WO2004055298A2

WO2004055298A2 - Procedure for the construction of building works by using prefabricated wall-elements and prefabricated basic and other wall-elements

Info

Publication number: WO2004055298A2
Application number: PCT/HU2003/000088
Authority: WO
Inventors: Jenö LEVAI; János TISZAVÖLGYI
Original assignee: Individual
Current assignee: Individual
Priority date: 2002-12-13
Filing date: 2003-10-29
Publication date: 2004-07-01
Anticipated expiration: 2005-06-13
Also published as: WO2004055298A3; HUP0204326A2; AU2003280031A1; HU0204326D0; AU2003280031A8

Abstract

The characteristic of the invention, is that the planning of the building, the manufacturing and execution of required wall elements (11, 12. …1n) is carried out in a closed order procedure using standardized type wall elements (11, 12, …1n) of required type and dimensions providing the total wall structure, then knowing these the material requirements of the wall structure are collected by planning software, then the selected type number and number of wall elements (11, 12, …1n) are manufactured with appropriate computer controlled equipment in accordance with the construction order and with the application of the selected material, then these are dressed with engineering accuracy and indicated with evident marks. Concrete foundation is developed, the upper surface of which is a prescribed accuracy flat plane, over which - in accordance with the prepared plan diagrams - the starting row of the building is laid, then lintlets are installed so that the adjacent and connected surfaces are sealed, thus the building is prepared in structure finished state.

Description

PROCEDURE FOR THE CONSTRUCTION OF BUILDING WORKS BY USING PREFABRICATED WALL ELEMENTS AND PREFABRICATED BASIC AND OTHER WALL

ELEMENTS

The subject of the invention is α procedure for construction of building works by using prefabricated wall elements and ready-made basic and other wall elements.

The procedure based on the invention and the prefabricated and designed wall elements can be used to their best advantage by the fast and economical consturction of the entire wall structure of dwelling houses using prefabricated, relatively small and precisely finished wall elements.

It is a well-known fact that according to the present-day practice of construction, the building process of a brick house is a meticulous and inconsistent work. Attempts at altering the above-mentioned procedure manifested themselves and became widely used in panel construction in the course of which the structure of the wall was prefabricated. The disadvantage of this construction method is that because of the size of the panels the construction involves a significant mechanical power and it fails to meet the present-day thermo-technological requirements (under 0.5W/m2K heat transmission coefficient) moreover it imposes major restrictions on the designer.

As a result of this insufficiency only procedures allowing considerable designer freedom and considering the intention of the customer managed to remain on the market.

The process of construction is well-known; the customer commissions a designer or a designing office who at the same time can be the general building contractor thus undertaking both designer and building contractor responsibilities. The customer produces an idea and after several consultation with the designer a final and workable version develops which is carried out with a view to the available financial resources, the requirements concerning the certain environment, static, thermo-technological and aesthetical requirements as well as other practical considerations. Nowadays, the work of the designer is helped by softwares.

The most commonly used design softwares on the Hungarian market are 'Archi CAD' and 'ArchUNE'. The latter has the following to tell about masonry. 'The designer is able to create walls of standard type according to which the designer can define the different layers, measurement, material, outline etc. The designer can easily use these data during his later work. The designer is able to determine the properties of the wall in advance and the drawn walls can be modified later.'

In addition to the documents of illustrations the documentation produced during the design of the building construction comprises the materials to be used, the variety and an almost unerring accuracy of indirect materials and it gives an informative account of the costs and schedule of execution.

The disadvantage of the documentation drawn up according to this method is the lack of electric and engineering design.

For the design of the load-bearing wall the following wall elements which allow relatively great designer freedom are at the designer's disposal:

Kiln framework ceramic with vertical cavities:

• UNIFORM

• POROTON

• THERMOPOR

• THERMOTRON

• POROTHERM Concrete building block:

• GAS AERATED CONCRETE BLOCK

• TUFFACEOUS CONCRETE BLOCK Porous concrete

• YTONG

Ground brick or bloated clay aggregate with cement bond and vertical cavities:

• LEIER Gravel concrete with heat-insulating sandwich construction:

• ISOPLUS Wall casting procedure according to which the wall element serves as a permanent formwork: β DURISOL bio-concrete (wood chips, reed, straw with cement bond) Wall casting procedure according to which the permanent formwork is heat-insulating polystyrene

Among the wall elements described above the three most widely used are the following:

- POROTHERM Kiln framework ceramic with vertical cavities (produced by WIENERBERGER)

- YTONG porous concrete

- LEIER ground brick or bloated clay aggregate with cement bond

Even multi-storey building works can be constructed using these wall elements. In the case of higher buildings the above-mentioned wall elements are used to build the exterior wall structure and the partition walls mostly after building the reinforced-concrete framework and floor structure. Though not that commonly used there are so-called lightweight construction methods in the course of which timberwork is covered with insulated asbestos wall-boards along with other methods according to which the entirely wooden framework is covered with natural wood or wooden griding panels. The disadvantage of these well-known method is that the movements deriving from drying after the building process makes these methods impossible to employ in the case of higher than two- or three-storey buildings.

Stirofoam panels assembled into so called permanent formworks have recently come into fashion of which cavities are filled with concrete making them serve as the frame structure of the building. An other drawback of these procedures is that the finished walls should be picked to make room for fittings and/or conductors of the electrical or the sanitary installations of the construction. Though also on the market prefabricated houses which can be assembled and dissambled are built on metal framework combining plastic and heat-insulating materials but they are expensive and therefore not widely used. Thus, according to the present-day construction process in Hungary the finished plan is based on either of the three most commonly used wall elements and the fact that the manufacturers of construction materials do not participate in the design of the buildings causes problems because in this way they have no or only limited influence on what type of wall elements are used, in other words the result of the design fails to have a direct influence on the specialization of production. The manufqcturers try to produce and design wall elements by surveying the „demands of the market" using mainly the orders of the commercial networks as a basis.

