig.17 - shows the lower base panel in axonometric view with lower reinforcement and rectangular fasteners adjusted for joining the walls, shown without the inner wall,
fig.18 - shows the lower base panel in axonometric view with lower reinforcement and with rectangular fasteners joining the walls, fig.19 - shows in an axonometric view the lower base panel with lower reinforcement, side wall and tubular fasteners, showed without inner wall,
fig.20 - shows in an axonometric view the lower base panel with lower reinforcement, side wall, overflow openings in the inner wall and tubular fasteners,
fig.21 - shows in an axonometric view the lower panel in a variant with an outer wall made of a thermal insulation material with a lower reinforcement with two side walls on the sides and with tubular fasteners, shown without the inner wall, fig.22 - shows, in axonometric view, the lower panel in a variant with an outer wall made of a thermal insulation material with lower reinforcement with two side walls and with tubular fasteners,
fig.23 - shows in axonometric view the lower panel in a variant with a two-layer outer wall with a lower reinforcement with a side wall with overflow openings made therein and with tubular fasteners, shown without an inner wall, fig.24 - shows in axonometric view the lower panel in a variant with a two-layer outer wall with lower reinforcement, a side wall with overflow holes made therein and with tubular fasteners,
fig.25 - shows, in axonometric view, the middle panel in a variant with a two-layer outer wall with not only side splines, but also along the top and lower edges of the panel and with tubular fasteners, shown without the inner wall,
fig.26 - shows, in axonometric view, a middle panel in a variant with a two-layer outer wall with not only side splines, but also along the top and lower edges of the panel and with tubular fasteners,
fig.27 - shows in an axonometric view the central base panel with splines on one side and also along the top and lower edges of the panel, with a side wall and with rectangular fasteners, showed without the inner wall,
fig.28 - shows in an axonometric view the central basic panel with splines on one side and also along the top and lower edges of the panel, with a side wall, overflow openings in the inner wall and with rectangular fasteners, fig.29 - shows in an axonometric view the central basic panel with splines along the top and lower edges of the panel, with two side walls and with tubular fasteners, showed without an inner wall,
fig.30 - shows in an axonometric view the central base panel with splines along the top and lower edges of the panel, with two side walls and with tubular fasteners,
fig.31 - shows in an axonometric view, the central panel in the variant with an outer wall made of thermal insulation material with splines on one side and also along the top and lower edges of the panel, with a side wall and overflow openings and tubular fasteners made in it, showed without the inner wall,
fig.32 - shows in an axonometric view, the central panel in the variant with an outer wall made of a thermal insulation material with splines on one side and also along the top and lower edges of the panel, with a side wall and overflow holes and with tubular fasteners made in it,
fig.33 - shows in an axonometric view, the upper base panel, with the upper outer wall and the tubular fasteners, showed without the inner wall,
fig.34 - shows in an axonometric view, the upper base panel, with the upper outer wall and the tubular fasteners,
fig.35 - shows in an axonometric view, the upper panel in a variant with an outer wall made of a thermal insulation material, with a higher outer wall, side wall and with tubular fasteners, showed without the inner wall,
fig.36 - shows, in an axonometric view, the upper panel in a variant with an outer wall made of a thermal insulation material, with a higher outer wall, side wall and with tubular fasteners, with overflow openings in the inner wall,
fig.37 - shows in an axonometric view, the top panel in a variant with a two-layer outer wall, with a higher outer wall, side wall with overflow openings and with tubular fasteners, showed without the inner wall, fig.38 - shows, in an axonometric view, the upper panel in a variant with a higher two-layer outer wall, and with side wall with overflow openings and with tubular fasteners,
fig.39 - shows in an axonometric view, the upper base panel with the upper outer wall, the side wall with overflow openings and rectangular fasteners, showed without the inner wall,
fig.40 - shows in an axonometric view, the upper base panel, with the upper outer wall, side wall with overflow openings and with rectangular fasteners, fig.41 - shows in an axonometric view, the panel in the variant with the higher outer wall made of a thermal insulation material that forms a lintel, with tubular fasteners,
fig.42 - shows in an axonometric view, the upper panel in the variant with the higher outer wall made of a thermal insulation material, with a cut-out for the panel that forms the lintel and with tubular fasteners,
fig.43 - shows in an axonometric view, the base panel with a higher outer wall that forms a lintel, with tubular fasteners,
fig.44 - shows in an axonometric view, the upper base panel with the upper outer wall, with a cut out for the panel that forms lintel and with tubular fasteners, fig.45 - shows a section through the lower panel with the outer wall made of a thermal insulation material, showing the location of the lower reinforcement relative to the panel layers, whereas
fig.46 - shows the detail of joining two panels and the position of the splines in a panel variant with a two-layer outer wall,
fig.47 - shows a panel with a marker in an axonometric view.
