DE102022004371A1 - Wall element and method for setting such wall elements - Google Patents

Abstract

In a multi-layer, prefabricated wall element (1) for the construction of a building, with at least one edged, vertically extending recess to be filled, a supporting layer (2) stabilizing the wall element is firmly connected to a thermal insulation layer (3) and the recess penetrating the wall element (1) over its entire height is arranged at least in sections in the thermal insulation layer (3).

Description

The invention relates to a multi-layer, prefabricated wall element for the construction of a building, with at least one edged, vertically extending recess to be filled.

The need for highly efficient, ecologically and climatically advantageous and at the same time highly thermally insulating building systems is increasing. This is reflected in the continuously increasing proportion of prefabricated houses in Germany, for example. Today, prefabricated houses are generally built using wooden construction methods. If prefabricated houses are built using solid construction methods, the factory typically needs to apply an additional thermal insulation composite system made of polystyrene or another highly insulating material.

Monolithic solid construction systems made of storey-high wall modules that encompass the entire wall structure and can be moved with high efficiency are not available. The main reason for this is that the load-bearing function of a solid wall system is traditionally the main focus. Due to the low thermal insulation capacity of load-bearing solid building materials, an additional thermal insulation composite system made of other insulating materials must be added. The result is ecologically disadvantageous combinations of mineral and mostly petrochemical substances.

Multi-layer wall elements are well-known and proven. For example, walls are used in prefabricated house construction in which, for example, a thermal insulation layer made of foam plastic is surrounded by fiberboard. However, such walls often lack sufficient mechanical stability. In order to increase mechanical stability, wall elements have become known that are provided with vertical pipes or recesses, which, if provided with reinforcement, are filled with concrete, for example, and which then form a load-bearing skeleton of a wall, for example in the WO 2012/158031 A1 explained.

The invention aims to transfer such a reinforced concrete skeleton construction to multi-layer, prefabricated wall elements.

This is achieved in the case of a wall element in question by the features of claim 1. Such wall elements can be designed in a known manner to be floor-high and can be provided with doors or windows. A connection to ceilings and floors is made, for example, by means of a casting or a mortar bed.

The invention presented here separates the production of the room-enclosing wall function spatially and temporally from the static wall function. To do this, the current manufacturing process for solid, large-format wall elements is inverted: First, a large-format wall module is manufactured in the factory from a mineral or biogenic building material that is not structurally stable but provides good thermal insulation. Recesses are provided in the wall elements manufactured in this way, which are later poured with in-situ concrete on the construction site and then, together with floors and ceilings, form the load-bearing structure of the building in the form of a reinforced concrete skeleton.

The vertical transfer of loads, for example from floor slabs, occurs through the filled recesses, in which reinforcement can also be provided, and hardly through the load-bearing layer.

The subsequent filling of the recesses in the thermal insulation layer with in-situ concrete is therefore of particular importance. When filling the recesses, forces such as increased pressure and vibrations act on the non-load-bearing material of the insulation layer. In order to absorb this pressure, the recesses, particularly in the area of the future posts of the supporting structure, are provided with specially designed formwork on the inside.

If formwork is provided, this can be attached to the base layer at the factory and, if necessary, fixed to it.

The base layer only absorbs forces to the extent that it supports the thermal insulation layer to which it is firmly connected, for example for transport from the production site to the construction site. This can be achieved by a base layer made of lightweight concrete and/or biogenic concrete such as wood concrete and/or carbon concrete or a mixture of these. The thermal insulation layer is particularly intended to be lightweight or infra-lightweight concrete, which can be provided with additives such as expanded glass, silicates or polystyrene, and/or biogenic concrete, for example hemp concrete, hemp lime or expanded clay concrete.

This construction makes it possible to use mineral building materials that are already available today, which are good insulators and at the same time ecologically beneficial and more resource-efficient, in an efficient construction process. These building materials are generally moderately heavy and have only a low load-bearing capacity, which has so far hindered their widespread use as a wall system.

The ecological balance of the wall element according to the invention is also further improved by these measures.

To ensure a secure connection between these different materials for the base layer and the thermal insulation layer, it can also be provided that the base layer and the thermal insulation layer are connected to one another in a form-fitting and force-fitting manner using anchoring elements. Such anchoring elements are preferably first introduced into one of the layers during production and then integrated into the second layer when it is applied.

It can also be provided that the supporting layer has openings and/or recesses into which the insulation layer engages. For example, the supporting layer can form a framework or have a honeycomb structure.

The measure that can further contribute to strength is that, in a side view, the support layer forms an L-shaped foot on which the thermal insulation layer sits in situ. If the support layer is provided with thermal insulation layers on both sides, the foot will be T-shaped. In addition, such a foot prevents damage to the thermal insulation layer when setting a wall element according to the invention and facilitates its alignment.