With the full knowledge of these facts production plans can be optimized by computer technology using the already existing manufacturing facilities.

Production based on this method has the disadvantage of detaching itself from the design resulting in a significant surplus of stock at the manufacturer and the trader which increases the price of the end-product to a considerable degree.

The process of consturction is executed according to the finished design which is previously examined by the building contractor who in accordance with the appropriate schedule prepares the building site, arranges the purchase of the required material and indirect material, the transport of these materials to the building site and their use.

Determining the order of the work phases is an important task of the building contractor in the course of which the opportunities offered by the software are taken advantage of to a certain extent based on the appropriate personal and external (eg. weather) conditions. Due to spontaneous planning, supplier unpunctualify and the problems arising from the technology the optimal utilization of computer technology is not possible. The disadvantage of the procedure of construction according to the above-mentioned method is that the material required for the construction should be purchased from the manufacturer or the commerce which is always made by a certain degree of constrained risk-taking which might lead to surplus of stock and in addition to these problems masonry requires a significant amount of indirect material moreover there is a great demand for labour force at the building site. Quality and efficiency is detemined by the expertise or lack of qualification of the employed labour force and the contract manager. Further problems arise from stockpiling, the appropriate storage and protection of the required material depending on the building site which results in the significant increase in the construction costs.

According to the description of patent there are further construction procedures and wall elements.

The technological level is represented by, for example, the method described in patent „Heat-insulating Wall Structure and Wall Element" HU 203 140 according to which the heat-insulating bonded walls are expediently laid in one layer row by row and shifted by half an element in each row containing a wall element with heat-insulating mat, mortar, corner wall element at the concurrent edges and in certain cases cover coat. Its main characteristics are the connecting holes suitable for inserting load-bearing structures eg. columns and fittings and/or conductors of the electrical or the sanitary installations of the construction in these holes of which axes runs parallel to the plane of the walls. The heat-insulating mat is on the exterior side of the walls while the cover coat on the exterior side is laid on directly under the exterior side of the heat- insulating mat. Wall elements of this kind have ribs and a framework around the cavities, the framework and rib is a binding material containing the afterhardening mixture of water and aggregates. An other characteristic of this wall element is an external open delve at least on one side making it possible to put heat-insulating mat in it. The external delve is flanked by an edge-rib suitable for fixing the heat-insulating mat or in certain cases by a comer-rib. The above-mentioned well-known method refers to putting up walls with proper heat-insulating qualities and it-is not suitable for the construction of an entire wall structure consisting of small precisely finished wall elements. The method described in 'Building Block or Panel' registered as PCT No. WO 0120092 also represents the technological level according to which the building element or panel comprises four parallelepiped frontal edges and two opposing main fronts. The frontal edges are formed joining the frontal edges of similar building elements. Each frontal edge comprises lateral stripes which are connected to either end of the central vertical axis of the frontal edge. One of each stripe of the frontal edges contains a notch and the other stripe of every frontal edge is made in a shape to complement the former one. The notches on the opposing frontal edges are always formed to suit the certain shapes.

This solution has the disadvantage that it is not produced for the construction of prefabricated wall structure and in spite of the fact that the frontal edges are fit together the result is not an exact fit so there are air-gaps between the surfaces.

The method described in patent 'Baustein', AT 390 090 also represents the technological level according to which the wall elements next to the bonded walls are expediently arranged at least on one of their lateral surfaces in a shape blocking binding. They are made to interlock so that by creating simultaneous vent spaces they form a blocking position in each case. In order to achieve this result the jutting edge-stripe of the lateral surface contains grooves or bolts which are jointly seperated by the central recessed field of the lateral surface. The disadvantage of this well-known method is that the joining surfaces are not accurate enough, they have no facing and the wall structure is not prefabricated. The method has a further disadvantage. The material of the wall element is terracotta which after a certain period of time starts shrinking which makes the seating surfaces less accurate.

An other solution described in patent 'Ziegel', EP 1045080 also represents the technological level according to which the brick especially a large-cavity brick containing a binding face made from binding materials attatched at least on both, of its seating surfaces. When inlaying this binding surface with the brick it forms - along with the binding material especially a thin embedding binder - a binding layer for the bricks.

The disadvantage of this well-known method is that the seating surface is made of inorganic fibres forming a wall structure that comprises the mixture of different materials making them merely load-bearing walls and not prefabricated ones.

The aim of the invention is to overcome the disadvantages of the well- known methods and establish a construction procedure which seizes the opportunities offered by computer technology. Never been used before in construction industry the small prefabricated and designed base and other wall elements can be fitted together with great accuracy and are made of a chosen base material resulting in a better quality, faster process from the design to the construction works at the building site, decreasing proportion of labour force, considerably lower cost of base material units and transportation.

