CA1115505A - Method and apparatus for producing pre-fabricated cells for use in building structures - Google Patents
Method and apparatus for producing pre-fabricated cells for use in building structuresInfo
- Publication number
- CA1115505A CA1115505A CA290,606A CA290606A CA1115505A CA 1115505 A CA1115505 A CA 1115505A CA 290606 A CA290606 A CA 290606A CA 1115505 A CA1115505 A CA 1115505A
- Authority
- CA
- Canada
- Prior art keywords
- rods
- plaster
- template
- walls
- room element
- 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.)
- Expired
Links
Classifications
-
- 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
- B28B7/22—Moulds for making units for prefabricated buildings, i.e. units each comprising an important section of at least two limiting planes of a room or space, e.g. cells; Moulds for making prefabricated stair units
Landscapes
- Engineering & Computer Science (AREA)
- Manufacturing & Machinery (AREA)
- Chemical & Material Sciences (AREA)
- Ceramic Engineering (AREA)
- Mechanical Engineering (AREA)
- Manufacturing Of Tubular Articles Or Embedded Moulded Articles (AREA)
- Conveying And Assembling Of Building Elements In Situ (AREA)
- Finishing Walls (AREA)
- Moulds, Cores, Or Mandrels (AREA)
- Forms Removed On Construction Sites Or Auxiliary Members Thereof (AREA)
- Automatic Assembly (AREA)
Abstract
ABSTRACT OF THE DISCLOSURE
The walls of a room-forming structure are formed by plastering opposed sides of a plaster base which is strengthened by rods or other reinforcement. After plastering, at least part of the reinforcement, which is not required in the structure of the wall, is removed to enable it to be re-used.
The walls of a room-forming structure are formed by plastering opposed sides of a plaster base which is strengthened by rods or other reinforcement. After plastering, at least part of the reinforcement, which is not required in the structure of the wall, is removed to enable it to be re-used.
Description
~S5i~5 ~, .
BAC~G~OU~D OF THE INV~N~ION
, . _ 1. Field of the Invention.
~his invention relates to the production of room eléments.
BAC~G~OU~D OF THE INV~N~ION
, . _ 1. Field of the Invention.
~his invention relates to the production of room eléments.
2. Description of the Prior Arb.
Prefabricated transportable room elements have been pro-posed in the form of a self-supporting construction or a non-self-supporting construction, and in the latter case they are also provided with a supporting structure. ~uch room elements can be used for erecting both multi-storey houses and also 10 bungalows.
Such room elements may be cast from a hydraulically sett-ing material such as for example concrete. ~or this purpose, a reinforcement is placed in shuttering into which the ca~ting material is then poured. Such shuttering is, however, expen-15 sive tc purchase and complicate~ in u~eO ~he fact that the expensive shuttering is out of use while the concrete is setting is an intolerable cost factor.
It has also been proposed to construct walls and/or ceilings of conventional buildings by the free application of 20 hydraulically setting material to plaster bases strengthened by a reinforcement. In this case, first the reinforcement is brought into a form corresponding to the shape of the basic structure to be erected, i.e. first of all a prQfile skeleton is set up consistingfor example of metal profiles welded to 25 one anotherg ~he skeleton comprises the walls and possibly 2 - ~
- , . .
, ...
- ,. : -:~:
. .:
s also structures within the room~ room dividers and ceiling.
Lattice girders may also be used for the constructionn ~hen, a pl~ster base is fixed to the profiles. As ~uch9 it is possible to use ribbed expanded metal, wire gauze, cardboard and similar structures, for example even matsO The actual walls or ceilings, as the case may be, are then produced by applying the hydraulically setting material to the reinforce-ment and plaster base. ~his can be done mechanically or b~
hand. In order to achieve a smooth surface, the freshly applied material is smoothed out flat and filled until smooth.
The h~draulicall~ setting material may for example be gypsum, plaster or concrete (Gunite).
A disadvantage of the method which has just been des-cribed is the relatively high reinforcing material costs.
EIowever, the reinforcement must be relatively stable in order to ~trengthen the plaster base adequately for the plastering process.
~Ur~RY ~F 'rHE INV~N~I~N
According to the present invention, there is provided a method of producing the walls Or a room element compris-ing the steps of providing a substrate for ~ach wall, rein- ;~
forcing the substrate with a removable reinforcement, apply-ing to each side of the substrate a hardenable composition in a fluid form, and removing the reinforcement a~ter the com-position has at least par~ly set~
. , : . . , :
. . . .:
: ............... . .
SS~5 Further according to the present invention, there is provided a method of producing a room element comprising the steps of forming walls of the element by plastering both sides of plaster bases which are strengthened by a reinforce-ment at least a part of which is superfluous to the structure of the co~pleted walls, and removing) after plastering, the reinforcement which is supert`luous to the structure of the completed walls.
In this manner, during the plastering process, the `
plaster base is kept adequately rigid so that it will not give way and bulge when the plaster is applied. ~his is particularly important since the various operations connected with plastering, such as application7 smoothing and finishing give rise to substantial lateral forces ~nd the plaster base itsélf is inherently unstable~ Excessive yiel~ing or vibra-tion would produce a structural fault such as for example ~-irregular wall thickness and location, and also eccentricity of the plaster base within the thickness of the wall~ ~he former faults would be noted as inaccurate and uneven wall 2Q surfaces, the latter as concealed ~tatic weakness.
After plastering, however, the relatively stable verti-cal reinforcement is no longer needed, since there is no further lateral loading on thewalls until the structure has hardened and developed its own stability~ The plaster base i~ preferably fixed to an underfloor frame of the structur~ -- ' -. , ~. ,:
: ' s~
; t~
and imparts sufficient vertical rigidity to the still wet wall. Any possible distortion is prevented by using a material which has as far as possible neutral e~pansion properties. After hardening, the walls themselves are stable. By removing the then superfluous reinforcement, manufacturing costs can be notably reduced, since the cost of the reinforcement represents a significant portion of the overall costs. '~hose parts of the reinforcement which are removed after plastering can be used again for producing further room elements.
. . , . : ........................... : :, ; , . :
,, . . :, .. . .
ii(35 i, ," , .
Preferably profile rods are used as the removable part of the reinforcement and are withdrawn from the wall after application of the plaster, in the direction of their length~
Profile rods are readil~ available propri~tory materials and are therefore inexpensive. By virtue of their cross-sectional form, they can easily be withdrawn again ~rom the wall in their longitudinal direction. An advantage of using profile rods of round cross-section is that by virtue of their round symmetrical cross-sectional form, they require no specific orientation when they are being inserted and extracted~ ;
So that profile rods can be used again quickly and so that only a small quan~ity of them is therefore required to be kept in circulation~ it is advantageous if the profile rods are withdrawn from the plaster before this has eet. In this way7 the actual period of use of the profile rods is minimal, and they can be used again rela-tively shortly after the plaster has been applied.
Withdrawal of the profile rods can also be facilitated by providing them with a separating layer prior to applica-tion of the plaster. Such a layer may be formed for example by a plastics sheath 9 a cardboard tube, a paper wrapping, a plastics tube, a metal tube, or a coating of grease, a release paint, a powder or a liquid.
The profile rods or the separating layer may be loosely connected to the plaster base prior to application of the , . . . . . ..
. . ~ . ;.~ . :, ... .
. : ~ i plaster. ~his can be done simply and positivel~ b~ wire loops, rings or the like or ~y means of spot welding or by threadin~ the rods to~ether with the separating layer through apertures in the lattice work of the plaster base.
~he rods may be held by templates. If the rods are fixed to one template they may be withdrawn from the wall by relative movement between the template and the wall.
Further according to the present invention, there i~
provided apparatu~ for producing a room element having walls formod by plastering both ~ides of a plaster base, said apparatus comprising a bottom template, a top template align-able with the bottom template at a distance above the bottom template, said templates ha~in~ guide bores in positions corresponding to the positions of the walls to be erected, andirods locatable in the bores and arranged to extend ~rom the top template to the bot-tom template, said rod~ serving to reinforce the plaster base, and said rod~ being removable after application of the plaster.
~he templates and their guide bores serve to establish the positions of the relevant rods and determine the location of the walls which are to be erected. ~he guide bores are therefore located inthe templates in accordance with the shape of the plan ~iew of the room element which i~
to be erected. ~hey are positioned within the wall zone of the walls which are to be produced~
. ~ . .
- In so far as each pair of templates is used only for - producing a sepcific type of room element, it is ade~uate for the templates to have guide bore~ only as required for this type of room elementO On the other hand, if the templates are to be generally used for different types of room element7 then they may be provided accordingly with further guide bores or with a substantially regular pattern of g~ide boresr With such templates, it is then possible to produce room elements of any desired form.
Such a pattern of gulde bores may be provided in the bottom template but the top template may only have bores corresponding to a specific plan of room element. I~ this way, when producing different room elements, it is necessary only to change the top template~ As a result it is possible for even unskilled workers to insert the rods accuratelyO
The time required for changing templates is minimised.
