EP0767281B1 - Method for making walls by means of modular building blocks with integrated plumbing and finishing - Google Patents

Description

The present invention relates to a modular block for elevation of walls with pre-equipment in networks, in particular supply of water, hot and cold, wastewater and rainwater drainage, electricity, hot water heating, cold water refrigeration, central aspiration, controlled mechanical ventilation, said modular block also comprising interior and / or exterior facings.

In the building sector, we are trying to reduce the costs of labor while making quality constructions with good thermal and sound insulation. We are also trying to reduce the delays of realization for a faster provision to the customer.

We know that the structural work requires a fairly short time but the other trades can hardly start anything during this period.

However, once the building is covered, the various trades, electrician, plumber, heating engineer, tiler, plasterer, carpenter meet simultaneously on the site and it is necessary to coordinate the different actions because there has a precise chronology of the work to be established.

It is the main source of delays on a site and in cases where everything happens in perfect synchronization, this succession of actions is nevertheless very time consuming.

We have already tried to save time by making panels prefabricated corresponding to a section of wall or a partition, these panels already including electrical pre-equipment with ducts embedded by example.

Such achievements remain insufficient to provide a gain of significant time.

Another important step is the decorations indoor / outdoor. Besides the fact that it takes time to realize them, we can note that they occur at the end of the work and that they are often dependent on climatic conditions.

Another phenomenon of taste, on the one hand, and simplicity of maintenance, on the other hand, leads buyers to ask for a stone exterior facade, even interior also stone.

A parameter dissuades the buyer, it is the price because the blocks of stone are expensive and are difficult to implement because the facade is no longer touched up, once the wall is raised, so there is no way to catch up any defect.

Anyway, the problem of equipment and finishing works is not solved.

On the other hand, we know that there is reconstituted stone which reproduces everything to the appearance and feel of cut stone at cost prices without comparison possible. In addition, this reconstituted stone, in the form of plates, has another very interesting advantage since it does not retain dust and other particles of pollution which tend to become encrusted in ashlar. Even in low thickness, it is perfectly waterproof and its fungicidal additives introduced during manufacture prohibit the proliferation of cryptograms and other foams.

Given the presence on the market of these new products, recent concepts have appeared and we have been able to make blocks of construction by raising walls and pillars or beams which combine a insulation in the form of foam, more particularly polyurethane, with reconstituted stone slabs, placed on the visible faces of construction elements, in particular facing.

Thus, the document FR-A-1.508.279 describes a concrete block having dimensions equivalent to those used in the building industry which comprises two lateral faces of cement, concrete, plaster or the like, arranged on either side of a central insulating material.

Document US-3,707,165 A describes a prefabricated wall which comprises a foam core and two plastic side walls with pipe networks with their joining means.

Document DE-43.34.377 A describes monolithic blocks in stone with some of the vertical ducts, others a horizontal duct and finally others communicating vertical and horizontal conduits in order to form a pre-integrated electrical network.

However, the different solutions proposed do not give fully satisfied.

Also, the present invention provides a new method of making a wall by assembling modular blocks comprising an insulator with at at least one face fitted with plates of reconstituted stone, which allow the elevation of walls with the resumption of compression forces, which integrate all the networks, which give a finished or almost finished state to the wall made up of these blocks.

• chaque bloc comprend au moins un logement horizontal intégré dans la matrice, lesdits blocs étant assemblés de manière à former un réseau horizontal,
• chaque bloc comprend des trous verticaux intégrés dans la matrice, lesdits blocs étant assemblés de manière à former un réseau vertical,
• des conduites d'alimentation ou de retour de fluide ou d'énergie sont disposées dans le réseau horizontal, et
• du béton est coulé dans le réseau vertical pour former des piliers de reprise des efforts.

To this end, the subject of the invention is a method for producing a wall obtained by assembling substantially parallelepipedal modular blocks, each comprising a matrix forming a core of foam of rigid insulating material, and a facing plate, at least at exterior, characterized in that:

• each block comprises at least one horizontal housing integrated in the matrix, said blocks being assembled so as to form a horizontal network,
• each block comprises vertical holes integrated in the matrix, said blocks being assembled so as to form a vertical network,
• supply or return lines for fluid or energy are arranged in the horizontal network, and
• concrete is poured into the vertical network to form pillars for the recovery of forces.

Advantageously, each modular block comprises one or more pipes fixed to the matrix of said block and in that each pipe includes at its ends arranged in line with the lateral abutment faces of said block, means of joining with the block or pipes of the blocks adjacent.

According to one embodiment, the modular blocks have large dimensions in length, of the order of 3m.