According to the invention the method is based on the realization that if the design of the building works, the production and planning of the required wall elements happens in a closed order procedure by using a computer design software and promoting harmony between the architectural, static and engineering parts of the design and the roughly simultaneous completion of the work phases employing standard basic and other wall elements of the required type and dimensions which demonstrate the entire outline of the walls. Theoretically, the basic wall element is the prefabricated specific sized unit of the entire, designed wall having at least one positioning guide face which is parallel or perpendicular to the edges and sides of the billet-shaped basic wall elements and is produced in accordance with the accepted discrepancies based on accuracy class 9 of the tolerance and fitting system and the other wall elements are expediently starting row wall element?, partition binding wall elements, corner wall elements, door-window case wall elements, crowning row wall elements. In the full knowledge of these wall elements the design software helps to collect the required material for the wall structure then the collected type and number of wall elements are manufactured according to the construction progress schedule by using the selected raw material and the necessary computer controlled equipment. After being manufactured with an engineering process accuracy the wall elements get an identification mark then the wall elements prefabricated in this way are packed and transported to the certain construction site on schedule. Based on the well-known method the construction works are prepared by making a concrete foundation with a prescribed accuracy, flat upper surface, over which - according to the previously prepared design drawing - the starting row of the building is laid down, the brow-posts are built-in as well so that the seating surfaces touching each other would close thus the building structure is made ready and by using the method of the invention the purposes of the construction are achieved.

Thus the invention is about a procedure established for prefabricated and other wall elements used for the building work.

According to the procedure based on the invention the construcion plan is made by computer using a design software, the required wall elements are prefabricated and transported to the construction site then they are built in and when the construction works are finished the building is handed over to the customer. The characteristic of the procedure is that the design of the construction, the prefabrication and production of the required wall elements is carried out in a closed order procedure by coordinating the almost simultaneous development of the architectural, static, electrical and engineering parts of the plan and employing standard basic and other wall elements of the required type and dimensions which demonstrate the entire outline of the walls. Based on the details mentioned above the required materials for the walling are selected with the help of the design software then according to the construction progress schedule the selected type and number of wall elements are prefabricated by using the selected raw material and the computer controlled "special equipment. After being dressed with an engineering process accuracy the wall elements get an identification mark. The wall elements manufarctured in this way are packed and transported to the certain construction site on schedule. Based on the well-known method the construction works are prepared by making a concrete foundation with a prescribed accuracy, flat upper surface, over which - according to the previously prepared design drawing - the starting row of the building is laid down, the brow-posts are built-in as well so that the seating surfaces touching each other would close thus the building structure is made ready.

According to the procedure of the invention during the design the possible and required wall elements are chosen from a given selection list with the help of a suitable design software. After the architectural and static design the electrical and engineering parts of the plan determines the the exact place and size of the required assembly holes in this way, at the end of the planning process, the order, the place and number of wall elements are determined then these data are stored making further data processing possible.

According to the procedure of the invention the required number and type of wall elements are prefabricated by using the selected basic material in accordance with the data determined by the design. The wall elements are prefabricated with moulding according to the laying down sequence and an identification mark is applied on each of the consecutive wall elements using a computer controlled special production line then after the moulding and the following kilning or consolidation time and binding material and facing is applied on the appropriate surfaces of the wall elements After solidification each seating surface is finished by cutting disc or grinder according to the accepted discrepancies based on accuracy class 9 of the tolerance and fitting system used in engineering then the prefabricated wall elements are packed and transported to the certain construction site based on the schedule and order determined by the computer software.

According to the procedure determined by the invention during the execution the upper side of the expediently prepared concrete foundation is finished using prefabricated footing elements that are filled in with fresh concrete then, preferably, prefabricated border rims are put on both upper sides of the footing elements where the rims are protruding upwards, preferably in some 10 to 20 mm, and after horizontal levelling of the border rims serving as guides, additional fresh concrete is filled in between the rims which is smoothed down to obtain an even, flat surface, preferably without wrinkles and swellings, whereon an insulating layer is overlaid. Then the starting row is laid down on it using exterior bearing wall elements in a way that their required locations are measured from the corner in the line of and along the wall and also in transversal direction, then all the partition binding wall elements of noses are put accurately to their measured place within the prescribed tolerance limit then the second and further rows are laid down, starting also from the corners in a way that first the binding material is spread evenly, preferably into the holes, with a predetermined thickness, preferably with a mortar spreader. Afterwards, the corner wall elements are laid down checking simultaneously the seating of the faces and, in a given case, the penetration of the binding material into the corresponding holes is facilitated with a light hammering using a rubber mallet, the additional wall elements are laid down pushing the ends against each other, in a way to obtain a close-packing between the wall elements and before laying down the last wall element in the full row, the available place is measured and - if required - it is ground off with a special tool to obtain the required length. Then it is laid down to its place and then the brow-posts that are divided in parallel to and along the exterior wall preferably consisting of three to four parts are built in at the exterior side of the marginal wall elements without backing, with a facing that corresponds to the same side pushing the end against the basic wall element which is the last one counted from the corner then putting into its place the next basic wall element is pushed against the end of the brow-post as well as the others laid side by side. Then the last wall element is put into its place after measuring the available space it is ground - if required - to the required length on the site with a special tool or, U shape elements, that have the same length as the basic wall elements are built in with backing, in the known way with armouring and concrete filling.

According to the invention the ready-made basic wall element has a quadrangular prism shape and a bearing basic body in its centre part. It is typical of the basic wall element to be unit sized, prefabricated piece of a theoretically designed wall structure that has as a minimum one finished positioning guide face. The positioning guide face is in parallel and/or perpendicular to the edges and lateral faces of the quadrangular prism shape basic wall element to facilitate the matching and it is ready made according to the accepted discrepancies based on accuracy class 9 of the tolerance and fitting system used in engineering.