Since the rods are guided both in the top and also in the bottom templates, adequate stability is achieved and also a sufficiently accuratewall shape is ensured. Both templates can ~e used for mounting the profile rods thereon, so facilitating removal of the profile rod~ from the room element~
~dvantageously the width of each template corresponds to the overall width of the room element to be erected~
With regard to the disposition of the templates, it i~
:
~ 8 -, . ~. .
5(~5 advantageous for both template~ to be mounted interchange-ably in a housing frame. In conse~uence, the two templates can on the one hand easily be associated with each other ~ while on the other, it is readily possible to exchange the templates for others of a different type.
With regard to the use of templates of different length, it is preferred for the housing frame to have four posts which are always located in the corner zone of the room element which is to be produced~ at least -two of these posts being movable. ~he posts can thus be moved to other positions adapted to the dimensions of the variouq templates.
To provide a simple structure for the housing frame, it is of advantage for the posts to be connected to one another via framework supports~ In this way, the housing frame forms one unit and can be moved to any desired place of use as re-quired, but nevertheless stable and dimensionall~ accurate.
It is also preferred for the framwwork supports to be pro-- vided below the bottom template~ They serve then as a means of stabilising and supporting the underneath of the template.
For ~urther reinforceme~t of the housing frame, it is preferred that the housing frame has at least one intermediate post for the template on at least two oppositely disposed sides. In order to make the housing frame nevertheless readily accessible, it is advantageous for the intermediate , - : - . ~ .. ..
S~
i posts to be disposed in such a way that they can be moved ~`
to one side. They can then be moved aside for fitment of a different template or for removal of the room element.
To facilitate work on the room element, it is preferred for the intermediate posts to have an L-shape, the horizontal arm o~ the L being adapted to be connected to the top tem-plate while the vertical arm extends at a distance from the room element which is to be erected. In this way, the top template is supported while it is nevertheless ensured that the walls are freely accessible to be worked upon.
Preferably, such templatesare made from metal profiles, preferably steel~ square-section tubes. Such templates are stable and can be very advantageously employed during plaster-ing as a wipe-off edge, in other words as a reference edga for the walls which are to be erected In order to achieve a reliable anchoring of the rods in the template, the continuous guide bores are preferably pro-vided with bushes which guide the rods over a substantial length (for example about 20cm) by housing them with minimal clearance.
~hey have conical or rounded mouths to facilitate inser~ion of the rods and are provided with a seating flange. '~he advantage of guiding the rods over a length of, for example, about 20 cm is that the ends of the rods are thus secured against rotation, so that their resistanceto beins pressed out laterally or càused to sag is su~stantially increased.
- 10 - .
,.
: ~ : : . -5Q~
This effect is known as the fitment or continuity moment~
A further advantage of using bushes is that they can easily be replaced when the~ show signs of wearO In order to reduce wear on the rods, the bushes ma~ be made from a softer material than that of the profile rods, e.g. bronze.
To avoid weak points in the walls to be erected, it is advantageous for the guide bores to be located in the central axis of the walls to be erected.
Preferably the rods are hollow, which provides an opportunity of introducIng through the rods themsel~e~ and into the interior of the wall1 a fluid which can be used either to facilitate withdrawal of the rods or to accelerate the setting process.
Wlthdrawal of the profile rocls can be facilitated by having them taper conically towards their free end.
B~IEF DE~CRIPl`ION OF ~HE D~AWINGS
`
The invention will now be described, by way of example only9 with reference to the accompan~ing diagrammatic drawings in which:
Figures 1 to 6 are per~pective views of apparatus for producing room elements, shown in various working sta~es:
Figure 7 is a cross-~ection through a top template of the apparatus and an already completed room element in the region of the ~unction between the ceiling and an outer wall;
~ Figure 8 i~ a cro~s-section through an alternative form . , .
of top template, the section also extendin~ through an intermediate post;
Figure 9 is a cross-section through a bottom template and a connecting girder of the apparatus and the bottom edge of an outside wall of a completed room element;
Figure 10 is a cross~section of the same height as Figure 9 but taken at the axis of a transverse wall in the completed room element;
Figure ll is a plan view of a transverse and lon~
tudinal wall in a completed room element;
Figure 12 is a plan, in section, through a door open-ing of the room element;
Figure 13 is a plan view of a transverse wall in a com-pleted room element at a position where this extends as far as the edge of the element without meeting a longitudinal wall;
Figure 14 is a schematic front elevation of the completed room eleme~t; and Figure 15 is a schematic plan view of the same room element.
DE~CRIP~I~N OF THE ~REFERR~D EMB~DlMEN'I'S
Figures 1 to 6 show an apparatus 1 for producing~room elements of the type shown in Figure 6 and also in Figures 14 and 15. The apparatus l has a rectangular housing frame
Prefabricated transportable room elements have been pro-posed in the form of a self-supporting construction or a non-self-supporting construction, and in the latter case they are also provided with a supporting structure. ~uch room elements can be used for erecting both multi-storey houses and also 10 bungalows.
Such room elements may be cast from a hydraulically sett-ing material such as for example concrete. ~or this purpose, a reinforcement is placed in shuttering into which the ca~ting material is then poured. Such shuttering is, however, expen-15 sive tc purchase and complicate~ in u~eO ~he fact that the expensive shuttering is out of use while the concrete is setting is an intolerable cost factor.
It has also been proposed to construct walls and/or ceilings of conventional buildings by the free application of 20 hydraulically setting material to plaster bases strengthened by a reinforcement. In this case, first the reinforcement is brought into a form corresponding to the shape of the basic structure to be erected, i.e. first of all a prQfile skeleton is set up consistingfor example of metal profiles welded to 25 one anotherg ~he skeleton comprises the walls and possibly 2 - ~
- , . .
, ...
- ,. : -:~:
. .:
s also structures within the room~ room dividers and ceiling.
Lattice girders may also be used for the constructionn ~hen, a pl~ster base is fixed to the profiles. As ~uch9 it is possible to use ribbed expanded metal, wire gauze, cardboard and similar structures, for example even matsO The actual walls or ceilings, as the case may be, are then produced by applying the hydraulically setting material to the reinforce-ment and plaster base. ~his can be done mechanically or b~
hand. In order to achieve a smooth surface, the freshly applied material is smoothed out flat and filled until smooth.
The h~draulicall~ setting material may for example be gypsum, plaster or concrete (Gunite).
A disadvantage of the method which has just been des-cribed is the relatively high reinforcing material costs.
EIowever, the reinforcement must be relatively stable in order to ~trengthen the plaster base adequately for the plastering process.
~Ur~RY ~F 'rHE INV~N~I~N
According to the present invention, there is provided a method of producing the walls Or a room element compris-ing the steps of providing a substrate for ~ach wall, rein- ;~
forcing the substrate with a removable reinforcement, apply-ing to each side of the substrate a hardenable composition in a fluid form, and removing the reinforcement a~ter the com-position has at least par~ly set~
. , : . . , :
. . . .:
: ............... . .
SS~5 Further according to the present invention, there is provided a method of producing a room element comprising the steps of forming walls of the element by plastering both sides of plaster bases which are strengthened by a reinforce-ment at least a part of which is superfluous to the structure of the co~pleted walls, and removing) after plastering, the reinforcement which is supert`luous to the structure of the completed walls.
In this manner, during the plastering process, the `
plaster base is kept adequately rigid so that it will not give way and bulge when the plaster is applied. ~his is particularly important since the various operations connected with plastering, such as application7 smoothing and finishing give rise to substantial lateral forces ~nd the plaster base itsélf is inherently unstable~ Excessive yiel~ing or vibra-tion would produce a structural fault such as for example ~-irregular wall thickness and location, and also eccentricity of the plaster base within the thickness of the wall~ ~he former faults would be noted as inaccurate and uneven wall 2Q surfaces, the latter as concealed ~tatic weakness.
After plastering, however, the relatively stable verti-cal reinforcement is no longer needed, since there is no further lateral loading on thewalls until the structure has hardened and developed its own stability~ The plaster base i~ preferably fixed to an underfloor frame of the structur~ -- ' -. , ~. ,:
: ' s~
; t~
and imparts sufficient vertical rigidity to the still wet wall. Any possible distortion is prevented by using a material which has as far as possible neutral e~pansion properties. After hardening, the walls themselves are stable. By removing the then superfluous reinforcement, manufacturing costs can be notably reduced, since the cost of the reinforcement represents a significant portion of the overall costs. '~hose parts of the reinforcement which are removed after plastering can be used again for producing further room elements.
. . , . : ........................... : :, ; , . :
,, . . :, .. . .
ii(35 i, ," , .