Such a foot is also penetrated by the recess, so that, for example, continuous reinforcement between a floor and a floor slab is possible.

The front sides of the base layer and the insulation layer can be in the same plane. Wall elements are then placed flush against each other. Alternatively, if a joint is planned between the wall elements, this can be closed with a seal or with mortar. It can also be considered that such a joint is only planned between the base layers or only between the insulation layers.

In the structural design, it can be provided that the base layer and the thermal insulation layer have a horizontal offset. When wall elements are placed, this results in overlaps between the base layer and the thermal insulation layer of wall elements arranged next to one another. As a result of these measures, a straight construction connection joint is avoided in a building wall constructed with wall elements according to the invention. In addition, joints filled with mortar or seals can also be provided between the insulation layers and/or between the base layers.

In the design of the wall element according to the invention, the thermal insulation layer has a corner recess on the top side towards the supporting layer. This measure creates a channel on the top side of the adjoining wall elements. A frame or a ring beam can be inserted into this channel. The advantage here is that reinforcement can be guided within the recesses or formwork up to this frame. Great mechanical stability is achieved through this connection.

It can be provided that the thermal insulation layer protrudes above the supporting layer, particularly vertically, and that the channel between the insulation layer and the supporting layer is formed through the corner recess. This means that a ceiling connection can be made at the same time as filling the channel with in-situ concrete.

Alternatively, if the insulation layer and the supporting layer are the same height, a ceiling can easily be placed on the wall element.

It is also advantageous if at least one vertically extending transport anchor is provided in the base layer. It can be thought of that a hook or eyelet protrudes from the top of the base layer for connecting a lifting device. An elegant option is for the transport anchor to end with a screw eyelet on the top of the base layer, into which a hook or eyelet can be screwed in or out and thus be reused.

Instead of or in addition to the above, a banding can also be provided around the wall element, on which the element is suspended for transport and relocation.

In a further embodiment of the wall element, a protective layer can be applied to the thermal insulation layer and/or the base layer, particularly in the case of a wall element forming an external wall to protect against the effects of the weather. Such a protective layer can also be provided for this and the base layer or the thermal insulation layer to have a horizontal offset. This offset can correspond to the offset between the thermal insulation layer and the base layer, but can also deviate from it. In the case of such a deviation, the construction connection joint between the wall elements is angled four times.

In a further embodiment of the wall element, it can be provided that on the thermal insulation layer and/or on the supporting layer a Plaster or protective layer is applied. Both the supporting layer and the thermal insulation layer can be located on the outside. Changing arrangements within a building are also possible.

The construction of a building wall with wall elements according to the invention requires a high degree of precision when setting the individual wall elements. This can be achieved in an advantageous manner by using a lifting device to set a wall element in a mortar bed and by ultimately aligning the wall element with wedges or blocks over a supporting foundation. Such a lifting device will in particular act on the transport anchor and/or the banding.

By erecting a building wall and inserting a frame into the corner recesses of the thermal insulation layer, the recesses or formwork of the wall elements can also be filled with the same casting.

The same applies to the creation of a connection between a building wall with wall elements according to the invention and a ceiling. The recesses or formwork of the wall elements can be filled when the ceiling is cast and/or the frame can be inserted. In this case, it can again be considered to continue reinforcement within the recesses or formwork in the frame or ceiling.

To ensure the accuracy of the placement of the wall elements and in particular to ensure sufficient stability when casting the frame or creating a ceiling connection, it has proven to be useful if the wall elements are clamped together, particularly permanently. This can be done by mechanical locking or by clamping elements such as inserted clamps or spindle screws. Recesses in the layers may then be provided for their operation.

Alternatively, or possibly additionally, wall elements arranged next to one another can have corresponding, vertically extending recesses that form a common filling channel that preferably extends over the entire height of the wall element. Filled with, for example, in-situ concrete. This not only connects two wall elements to one another, but also increases the load-bearing capacity of the connection against forces perpendicular to the wall elements.

• 1: einen Schnitt durch die Schichten eines Wandelements,
• 2: einen Schnitt durch eine Schalung,
• 3: in einer Draufsicht zwei stumpf aneinander stoßende Wandelemente,
• 4: in einer Draufsicht zwei Wandelemente mit einer dazwischen angeordneten Fuge,
• 5: in einer Draufsicht zwei aneinander gesetzte und verspannte Wandelemente und
• 6: in einer Draufsicht zwei durch einen ausgegossenen Kanal verbundene Wandelemente.