One typical feature of the wall element based on the invention is that the positioning guide faces are preferably rims that are load-bearing, dry fit, horizontal seating faces and lateral guide faces and in certain cases vertical seating faces and vertical guide faces. Additionally on the upper side of the wall element between the positioning guide faces there is a setting space suitable for placing the binding material on it while on the bottom there is a discharge hole for discharging the superfluous binding material.

An other feature of the wall element based on the invention is that at least on one longitudinal side, preferably on its exterior side a layer of binding material covered by facing is applied which is preferably mortar or coating.

A further feature of the wall element based on the invention is that the positioning guide faces in certain cases are made from an other material than that of the above mentioned wall element. A further feature of the wall element based on the invention is that there are assembly holes provided in the wall elements for the installation of fittings and/or conductors of the electrical or sanitary installations of the construction.

One feature of the prefabricated wall elements is that the starting row wall elements, partition binding wall elements, corner wall elements door- window case wall elements, crowning row wall elements determined by manual or automatic selection from the availability list of the design software by replacing the corresponding basic wall elements in the already designed wall structure. Their surfaces are created according to the accepted discrepancies based on accuracy class 9 of the tolerance and fitting system used in engineering.

A further prefereable feature of the wall elements based on the invention is that the selected material of the above mentioned wall elements is kiln ceramic in which there are vertical cavities provided to facilitate the heat insulation and, in certain cases there are assembly holes required for the installation of fittings and/or conductors of the electrical or sanitary installations. After kilning a facing is applied at least on one longitudinal side of the wall element.

A further prefereable feature of the wall elements based on the invention is that the selected material of the wall elements is porous concrete and the sides of the wall element are previously cut to be horizontally parallel to the plain of the wall structure the rows and in which in certain cases there are assembly holes required for the installation of fittings and/or conductors of electrical or sanitary installations of the construction. On the interior side of the wall element there is either a polished surface or in certain cases a facing while on the exterior longitudinal side a facing is applied.

A further prefereable feature of the wall elements based on the invention is that the selected material of the wall elements is ground brick in certain cases completed with pearl polystyrene and there are heat insulation seats for heat insulating inserts and in certain cases there are assembly holes are required for the installation of the fittings and/or conductors of the electrical or the sanitary installations of the construction and there is a facing applied at least on one longitudinal side of the wall element.

A further prefereable feature of the wall elements based on the invention is that a heat insulating material is bonded at least at one of the lateral sides of the wall element and over these a facing is applied making aeration holes between, the facing and the heat insulating material. There are strengthening carrier pins built in and fixed with bonding that are extending from the bearing basic body into the facing. The procedure based on the invention is presented according to the following drawings:

Illustration No. 1 : the flowchart based on the main point of the procedure Illustration No. 2: the axonometric projection of wall element Illustration No. 3: the axonometric projection of the preferable working design of the wall element based on the invention Illustration No. 4: the axonometric projection of the preferable working shape of the wall structure built according to the invention Illustration No. 5: the axonometric projection of the preferable working shape of the wall element made from kiln ceramic

Illustration No. 6: the axonometric projection of the preferable working shape of the wall element made of porous concrete basic material according to the invention

Illustration No. 7: the axonometric projection of the preferable working shape of the wall element made of ground brick basic material according to the invention

Illustration No. 8: the sectional drawing of the preferable working shape of a vent hole between the facing and the heat insulation on the basic wall element

The first illustration presents the flowchart of the procedure's main point. First the customer pays a visit to a designer or a designer office about his intention and as a result of one or more meeting the customer commissions the designer to design a building. According to the procedure based on the invention the design is created by a design software using the available wall elements in a way to make the design, the production and the execution a close order procedure harmonizing the nearly simultaneous preparation of the architectural, electrical, static and construction parts of the design thus the size and place of the fittings and/or conductors of electrical or sanitary installations and required assembly holes in the wall structure are also designed. Thus every important detail concerning the final shape of the construction is made clear. As a result of the participants' cooperation CAD documentation, the selection of required material for each wall element is already available, which is a considerable advantage during the execution of the design. The design based on the invention is created by a design software for example the modificated and specifically improved version of ArchiCAD which is widely used and well known in Hungary in itself.

The data concerning the required material for the constraction of the wall structure are stored suitably for further data-processing then in due time they are directly and purposefully handed to the manufacturer. The prefabrication of the required type and number of wall elements is carried out by using the selected basic material and a computerized target equipment which is operated according to the certain data determined during the design process. The target equipment has an expedient moulding box containing quadrangular prism shaped bordering elements in which the bordering elements should be changeble depending on the type of the elements which could be achieved by placing a memory and a connecting robot next each element similar to the procedure of changing tools in controlled machine-tools. Since the list made of the type and number of wall elements selected by the designer can be directly read in the target equipment these wall elements are manufactured according to the order of construction. The wall elements made in moulds get an unambigous identification mark then after a certain period of time binding material and facing is applied on the appropriate surfaces then after their solidification each seating face is finished according to the accepted discrepancies based on accuracy class 9 of the tolerance and fitting system and the finished and marked wall elements are packed. The preparation of the building site is done simultaneously with the start of production which happens in the well known way of creating a concrete foundation of upper part is completed by using prefabricated footing elements so that the rim is unit-sized wide and parallel. With the help of a clamp the expediently prefabricated border rims are put on both sides of the footing elements so that the rims protrude over the footing elements by 10 to 20 mm and after the horizontal levelling of the border rims serving as guides additional fresh concrete is filled in between the rims which is smoothed down to obtain a flat, even surface preferably without wrinkles and swellings. Then near this theoretically level surface accurately flat as prescribed a heat insulating material is placed. During the procedure it is important to have a flat, even surface. When the procedure is finished the packed wall elements are transported to the building site according to the order and schedule determined by the software then the construction is started based on the previously created blueprint. The most important part of the procedure is to lay down the starting row using exterior bearing wall elements by measuring their required locations starting from the corner along the side of the wall and diagonally as well then every jutty partition binding wall element is laid accurately on their measured place within the prescribed tolerance limit (expediently 1 mm). Afterwards, the second and the further rows are laid down starting also from the corners in a way that first the binding material is spread evenly, preferably into the grooves with previously determined thickness preferably with a mortar spreader to fill mortar cases if that is the adopted procedure. (The mortar case is used to provide wadding between the wall elements laid down side by side.)