Preferably profile rods are used as the removable part of the reinforcement and are withdrawn from the wall after application of the plaster, in the direction of their length~
Profile rods are readil~ available propri~tory materials and are therefore inexpensive. By virtue of their cross-sectional form, they can easily be withdrawn again ~rom the wall in their longitudinal direction. An advantage of using profile rods of round cross-section is that by virtue of their round symmetrical cross-sectional form, they require no specific orientation when they are being inserted and extracted~ ;
So that profile rods can be used again quickly and so that only a small quan~ity of them is therefore required to be kept in circulation~ it is advantageous if the profile rods are withdrawn from the plaster before this has eet. In this way7 the actual period of use of the profile rods is minimal, and they can be used again rela-tively shortly after the plaster has been applied.
Withdrawal of the profile rods can also be facilitated by providing them with a separating layer prior to applica-tion of the plaster. Such a layer may be formed for example by a plastics sheath 9 a cardboard tube, a paper wrapping, a plastics tube, a metal tube, or a coating of grease, a release paint, a powder or a liquid.
The profile rods or the separating layer may be loosely connected to the plaster base prior to application of the , . . . . . ..
. . ~ . ;.~ . :, ... .
. : ~ i plaster. ~his can be done simply and positivel~ b~ wire loops, rings or the like or ~y means of spot welding or by threadin~ the rods to~ether with the separating layer through apertures in the lattice work of the plaster base.
~he rods may be held by templates. If the rods are fixed to one template they may be withdrawn from the wall by relative movement between the template and the wall.
Further according to the present invention, there i~
provided apparatu~ for producing a room element having walls formod by plastering both ~ides of a plaster base, said apparatus comprising a bottom template, a top template align-able with the bottom template at a distance above the bottom template, said templates ha~in~ guide bores in positions corresponding to the positions of the walls to be erected, andirods locatable in the bores and arranged to extend ~rom the top template to the bot-tom template, said rod~ serving to reinforce the plaster base, and said rod~ being removable after application of the plaster.
~he templates and their guide bores serve to establish the positions of the relevant rods and determine the location of the walls which are to be erected. ~he guide bores are therefore located inthe templates in accordance with the shape of the plan ~iew of the room element which i~
to be erected. ~hey are positioned within the wall zone of the walls which are to be produced~
. ~ . .
- In so far as each pair of templates is used only for - producing a sepcific type of room element, it is ade~uate for the templates to have guide bore~ only as required for this type of room elementO On the other hand, if the templates are to be generally used for different types of room element7 then they may be provided accordingly with further guide bores or with a substantially regular pattern of g~ide boresr With such templates, it is then possible to produce room elements of any desired form.
Such a pattern of gulde bores may be provided in the bottom template but the top template may only have bores corresponding to a specific plan of room element. I~ this way, when producing different room elements, it is necessary only to change the top template~ As a result it is possible for even unskilled workers to insert the rods accuratelyO
The time required for changing templates is minimised.
Since the rods are guided both in the top and also in the bottom templates, adequate stability is achieved and also a sufficiently accuratewall shape is ensured. Both templates can ~e used for mounting the profile rods thereon, so facilitating removal of the profile rod~ from the room element~
~dvantageously the width of each template corresponds to the overall width of the room element to be erected~
With regard to the disposition of the templates, it i~
:
~ 8 -, . ~. .
5(~5 advantageous for both template~ to be mounted interchange-ably in a housing frame. In conse~uence, the two templates can on the one hand easily be associated with each other ~ while on the other, it is readily possible to exchange the templates for others of a different type.
With regard to the use of templates of different length, it is preferred for the housing frame to have four posts which are always located in the corner zone of the room element which is to be produced~ at least -two of these posts being movable. ~he posts can thus be moved to other positions adapted to the dimensions of the variouq templates.
To provide a simple structure for the housing frame, it is of advantage for the posts to be connected to one another via framework supports~ In this way, the housing frame forms one unit and can be moved to any desired place of use as re-quired, but nevertheless stable and dimensionall~ accurate.
It is also preferred for the framwwork supports to be pro-- vided below the bottom template~ They serve then as a means of stabilising and supporting the underneath of the template.
For ~urther reinforceme~t of the housing frame, it is preferred that the housing frame has at least one intermediate post for the template on at least two oppositely disposed sides. In order to make the housing frame nevertheless readily accessible, it is advantageous for the intermediate , - : - . ~ .. ..
S~
i posts to be disposed in such a way that they can be moved ~`
to one side. They can then be moved aside for fitment of a different template or for removal of the room element.
To facilitate work on the room element, it is preferred for the intermediate posts to have an L-shape, the horizontal arm o~ the L being adapted to be connected to the top tem-plate while the vertical arm extends at a distance from the room element which is to be erected. In this way, the top template is supported while it is nevertheless ensured that the walls are freely accessible to be worked upon.
Preferably, such templatesare made from metal profiles, preferably steel~ square-section tubes. Such templates are stable and can be very advantageously employed during plaster-ing as a wipe-off edge, in other words as a reference edga for the walls which are to be erected In order to achieve a reliable anchoring of the rods in the template, the continuous guide bores are preferably pro-vided with bushes which guide the rods over a substantial length (for example about 20cm) by housing them with minimal clearance.
~hey have conical or rounded mouths to facilitate inser~ion of the rods and are provided with a seating flange. '~he advantage of guiding the rods over a length of, for example, about 20 cm is that the ends of the rods are thus secured against rotation, so that their resistanceto beins pressed out laterally or càused to sag is su~stantially increased.
- 10 - .
,.
: ~ : : . -5Q~
This effect is known as the fitment or continuity moment~
A further advantage of using bushes is that they can easily be replaced when the~ show signs of wearO In order to reduce wear on the rods, the bushes ma~ be made from a softer material than that of the profile rods, e.g. bronze.
To avoid weak points in the walls to be erected, it is advantageous for the guide bores to be located in the central axis of the walls to be erected.
Preferably the rods are hollow, which provides an opportunity of introducIng through the rods themsel~e~ and into the interior of the wall1 a fluid which can be used either to facilitate withdrawal of the rods or to accelerate the setting process.
Wlthdrawal of the profile rocls can be facilitated by having them taper conically towards their free end.
B~IEF DE~CRIPl`ION OF ~HE D~AWINGS
`
The invention will now be described, by way of example only9 with reference to the accompan~ing diagrammatic drawings in which:
Figures 1 to 6 are per~pective views of apparatus for producing room elements, shown in various working sta~es:
Figure 7 is a cross-~ection through a top template of the apparatus and an already completed room element in the region of the ~unction between the ceiling and an outer wall;
~ Figure 8 i~ a cro~s-section through an alternative form . , .
of top template, the section also extendin~ through an intermediate post;
Figure 9 is a cross-section through a bottom template and a connecting girder of the apparatus and the bottom edge of an outside wall of a completed room element;
Figure 10 is a cross~section of the same height as Figure 9 but taken at the axis of a transverse wall in the completed room element;
Figure ll is a plan view of a transverse and lon~
tudinal wall in a completed room element;
Figure 12 is a plan, in section, through a door open-ing of the room element;
Figure 13 is a plan view of a transverse wall in a com-pleted room element at a position where this extends as far as the edge of the element without meeting a longitudinal wall;
Figure 14 is a schematic front elevation of the completed room eleme~t; and Figure 15 is a schematic plan view of the same room element.
DE~CRIP~I~N OF THE ~REFERR~D EMB~DlMEN'I'S
Figures 1 to 6 show an apparatus 1 for producing~room elements of the type shown in Figure 6 and also in Figures 14 and 15. The apparatus l has a rectangular housing frame
3 with four individually supported corner posts ~ and four ~: ' . , .
IL5S~i intermediate posts 5. The corner posts are at the corners of the rectangular housing frame and are connected to one another through frame members 60 The intermediate posts 5 are mounted on transverse members 9 projecting laterally beyond the long sides of the housing frame. ~he~ are dis-posed in pairs substantially at the same intervals ~rom one another and from the corner posts ~, i.e. in each case more or less in one third of the length 8 of the apparatus.
The posts of the pair~ of intermediate posts which are disposed on one side of the apparatus are pivotal into a horizontal position in a vertical plane parallel with the long side oP the apparatus, i~e. in the direction of the arrow P in Figure 3, to facilitate the suppl~ of tools and materials and the removal o~ the completed room element.
The intermediate posts of the pairs which are disposed on the other side of the apparatus are rigidly or removably mounted on the transverse members of the frameO The posts are con~
stituted b~ structural steel profiles, possibly rectangular metal tubes or double-~ members. Similarly, the frame members 6 are constructed of structural steel profiles.
The left-hand pair (as viewed in Figure 1) of the main or corner posts 4 are displaceable on the frame members 6. ~he frame members 6 and the botto~ parts of the corner posts have fixing holes 9 to receive rigidly fitted plugs Por locking the corner posts in various positions for the production of , ,, - ~
.- . ~ ~ , : ~ ::
5a!S
room elements of different lengths~ The intermediate posts need not be movable, but if desired several points of articulation may be provided for the pivotal posts and a plurality of fixing locations for the fixed intermediate posts.