[0061] The developed invention provides for the building partition, i.e. walls made of prefabricated construction elements, i.e. panel 1, each of which consists of two walls joined together, i.e. the inner wall 2 and the outer wall 3.
[0062] The developed prefabricated construction element forms therefore a panel 1, which is manufactured in the factory by combining, at least, the following elements: the inner wall 2 and the outer wall 3, which are joined by means of fasteners 4.
[0063] Each fastener 4 may be in the form of a tube, a rectangular plate, a sheet or a block, for example a prism, and is fixed to the inner wall 2 and the outer wall 3 permanently using binder 5. As a binder 5, for example, a set of bolts, screws, rivets, adhesive or other bonding compound is used.
[0064] To join walls of the panel 1 must be used at least one fastener 4. If there is more than one, they are arranged so that the greatest concentration of fasteners 4 occurred in the lower part of the panel 1. The fasteners 4 are preferably made of plastic material.
[0065] Each panel 1, which is placed directly on foundation or on ceiling of a given storey, additionally has at least one lower reinforcement 6, for example in the form of a bracket.
[0066] Panels 1 must be fitted with splines 7. The task of the splines 7 is mutual blocking, bonding and stabilizing of adjacent panels 1 once they have been positioned at the installation site, for the time necessary to stabilize the panels 1 pre-attached with additional filling material 8 (e.g. with concrete mix), which the panels 1 are filled with immediately after positioning.
[0067] The splines 7 are permanently attached to the panel 1, on its walls from the inner side also by means of a set of bolts, screws, rivets, adhesive or other bonding material. They are attached to both the inner wall 2 and the outer wall 3 in such a way that, after the panels 1 have been assembled, the splines 7 of the adjacent panels 1 will adjoin. After setting adjacent panels 1, they are joined together by screwing each spline 7 with bolts, screws or rivets to the adjacent panel 1.
[0068] The splines 7 are placed outside, at least, one edge of the inner wall 2 and the outer wall 3 of the panel 1.
[0069] They facilitate the positioning of subsequent, fastened panels 1, which are prepared to be filled and added to both sides and from the top of the panel 1. The panels 1, especially corner ones, may have one or two side walls 9. In the inner wall 2, the outer wall 3 or the side wall 9, overflow openings 10 can be made, through which, during filling of the panels 1 with the additional filling material 8, it overflows and consolidates the masses on their both sides.
[0070] The height of the panels 1 generally do not exceed the height of 1.5 meters and they are designed so that the height of usually three panels 1 arranged adequately on each other corresponds to the designed height of a given storey in the building.
[0071] However, the total width of panels 1 in a given wall of an erected object is at the design and manufacturing stage of prefabricated construction elements adapted to the construction design, preferably being a multiple of 30 centimetres.
[0072] On the construction site, on the ground in the erected object (i.e. on the foundation or ceiling) at the beginning, by setting the first row, the panels 1 with lower reinforcement 6 are positioned. In the correct and rigid positioning of the panels 1, the above-described splines 7, which adjoin the splines 7 attached to the next, adjacent panel 1, are helpful.
