Note: Descriptions are shown in the official language in which they were submitted.
1
This invention relates to a method of manufac~uring an
insulatable reinforced building or construction element
(foundation, wall, roof, ceiling or floor element) in
concrete, one side of said element being formed by a
reinforced conc~~ete plate, the other side face exhibitinc
nailing strips in the form of longitudinall:r or lateral~,v
extending wooden ledges connected to the r=inforcement and
joining said concrete plate via longitudinally o. laterally
extending reinforced concrete ribs, and wherein the element
for the subsequent embedment of isolation ;hats exhibits
countersunk laterally open cavities, and wherein is used a
rectangular horizontally oriented upward open casting mould
having a bottom as well as lateral and end walls, said
casting mould having a length corresponding either to the
length/height of use of the resulting element or to a
multiple of said length!height of use.
rectangular building or construction element in reinforced
concrete having hailers in the form of longitudinally and
laterally extending wooden ledges equally spaced over one
side or lateral face of the element, is sown and described
in Norwegian patent application No. 863fo7. This e'_ement
exhibits a high compression, tensile and bending stre.~.gth in
relation to weight per surface area uni~~. '"hus, in this
known element one side race is formed by the concrete, while
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the OpOOSlt2 S'~de face dile t0 the nai lers jnaii.inQ Stripg)
may be provided with clothing plat's, panels or the li'~
nailed t::erecn. More particularl_r, the concrete plate has
one side face forming one external face of the element, the
opposite sid= face o-f the concrete plate being formed with
r
rein~orced longitudinally or late=ally-extanding concrete
ribs, to whic~ the wooden ledges ~.re anchored and Between
:vhich soft insulation mars are being embedded prior to t~.e
application of -:apour barrier and external building plate/
panel or other prate, coating or covering material.
In order to form said longitudinally or laterally extending
reinforced concrete ribs and their intermediate cavities for
the embedment of said soft insulation mats, the castincr
mould exhibits so-called cavity 'poxes.
The concrete _ibs and tc:e nailer-=orming wooden ledges
connected ther=to ws well as the cavities for soft
insulation mats or said rigid i:isulation plates,
respectively, may extend in the longitudinal or lateral
direction of t::e casting mould. ~:sually, they will extend in
the lateral direction of the mould, but with elements
receiving a substantial height in tre position of use,
concrete ribs etc. have to be formed in the longitudinal
direction of the casting mould.
Building elements of the above-mentioned general type are
quite complex in their construction, and it has hitherto
been difficult to arri~~e at a rational production method.
In accordance to current technique, the casting is effected
in such a manner that the continuous concrete face ~~s formed
at the bottom ace of the casting mould. Such a met!:od
involve technical disadvantages and limitations in the
manufacturing step, because most of the area ef the too of
the mould duri:~g casting is being covered by said cavity
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boxes. Therefore, the Lining cf concrete into the mould has
to be carefully controlled when executed.
mother disadvan rage of known casting tec'.~.nique is t:-:at no
steps are taken in order to facilitate a working of the
concrete surface, e.g. decoratively (facing, admixing
shingle in the sur~a~~e layer etc.). Facing of the concrete
face is impossi'ole when the element is laving in t::~.e mould,
because said face is quite inaccessible in this position.
Of couse, one may place a layer of shingle - as resulting
surface layer on the concrete face - at t~:e bottom of the
mould, but such a me~hod is less controllable, and the
results thereof have mostly been very poor.
SE-B-416 5'2 discloses a building element, namely a wall
elemen~ exhlbitlng some of the features of the
introductorily disclosed structure. The method for its
manufacturing distinguishes itself through_the use of a
mould lacking fixed cavity boxes; placing rigid isolation
plates and wooden. ledges which form fixing battens
alternately side by side at the OOttom of the mould;
connecting said wooden ledges by ties either in a previous
working operation, or subsequent to their embedment while
resting against the mould bottom; embedding a main
reinforcement, e.g. in the form of a reinforcing net, to be
located in a plane extending parallel to the side faces of
the resulting element; filling the mould with concrete from
above and allowing said concrete to harden, possibly after
having performed desired working on its freely accessible
top surface; and removing the element from the mould.
CH-a-X90 98? discloses a building element exhibting some of
the features c= the introductorily defined. structure wherein
nailer-forming wooden beams are connected to the
reinforcement through the intermediary of connecting means.
This prior art building element comprises rigid panels,
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pr=ferably cf _..~.sulation material and accommodating a
stlOStanLlal pCirtiOn Cf the total CrvSS-SeCtiCna~ are Of the
°_i2ment.
The building element of SE-B-4_o S72 and that of CH-a-
S90 987 comprise rigid isolation plates which, usually, are
ver_; expensive as compared to soft isolation mats of similar
or superior insulating properties. The methods according to
these prior art publications require comprehensive formwork
operations.
