Patent Application
20170234009
The present invention relates to a method for manufacture of a fire-proof and insulating prefabricated building wall comprising a wall core of an expanded, foamed plastic material, such as EPS (expanded polystyrene), with an integrated reinforcement structure and a coating of a cementitious material.
In the present specification the term “building wall” is used as meaning interior as well as exterior building walls, floors and roofs.
Using an expanded, foamed plastic material, such as EPS, as an insulating wall component is well known in the art of building construction.
The term “insulating concrete form” or “ICF” is used for a widely applied in situ technology for manufacturing building walls. A system of formwork for reinforced concrete (the ICF) is made with rigid blocks of EPS that stay in place as a permanent interior and exterior substrate for walls, floors, and roofs. The forms are interlocking modular units that are dry-stacked without mortar to form a hollow core space into which concrete is poured. The units lock together and create a form enclosing the hollow core space in which an enforcement structure usually comprising reinforcing steel bars is positioned before injecting the concrete. The reinforcement structure, concrete core and EPS blocks form a wall core, which are coated on its major surfaces with plaster.
Plumbing and electrical conduit can be placed inside the ICF forms, though settling problems may cause them to break, creating costly repairs. For this reason, plumbing and conduit are usually embedded directly into the foam before the wall coverings are applied. A hot knife is commonly used to create openings in the foam to lay piping and cabling, while ICFs made from other materials are typically cut or routed with simple carpentry tools. As ICF building walls are manufactured in situ, manufacture is sensitive to labour costs, and quality of the construction may also be an issue.
WO 2004/042163 A2 discloses a building wall module with a polystyrene core plate with outer layers of welded wire mesh encased in concrete, potentially comprising steel wire trusses that extend through the core plate. The core plate is constructed of several premanufactured polystyrene blocks that are positioned to abut each other after having been cut into shape.
AU 4573696 A discloses a wall panel in which reinforcing, U-shaped members are placed in a mould and held in position. Thereafter, polystyrene beads are placed under pressure with the use of steam to cause them to expand and form the wall panel.
On this background it is an object of the present invention to provide a method for manufacture of a fire-proof and insulating building wall, which provides a wider range of possibilities for the manufacture and features of the wall.
Thus, the present invention provides a method for manufacture of a fire-proof and insulating prefabricated building wall, comprising the steps of
positioning an interior load-bearing reinforcement structure with a number of reinforcing members into an expansion mould with a mould wall comprising interior mould surfaces enclosing a plate shaped volume,
blowing beads of an insulating expandable plastic material into the expansion mould,
expanding the beads in the expansion mould and allowing them to melt together to form a foamed core plate of a plate shape corresponding to the plate shape of said plate shaped volume, said plate shape of the core plate comprising plate surfaces including two major plate surfaces, the beads ultimately expanding to encase the reinforcement structure so that the reinforcement structure extends through and is embedded within the core plate with substantially all surfaces of the reinforcement structure that are positioned within said plate surfaces of the core plate being in contact with the core plate, the reinforcement structure and the foamed core plate thereby together forming a load-bearing, insulating wall core, which assumes the general plate shape of the core plate,
positioning of the wall core in a formwork mould with a mould wall encasing the wall core, the mould wall comprising interior mould surfaces forming a plate shaped volume, at least one of the major surfaces of the wall core being positioned at a distance from the mould wall,
injecting a fire-proof cementitious material into the formwork mould and allowing it to extend at least between the mould wall and said one major surface of the wall core, and
allowing the cementitious material to at least partly cure, the cementitious material adhering to said one major surface to thereby provide coating of the one said major surface of the wall core with the cementitious material to form a coating having an outer surface forming a first major surface of the building wall.
A complete building wall according to the invention can thus be manufactured in a factory, which alleviates the drawbacks associated with building walls manufactured in situ. The building wall resulting from the method according to the invention can be removed from the formwork mould and transported to the building site where it can be readily lifted into position, e.g. using a crane. Thus a building with a fire-proof, insulating, load-bearing prefabricated building wall comprising a wall core with an insulating core can be manufactured. Several building walls that may be in the form of building wall modules can be attached to each other using connecting or anchoring devices that may also be integrated in the plate-shaped building wall and extend outside the wall from the surfaces of the wall.
The building wall can also be used as horizontal construction walls, i.e. roofing or flooring modules, in the building that similarly may be connected to each other and the outer walls of the building. The building wall according to the invention may be used as outer walls forming part of the building's weather screen as well as interior walls.
The coating layer is preferably able to carry itself, but is otherwise not load-bearing. The enforcing members usually are reinforcing bars or beams, preferably of steel, that may carry the load of the wall itself as well as other building parts. They may provide flexural strength sufficient to allow use of the building wall in flooring and roofing. The bars preferably have a cross-sectional profile that allows the bars to function as load-bearing columns in a static system of the building, such as a U-beam, an H-beam or an I-beam.
The reinforcement members may also comprise reinforcing steel trusses and/or steel wiring.
The major surfaces of the building wall may be painted and/or wall covering or panels may be attached to the outer surface of the building wall at the factory or at the building site.
Expansion of the plastic material can be accomplished using steam provided from a steam generator at the manufacturing site.
The cementitious fire-proof material may comprise one or more of plaster and light-weight concrete. The expanded plastic material preferably comprises at least 90% of a polymer and optionally one or more additives or fillers. Preferably steel bars are provided to provide load-bearing properties sufficient to allow the building wall to carry both its own weight and the weight of building elements. They preferably have a cross-sectional profile, such as a U-profile or an I-profile, that allows the bars to function as load-bearing columns in a static system of a building in which the wall is positioned.