The invention is explained in more detail with reference to the drawing, in which only embodiments are shown schematically. In the drawing:

• 1 : a section through the layers of a wall element,
• 2 : a section through a formwork,
• 3 : in a top view two butt-fitting wall elements,
• 4 : in a top view two wall elements with a joint in between,
• 5 : in a top view two wall elements placed together and braced and
• 6 : a top view of two wall elements connected by a cast channel.

In the 1 and 2 Vertical sections through a wall element 1 are shown. In particular 1 reveals the structure of three layers, a supporting layer 2 on the inside of the building, a middle thermal insulation layer 3 and an external protective layer 4 that protects the thermal insulation layer 3 from the effects of the weather.

Not shown in the drawing are anchoring elements that enable a positive and non-positive connection between the supporting layer 2 and the thermal insulation layer 3.

The in situ representations of the wall element 1 show an L-shaped formation of the supporting layer 2. The thermal insulation layer 3 sits on the foot 5 formed thereby.

On the upper side, the thermal insulation layer 3 projects beyond the supporting layer 2 and has a corner recess 6 towards the supporting layer 2. A frame 8 is introduced on an insulating or pressure distribution layer 7, on which a ceiling 9 rests.

A transport anchor 10 is inserted into the supporting layer 2 in a pull-out-proof manner. On the top, the transport anchor 10 has a socket 11 with an internal thread into which a hook or an eyelet can be screwed. This allows the wall element 1 to be easily lifted with a lifting device and placed on a floor 12. This placement takes place in a mortar bed 13, which may have a moisture barrier. The wall element 1 is precisely aligned using wedges or blocks.

To stiffen the wall element 1 and in particular to absorb vertical loads, a tubular formwork 20 is embedded in the thermal insulation layer 3, which can, for example, have reinforcement and a concrete filling. The tubular formwork 20 is located on the load-bearing layer 2 and, in the exemplary embodiment, has a diameter that corresponds to the depth of the corner recess 6. This enables such tubular formwork 20 of wall elements forming a building wall to be filled in the course of forming the frame 8. In such a case, the tubular formwork 20 ends in the lower level of the corner recess 6. In order to fill such a tubular formwork 20 with the introduction of the frame 8, the insulating or pressure distribution layer 7 provided here must be provided with corresponding openings.

2 shows a section through such a tubular formwork 20. The tubular formwork 20 is filled with concrete during the pouring of a ceiling 21. The tubular formwork 20 can therefore end at the top with the supporting layer 2. Due to the direct support of the ceiling 21 on the filled tubular formwork 20 which bears the load, a frame can then be dispensed with. It can be advantageous to foresee a common reinforcement of the tubular formwork, ceiling and, if necessary, the frame.

Alternatively, however, a frame can also be cast with the ceiling 21 and the connection to the tubular formwork 20.

Not shown in the drawing is a possible reinforcement within such a tubular formwork 20, which merges into the frame 8 or a ceiling 21, thus creating an extraordinarily load-bearing connection.

If the thermal insulation layer and the supporting layer are designed to be congruent, wall elements can be placed directly adjacent to one another. The continuous construction connection joint can, if necessary, have a layer of mortar or an insulating layer.

An alternative shows 3 There, two wall elements 25, 26 are shown in a top view. The wall elements 25, 26 are of the same type. They each consist of a supporting layer 27, a thermal insulation layer 28 and a protective layer 29. A tubular formwork 30 is embedded in each thermal insulation layer 28 adjacent to the supporting layer 27. Furthermore, each supporting layer 27 has two supporting anchors 31, 32.

The base layer 27, the thermal insulation layer 28 and the protective layer 29 have the same wall widths. The thermal insulation layer 28 is connected to the base layer 27 with a horizontal offset v. This means that the connection joint 33 between the wall elements 25, 26 does not run in a straight line.

The protective layer 29 is also connected to the thermal insulation layer 28 with a horizontal offset. This offset can, but does not have to, correspond to the offset v between the supporting layer 27 and the thermal insulation layer 28.

Empty pipes for installations of all kinds can be provided in the thermal insulation layer 28 and/or the supporting layer 27, which are accessible through appropriately designed openings in the supporting layer 27 or in the protective layer 29. Wall modules 25, 26 according to the invention can also be provided with openings for windows, doors or the like.

Also 4 Overlapping wall elements 35,36 are shown, so that a continuous construction connection joint is avoided. However, the insulation layers 37,38 and the supporting layers 39,40 do not meet one another directly, but rather the joints 41,42 are filled, for example with a mortar, an insulating layer or an adhesive layer.

In 5 the thermal insulation layers 45,46 of the wall elements 47,48 butt against each other. A U-shaped profiled connecting element is inserted into opposite recesses in the supporting layers 49,50, which clamps the wall elements 47,48 together by means of screws 51,52 or the like inserted into the supporting layers 49,50.