The object of the present invention is to indicate a very
rational method of manufacturing building elements of the
introductorily defined kind, i.e. of the kind lacking
casted-in rig'_d isolation plates and instead exhibiting
countersunk cavities; wherein the =,vooden ledges are
connected directly to the reinforcement, and wherein the
reinforcing net is fixed in position by connection to
upright reinforcing means, thereby eliminating or
substantially reducing said disad-rantages, deficiencies and
limitations of the prior art.
To this end, the invention is characterized through the
features defined in the following claims.
Thus, the method according to the in-rention is to be
utilized in connection with one main type of the present
building elements only) namely elements having cavities for
the subsequent embedment of soft insulation mats.
Consequently, when casting elements having cavities for
subsequent embedment of soft insulation mats, a casting
mould is used navi.~,g permanent cavity boxes the spacing
tt:ereof somewhat exceeding the width of said nailer-forming
wooden ledges, the width of the cavity boxes somewhat
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xCeeding the .vide h Of Sald .'flatS . i::e C~?S ring mOl:id iS
elongated rectangular and upward oven as well as :~avir~a a
fiat bottom and short walls e:ctending along the lateral and
end edges. For e.cample, the mould may have a length of 0
metres. The lateral and end walls may have a height of about
1~ Centimetres. c~~eLerably, the wldt:l iS ddapted t0 a
standard measure for r_he height;rNidth of use of the
resulting element. In connecticn with such a large efficient
mould iengt'.~, as of t:te order ~ 0 me tr es , i t is , of cour se , a
supposition that the resulting casted element subseauent'_v
is being cut into the necessary len.gths/heights of use. j
Firstly, in the spacings. between the cavity boxes on the
mould bottom, ene places the hailer-forming wooden ledges
which previously or after their insertion into the mould,
respectively, have been provided with upright reinforcement
means for subsequent connection to the main reinforcement oz
the element. In wall elements, cavity frames for doors/
w_ndows are thereafter placed upon the cavity boxes and the
wooden ledges. The main reinforcement of the element which
mar consist of a cross reinforcement in the form of a net
(having cavities for the door/window cavity frames), is now
placed parallel to the mould bottom, and is kept adequately
spaced from the top of t~.e cavity boxes through the
reinforcement net's connection to the ~,:pright reinforcement
means of the wooden ledges. Thereby one achieves partlyr a
temporary attachment ef the reinforcement net at a desired
level above the mould bottom and at an intentional distance
from the resulting upper concrete surface, and partly that
the wooden ledges in the finished element are securely
anchored to the main reinforcement.
Everything is now ready fo.r casting, which may take place
very rationally because of the large aria of filling (t'_:c-
cavity bcxes are countersunk in relation. to the "fil l i ng
opening" represented by the en=ire efficient area of the
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mCU1 C ~ FOr e:Cdlllple , 1 t 1s ~e3S1'01 °_ t,'~ ~.:Sf? a Sv-Called
production jig arranged above the casting mould and movable
therealong) and wherefrom the concrete may be distributed.
:application or mould oil, hoisting of the tasted element as
well as transpcrtation or the latter for storage, etc., :na~r
also be effected b_r :means of a production jig.
~lona one edge cf the casting mould, prior to casting, a
girder or beam magi be embedded, and possibly a wooden beam
along the other edge. Thus, the elements to be manufactured
mav, beyond the previously mentioned general shape, exhibit
constructive differences or differing detail designs.
In a way of manufacturing as outlined above, the resulting
concrete face of the element is located uppermost; this
being in marked contrast with prior art casting techniaue
wherein the concrete face is being formed at the bottom face
of the casting mould. according to the invention, it is,
therefore, easy to work on the upward facing concrete
surface as desired. Fcr example, said surface may 'oe
assigned a desired surface layer through appropriate working
cf the concrete face or through the application of
decorative materials, e.g. shingel, upon the same.
Examplary embodiments of the invention are further described
in the following, reference being made to the accompanying
drawings, wherein:
Figure 1 in perspective view shows an element of the general
type advantageously manufacturable by means of the method
according to the invention;
figure 2 is a sector of a longitudinal section through a
mould containing a precast element having cavities for the
embedment of loose soft insulation mats, wherein the
naiier-formine woode.~. ledges and said cavities e:ctend
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1 _ - LL, 1 ' 1 3.H
1G l.~rC ' 1 V oL Llle ~~'l1 V 1 ~.,.t~w ~~::a~ d~1 eL '.~l~n o t~.le
'.aj'_Z:iCj
mould;
,figure 3 in a simplif led perspectiv a vie~N shows t~:e cas ring
mould in ccnnection with a particular arrangement cf a
cavity frame for a resulting window cavity in a wall
element.
In figure 1 the reference numeral 1 generally denotes a
house buildi.~.g element of the kind concerned.
T':e element 1 consists of a concrete plate Z having let=ral
ribs 3 in this embodiment. The conti:.uous side face cf the
concrete plate 2 is indicated by 2' . Both the concrete
plate 2 and its r_bs 3 are reinforced. For the concrete
plate 2, the cross reinfor-,.ement net s is visible at the
upper left corner of figure 1.