Afterwards the corner wall elements are laid down and the seating of the faces is checked. In certain cases the penetration of the binding material into the corresponding holes is helped by a light hammering using a rubber mallet the additional wall elements are laid down pushing the ends against each other in a way to obtain a close-packing between the wall elements. After measuring the available space the last wall element in the full row - if required - is ground off with a special tool to obtain the required length then it is laid down to its place. Discrepancies that add up due to the permitted inaccuracy limit the degree of grinding to no more than l-2mm. In case there is any space left for door-window case in a row discrepancies will occur around those spaces. Afterwards the lintels which consist of preferably three to four parts and are divided parallel to the longitudinal side of the exterior wall are built in at the exterior wall without backing and with a facing that corresponds to the side then starting from the corner the wall elements are built in one by one pushed against the last one in the row then the following wall element is placed against the lintels and the last wall element of the row is ground with a special tool at the building site and put into its place - if required- after the measurement of the available space. According to an other method U shape elements having the same length as basic wall elements are built in with backing in the well-known way with armouring and concrete filling.

The end of the procedure based on the invention is either when the building structure is completed and handed over or when it includes the certain trade works as well.

The second illustration presents the theoretical axonometric projection of the basic wall element which has a quadrangular prism shape and a bearing basic body 1 11 in its centre part. The 1 1 basic wall element is a unit size, prefabricated piece of a theoretically designed wall structure that has at least one finished positioning guide face 1 12 - shown at the bottom and in the middle of the illustration - which is parallel and/or perpendicular to the edges and lateral faces of the quadrangular prism shape basic wall element \ 1 and it is made in accordance with the accepted discrepancies based on accuracy class 9 of the tolerance and fitting system. This means that the tolerance of the matching faces is approximately 0.1 -0.2mm accurate.

The third illustration presents the axonometric projection of a preferable working shape of the basic wall element based on the invention. According to this preferable working shape the positioning guide faces are 1 12 preferably rims and they are load bearing, dry fit, horizontal seating faces 1 121 and lateral guide faces 1 122. In certain cases and if required vertical seating faces 1 123 and vertical guide faces 1 124 are created which makes matching even more accurate. On the upper side of the wall element between the positioning guide faces 1 12 there is a setting space 1 13 suitable for placing the binding material 3 there while at the bottom of the wall element there is a discharge hole 1 14 for discharging the superfluous binding material which is solved for example by creating overflow channels. At least on one longitudinal preferably exterior side of the basic wall element 1 1 a layer of binding material 3 then facing 4 is applied which is preferably mortar or coating. The positioning guide faces 1 12 in certain cases are made from an other material than that of the wall element for example asbestos or plastic slate.

The broken line in the illustration shows the assembly holes 2 in the basic wall elements that are suitable for the installatiQn of fittings and/or conductors of electrical or sanitary installations of the construction. The illustration shows the holes for service lines, their drilled casing tube and the cable box.

The fourth illustration presents the axonometric projection of a preferable working shape of the basic wail element made in accordance with the procedure of the invention in which apart from the basic wall element 1 1 there ^are other ready-made wall elements 11 , 12 I n shown in binding such as, the starting row wall element 12, partition binding wall element 13, corner wall element 14 and the door-window case wall element 15. The different kind of wall elements 1 1 , 12, ... I n are determined automatically during the design of the building construction by selecting from the availability list of the design software and by replacing the certain elements in the wall structure consisting of the basic wall elements 1 1 furthermore their faces are finished according to the accepted discrepancies based on the accuracy class 9 of tolerance and fitting system of used in engineering. Other wall elements 1 1, 12, ... I n fit laterally when joining them together with zero point millimetre accuracy and after the finished guide faces are joint together they make a dry fit and a closed space for the binding material then after the application and solidification of the binding material 3 loading is taken by the entire wall structure. Apart from this there are other wall elements 1 1 , 12,.... I n that are not shown in the drawing for example half or three-quarters, basic wall element 1 1 , crowning row wall element which is cellular and it serves as a permanent shuttering for the crowning.

The fifth illustration presents the axonometric projection of a preferable working design of the basic wall element made from kiln ceramic as a basic material.

The selected basic material is the widely used kiln ceramic which has vertical cavities 5 helping heat insulation and in certain cases it also has assembly holes 2 required for the installation- of fittings and/or conductors of electrical or sanitary installations of construction. After kilning facing 4 is applied at least on one longitudinal side of the wall element. There is an other possible solution as well according to which mortar is applied to both sides after kilning then the final preparation helping heat insulation takes place according to the previously mentioned accuracy class 9 of tolerance and fitting system used in engineering. According to this preferable working design the width sides have three mortar cases and vertical cavities 5 in order to discharge the superfluous binding material.

The sixth illustration presents the axonometric projection of a preferable working shape of the basic wall element made from porous concrete as a basic material.