[0073] If necessary, it is possible to attach additional splines 7 to the panels 1 just on the construction site, when positioning the panels 1.
[0074] After installing one, complete row of panels 1, they are filled with additional filling material 8, e.g. with concrete. However, they are filled in such a way as not to fill the panels 1 to their upper edge. Their upper part is not filled, leaving room for fastening the splines 7 of the next row of panels 1, which will be placed on previous row of panels 1.
[0075] Additional filling material 8 can be appropriately compacted with vibrators. Then, after positioning and filling panels 1 of one row, after filling them with filling material 8 and after at least pre-setting of the filling material, possibly a further row of panels 1 is arranged on them.
[0076] The next row of panels 1 is positioned so that the vertical joining points of the adjacent panels 1 of individual rows adjoin the vertical joining points of the adjacent panels 1 of the other rows. [0077] The second row of panels 1 - after at least 15 minutes - is filled with additional filling material 8, as was the case with the first row of panels 1. At this point, also the upper part of panels 1 of the previous row, is filled with additional filling material 8.
[0078] The process of laying and filling subsequent layers of panels 1 is repeated so as to achieve the desired height of a given storey.
[0079] The last and highest row of panels 1 on a given storey arranged and prepared earlier may have an outer wall 3 higher than the inner wall 2 by the arranged ceiling height, which will be laid over the storey. Then, filling the last, top layer of panels 1 with additional filling material 8, panel 1 is filled with filling 8 to the inner wall's 2 height. In the case of division wall, both described walls will have an equal height.
[0080] After making the ceiling with known methods, it is possible to build another storey of the building in a similar way. The process described above is then repeated.
[0081] Panels 1 form a stay-in-place formwork. This is a formwork that after being filled (for example pouring concrete) - does not need to be dismantled, but remains a part of the built building partition.
[0082] In the basic variant of the prefabricated construction element, its inner wall 2 and the outer wall 3 - are made of magnesium boards (MgO) or of cement- particle boards.
[0083] The outer wall 3 can be one or two-layer.
[0084] The single-layer outer wall 3 can be made of a magnesium board or a cement-particle board, but it can also be made of a thermal insulation material, e.g. polystyrene, styrodur or mineral wool.
[0085] The outer wall 3 in a two-layer variant consists of either a magnesium board or a cement-particle board as well as a thermal insulation material. Then, the magnesium board or cement-particle board forms the outer part of the panel 1, while the insulating material is the inner part of the panel 1, between the magnesium board or the cement-particle board (depending on which one was used) and the additional filling material 8.
[0086] The panels 1 are designed in such a way that they are adapted in advance to the window and door openings. Some of them are, among others, lintels. Such panels are equipped with regular horizontal additional walls 12 that form the upper or lower part of the panel 1 (figs. 41 and 43).
[0087] The basic panels 1 adjacent to the panel 1, that forms a lintel, have additional cut outs (figs. 42 and 44).
[0088] In order to facilitate and accelerate the construction process - the panels 1 can be equipped with markings, i.e. markers 13, e.g. in the form of a QR code or a bar code. Such designation is different on each prefabricated element, i.e. on each panel 1. The marker 13, after reading it precisely indicates where the specific element should be built in. This place and suitable marker 13 are designed and applied at the design and execution stage of prefabricated construction elements, preparing the construction process of a given object.
[0089] During the construction process, the marker 13 is read using a suitable device, e.g. application in a mobile phone, or using the software BIM (Building Information Modelling), which is used more and more frequently in the construction industry, which supports building information about a given element. It is then possible to precisely determine the place in which a given panel 1 should be located as planned.
[0090] The panels 1 can be additionally equipped with installation troughs 11.
[0091] The walls made out of panels 1 in the manner described can be additionally equipped with reinforcement placed and exposed. They are used when there is a necessity of pouring out of reinforced concrete walls, that is, using a reinforced concrete structure in the building.