For room elements of different lengths, in each case one or more apparatuses may be provided, the length of which need not then be variable~ ~he apparatus shown in the drawin~s, is a stationary apparatus with no rollers or other means for facilitating movement although such means can readily be fitted.
~he frame members 6 support a bottom template 10. ~his has, engaging the bottom webs of the frame members 6, ~ n-ing fittings 11 for lateral alignment of the template (Figure 9). As can also be seen from this ~igure~ the bottom tem- ;
plate is made of rectangular metal tubes, the width of which is equal to the wall thickness 12 envisaged for the room element. The template represents the plan view of the room element which is to be produced. By means of the template shown in ~igures 1 to 6, room elements of two different plan formats can be produced9 one of which is shown in Figure 15.
The bearers of the template have on their top and bottom faces ali~ned bores 13 into which in each case a guide bush 14 is fitted. The upper ends of the bushes 14 and bottom ends of vertical rods 15 which are to be introduced into them may have rounded edges or a conical shape to facilitate .
. , - ., .
, . .
' ~.15S~5 insertion In order to achieve bottom edge~ 16 of a room element which may b~ chamfered off at any desired angle, wedges or possibly half-moon shaped spacers can be placed under the templ~te.
~he main or corner posts ~ have at the top end in each case a carrying lug and a guide pin 17, 18 respectively~
~he carrying lugs 17 serve for attachment of a prefabricated rectan~ular ceiling frame 19 (Figure 2)~ ~he rectangular celling frame 19 has longitudinal members 20 formed from C-profiles and which can be fitted by plugs or bolts on the lugs 17 and which are connected to one another via transverse lattice girders 21 which are welded to them. A substrate or plaster base 22 consisting of cardboard provided with aper-tures and interlaced with wire braid i5 fixed by means of wires 23 or b~ spot welding to the underside of the lattice girders. In an alternative arrangement, the ceiling frame 19 which is provided with the plaster base 22 mag already be given an application o~ plaster prior to insertion into the apparatus 1. This can be achieved by pouring the plaster 2 into a t`lat mould or by dipping into a plastering material followed by surface fillingO Prior to insertion into the apparatus, such a plastered structure must haveset at least to a large extent. ~urthermore~ measurès must be taken to facilitate connecting the wall plaster to the plaster of the prefabricated ceiling; for e~ample corresponding areaSma~ be .
;5~5 left unplastered or parts of the plaster base in these areas may project downwards beyond the substantially completed ceiling suIface.
The guide pins 18 serve for accurate orientation of a top template 25. ~his has a form similar to that of the bottom template 10 but is made from broader profiles or mem-bers than the latter, since it is not supported o~er its entire length. Furthermore, the members of the top template serve to determine the wall thickness of the room element only from the outside. The top template 25 has, correspond-ing to those of the bottom template 10 and in line therewith, bush-lined ~uide bores 13. As can be seen from Figures ~
and 4, the top template 25 has fewer guide bores 13 than the bottom template. This is because the top template is in-tended only for the production of room elements of the pla~
shown in Figure 15~ For the production of room elements having a different plan, a different top template is needed having guide bores which are aligned with those guide bores of the bottom template which are unoccupied in P'igure 4. In another arrangement, not shown, the bottom template has a lattice-like arran~ement of guide bores spaced apart from one another by approximately 50 cm, of which in each case onl~
those corresponding to those used in the top template remain occupied, while the others are left free.
~he left-hand edge (as ~iewed in Figure 7) i.e. the outer _ 16 ~
- ,- : . I
- . , : :
;i5(~
edge, of the top template ~5 forms a reference surface for aligning the outer wall surface 27 of the room element after application of the plaster 2~ his ed~e ~6 thus determines the width of the room element overall and al90 the smooth-ness and evenness of the outer wall surface and thus the dimensional accuracy of the completed element.
As can also be seen in Figure 7, the top template 25 has a locking clamp 28 for gripping the ceiling frame 19 by pressing the longitudinal member 2~ thereof a~ainst the under-side of the template. In another arran~ement, the longitu-dinal members may have their vertical webs holes for engage-ment of holding means independent of the top template, in which case then the locking clamps 28 can be omitted.
During production of a room element~ the top template which is resting on the corner posts 4 and which is aligned b~ means of the guide pins l8, is additionall~ supported vertically and laterall~ b~ the intermediate posts 5.
End faces 29 of horizontal arms of the posts 5 bear against the outside faces 26 of the template in order to brace them laterally. Located iu horizontal bores 30 of the post~
guide retractable pins 31 which engage into ~omplementar~
bores 32 in the template in order to provide additional : vertical support (Figure 8). The vertical arms of the individual intermediate posts 5 are located at a certain distance from the outsides of the room element which is to be . - 17 -.
: .
~ - :
' . . ~: :
,, ~ , , I.l.S5q~5 produced~ so that this is freely accessible -to be worked upon. As shown in Figure 8, the intermediate posts 5 have below the pins 31 and parallel to those pins 33 which en-gage holes 34 provided for the pl~pose in the ceiling frame -in order to support this latter independently of the te~plate, as previously mentioned~
In this arrangement9 the top template 25 also has laterally projecting supports 35 which transmit the weight of the template 25 to the intermediate posts without excessively straining the pins 31. In this case, the top~ of the inter-mediate posts 5 tben extend somewhat lo~rer than in the arrangement shown in Figures 3 to 5. The bottom extensible.
pin 33 has a conical ring 36 for laterall~ supporting the ceiling frame 19. This arrangement offers the advantage that the ceiling frame of a room element with the plaster not yet set is also supported after the top template has been re-moved.
As can be seen particularly in ~igure 1, the corner posts
IL5S~i intermediate posts 5. The corner posts are at the corners of the rectangular housing frame and are connected to one another through frame members 60 The intermediate posts 5 are mounted on transverse members 9 projecting laterally beyond the long sides of the housing frame. ~he~ are dis-posed in pairs substantially at the same intervals ~rom one another and from the corner posts ~, i.e. in each case more or less in one third of the length 8 of the apparatus.
The posts of the pair~ of intermediate posts which are disposed on one side of the apparatus are pivotal into a horizontal position in a vertical plane parallel with the long side oP the apparatus, i~e. in the direction of the arrow P in Figure 3, to facilitate the suppl~ of tools and materials and the removal o~ the completed room element.
The intermediate posts of the pairs which are disposed on the other side of the apparatus are rigidly or removably mounted on the transverse members of the frameO The posts are con~
stituted b~ structural steel profiles, possibly rectangular metal tubes or double-~ members. Similarly, the frame members 6 are constructed of structural steel profiles.
The left-hand pair (as viewed in Figure 1) of the main or corner posts 4 are displaceable on the frame members 6. ~he frame members 6 and the botto~ parts of the corner posts have fixing holes 9 to receive rigidly fitted plugs Por locking the corner posts in various positions for the production of , ,, - ~
.- . ~ ~ , : ~ ::
5a!S
room elements of different lengths~ The intermediate posts need not be movable, but if desired several points of articulation may be provided for the pivotal posts and a plurality of fixing locations for the fixed intermediate posts.
For room elements of different lengths, in each case one or more apparatuses may be provided, the length of which need not then be variable~ ~he apparatus shown in the drawin~s, is a stationary apparatus with no rollers or other means for facilitating movement although such means can readily be fitted.
~he frame members 6 support a bottom template 10. ~his has, engaging the bottom webs of the frame members 6, ~ n-ing fittings 11 for lateral alignment of the template (Figure 9). As can also be seen from this ~igure~ the bottom tem- ;
plate is made of rectangular metal tubes, the width of which is equal to the wall thickness 12 envisaged for the room element. The template represents the plan view of the room element which is to be produced. By means of the template shown in ~igures 1 to 6, room elements of two different plan formats can be produced9 one of which is shown in Figure 15.
The bearers of the template have on their top and bottom faces ali~ned bores 13 into which in each case a guide bush 14 is fitted. The upper ends of the bushes 14 and bottom ends of vertical rods 15 which are to be introduced into them may have rounded edges or a conical shape to facilitate .
. , - ., .
, . .
' ~.15S~5 insertion In order to achieve bottom edge~ 16 of a room element which may b~ chamfered off at any desired angle, wedges or possibly half-moon shaped spacers can be placed under the templ~te.
~he main or corner posts ~ have at the top end in each case a carrying lug and a guide pin 17, 18 respectively~
~he carrying lugs 17 serve for attachment of a prefabricated rectan~ular ceiling frame 19 (Figure 2)~ ~he rectangular celling frame 19 has longitudinal members 20 formed from C-profiles and which can be fitted by plugs or bolts on the lugs 17 and which are connected to one another via transverse lattice girders 21 which are welded to them. A substrate or plaster base 22 consisting of cardboard provided with aper-tures and interlaced with wire braid i5 fixed by means of wires 23 or b~ spot welding to the underside of the lattice girders. In an alternative arrangement, the ceiling frame 19 which is provided with the plaster base 22 mag already be given an application o~ plaster prior to insertion into the apparatus 1. This can be achieved by pouring the plaster 2 into a t`lat mould or by dipping into a plastering material followed by surface fillingO Prior to insertion into the apparatus, such a plastered structure must haveset at least to a large extent. ~urthermore~ measurès must be taken to facilitate connecting the wall plaster to the plaster of the prefabricated ceiling; for e~ample corresponding areaSma~ be .