According to this preferable working shape the selected material is porous concrete which is already cut to make it parallel to the plane of the wall structure to be built and horizontally parallel to the rows in which in certain cases there are assembly holes 2 required for the installation of fittings and/or conductors of electrical or sanitary installations of the construction on the interior side of the said wall element there is either a polished surface or in certain cases a facing 4 and on the exterior longitudinal side a facing 4 is applied.

According to the method of the invention the wall element made from porous concrete can be cut to the final shape after it is taken out of the mould. The wall element having approximately the required shape created by the above mentioned method is provided with assembly holes 2 required for the installation of fittings and/or conductors of electrical or sanitary installations of the construction then the case of the door-window case is completed and the loss due to cutting is complemented on the interlocking sides with two mortar cases so that after the final grinding the faces fit accurately. The use of this method does not necessarily involve applying mortar on the interior side since grinding makes a smooth, polished surface which can be wallpapered while the exterior side needs mortar or coating. This method also uses discharge holes to drain surplus binding material 3. The seventh illustration presents the axonometric projection of a preferable working shape of the basic wall element made from ground brick as a basic material. According to this preferable working shape the selected material is ground brick which in certain cases is supplemented by using pearl polystyrene in which contains heat insulation seats 6 for heat insulating inserts or in certain cases assembly holes 2 required for the installation of fittings and/or conductors of electrical or sanitary installations of building and facing 4 is applied at least on one longitudinal side of the wall element.

This wall element is made either from ground brick or the blend of cement-bound water containing blown clay grains which apart from the assembly holes can contain - if required - heat insulating pearl polystyrene which in certain cases can give room for heat insulating inserts 7 filling the heat insulation seats 6 made for this purpose. After the moulding and packing period or towards the end of it the required amount of mortar is applied on both sides while coating on the external side then the accurate dressing of the seating faces takes place after the period of packing. According to this preferable working shape the sides have three mortar cases.

Apart from the mentioned and most frequently used and selected basic materials it is possible to make wall elements of new composition as well which has never been put into practice or has not been applied before having no appropriate procedure. The aim in this case also is to produce wall elements by taking the cross-section of the wall structure into consideration.

The eigth illustration of the invention presents the axonometric projection of the aeration hole made between the heat insulation and the facing applied to the bearing basic body of the wall element. According to this method the working shape of the wall element, which is the most favourable but relatively expensive, heat insulating material 8 is bonded at least on one of the lateral sides and over the the heat insulating material facing 4 is applied creating vent holes 9 between the facing 4 and the heat insulating material 8. Extending from the bearing basic body 1 1 1 into the facing 4 there are strengthening carrier pins 10 built in and fixed with bonding. According to this method heat-insulating material 8 is applied to the bearing basic body while facing is applied over the heat-insulating material which is preferably a coating, namely ceramic, of which inwardly protruding parts serving as distance pieces provide a vent hole between the heat-insulating material 8 and the facing 4. All three of these parts, such as the bearing basic body 1 1 1 , heat-insulating material 8 and the facing 4 are held together and strengthened by carrier pins 10 that are previously pressed and placed into the holes extending from the bearing basic body 1 1 1 into the facing 4 thus increasing solidity.

According to the method of the invention if the facing 4 on the wall elements 1 1 , 12 is mortar then it is internal and external mortar and if it is coating then it can be either ceramic or asbestos slate which under the heat-insulating material is joint with the bearing basic body 1 1 1 by solid binding or adhesive bonding. The binding of the seating faces of the sides of wall elements 1 1 , 12,... I n in itself can be for example interlocking, groove- and-tongue, gripping groove with two mortar cases. The joining wall elements 1 1 , 12, ...., I n when being joint together fit laterally with a few millimetres accuracy and are provided for example with a groove-and- tongue positioning guide face 1 12 being parallel to the plane of the wall structure helping the wall elements to fit and preferably serving as rims so that they form a setting space that is a closed space suitable for placing binding material on them. There is a discharge hole 1 14 discharging the superfluous binding material, which in the case of for example kiln ceramic planes having discharge holes is achieved by creating vertical cavities. In the last phase of prefabrication the wall elements are ground so that the quadrangular prism shaped wall elements 1 1 , 12,.... I n achieve the required geometric parallelism, perpendicularity and dirhensional accuracy. These finished positioning guide faces 1 12 achieve a dry fit after being placed on one another and joint together.

According to the invention the width of the positionjng guide faces 1 12 are expediently 3-5 cm which is 7.5-12.5 per cent of the width of a wall element being preferably finished to be 40 cm in width, 30 cm in height and 45-60 cm in length. This rim, though relatively narrow in width, is enough to instantly bear a slight load even before the solidification of the binding material 3 without the danger of shifting. After the solidification of the binding material 3, however, loading is taken by the entire wall structure. The weight of the wall elements 1 1 , 12, ... depending on the size and the chosen basic material is between 25 and 40 kilogramms. This size and weight makes it possible for at most two persons during a shift, without doing themselves injury, to move and fit the wall elements 1 1 , 12, I n even without a lever by using special pliers at the most.

There are wall elements 11 , 12 I n which are made to have the required cases and ledge spaces^" for the doors and windows like for example the door-window case wall element. Apart from this wall elements 11 , 12 I n can also be provided with frontal decorative juts even during production.

Since the methods of connection, cases and the spaces for ledges are previously cut away there is no need for cutting and carving when joining the wall elements 1 1 , 12, based on the design software they outline the entire design of the geometry of the wall structure without remainders. Longitudinal grinding of the positioning guide faces 1 12 of the last wall element in a row might be necessary at the building site with an equipment developed for this purpose because starting from the corner in a row, the allowed discrepancies deriving from the differences in size within the tolerance accuracy of the tolerance and fitting system add up.