[0092] In addition, during the design of the building, the places are determined where the construction joint (movement joint; dilatation) should occur and the panels 1 can be appropriately prepared for the construction joint. The length of the panel 1 is then set and an additional side wall 9 is placed in the planned location, which in this case is a construction joint.
[0093] In this case, the side wall 9 (which is always vertical and perpendicular to the base wall in the panel 1, i.e. to its inner wall 2 and the outer wall 3), because it forms construction joint element - is placed inside the panel 1. Preferably, if the location of the side wall 9 that forms a construction joint does not coincide with the edge of the panel. Then, during the operation of the building, there will not appear visible cracks on the outside walls.
[0094] The solution, according to the invention, also provides the possibility of making building posts out of developed panels 1. The panels 1 are then selected so that the outer walls 3 of the post are made of and formed magnesium or cement-particle boards.
[0095] Four panels 1 with outer walls 3, which are to have the outer surfaces of the post, are joined so that they form a quadrilateral in cross-section. The reinforcement is inserted into the panels 1 that are joint in the factory or on the construction site. Pre-joint walls of the post are protected for transport and their filling. They are fastened with a metal or plastic tape, which forms securing rings around the walls. Thus prepared, still very light post is transported to the construction site and then poured with concrete.
[0096] The height of the post depends on the planned height of the storey and starts on the upper surface of the ceiling of the lower storey, and ends on the lower surface of the ceiling of the upper storey.
[0097] Developed prefabricated construction elements can be used to build outer construction walls, outer insulating walls, inner construction walls, partition walls, partitions between residential rooms, and a staircase, or a corridor and lintels.
[0098] Due to the method applied in the invention, it is possible to completely change the organization of building materials supply to the construction site, to completely modernize the construction process, to significantly accelerate and reduce costs in terms of construction process of the buildings. List of elements:
,

Claims

Patent claims
1. A prefabricated construction element, which is a panel consisting of two walls joint together, i.e. an inner wall and an outer wall, joint by means of, at least, one fastener, in which between the inner wall and the outer wall is additional filling that is typically a concrete mix characterized in that the panel (1) is provided with splines (7) which are fixed permanently to the panel (1) on its walls from their inner side, namely, to the inner wall (2) and the outer wall (3), however, the splines (7) are placed beyond at least one edge of the inner wall (2) and the outer wall (3) of the panel (1) and:
- the inner wall (2) is made of a magnesium board (MgO) or a cement- particle board, while the outer wall (3) is one-layered and made of a magnesium board (MgO) or a cement-particle board or a thermal- insulating material, or
- the inner wall (2) is made of a magnesium board (MgO) or a cement- particle board, while the outer wall (3) is two-layered and consists of either a magnesium board (MgO) or a cement-particle board and a thermal insulation material, and then a magnesium board (MgO) or cement-particle board forms the outer part of the panel (1), while the insulating material is the inner part of the panel (1), between the additional filling material (8) and the magnesium board (MgO) or the cement-particle board, depending on which one was used.
2. Prefabricated construction element according to claim 1, characterized in that the splines (7) of the panel (1) are fixed so that after the assembly of panels (1) the splines (7) of adjacent panels (1) adjoin each other.
3. Prefabricated construction element according to claim 1, characterized in that the panel (1) has, at least, one lower reinforcement (6) preferably, in the form of bracket.
4. Prefabricated construction element according to claim 1, characterized in that the fastener (4) has the form of a tube, a rectangular plate, sheet or a block, for example a prism, and is fixed to the inner wall (2) and the outer wall (3) permanently with a binder (5).
5. A prefabricated construction element according to claim 1 or 2, characterized in that the splines (7) are attached to the panel (1) on its walls of their inner side with a set of bolts, screws, rivets, adhesive or other bonding material.
6. Prefabricated construction element according to claim 1, characterized in that the panel (1) has, at least, one side wall (9).
7. A prefabricated construction element according to claim 1, characterized in that in the inner wall (2) of the panel (1) or in its outer wall (3) or side wall (9) at least one overflow opening (10) is made.