;5~5 left unplastered or parts of the plaster base in these areas may project downwards beyond the substantially completed ceiling suIface.
The guide pins 18 serve for accurate orientation of a top template 25. ~his has a form similar to that of the bottom template 10 but is made from broader profiles or mem-bers than the latter, since it is not supported o~er its entire length. Furthermore, the members of the top template serve to determine the wall thickness of the room element only from the outside. The top template 25 has, correspond-ing to those of the bottom template 10 and in line therewith, bush-lined ~uide bores 13. As can be seen from Figures ~
and 4, the top template 25 has fewer guide bores 13 than the bottom template. This is because the top template is in-tended only for the production of room elements of the pla~
shown in Figure 15~ For the production of room elements having a different plan, a different top template is needed having guide bores which are aligned with those guide bores of the bottom template which are unoccupied in P'igure 4. In another arrangement, not shown, the bottom template has a lattice-like arran~ement of guide bores spaced apart from one another by approximately 50 cm, of which in each case onl~
those corresponding to those used in the top template remain occupied, while the others are left free.
~he left-hand edge (as ~iewed in Figure 7) i.e. the outer _ 16 ~
- ,- : . I
- . , : :
;i5(~
edge, of the top template ~5 forms a reference surface for aligning the outer wall surface 27 of the room element after application of the plaster 2~ his ed~e ~6 thus determines the width of the room element overall and al90 the smooth-ness and evenness of the outer wall surface and thus the dimensional accuracy of the completed element.
As can also be seen in Figure 7, the top template 25 has a locking clamp 28 for gripping the ceiling frame 19 by pressing the longitudinal member 2~ thereof a~ainst the under-side of the template. In another arran~ement, the longitu-dinal members may have their vertical webs holes for engage-ment of holding means independent of the top template, in which case then the locking clamps 28 can be omitted.
During production of a room element~ the top template which is resting on the corner posts 4 and which is aligned b~ means of the guide pins l8, is additionall~ supported vertically and laterall~ b~ the intermediate posts 5.
End faces 29 of horizontal arms of the posts 5 bear against the outside faces 26 of the template in order to brace them laterally. Located iu horizontal bores 30 of the post~
guide retractable pins 31 which engage into ~omplementar~
bores 32 in the template in order to provide additional : vertical support (Figure 8). The vertical arms of the individual intermediate posts 5 are located at a certain distance from the outsides of the room element which is to be . - 17 -.
: .
~ - :
' . . ~: :
,, ~ , , I.l.S5q~5 produced~ so that this is freely accessible -to be worked upon. As shown in Figure 8, the intermediate posts 5 have below the pins 31 and parallel to those pins 33 which en-gage holes 34 provided for the pl~pose in the ceiling frame -in order to support this latter independently of the te~plate, as previously mentioned~
In this arrangement9 the top template 25 also has laterally projecting supports 35 which transmit the weight of the template 25 to the intermediate posts without excessively straining the pins 31. In this case, the top~ of the inter-mediate posts 5 tben extend somewhat lo~rer than in the arrangement shown in Figures 3 to 5. The bottom extensible.
pin 33 has a conical ring 36 for laterall~ supporting the ceiling frame 19. This arrangement offers the advantage that the ceiling frame of a room element with the plaster not yet set is also supported after the top template has been re-moved.
As can be seen particularly in ~igure 1, the corner posts
4 have rigidly mounted thereon vertical rails 37 which serve . to determine the outside dimensions of the room element, i.e~
they serve as reference edges for finishing the outer wall faces as well as serving shuttering for the edges of the end ~.
wall faces~
Round rods 15 which connect the template~ to one another are inserted vertically into the guide bushes of the aligned - , . . : . ............. . , , - :
....
., - ,~
~LllS~
bores 13 in the top and bottom template. q'he rods 15 have at the top end a screw thread and carry screwed onto -this a nu-t which together with a washer forms a seating flange 37. Above the seating flange 38, each rod is shaped into a ring or lug 39 to facilitate handlingO In another arran~ement, i-t is possible to screw onto the top end of each rod a nut which is rigidly connected to a rin~ or lug.
As can be seen in Figure 9, each rod has a rounded or conical bottom end 40 which facilikates insertion of the rod throu~h the top template and a separating shell into the bottom tem-plate.
Since the material in the central portion of a round rod contributes only a little to its rigiditya the rods 15 can be made hollow, i.e. they may be constructed as tubesO ~uch a tube permits the incorporation of fluid media into the wall;
for example, a pressurised medium to facilitate extraction of the rods or tubes, a heated medium to accelerate setting of the plaster, a cooled medium to retard setting or a medium containing certain chemicals may be introduced through the tubes to escape through holes in the walls of the tubes and sheaths, into the plaster mass.
In the arrangement shown in Figures 7, 9 and 10, the rods are enclosed by a sheath 41 in -the form of a loosely pushed-on cardboard tube. The rods are passed through the top tem-plate and thereupon through the relevant sheath and into the ~, 9 - , , .
. . -55~i bottom template. The rod~ 15 shown here are solid but the~
may alternativel~ be hollow.
As can be seen in Figures 4, 5 and 7, the cardboard tubes 41 which co~itute the separating sheaths and which are
they serve as reference edges for finishing the outer wall faces as well as serving shuttering for the edges of the end ~.
wall faces~
Round rods 15 which connect the template~ to one another are inserted vertically into the guide bushes of the aligned - , . . : . ............. . , , - :
....
., - ,~
~LllS~
bores 13 in the top and bottom template. q'he rods 15 have at the top end a screw thread and carry screwed onto -this a nu-t which together with a washer forms a seating flange 37. Above the seating flange 38, each rod is shaped into a ring or lug 39 to facilitate handlingO In another arran~ement, i-t is possible to screw onto the top end of each rod a nut which is rigidly connected to a rin~ or lug.
As can be seen in Figure 9, each rod has a rounded or conical bottom end 40 which facilikates insertion of the rod throu~h the top template and a separating shell into the bottom tem-plate.
Since the material in the central portion of a round rod contributes only a little to its rigiditya the rods 15 can be made hollow, i.e. they may be constructed as tubesO ~uch a tube permits the incorporation of fluid media into the wall;
for example, a pressurised medium to facilitate extraction of the rods or tubes, a heated medium to accelerate setting of the plaster, a cooled medium to retard setting or a medium containing certain chemicals may be introduced through the tubes to escape through holes in the walls of the tubes and sheaths, into the plaster mass.
In the arrangement shown in Figures 7, 9 and 10, the rods are enclosed by a sheath 41 in -the form of a loosely pushed-on cardboard tube. The rods are passed through the top tem-plate and thereupon through the relevant sheath and into the ~, 9 - , , .
. . -55~i bottom template. The rod~ 15 shown here are solid but the~
may alternativel~ be hollow.
As can be seen in Figures 4, 5 and 7, the cardboard tubes 41 which co~itute the separating sheaths and which are
5 - reinforced by the rods 15 are connected, li~e the lattice girders of the ceiling 19, to one another by a plaster ba~e 22. In the embodiment shown, the plaster base 22 i5 con-structed of an open-work cardboard through the holes in which a wire braid is passed, and is secured by wires to the likewise cardboard sheaths 41~ If metal sheaths are used, th~ plaster base can be welded to it. In this case, fixing can alter-natively be achieved by an adhesive. If the sheath has an oil, grease or paste coating, then care must be taken that the fixing of the plaster base does not attack the rods 15 themselves. In this case, short lengths of pipe, cylindrical rings or the like may be secured to the plas-ter base by means of wire, ~elding or gluing.
The plaster base may be continuously fitted on one side of the rods or may be alternately threaded through and be-tween them. Where the plaster base 22 is disposed in the middlo of the w~ll, in other words in line with the axes of the rods, it can be so shaped that it extends around a part of the rods, or the wires of the interwoven braid can be shaped alternately to one side and the other so that the rod can be insertea between them substantially in the same plane -; :.' '- , . . . ~
S~i as the plaster base. The rods with their sheaths are preferably disposed in the middle of the thickness of the wall in order to avo1d an~ weakening towards one side and in order to ensure that the wall is of symmetrical construc-tion, so that the risk of distortion is as low aB possible.
Area5 of the room element, ~uch as for example the corners between walls or between walls and ceilings~ which are sub-ject to high stresses~ and also the areas around door and window openings can additionally be strengthened by a thin layer of expanded metal or what is known as lozenge lattice.
Instead of this or in addition to it, other known reinforc-ing aids-may be used~
~igure 5 also shows working platforms and areas 43, l~4 diagrammaticall~. This illustration serves however purely as an indication and other expedient arrangement~ may be used instead.