There is an other possible solution according to which the positioning guide faces 1 12 are askew.

The procedure based on the invention has achieved its targets and its advantages are the following:

• The entire wall structure can be constructed quickly

• No overcasting at the building site

• No unskilled labo^'ur force needed

• No accessorial costs (eg.: moulding element, external scaffolding)

• No remainders from indirect materials (eg.: sand, cement, lime, brick) • After putting up the wall structure specialists of the certain trades get a geometrically accurate surface made in accordance with the allowed discrepgncies based on accuracy class 9 of the tolerance and fitting system used in construction

• Costs of picking for electric fittings are eliminated since the assembly holes and spaces for conduit boxes can previously be created

• For telephone, computer, television, alarm system cables, which are not advised to run near heavy-current cables, an assembly hole can be made which runs around the wall structure above the height of the doors.

» Costs of picking for plumbing qre eliminated w Costs of picking and drilling for through-holes of heating pipes

• The setting-in of doors and windows are more reliable and accurate than that of the present practice, namely:

- the thickness of partition walls is constant, the interor doors with the covering cases fit to the wail

- after the doors and windows are set in there is no 'shuttering' so rendering does not cause damage to the doors and windows

- after the doors and windows the borders can also be set in so that experts are not expected to return to the building site after the follow-up masonry works

- a case is formed to facilitate the setting-in of exterior doors and windows and placing them with filling-in on the case prevents heat build-up

- the room for window-ledges shall not be picked since they are ready-made during the construction of the wall structure

- the lateral discrepancy of the wall structure from the theoretical plane is minimal since when two wall elements are joint the finished matching faces at their two edges parallel to the plane of the wall structure achieve an almost tight fit having only some zero point millimetres gap between them. Practically there is no vertical discrepancy between the rows since the finished matching faces produce a dry-fit creating a closed surface for the binding material. Real discrepancies can only occur when the differences in size of the exterior or interior sides deriving from grinding add up on one side within tolerance which is 2 millimetres at the most in the case of for example ten rows (300 cm). In this case the lateral bend adds up to 1.5 mm.

LIST OF REFERENCE NUMBERS

1 1 basic wall element

1 1 1 load-bearing basic body

1 12 positioning guide face

1 121 horizontal seating surface

1 122 lateral guide face

1 123 vertical seating surface

1 124 vertical guide face

1 13 setting space

1 14 discharge hole

12 starting row wall element

13 partition binding wall element

^■14 corner wall element

15 door-window case wall element

2 assembly hole

3 binding material

4 facing

5 vertical cavity

6 heat insulation seat

7 heat insulating insert

8 heat-insulating material

9 vent-holes

10 carrier pin

Claims

What 1 claim are:

1. Building process with prefabricated wall elements to construct a building work during which the building work is designed using a computer and a design software, the wail elements required for the construction are prefabricated and then transferred to the building site where these are built in, the building work is erected and the ready made building is handed over to the purchaser, wherein the design of the building, the prefabrication and production of the wall elements [1 1 , 12, ....I n) are made within a close order procedure, in a way that the architectural, static, electrical and engineering designs are made in concerted action, almost simultaneously, using standardised type wall elements (1 1 , 12, ....I n) of required type and dimensions that are the required components of the whole wall structure then, when the required materials of the wall structure are already known, these materials are collected with the design software and the collected type and dimension wall elements (1 1 , 12, ....I n), preferably, according to the construction progress schedule, are prefabricated using a selected raw material, dressing them with an engineering accuracy and applying on each one an identification mark, using a computer controlled special production line; then the wall elements (1 1 , 12 I n) prepared in this way are packed and transferred on schedule to the construction site, while the building procedure is prepared in a well known manner, expediently, by making a concrete foundation with a prescribed accuracy, flat upper surface, over which - according to the previously prepared design drawing - the starting row of the building is laid down, as well as the lintels are built-in so that the seating surfaces touching each other would be closed thus the building structure is made ready.

2. The process of claim 1. wherein the selection of the possible and required wall elements (1 1 , 12, ....I n) is made during the design from a_. given list with a suitable design software and, after the architectural and static designs, during the partial electric and engineering designs the accurate locations and sizes of the assembly holes (2) required in the wall structure are also determined and, in this way, at the end of the design the type, the number, the accurate location in the wall and the building-in sequence of each wall element (1 1 , 12 I n) are also determined and these data are stored in the memory in a form that is suitable for further processing by computer.

3. The process of claim 1. or 2. wherein during the production, using the selected raw material and on the basis of the data determined during the design phase, the^' required types and number of the wall elements

(1 1 , 12 I n) are prefabricated with moulding, according to the laying down sequence and an identification mark is applied on each one of the consecutive wall elements (1 1 , 12, ....I n) using a computer controlled special production line then, after the moulding and the consecutive kilning or consolidation time a binding material (3) and a facing (4) is applied at the proper surfaces of the wall elements (1 1 , 12 I ) and, after the solidification, each one of their seating surfaces are finished, preferably with a cutting disk or grinder, with an accuracy class 9. allowed tolerance according to the tolerance and fitting system used in the mechanical engineering and then, the finished wall elements (1 1 , 12, ....I n) are packed and transferred to the construction site according to the sequence and time schedule determined by the computer software.