In this embodiment too, in the case of a spaced-apart wall element 47, 48, the construction connection joint can be provided with a mortar, an insulating or adhesive layer.

In the 6 The connection shown between two wall elements 55,56 is made by casting corresponding, vertically extending recesses 57,58 in the thermal insulation layers 59,60, which form a common filling channel 61. This filling channel 61 extends in particular over the entire height of the wall elements 55,56 and connects to the supporting layers 62,63.

List of reference symbols:

1

Wall element

2

Base layer

3

Thermal insulation layer

4

Protective layer

5

Foot

6

Corner recess

7

Pressure distribution layer

8th

Rähm

9

Ceiling

10

Transport anchor

11

sleeve

12

Floor

13

Mortar bed

20

formwork

21

Ceiling

25

Wall element

26

Wall element

27

Base layer

28

Thermal insulation layer

29

Protective layer

30

formwork

31

Support anchor

32

Support anchor

33

Connection joint

35

Wall element

36

Wall element

37

Thermal insulation layer

38

Thermal insulation layer

39

Base layer

40

Base layer

41

Gap

42

Gap

45

Thermal insulation layer

46

Thermal insulation layer

47

Wall element

48

Wall element

49

Base layer

50

Base layer

51

Connecting element

52

screw

53

Screw

55

Wall element

56

Wall element

57

Recess

58

Recess

59

Thermal insulation layer

60

Thermal insulation layer

61

Filling channel

62

Base layer

63

Base layer

QUOTES INCLUDED IN THE DESCRIPTION

This list of documents listed by the applicant was generated automatically and is included solely for the better information of the reader. The list is not part of the German patent or utility model application. The DPMA accepts no liability for any errors or omissions.

Cited patent literature

• WO 2012/158031 A1 [0004]

Claims (16)

Multi-layer, prefabricated wall element (1) for the construction of a building, with at least one edged, vertically extending recess to be filled, characterized in that a supporting layer (2) stabilizing the wall element is firmly connected to a thermal insulation layer (3) and that the recess penetrating the wall element (1) over its entire height is arranged at least in sections in the thermal insulation layer (3). Wall element according to Claim 1 , characterized in that the recess has a separately formed formwork (20). Wall element according to one or more of the preceding claims, characterized in that the recess or the formwork (20) adjoins the supporting layer (2). Wall element according to one or more of the preceding claims, characterized in that the supporting layer (2) is formed from a lightweight concrete and/or a biogenic concrete and/or a carbon concrete and/or that the thermal insulation layer (3) is formed from a lightweight, infra-lightweight concrete and/or a biogenic concrete. Wall element according to one or more of the preceding claims, characterized in that the supporting layer (2) and the thermal insulation layer (3) are connected to one another in a form-fitting and force-fitting manner by anchoring elements. Wall element according to one or more of the preceding claims, characterized in that the supporting layer has openings and/or recesses into which the insulating layer engages. Wall element according to one or more of the preceding claims, characterized in that in a side view the supporting layer (3) forms an L-shaped or T-shaped foot (5) on which the thermal insulation layer (2) or the thermal insulation layers sit. Wall element according to one or more of the preceding claims, characterized in that the supporting layer (27) and the thermal insulation layer (28) have a horizontal offset (v). Wall element according to one or more of the preceding claims, characterized in that the thermal insulation layer (3) has a corner recess (6) on the upper side towards the supporting layer (2). Wall element according to one or more of the preceding claims, characterized in that at least one vertically extending transport anchor (10) is provided in the supporting layer (2). Method for constructing a building wall with wall elements according to one or more of the preceding claims, characterized in that a wall element (1) is placed into a mortar bed (13) by a lifting device and that the wall element is aligned with wedges or blocks. Method for constructing a building wall with wall elements according to one or more of the preceding claims, characterized in that a frame (8) connecting the wall elements is introduced into the corner recess (6) of the thermal insulation layer (3). Procedure according to Claim 12 , characterized in that the recesses or formwork (20) of the wall elements (1) are filled with the casting of the frame (8). Method for creating a connection between a building wall with wall elements according to one or more of the preceding claims and a ceiling, characterized in that the recesses or the formwork (20) of the wall elements (1) are filled with the casting of the ceiling (9,21) and/or the casting of the frame (8) takes place. Method for constructing a building wall with wall elements according to one or more of the preceding claims, characterized in that wall elements (47, 48) arranged next to one another are clamped together. Method for constructing a building wall with wall elements according to one or more of the preceding claims, characterized in that wall elements (55, 56) arranged next to one another have corresponding, vertically extending recesses (57, 58) which form a common filling channel (61).

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