In another arrangement, side parts 45, 46 of the template 25, 10 may be independent of the other parts thereof. In this case, then, it is possible to make up outside of the apparatus and from the side parts, the rods 1~, the sheaths 41, an elastic underlay 47, the plaster base 22 and the afore-said strengthenings and other parts, a complete frame for a side wall which now only needs to be introduced into the apparatus and provided with plaster. This has the advantage tha-t the time wastage involved by the apparatus can be :
' ~ :
~ .: :
- . .
- .. , LS~
shortened and that it i~ possible to .work on a horizontal backing.
In order to ho.ld together the side wall :~rame which is so built up, it i5 possible instead of using the guide bushes 14 to use clamping means which pass through slots in the out-sides of the template parts, engage the rods 15 and hoId them fast.
The assembled side wall frame is inserted into the apparatus after the ceiling frame 19 has been fitted. In this . 10 case, bores in the ends of the upper side parts receive the guide pins 18 at the upper ends of the corner posts, and the .
fittin~s 11 en~age the top webs of the frame members 6 in order to align the lower side part 46~
The procedural steps when makin~ a room element can be seen from the Figures 1 to 6. In Figure 1, the bottom tem-plate 10 is inserted into the apparatus 1. In ~igure 2~ the prefabricated ceiling frame 19 is fixed by bolts on the lugs 17 of the corner posts 4. '~he ceiling frame illustrated is composed of the longitudinal and transverse member,s 20 and 21 ~rhich are rigidly connected to one another, and the plaster base 22 has not yet been plastered~ In another arrange~e~t the ceiling frame may already be provided with plaster 24 which must however be already substantially set before insertion into the apparatus.
In Figure 3, the top template 25 is fitted and aligned .
..
: : . , . , : -:, . , . : :
-: . : . , , ;. . :
by the guide pins 18. '~he intermediate posts 5 which for the sake of clarity are not shown in Figures 1 and 2 are here set up and engage the top template.
In Figure 4~ the round rods 15 are inserted into the bores 13 so that their mou~ting flanges 38 are resting on the top of the top template 25. After insertion of the rods 15 through the bores 13 in the top template 25, the cardboard tubes 41 which serve as sheaths are pushed on. Before the rods 15 enter the bores 13 in the bottom template, strips 47 of an elastic material, possibly a foam material, are placed on the top of the bottom template so that they later form a part thereof which is rigidly connected to the bottom edge of the wall which is to be made. 'rhe elastic strips 47 have prestamped holes throu~h which the rods 15 can be passed. In this condition, then, door and window frames 48, 49 and other parts and equipment intended to be installed rigidly into the walls and ceiling of the room element can be positioned and bonded on or welded to the eheath 41 or plas-ter base 2~. In the front part of Fi~ure 4, the plaster base is in the form of open-work cardboard 2~ through which a wire gauze is threaded, and is secured by tie wires 42 to the cardboard tubes 41 which surround the rods 15 which rigidify the said tubes~ In heavily stressed areas, an additional reinforcement in the form of expanded metal or in the form of additional vertical or horizontally disposed - 23 ~
..
;
, . . , ! : , . ' .
LS5~
metal rods tied or welded in place in situ may be provided and be left in position. ~he subsequently removabls verti-cal rods 15 represent an aid for alignin~ the various fit-ments, and the sheaths 41 may be colour coded for this purpose.
In a similar manner, electrical conductors, pipes, plumbing and other installations may be laid and fitted.
In the arrangement in which the side parts 46, 45 are independent of the other parts of the templates 10, 25, the rods 15 are provided with their sheaths 41, inserted into the bores or slots in the template parts and secured therein by means of clamps~ Then the necessary reinforcements and other fitments are placed in position, whereupon the completed side ~all frame can be inserted into the apparatus after the ceiling frame has been suspended. When this happens, the bores in the ends of the -top side part 45 receive the ~,uide pins 18 at the top ends of the corner pos-ts 4 and the align~
ing fittings ]1 of the hottom side part 46 enga~es the frame member 6. Whereupon, the other parts of the top template are inserted between the side ~arts thereof and secured to them by screws or by form-locking engagementO The inter-mediate walls in the interior of the room element are then set up in the manner previously described.
At those places where a transverse wall 50 of a room ;~
elementg as shown in Figures 13 and 15, extends to an outside ,:
- 2~ --~ , ,: , . .
s~
thereof, so that in a completed building it abuts a corre~-ponding transverse wall of an adjacent room element, there is at the relevant side of the apparatus a ~uide rail 51 formed from a structural profile, possibly a square section metal tube, the width of which is equal to the envisaged thickness of the transverse wall. ~he rail serves as a screed guide and as a boundary for the transverse wall to ensure its dimansional accuracy. Such guide rails 51 are fixed to the sides of the apparatus by mean~ o~ known devices7 possibly in bores in the frame members 6 and pin members which can be inserted into the top template 25.
Then, a plaster consisting of gypsum or other wet setting material is applied around the rods 15, conduits and other fitments and onto the plaster base 22. In the arrange-ment in Figure 5, this is done by a special spray gun 52, although application may be carried out in any desired manner.
- Prior to setting, the plaster can then be screeded and then rubbed smooth. '~he reference surfaces 25 t 51~ 53, 37 of the apparatus as well as certain fitments, such as door frames 4a, can serve as guides when the plastering is screeded~ so that the thickness and alignment of the walls can be accurately observedO Usually, the walls are plastered and screeded on both sides. If an already plastered ceiling 19 has not already been placed in the apparatus 1, -the ceiling can be plastered when plastering the walls; the ceiling can be .. .
, - ', . ~ ' ` ' ~ ' ~S~QS
pl~stered only on the underside or on both sides~ The plaster is then finished off flush with previously installed equipment such as electrical switches and socket housings, conduit connecting flan~es, anchorings and the afore~aid door and window frames.
Mow follow the secondary jobs which have to be carried out while the plaster is still wet, such as making good, fitting picture rails and batons and the like~ Prefera~ly, at this point in time, as far as possible, also all the other secondary aobs are carried out such as incorporation of electrical conductors in conduits, fitting of skirting boards, etc., without having to wait for the plaster to set.
After all the jobs which are possible in the wet state have been carried out, initially no further significant lateral loadin~ of the room element will occur, so that the top template 25 with the rods 15 suspended therefrom via the mounting ~lan~e 3~ can be lifted off (Figure 6). When this happens the rods 15 are withdrawn from the sheaths 41, which remain in the wall structure of the room element together with the plaster base 22~ ~he top template 2~ has support-- ing lugs 54 to which a crane can be applied to lift out these e~ements. Otherwise, the corner posts may have hydraulic or spindle operated lifting means which engage the template and lift it off. In this way~ those reinforcements which are no longer required for -the supportin~ strength of SS~
the walls of the room element can be removed to be used again later. ~he cavities remaining in the sheath 41 may if necessary be filled with plaster.
In another arrangement the vertical rods 15 may be fixed into the bottom template 10, in which case then the completed room element is lifted off them. If the room element is thereby securely fixed to a top template or-is otherwise re-inforced and if the plaster base is vertically continuous or is so fixed that it can withstand relatively high traction forces, then the room element can be lifted of~ even prior to complete setting of the plaster~
If the apparatus 1 is movable, the plaster can be set by running the room element into an o~en or autoclave to accelerate the process. Otherwise, the element remains in the apparatus until the plaster has set.
Once the room element has acquired sufficient strength by the plaster setting, it can be removed from the apparatus and conveyed to a work site at which those jobs which can be carried out in the set state or which could not otherwise be completed earlier can be performed. After sufficient drying out, which usually coincides with solidification by setting, the room element can then be painted or decorated and is then ready for use.
~he element can be used in a supporting frame con-2~ struc-tion such as is described in Swiss Patent Applicati~ns .
s~
VE I-116~-74 and VE 75 183. In this form, the room element is particularly suitable ~or setting up multi-storey build-ings.
For erecting single store~ buildings such as bungalows and the like, the room element can be made up with other room elements on a building site without using a supporting frame construction.
Figures 14 and 15 show a front view and plan view re-spectivel~ of a room element suitable for the afoxementioned purposes. It is open at a side 55 and this side allows it to be applied against another room element in order to form a complete dw011ing unit. The room element 2 illustrated contains a part 56 of a living room, a kitchen 57 with a cooker 58 and a sink 59 and also a sanitary closet with a flushing toilet 60, a shower cubicle 61 and a wash basin 62.
~he room element is rectan~ular and is of dimensions ~uch that it can without difficulty be transported by road.
The aforementioned suppor-ting frame construction 63 is shown by broken lines in Figures 14 and.15.
, ~.................................... .. , ... :
, . : ~
-, , ,: .,. ~ . : . : .: .