8. Prefabricated construction element according to claim 1, characterized in that the outer wall (3) of the panel (1) is higher than the inner wall (2).
9. Prefabricated construction element according to claim 1, characterized in that the panel (1) is provided with at least one additional usually horizontal wall (12), which forms the upper or lower part of the panel (1). (figures 41 and 43).
10. Prefabricated construction element according to claim 1, characterized in that the panel (1) has an additional cut out. (figures 42 and 44).
11. Prefabricated construction element according to one of the claims from l to 10, characterized in that the panel (1) has, at least, one marker (13), preferably in the form of QR code or bar code.
12. Prefabricated construction element according to claim 1, characterized in that the panel (1) has, at least, one installation trough (11).
IB. Prefabricated construction element according to claim 1, characterized in that the walls made of panels (1) are provided with led out and stuck out reinforcement.
14. Prefabricated construction element according to claim 1, characterized in that the vertical and perpendicular to the walls of the base panel (1) - i.e. its inner wall (2) and outer wall (B), - the side wall (9) is placed inside the panel (1), however, preferably, the location of the side wall (9) that forms construction joint does not coincide with the edge of the panel (1).
15. Prefabricated construction element, which is a panel consisting of two walls joint together, i.e. the inner wall and the outer wall, joint by means of, at least, one fastener, and between the inner wall and the outer there is an additional filling material, which is usually a concrete mix, characterized in that it is made of four assembled panels (1) that are joined together so that they form a quadrilateral in cross-section, with the outer walls (3) made of magnesium (MgO) or cement-particle board they form the outer surfaces of the post in which the reinforcement is placed.
16. The method of erecting objects from prefabricated construction elements with previously arranged shape, in which the building partition, i.e. the wall is made of prefabricated construction elements in the form of panels consisting of two walls joint together, i.e. the inner wall and the outer wall, which are factory-joint by means of, at least, one fastener characterized in that the panels (1) are manufactured using magnesium (MgO) or cement- particle boards and in the panel (1) are factory-installed splines (7) so that they are placed out of, at least, one edge of the inner wall (2) and outer wall (3) of the panel (1) and fasten them both to the inner wall (2) and the outer wall (3) in such a way that after assembling the panels (1) the splines (7) of adjacent panels (1) adjoin each other, and the panels (1) prepared for assembly, factory-adjusted and:
- preferably, the panels (1) are prepared, the outer wall (3) of which is one or two-layered, and then the outer one-layer wall (3) is made of a magnesium or a cement-particle board or a thermal-insulating material, whereas the outer wall (3) in the two-layer variant consists of both a magnesium or a cement-particle board as well as a thermal insulation material,
- preferably in the panel (1) - in the inner wall (2), the outer wall (3) or the side wall (9) - overflow openings (10) are made,
- preferably in the panel (1), at least one lower reinforcement (6) is fastened, for example in the form of a bracket,
- preferably the panels (1) are equipped with installation troughs (11),
- preferably the fasteners (4) are arranged so that their greatest concentration occurs at the lower part of the panel (1),
- preferably, the lintels from the panels (1) are provided with additional horizontal walls, which form the upper or lower part of the panel (1) (figs. 41 and 43),
- preferably, in the basic panels (1) adjacent to the panel (1), which forms a lintel, additional cut outs are made (figs. 42 and 44),
- preferably, the panels (1) are provided with markings, i.e. markers (13), e.g. in the form of a QR code or bar code,
- preferably, the panel (1) is provided with a side wall (9) which is vertical and perpendicular to the walls in the base panel (1), i.e. to its inner wall (2) and outer wall(3), placed inside the panel (1), preferably, so that the location of the side wall (9) that forms construction joint does not coincide with the edge of the panel, then the panels (1) are delivered to the construction site, where they are set in the arranged place and positioned by attaching subsequent, fixed panels (1) to adjacent panels (1) and they are joined together by screwing each spline (7) - preferably using bolts, screws or rivets - to the adjacent panel (1), and then after the assembly of the complete first row of panels (1) they are filled with a filling material (8), preferably with a concrete mix, however, the process of laying and pouring subsequent layers of panels (1) is optionally repeated so as to achieve the desired height of a given storey, and in the object being made, after the ceiling is made by known methods, preferably the process described above is repeated in a similar manner.