4. The process of any claims 1. to 3. wherein during the execution the upper side of the expediently prepared concrete foundation is finished, using prefabricated footing elements, that is filled in with fresh concrete, then, preferably, prefabricated border rims are put at both upper sides of the footing elements where the rims are protruding upwards, preferably by 10 to 20 mm and, after horizontal levelling of the border rims as guides, additional fresh concrete is filled in between the rims and that is smoothed down to obtain an even, flat surface, preferably without wrinkles and swellings, whereon an insulating layer is overlaid and, then the starting row is laid down on it, using exterior load-bearing wall elements, in a way, that their required locations are measured from the corner in the line of and along the Wall and also in transversal direction, then all the partition binding wall elements (13) of noses are put accurately to their measured place within the prescribed tolerance limit and, after this, the second and the further rows are laid down, starting also from the corners, in a way, that at first the binding material (3) is spread evenly, preferably into the holes, with a predetermined thickness, preferably with a mortar spreader, afterwards, the corner wall elements (14) are laid down checking simultaneously the seating of the surfaces and, in a given case, the penetration of the binding material (3) into the corresponding holes is facilitated with a light hammering using a rubber mallet, the additional wall elements (1 1 , 12 I n) are laid down pushing the ends against each other, in a way to obtain a close-packing between the wall elements and before laying down the last wall element in the full row, the available place is measured and - if required - it is ground off with a special tool to obtain the required length, then it is laid down to its place and, after this procedure, either the lintels that are divided in parallel to and along the exterior wall, preferably consisting of three to four parts, are built in at the exterior side of the marginal wall elements, without backing, with a facing (4) that corresponds to the same side, pushing the end against the basic wall element (1 1 ) which is the last counted from the corner, then putting into its place the next basic wall element (1 1 ), pushing against the end of the lintel, then the others, each one consecutively side by side and then the last wall element is to be put into its place after measuring the available space it is ground - if required - to the required length on the site with a special tool or, U shape elements, that have the same length as that of the basic wall elements (1 1 ), are built in with backing, in the known way with armouring and concrete filling.

5. Reαdy-mαde basic wall element for the construction of a building that has a quadrangular prism shape and a bearing basic body (1 1 1 ) in its centre part, wherein said basic wall element is a unit size, prefabricated piece of a theoretically designed wall structure that has as a minimum one finished positioning guide face (1 12) that is in parallel and/or perpendicular to the edges and lateral surfaces of the quadrangular prism shape basic wall element (1 1 ), to facilitate the matching and it is ready made at least with an accuracy class 9 allowed tolerance according to the tolerance and fitting system used in the engineering. ό. The basic wall element of claim 5. whereon positioning guide faces (1 12), preferably rims are prepared, that are load bearing, dry fit, horizontal seating surfaces (1 121 ) and lateral guide faces (1 122), as well as, in a given case, vertical seating surfaces (1 123) and vertical guide faces (1 124) are prepared and, additionally, on the upper side of the said wall element, between the positioning guide faces (1 12), there is a setting space (1 13) prepared that is suitable to place there the binding material (3), while in the bottom of the said wall element there is a discharge hole (1 14) prepared to discharge the superfluous binding material.

7. The basic wall element of claim 5. or 6. wherein at least on one longitudinal side, preferably on its exterior side a layer of binding material (3) is applied and, over it a facing (4) is applied that is preferably mortar or coating.

8. The basic wall element of claim 6. wherein the positioning guide faces (1 12), in a given case, are made from an other material than that of the said wall element.

9. The wall elements of any claims 5. to 8. wherein there are assembly holes (2) provided in the said wall elements that are suitable for the installation of the fittings and/or conductors of the electrical or the interior sanitary installations.

10. Ready-made other wall elements for the construction of a building wherein the said wall elements can be starting row wall elements (12), partition binding wall elements (13), corner wall elements (14), door- window case wall elements (15), crowning row wall elements, that are determined by manual or automatic selection from the availability list of the design software and which are replacing the corresponding basic wall elements (1 1 ) in the already designed wall structure and, their surfaces are finished with an accuracy class 9 allowed tolerance according to the tolerance and fitting system used in the mechanical engineering.

1 1. The wall elements of any claims 5. to 10. wherein the selected material of said wall elements is kiln ceramic in which there are vertical cavities (5) provided to facilitate the heat insulation and, in a given case, there are assembly holes (2) provided that are required for the installation of the fittings and/or conductors of the electrical or the interior sanitary installations and, after kilning, there is a facing (4) applied at least on one longitudinal side'of the wall element.

12. The wall elements of any claims 5. to 10. wherein the selected material of said wall elements is porous concrete and the said wall element sides are already cut to be in parallel to the plain of the wall structure to be built and horizontally in parallel to the rows and in which, in a given case, there are assembly holes (2) provided that are required for the installation of the fittings and/or conductors of the electrical or the interior sanitary installations, on the interior side of the said wall element there is either a polished surface or, in a given case, a facing (4), while on the exterior longitudinal side a facing (4) is applied.

13. The wall elements of any claims 5. to 10. wherein the selected material of said wall elements is ground brick that, in a given case, made up with pearl polystyrene and, on the said wall elements there are heat insulation seats (6) provided for the heat insulating inserts (7) and, in a given case, there are assembly holes (2) provided that are required for the installation of the fittings and/or conductors of the electrical or the interior utilities of the building engineering and, there is a facing (4) applied at least on one longitudinal side of the wall element.

14. The wall elements of any claims 5. to 13. wherein a heat insulating material (8) is bonded at least at one of the lateral sides of the said wall element and over these a facing (4) is applied, in a way, that between the facing (4) and the heat insulating material (8) vent-holes (9) are created and, there are strengthening carrier pins (10) built in and fixed with bonding, that are extending from the load-bearing basic body (1 1 1 ) into the facing (4).