. . : . ,
The plaster base may be continuously fitted on one side of the rods or may be alternately threaded through and be-tween them. Where the plaster base 22 is disposed in the middlo of the w~ll, in other words in line with the axes of the rods, it can be so shaped that it extends around a part of the rods, or the wires of the interwoven braid can be shaped alternately to one side and the other so that the rod can be insertea between them substantially in the same plane -; :.' '- , . . . ~
S~i as the plaster base. The rods with their sheaths are preferably disposed in the middle of the thickness of the wall in order to avo1d an~ weakening towards one side and in order to ensure that the wall is of symmetrical construc-tion, so that the risk of distortion is as low aB possible.
Area5 of the room element, ~uch as for example the corners between walls or between walls and ceilings~ which are sub-ject to high stresses~ and also the areas around door and window openings can additionally be strengthened by a thin layer of expanded metal or what is known as lozenge lattice.
Instead of this or in addition to it, other known reinforc-ing aids-may be used~
~igure 5 also shows working platforms and areas 43, l~4 diagrammaticall~. This illustration serves however purely as an indication and other expedient arrangement~ may be used instead.
In another arrangement, side parts 45, 46 of the template 25, 10 may be independent of the other parts thereof. In this case, then, it is possible to make up outside of the apparatus and from the side parts, the rods 1~, the sheaths 41, an elastic underlay 47, the plaster base 22 and the afore-said strengthenings and other parts, a complete frame for a side wall which now only needs to be introduced into the apparatus and provided with plaster. This has the advantage tha-t the time wastage involved by the apparatus can be :
' ~ :
~ .: :
- . .
- .. , LS~
shortened and that it i~ possible to .work on a horizontal backing.
In order to ho.ld together the side wall :~rame which is so built up, it i5 possible instead of using the guide bushes 14 to use clamping means which pass through slots in the out-sides of the template parts, engage the rods 15 and hoId them fast.
The assembled side wall frame is inserted into the apparatus after the ceiling frame 19 has been fitted. In this . 10 case, bores in the ends of the upper side parts receive the guide pins 18 at the upper ends of the corner posts, and the .
fittin~s 11 en~age the top webs of the frame members 6 in order to align the lower side part 46~
The procedural steps when makin~ a room element can be seen from the Figures 1 to 6. In Figure 1, the bottom tem-plate 10 is inserted into the apparatus 1. In ~igure 2~ the prefabricated ceiling frame 19 is fixed by bolts on the lugs 17 of the corner posts 4. '~he ceiling frame illustrated is composed of the longitudinal and transverse member,s 20 and 21 ~rhich are rigidly connected to one another, and the plaster base 22 has not yet been plastered~ In another arrange~e~t the ceiling frame may already be provided with plaster 24 which must however be already substantially set before insertion into the apparatus.
In Figure 3, the top template 25 is fitted and aligned .
..
: : . , . , : -:, . , . : :
-: . : . , , ;. . :
by the guide pins 18. '~he intermediate posts 5 which for the sake of clarity are not shown in Figures 1 and 2 are here set up and engage the top template.
In Figure 4~ the round rods 15 are inserted into the bores 13 so that their mou~ting flanges 38 are resting on the top of the top template 25. After insertion of the rods 15 through the bores 13 in the top template 25, the cardboard tubes 41 which serve as sheaths are pushed on. Before the rods 15 enter the bores 13 in the bottom template, strips 47 of an elastic material, possibly a foam material, are placed on the top of the bottom template so that they later form a part thereof which is rigidly connected to the bottom edge of the wall which is to be made. 'rhe elastic strips 47 have prestamped holes throu~h which the rods 15 can be passed. In this condition, then, door and window frames 48, 49 and other parts and equipment intended to be installed rigidly into the walls and ceiling of the room element can be positioned and bonded on or welded to the eheath 41 or plas-ter base 2~. In the front part of Fi~ure 4, the plaster base is in the form of open-work cardboard 2~ through which a wire gauze is threaded, and is secured by tie wires 42 to the cardboard tubes 41 which surround the rods 15 which rigidify the said tubes~ In heavily stressed areas, an additional reinforcement in the form of expanded metal or in the form of additional vertical or horizontally disposed - 23 ~
..
;
, . . , ! : , . ' .
LS5~
metal rods tied or welded in place in situ may be provided and be left in position. ~he subsequently removabls verti-cal rods 15 represent an aid for alignin~ the various fit-ments, and the sheaths 41 may be colour coded for this purpose.
In a similar manner, electrical conductors, pipes, plumbing and other installations may be laid and fitted.
In the arrangement in which the side parts 46, 45 are independent of the other parts of the templates 10, 25, the rods 15 are provided with their sheaths 41, inserted into the bores or slots in the template parts and secured therein by means of clamps~ Then the necessary reinforcements and other fitments are placed in position, whereupon the completed side ~all frame can be inserted into the apparatus after the ceiling frame has been suspended. When this happens, the bores in the ends of the -top side part 45 receive the ~,uide pins 18 at the top ends of the corner pos-ts 4 and the align~
ing fittings ]1 of the hottom side part 46 enga~es the frame member 6. Whereupon, the other parts of the top template are inserted between the side ~arts thereof and secured to them by screws or by form-locking engagementO The inter-mediate walls in the interior of the room element are then set up in the manner previously described.
At those places where a transverse wall 50 of a room ;~
elementg as shown in Figures 13 and 15, extends to an outside ,:
- 2~ --~ , ,: , . .
s~
thereof, so that in a completed building it abuts a corre~-ponding transverse wall of an adjacent room element, there is at the relevant side of the apparatus a ~uide rail 51 formed from a structural profile, possibly a square section metal tube, the width of which is equal to the envisaged thickness of the transverse wall. ~he rail serves as a screed guide and as a boundary for the transverse wall to ensure its dimansional accuracy. Such guide rails 51 are fixed to the sides of the apparatus by mean~ o~ known devices7 possibly in bores in the frame members 6 and pin members which can be inserted into the top template 25.
Then, a plaster consisting of gypsum or other wet setting material is applied around the rods 15, conduits and other fitments and onto the plaster base 22. In the arrange-ment in Figure 5, this is done by a special spray gun 52, although application may be carried out in any desired manner.
- Prior to setting, the plaster can then be screeded and then rubbed smooth. '~he reference surfaces 25 t 51~ 53, 37 of the apparatus as well as certain fitments, such as door frames 4a, can serve as guides when the plastering is screeded~ so that the thickness and alignment of the walls can be accurately observedO Usually, the walls are plastered and screeded on both sides. If an already plastered ceiling 19 has not already been placed in the apparatus 1, -the ceiling can be plastered when plastering the walls; the ceiling can be .. .
, - ', . ~ ' ` ' ~ ' ~S~QS
pl~stered only on the underside or on both sides~ The plaster is then finished off flush with previously installed equipment such as electrical switches and socket housings, conduit connecting flan~es, anchorings and the afore~aid door and window frames.
Mow follow the secondary jobs which have to be carried out while the plaster is still wet, such as making good, fitting picture rails and batons and the like~ Prefera~ly, at this point in time, as far as possible, also all the other secondary aobs are carried out such as incorporation of electrical conductors in conduits, fitting of skirting boards, etc., without having to wait for the plaster to set.
After all the jobs which are possible in the wet state have been carried out, initially no further significant lateral loadin~ of the room element will occur, so that the top template 25 with the rods 15 suspended therefrom via the mounting ~lan~e 3~ can be lifted off (Figure 6). When this happens the rods 15 are withdrawn from the sheaths 41, which remain in the wall structure of the room element together with the plaster base 22~ ~he top template 2~ has support-- ing lugs 54 to which a crane can be applied to lift out these e~ements. Otherwise, the corner posts may have hydraulic or spindle operated lifting means which engage the template and lift it off. In this way~ those reinforcements which are no longer required for -the supportin~ strength of SS~
the walls of the room element can be removed to be used again later. ~he cavities remaining in the sheath 41 may if necessary be filled with plaster.
In another arrangement the vertical rods 15 may be fixed into the bottom template 10, in which case then the completed room element is lifted off them. If the room element is thereby securely fixed to a top template or-is otherwise re-inforced and if the plaster base is vertically continuous or is so fixed that it can withstand relatively high traction forces, then the room element can be lifted of~ even prior to complete setting of the plaster~
If the apparatus 1 is movable, the plaster can be set by running the room element into an o~en or autoclave to accelerate the process. Otherwise, the element remains in the apparatus until the plaster has set.
Once the room element has acquired sufficient strength by the plaster setting, it can be removed from the apparatus and conveyed to a work site at which those jobs which can be carried out in the set state or which could not otherwise be completed earlier can be performed. After sufficient drying out, which usually coincides with solidification by setting, the room element can then be painted or decorated and is then ready for use.
~he element can be used in a supporting frame con-2~ struc-tion such as is described in Swiss Patent Applicati~ns .
s~
VE I-116~-74 and VE 75 183. In this form, the room element is particularly suitable ~or setting up multi-storey build-ings.