17. A method of erecting objects from prefabricated construction elements according to claim 16, characterized in that when the next row of panels (1) is scheduled, their lower row is filled in such a way that the panels (1) are not filled to their upper edge, leaving not covered space for installing splines (7) of the next, higher row of panels (1), and then, after filling with additional filling material (8) the panels (1) of the first row and after at least pre-setting of the filling material - after at least ¾ hour - the next row of panels (1) is arranged and fastened higher, in a similar way, which is filled with additional filling material (8), at the same time, also filling with additional filling material (8) the upper part of the panels (1) of the previous row.
18. The method of erecting objects from prefabricated construction elements according to claim 16 or 17, characterized in that the panels (1) are used for mounting the highest row of panels (1) in a given storey, the outer wall (3) of which is higher than the inner wall (2) and then filling the highest layer of panels (1) with an additional filling material (8) the panel (1) is filled with filling material (8) up to the height of the inner wall (2).
19. A method of erecting objects from prefabricated construction elements according to one of claims from 16 to 18, characterized in that additional splines (7) are fastened to the panels (1) - during assembly on the construction site.
20. A method of erecting objects from prefabricated construction elements according to one of claims from 16 to 19, characterized in that in panels (1) - during assembly on the construction site - additional overflow openings are made (10).
21. A method of erecting objects from prefabricated construction elements according to one of claims from 16 to 20, characterized in that the panels (1) with, at least, one additional lower reinforcement (6), are used for mounting the lowest row of panels (1) in a given storey, which is placed directly on the foundation or on the ceiling of a given storey with, at least, one additional lower reinforcement (6).
22. A method of erecting objects from prefabricated construction elements according to one of claims from 16 to 21, characterized in that for the construction of a given storey, the rows of panels (1) are made, whose total height corresponds to the designed height of a given storey in the building.
23. A method of erecting objects from prefabricated construction elements according to one of claims from 16 to 22, characterized in that after delivery on the construction site of the panels (1) with the marker (13), the place where the panel (1) is to be built in is read and determined on its basis, corresponding to the designed position that has been saved, usually coded at the design and execution stage of prefabricated construction elements, during the preparation of the construction process of a given object, whereby the marker (13) is read using a suitable device, e.g. application in a mobile phone or using BIM (Building Information Modelling) software.
24. A method of erecting objects from prefabricated construction elements according to one of claims from 16 to 23, characterized in that in the panels (1), before filling with the additional filling material (8), reinforcement is placed.
PCT/PL2018/000121 2018-05-15 2018-11-29 Prefabricated construction element and the method of erecting objects made of prefabricated construction elements WO2019221617A1 (en)

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PLP.425559 2018-05-15

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CN112819338A (en) * 2021-02-02 2021-05-18 郑州铁路职业技术学院 Assembly type building construction quality monitoring system based on Internet of things
CN112818440A (en) * 2020-12-31 2021-05-18 中建材行业生产力促进中心有限公司 Assembly type building slat internal partition wall and slat arranging method and building method thereof
WO2021207786A1 (en) * 2020-04-15 2021-10-21 Design Flow Pty Ltd A barrier
CN115129958A (en) * 2022-08-17 2022-09-30 北京市政路桥股份有限公司 BIM technology-based visual production scheduling method for precast beam
CN115186350A (en) * 2022-07-20 2022-10-14 中国建筑西南设计研究院有限公司 Lintel generation method and device, electronic equipment and storage medium

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CN115129958A (en) * 2022-08-17 2022-09-30 北京市政路桥股份有限公司 BIM technology-based visual production scheduling method for precast beam

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