The reinforced concrete ri~os 3 carry nailer-forming wooden
ledges ~' casted thereon. The element shown in figure 1 has
also a wooden beam S extending alone its upper edge.
Between the ribs 3 are formed cavities 5 countersunk in
relation to one side face of the element as represented
througrl the front faces of the wooden ledges 4' . These
cavities 6 are shaped in order to receive loose soft
insulation mats 7.
when the insulation mats ? are embedded, card board 8
forming vapour barrier i~ nailed thereon. Thin wooden ledges
9 are nailed on the outside of the card board plates 8 using
the wooden loges ~' as nai'_ing strips.
Tie element 1 may therea-_ter be provided with e.g. panel 1G,
buidling or covering plates o.r the like, nailed thereon.
It appears from figure ~ that the main reinforcement, the
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filet ~ , ! S c0.~.i1°C taG' t'C ~ 1 png~t~ d; nal rel:l~OrClng r.~~d
11 ,
e.~. in tile form Of .. ~O-Called Cam Steel, whereto arc
welded short reinforcing bows or inclined struts i?, the
connection betw2~n ~a :rain reinforcement net :~ and the bows
12 being effac=ed ov means of ordinary binder wire or in any
other convenient wav.
The continuous ..fide face 2' of the concrete plate 2 opposite
the ribs 3 and the wooden ledges ~', may be plain. However,
wherever another surface structure is desired, e.g. when
shingle, facing, etc. ~s being used, this ~... verv easy: to
perform in connection with the production process according
to the present invention already when, the element is still
occupying the casting mould, giving rise to large
productiontechnical advantages concerning the surface
treatment.
Figure Z snows a short sector of a longitudinal cross-
section through a casting mould, here represented by the
bottom 13 and two adjacent lateral cavity boxes 14, the top
edge of the mould being indicated at 13' . The cavities
which are defined by the cavity boxes 14 and are to serve
for t~.e reception of subseauently embedded loose soft
insulation mats 7, are indicated at 15.
For the manufacturing of elements having lateral or
longitudinal cavities 15 for soft insulation mats, the
method is as follows:
An upward open rectangular mould 13,13' is used having
permanent cavity boxes 14 placed with a spacing
corresponding to the width of the nailer-forming wooden
ledges 4' desired to be used. When manufacturing most types
of elements, the cavity boxes 14 will extend in the lateral
direction or the mould. For floor elements and tall walls
only, a longitudinal orientation of the cavity boxes 1~ will
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be pr°ferred.
ibi ~~ ~i a~;
Between the cavity boxes 14 are embedded wooden 'edges
ih.aVlng a L1'llC:CilE.'SS eqLlal tG Gui;i a fraCt~On Cf the I'lPlgClt OL
the cavity boxes 14 and the width of wh_ch being adapted to
the spacing between the cavity boxes 11, so that the wooden
ledges ~' when sestina against the botLOm 13 cf the mould
with their future front face, fill said spacing entirel,~.
The wooden ledges =~' are thereafter at each end connecte~to
the cam steel 11 by means of in per se known clips to having
a spike 1~ which is driven into the wooden ledge 4' .
T~Ihen this is done, the reinforcement net 4 is placed and
fixed at appropriate level below the top 13' of the mould
through the connection to the upright reinforcing bows 12
welded to the cam steel 11. The upper ends of the bows 12
are attached to tre reinforcement net 4 by means of common
birder wire.
The casting mould is thereafter ready to receive the
concrete supplied from above b=r means of e.g. a production
jib movable in the longitudinal direction of the mould; said
jig may be a multi-function jig (for the application of
mould oil, hoisting og possibly transportation. or the
finished element, etc.). During the casting process, the
wooden ledges 4' are secured by casting to the concrete ribs
3, which are reinforced partially through the cam steel,
partially through the bows 12, simultaneously as the wooden
ledges are connected to the reinforcement.
After the mould has been filled with concrete, the top
concrete surface is freely accessible to be worked en in
non-hardened!hardened condition; this in contrast with prior
art casting technique wherein the concret surface 2' is
formed at the bottom 13 of the mould.
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iu figur2 ~, the SpaCings bet.Jee.~. ad~aCe~lt CaVlt:/ bOXes 1:1
are indicated at 18. A cavity frame 19 for a resulting
window cavity is placed upon some cavity bones and has
suspended lugs ?0 shaped to engage into the spacing 13 and
seal the same with regard to the cavity frame 19, so that
concrete cannct penetrate into the frame 19 via said
spacings. Arcund cavities for doors; windows, nailing ledges
(not shown) are placed. Additionally, one may place beams at
the resulting top edge and possibly at the bottom edge. of
the element to be manufactured.
The attachment of the cam steel 11 and the bows i2 on the
wooden ledges 4' may take place optionally prior to the
embedment of the wooden ledges ~' into the mould o~_.
subesequent to their embedment into the same.
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