For erecting single store~ buildings such as bungalows and the like, the room element can be made up with other room elements on a building site without using a supporting frame construction.
Figures 14 and 15 show a front view and plan view re-spectivel~ of a room element suitable for the afoxementioned purposes. It is open at a side 55 and this side allows it to be applied against another room element in order to form a complete dw011ing unit. The room element 2 illustrated contains a part 56 of a living room, a kitchen 57 with a cooker 58 and a sink 59 and also a sanitary closet with a flushing toilet 60, a shower cubicle 61 and a wash basin 62.
~he room element is rectan~ular and is of dimensions ~uch that it can without difficulty be transported by road.
The aforementioned suppor-ting frame construction 63 is shown by broken lines in Figures 14 and.15.
, ~.................................... .. , ... :
, . : ~
-, , ,: .,. ~ . : . : .: .
. . : . ,
Claims (35)
1, A method of producing a room element comprising the steps of forming walls of the element by plastering both sides of plaster bases which are strengthened by a reinforcement at least a part of which is superfluous to the structure of the completed walls, and removing,after plastering,the reinforce-ment. which is superfluous to the structure of the completed walls.
2. A method according to claim 1, wherein said rein-forcement includes removable rods and wherein the step of removing the reinforcement includes the removing of said rods.
3, A method according to claim 2, wherein the rods are with-drawn from the walls in their longitudinal direction after the plaster has been applied,
4, A method according to claim 2, wherein the rods are with-drawn from the plaster before the plaster has set,
5, A method according to claim 2, comprising varying the tem-perature of the rods in order to influence the setting time of the plaster,
6. A method according to claim 2, wherein the rods are provided - 29 - .
with a separating layer prior to application of the plaster,
with a separating layer prior to application of the plaster,
7, A method according to claim 2, wherein the rods are loosely connected to the plaster base prior to application of the plaster,
8, A method according to claim 6, wherein the separating layer is loosely connected to the plaster base prior to ' application of the plaster,
9, A method according to claim 2, comprising the step of applying templates to hold the rods rigidly and with dimensional accuracy, .
10, A method according to claim 2, wherein the rods are used in order to determine the spatial construction as well as the dimensional accuracy of the walls of the room element,
11, A method according to claim 2, comprising the step of fixing the rods to a template and withdrawing the rods from the wall by a relative movement between the template and the wall,
12, A method according to claim 2, comprising the step of feeding a pressurised fluid to facilitate withdrawal of the rods,
13. Apparatus for producing a room element having walls formed by plastering both sides of a plaster base, said apparatus comprising a bottom template, a top template aligned with the bottom template and disposed at a distance above the bottom template, said templates having guide bores in positions corresponding to the positions of the walls to be erected, and rods located in the bores and extending from the top template to the bottom template, said rods serving to re-inforce the plaster base,and said rods being removable after application of the plaster.
14. Apparatus according to claim 13, further comprising a housing frame, said templates being removably mounted in the housing frame.
15. Apparatus according to claim 14, wherein the housing frame comprises four posts located in positions corresponding to the corner zones of the room element.
16. Apparatus according to claim 15, wherein at least two of said posts are removable,
17. Apparatus according to claim 15, wherein at least two of said posts are adjustable,
18. Apparatus according to claim 14, wherein the housing frame comprises frame members provided under the bottom template,
19, Apparatus according to claim 14, wherein the housing frame comprises, on at least two oppositely disposed sides, at least, one intermediate post for the top template,
20. Apparatus according to claim 13, wherein each template is made up of metal profiles,
21, Apparatus according to claim 20, comprising guide bushes in the metal profiles, said guide bushes defining said guide bores,
22, Apparatus according to claim 13 9 wherein the guide bores are located on the central axis of the walls which are to be erected.
23, Apparatus according to claim 20, wherein the metal profiles have a width corresponding to the required thickness of the walls.
24, Apparatus according to claim 13, wherein the rods are of circular cross-section,
25. Apparatus according to claim 13, wherein the rods are hollow,
26, Apparatus according to claim 13, wherein the rods are fixed to at least one of the two templates,
27, Apparatus according to claim 13, further comprising a layer surrounding the rods to facilitate their removal,
28, Apparatus according to claim 27, wherein the said layer is a coating selected from the group consisting of a liquid, a powder or a paint,
29, Apparatus according to claim 27, wherein the layer is defined by a sheath which houses the rod,
30, Apparatus according to claim 13, further comprising screeding guides on the templates,
31, Apparatus according to claim 14, further comprising screeding guides on the housing frame,
32, Apparatus according to claim 13, wherein the width of each template corresponds to the overall width of the room element to be erected,
33, Apparatus according to claim 15, further comprising lug means on each of the posts for attachment of a ceiling frame of the room element.
,
,
34. Apparatus according to claim 13, wherein the guide bores in at least one of the templates are located in a substan-tially regular pattern,
35, A method of producing the walls of a room element com-prising the steps of providing a substrate for each wall, rein-forcing the substrate with a removable reinforcement, applying to each side of the substrate a hardenable composition in a fluid form, and removing the reinforcement after the composition has at least partly set.
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| DE19762651558 DE2651558A1 (en) | 1976-11-11 | 1976-11-11 | METHOD AND DEVICE FOR PRODUCING SPACE ELEMENTS |
| DEP2651558.2 | 1976-11-11 |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA1115505A true CA1115505A (en) | 1982-01-05 |
Family
ID=5992956
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA290,606A Expired CA1115505A (en) | 1976-11-11 | 1977-11-10 | Method and apparatus for producing pre-fabricated cells for use in building structures |
Country Status (12)
| Country | Link |
|---|---|
| AU (1) | AU514971B2 (en) |
| BE (1) | BE860647A (en) |
| BR (1) | BR7707549A (en) |
| CA (1) | CA1115505A (en) |
| CS (1) | CS209885B2 (en) |
| DE (1) | DE2651558A1 (en) |
| ES (2) | ES463933A1 (en) |
| FR (1) | FR2370563A1 (en) |
| GB (1) | GB1584749A (en) |
| GR (1) | GR62000B (en) |
| MX (1) | MX145133A (en) |
| ZA (1) | ZA776328B (en) |
Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US8276328B2 (en) | 2009-05-14 | 2012-10-02 | Technostructur Inc. | Wall module, housing module and building made of such wall module |
Families Citing this family (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| EP3572198B1 (en) * | 2018-05-24 | 2020-09-23 | RATEC Maschinenentwicklungs- und Verwaltungs-GmbH | Formwork core for a formwork system for the concreting of a bell body |
Family Cites Families (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US2027784A (en) * | 1934-04-26 | 1936-01-14 | Page John | Partition structure |
| FR2142615B1 (en) * | 1971-06-22 | 1973-08-10 | Sopreto | |
| FR2278868A1 (en) * | 1974-06-07 | 1976-02-13 | Armani Tulio | Insitu formed partition wall - uses temporarily propped cane screen coated withplaster |
-
1976
- 1976-11-11 DE DE19762651558 patent/DE2651558A1/en active Pending
-
1977
- 1977-02-10 MX MX171277A patent/MX145133A/en unknown
- 1977-09-30 GR GR54467A patent/GR62000B/en unknown
- 1977-10-24 ZA ZA00776328A patent/ZA776328B/en unknown
- 1977-10-27 GB GB44664/77A patent/GB1584749A/en not_active Expired
- 1977-10-28 AU AU30149/77A patent/AU514971B2/en not_active Expired
- 1977-11-07 ES ES463933A patent/ES463933A1/en not_active Expired
- 1977-11-09 FR FR7733707A patent/FR2370563A1/en active Granted
- 1977-11-09 BE BE182482A patent/BE860647A/en unknown
- 1977-11-10 CA CA290,606A patent/CA1115505A/en not_active Expired
- 1977-11-10 BR BR7707549A patent/BR7707549A/en unknown
- 1977-11-11 CS CS777404A patent/CS209885B2/en unknown
-
1978
- 1978-08-10 ES ES472487A patent/ES472487A1/en not_active Expired
Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US8276328B2 (en) | 2009-05-14 | 2012-10-02 | Technostructur Inc. | Wall module, housing module and building made of such wall module |
Also Published As
| Publication number | Publication date |
|---|---|
| ES463933A1 (en) | 1979-01-01 |
| GB1584749A (en) | 1981-02-18 |
| FR2370563B1 (en) | 1983-01-28 |
| ZA776328B (en) | 1978-07-26 |
| AU3014977A (en) | 1979-05-03 |
| BE860647A (en) | 1978-03-01 |
| DE2651558A1 (en) | 1978-05-24 |
| MX145133A (en) | 1982-01-06 |
| FR2370563A1 (en) | 1978-06-09 |
| ES472487A1 (en) | 1979-02-16 |
| GR62000B (en) | 1979-02-14 |
| CS209885B2 (en) | 1981-12-31 |
| BR7707549A (en) | 1978-06-20 |
| AU514971B2 (en) | 1981-03-12 |
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