The invention also relates to a modular corner block for the junction angular straight blocks, which includes a large diameter hole intended forming a column by stacking said corner blocks one on the other others, each block having a removable, accessible plug on the interior facing side to allow easy access to the column, said block having extensions provided to cooperate with the blocks of the walls or partitions.

Therefore, the column can receive the safety elements of the pipes networks such as circuit breakers or shut-off valves for fluids.

• figure 1, une vue en perspective d'un angle de mur réalisé à partir de blocs modulaires selon l'invention,
• figure 2, une vue en coupe transversale d'un bloc modulaire,
• figure 3, une vue de dessus de détail d'un bloc modulaire d'angle,
• figure 4, une vue de dessus de détail d'un bloc modulaire droit, avec jonction modulaire d'angle,
• figure 5, une vue de détail d'une connexion en T,
• figure 6, une vue en élévation d'un mur assemblé à partir de blocs modulaires avec représentation des différents réseaux, et
• figure 7, une vue en coupe d'une huisserie posée, encastrée dans le mur réalisé à l'aide de blocs modulaires selon l'invention.

The invention is described below according to a preferred nonlimiting embodiment, with reference to the appended drawings, which illustrate said invention schematically, in which the following figures represent:

• FIG. 1, a perspective view of a wall angle produced from modular blocks according to the invention,
• FIG. 2, a cross-sectional view of a modular block,
• FIG. 3, a top view of a detail of a modular corner block,
• FIG. 4, a top view of detail of a straight modular block, with modular corner junction,
• FIG. 5, a detailed view of a T-shaped connection,
• FIG. 6, an elevation view of a wall assembled from modular blocks with representation of the different networks, and
• Figure 7, a sectional view of a frame installed, embedded in the wall made using modular blocks according to the invention.

In FIG. 1, modular blocks 10 are shown, out of two heights with modular corner blocks 12.

Each modular block comprises a matrix 14 of foam polyurethane, forming a core, on the visible faces of which are attached plates 16 of reconstituted stone in this embodiment.

The connection can be made using attached tie rods but in a way preferential, by adhesion of the stone plate on the foam block in polyurethane. Indeed, during the polymerization of polyurethane, there is a strong adhesion which develops as a cream when filling polyurethane in cream form then during foaming and polymerization.

Note on this same Figure 1 and on Figure 4, the presence of holes 18 and 20 whose longitudinal axis is oriented vertically.

The holes 18 are preferably provided to receive a frame metallic if necessary and concrete, to form pillars for the recovery of efforts.

The polyurethane matrix serves as formwork. Only the columns concerned, formed of a vertical succession of aligned holes, are used, the others can remain empty.

The holes 18 of larger diameter also form columns and these are used for the realization of pillars of recovery of efforts but also for the evacuation of wastewater and rainwater. Tubes can be added but it is preferable to use the columns directly, the connections between the succession of holes being sealed.

Advantageously, taking into account the arrangement of the various columns, the pillars can be staggered, which strengthens the stability of the wall in its thickness and allows the recovery of the forces generated by the breakdowns of the roof, a post being placed under each breakdown intermediate.

In this case, the polyurethane used is, for example a polyisocyanurate, especially sold commercially under the brand "Piruntec", dense enough and with closed porosity to be waterproof flows and odors, knowing that the evacuations work without pressure, by simple gravity flow.

It is nevertheless useful to provide a seal at the interface between two superimposed blocks, such as seals 22 in a first mode of production. Thus in the mode shown in FIG. 2, a groove and a bead provided to cooperate at the interface, this baffle being sufficient.

For example, you can use a commercially available joint under the name ORDOLENE PCE 29 Kg, of sufficient thickness and which runs the entire length of the block, the different holes of the vertical network being previously fitted out.

As an additional precaution, we can consider any joint complementary.

As a variant, it has also been imagined to provide for a deletion of this joint reported in favor of an integrated seal. This is obtained by a mold base paint which is intended for production with the block, place before pouring the polyurethane in the cream state and its polymerization. This mold base paint is integrated into the skin on the polyurethane matrix and ensures, under the compressive stress of the load during stacking of the blocks, an effective seal in line with the plane of joint of the stack by pressure of paint on paint.

On the facade, an additional seal is made between the facing elements in the form of a joint of known type such as the joint "NOVOLASTIK" or simply a traditional mineral-based joint.

Each straight modular block also comprises at least one housing 24 coming from manufacturing with the polyurethane matrix, in the form reserve in which a network pipe 23 is arranged.

These housings have their longitudinal axis oriented horizontally.

By network pipe is meant a supply line for hot or cold water, a sheath for electric cables or cables electrics themselves, polyurethane foam being an excellent electrical insulation, a hot water circulation pipe for the heating as will be described below.

The network pipes are preferably fixed in the blocks modular by bridges 26 of polyurethane foam, from manufacturing with the matrix.

These network pipes include junction means end 28 which may be leaktight fluid connections or fast electrical connections of known type.

Regarding heating or cooling for an effect of temperature regulation, it is possible to integrate a fluid circulation for a hot water heating or a cold water air conditioning. In this goal, reserves 30 are provided in the matrix 14, itself. The reserves 30 are closed on their open face by the interior facing itself, during the manufacture of the block or by added means such as plate. It is enough for that to mix with the reconstituted stone a product water repellent, in the preferred embodiment according to the invention. We can also add a sealing material 32, interposed between the block of polyurethane foam to further strengthen the seal. This material can be a plate whose adhesion with the matrix is obtained during manufacture, this plate being integrated in manufacturing in the mold before casting and polymerization of polyurethane.

We also note that thereafter, if necessary, we can circulate a composition in the circuit of heating / cooling, the role of which is to tighten the seal, to each of the reservations in contact with said composition.

The interior coating on the interior facing of each modular block is reported either later once the wall is raised, especially in the case where the heating / cooling option is not provided, either at the time of realization of the block in the case where the facing for example is stone reconstituted and in the case where the block also includes the Heating Air Conditioning.

The network pipe 23 is a water pipe at temperature adequate and at atmospheric pressure, hot or cold, fitted with a tee (T) 34 as shown in Figure 5, in isolation.

The tee opens into a reserve 30 and supplies all of the reserves of the row which are interconnected by the tubes 36.

In FIG. 6, a vertical interconnection 37 has been shown, between the different rows, up to the lowest row which is, thanks to a tee 34, connected to circulation pump 44.

This type of heating works without pressure, and for this purpose it is provided in the upper part a regulator to remove any overpressure generated by the pump and so that the water circulates at atmospheric pressure as planned.

We can thus realize complete walls with the different networks to different predetermined heights, the electrical network 38 at the bottom and high, the sanitary hot and cold water networks 40, 42 at the standard height of fixtures and hot or cold water from heating or air conditioning 44 at the top and bottom.

It is thus understood that it is possible to carry out water tapping sanitary by drilling with a bell tap for example, perpendicular to the desired network pipe.

When the fluid line is reached, a free volume around said pipe makes it possible to have tapping pins of known type and sold commercially, including clamps, lug and a seal.

Similarly for electrical cables, we can provide for the installation of sockets in any location, in addition to the locations initially selected, by nozzles identical to fluid nozzles. The connection connectors electric cables will advantageously be quick connection.

Regarding low pressure heating, the network is pre-established and the different reserves 30, in which the hot water circulates, constitute a mosaic of radiant surfaces, which, as everyone knows, is the heating providing the best performance and above all the best comfort for the user.

There remains a problem, that of the angles of connection between the walls.

Indeed, it is necessary to ensure a fluid and electrical continuity from a wall to the other or from a wall to a partition.

In FIGS. 1 and 3, a modular block of angle 12 has been shown. This block includes a hole intended to form a column by stacking blocks on top of each other.

The dimensions of this column are large enough to allow easy access and the installation of security elements in particular, such as a circuit breaker or shut-off valves for fluids.

In Figure 3, there is a removable plug 41 sort of allow access to the inside of the column immediately and without tools or blocking of any kind.

The reconstituted stone facing ensures a certain overlapping which masks the various plugs which are integrated on the wall. Indeed, the cap is a small block with foam polyurethane and an engineered stone corner plate.

In Figure 7, there is shown a frame 43 which is embedded in the blocks with fixing lugs 45 which pass through the matrix polyurethane to open into the columns intended to form pillars. Thus, the fixing lugs are embedded in the concrete which is poured in the corresponding columns. The door frame is fixed so perfectly rigid and is integrated into the wall.

In order to hide the frames of the door frame with the wall and avoid water penetration from outside projections, plates specific 46, in reconstituted stone, are reported on the periphery of the opening, apart from the support. These plates are immobilized using fixing lugs 48. The screws 50 ensure the fixing of the plates facing, inside and outside.

On the inside, a joint cover is sufficient to fulfill the masking function aesthetic between the interior facing and the frame.

With regard to sealing, provision must be made for polymerizable material, injected after installation of the frames, this known way.

In addition, for sealing between blocks, recesses form chicane, as shown in the different figures and are optionally supplemented with elastomer cords arranged during the elevation of the wall and by possible reserves with an injection of polyurethane spray can, in situ.

The facing plates are joined in a known manner by a water repellent coated material.

Such a wall is raised from foundations of known type, in the form shooting soles or any other suitable support.

In the upper part, a concrete chain ensures the rigidity of the structure and allows the installation of a floor of an upper floor or the installation of a roof.

Advantageously, the basic straight blocks will have a surface lower installation without hanging and straight blocks from the top of the wall may have a horizontal reservation, parallel to the network conduits to serve as formwork for the concrete in the chain and for the recovery of the pillar.

The modular blocks according to the invention thus allow an elevation rapid of complete walls, with interior / exterior decorations, with utility networks, with very high thermal and sound insulation quality, with the pre-established or according to convenience stitching possibilities, to posteriori.

In addition, these blocks can easily be produced industrially with little or no manual rework so the cost is reduced especially.

As for saving time and manpower, it is obvious from reading from the foregoing description.

This gain is all the more important as the length of the blocks is important, of the order of 3 meters to give an idea, the height corresponding, of course, to the standard height of traditional blocks.

Regarding the finishing of the shell, the breakdowns are arranged in a known manner over the entire surface of the roof, a post having been poured in place and place necessary for the support of the breakdowns, in order to resume charging.

The pinions are mounted using blocks of the same type as described above. and specific finishing blocks, corresponding to the roof slope and therefore the offset of the blocks between them. These specific blocks provide continuity of the slope of said pinion.

According to an improvement of the invention, it is proposed to have a plinth in the lower part of the high wall using the blocks according to the invention, which makes it possible to identify the various conduits of the networks, the storage locations for heating or air conditioning and more usually the ends of the blocks. Indeed after decoration on the interior facing, it can be difficult to find the different reference positions of integrated equipment items.

It is also possible, according to other characteristics of the invention, to provide a access to the right of the juxtaposition plan of two blocks if one wishes to change a joint of a connecting means 28 of the sanitary water network. For this purpose, the invention proposes to place a vertical masking plate, projecting, removable, maintained by any suitable means such as clips.

According to another improvement of the invention and for reasons of cost basically we can predict that some of the network pipes are installed after the assembly of a row of blocks.

This is the case for hot water and cold water pipes by example which are reported in a longitudinal reserve on top of the block. So when the row of blocks at the correct height is fully laid, the pipes are butted to form a great length corresponding to that of the row of blocks, therefore to the wall section. These pipes are possibly sleeved in line with the fittings and sealing is achieved by means of bonding.

This very long pipeline is reported in the reserve on the top of the blocks in the row. Legs with necklaces are regularly distributed and provided to support this pipe, said legs having a shape such that the end of each comes in line with the holes provided for pouring the concrete pillars once the top blocks are mounted and the totally high wall. These legs will thus be embedded in the concrete, permanently immobilizing the collars and therefore the associated pipe.

This eliminates the need for many higher cost fittings and above all it allows to make blocks of length smaller than 3 meters given as an example but which remain very long by compared to traditional blocks or bricks.

The price is also reduced because the fittings are then only necessary for heating pipes, which reduces the initial number. Indeed, the bonding connections with possible sleeving of water pipes hot and cold water are much cheaper.

This variant embodiment is also of interest in some cases and it is part of the invention.

Claims (6)

1. Method of making a wall obtained by assembly of substantially parallelepipedal modular blocks, each comprising a matrix (14) forming a core made of rigid insulating foam, and a facing panel (16), at least on the outside, characterised in that:

   each block comprises at least one horizontal housing (24) integrated in the matrix, said blocks being assembled so as to form a horizontal network;

   each block comprises vertical holes (18, 20) integrated in the matrix, said blocks being assembled so as to form a vertical network;

   fluid or energy supply or return ducts are disposed in the horizontal network, and

   concrete is poured into the vertical network to form load bearing pillars.
2. Method of making a wall according to Claim 1, characterised in that one or more ducts are fixed to the matrix of each modular block, and in that there are provided at the end of each duct, disposed at right angles to the lateral abutting faces of said block, means of joining with the duct or ducts of the adjacent blocks.
3. Method of making a wall according to Claim 1 or 2, characterised in that modular blocks of large size lengthwise, of the order of 3 m, are made.
4. Method of making a wall according to any one of the preceding claims, characterised in that there is made, in each modular corner block, a hole of large diameter intended to form a column, a removable sealing plug accessible from the internal facing side for allowing access to the column, and extensions for cooperating with the adjacent blocks, and these modular corner blocks are stacked one upon another.
5. Method of making a wall according to Claim 4, characterised in that safety elements for the network ducts such as circuit breakers or stop valves for fluids are disposed in the column of the modular corner blocks.
6. Method of making a wall according to any one of the preceding claims, characterised in that heating or air conditioning system ducts are installed in the horizontal housings (24), reserves being made in the matrix, opening out towards the internal facing, the opening-out face being sealed by the facing material itself made impervious or by added-on elements.

Images