The term building wall also comprises walls used in a roof or a floor of a building.
The wall core is preferably shaped substantially as a parallelepiped that is positioned with its major surfaces substantially perpendicular and preferably substantially horizontally during the injecting step. Similarly, the building wall is preferably shaped as a parallelepiped. Accordingly, the interior volumes of the expansion mould and the formwork mould are preferably each shaped as a parallelepiped. A lid may be positioned on top of the moulds to form the mould wall of the upper minor surfaces of the building wall.
Coating is preferably carried out on both major surfaces of the plate-shaped wall core, more preferred also on some or all minor surfaces of the wall core. A separately provided adhesive can be applied to the surfaces of the wall core before the injection step to ensure sufficient adhesion between the wall core and the coating. If all surfaces of the wall core are coated, there is less need for such an adhesive since the coating completely encases the wall core and thus is inherently attached in position to abutting the surfaces of the wall core.
Coating of the bottom minor surface of the wall core may be achieved by positioning one or more spacer blocks beneath the wall core to space the wall core from a bottom mould surface of the formwork mould. The spacer blocks may comprise concrete, such as light-weight concrete, and are preferably moulded into the coating during the injection step.
Before the injection step the formwork mould can be filled with an insulating filler material, such as loose insulating, pellatised ceramic or perlit beads, e.g. LECA beads, around the wall core between which the cementitious material is being distributed during the injection step so that the beads are integrated into the coating. The coating is preferably fire-proof.
Before the injection step, and potentially before a bead filling step, a wire mesh, such as a steel wire mesh, can be positioned in the formwork between the wall core and the mould wall, preferably attached to the reinforcing members of the wall core. Usually the wire mesh positioned at the major surfaces of the wall core, and the wire mesh is positioned to be substantially co-planar with the major surfaces. The wire mesh is then moulded into the coating during the injection step, which provides improved structural integrity and flexural strength of the coating.
A wire mesh, such as an acrylic wire mesh, may also be positioned close to the mould wall surface at each of the major surfaces of the wall core before the injection step so as to be integrated into the coating during the injection step. This provides stronger outer surfaces of the building wall.
The cementitious material is preferably pumped into the formwork mould from a lower point of the mould, preferably from the bottom of the mould to allow it to disperse within the mould. It is preferred that the cementitious material is pumped into the formwork mould from a point beneath the mould. The formwork mould is closed, and preferably a vacuum is applied to the space to be filled with cementitious material, which is usually in the form of cementitious pasta, which improves dispersing of the material.
The method according to the invention is especially suitable for manufacture of several building walls of similar configuration. In this case the method comprises the further step of repeating the method according to the invention to manufacture a further building wall using the same equipment in the same manner. The invention is thus suited for manufacture of building walls for standard houses where several building walls of similar configuration can advantageously be mass produced.
An embodiment of the method according to the invention comprises previous to the blowing step the further step of positioning piping, channels and/or cabling in the expansion mould to fit to desired positions in the resultant building wall, the piping, channels and/or cabling being embedded in the wall core during the expansion step. At the factory the piping, channels and/or cabling can thus be positioned in exact locations in the building wall at the factory, and cutting in the building wall at the building site can be completely avoided. Since the foamed plastic is very elastic, settling problems are not an issue. The plastic material within the surfaces of the wall core are typically substantially everywhere in contact with outer surfaces of the piping, channels and cabling since the plastic material is expanded to enclose these. The piping, channels and/or cabling may at respective ends project out of the wall core and the building wall to allow for connection.
Another embodiment further comprises previous to the blowing step the further step of positioning of a frame within the expansion mould, the frame extending between two parts of the mould wall, a frame volume enclosed within the frame being kept free of the plastic material during the blowing and expansion steps, said frame volume forming a door or window aperture in the wall core and the resultant building wall. The frame preferably comprises four side surfaces that function as formwork for the side surfaces of the aperture. Hereby, in a cheap and easy manner window and door apertures can also be included in the wall without the need to cut out apertures in the wall core after manufacture. Cutting out space for piping, window apertures and the like is generally imprecise and may produce areas of lowered insulation abilities of the resultant building wall.
In another embodiment the expansion mould on a mould wall surface facing said one major surface of the wall core comprises at least one longitudinally extending projection that extends coplanarly with the mould wall surface so that the expanded wall core on said major surface thereby comprises an associated longitudinally extended groove shaped by the longitudinally extending projection, and previous to the injecting step further comprising the step of
positioning at least one solar heating liquid pipe in the groove so that after the injecting step in the resultant building wall the liquid pipe extends between said one of the major surfaces of the wall core and the coating, a channel for the liquid pipe being provided by oppositely disposed grooves in the wall core and the coating, respectively. Hereby at the factory a solar heating liquid pipe can be readily included in the building wall close to the major surfaces of the building wall and at the outer side of the insulation. The liquid pipe is thus able to collect and store heat energy from the coating. The heat may be produced from the sun at an outer major surface of the building wall and so that the wall effectively functions as a solar heat collector, the liquid pipes forming part of a solar collector system with re-circulating liquid. Alternatively or additionally, the building wall is able to cool down the circulating liquid during the night to provide cooling during daytime. In a development of the embodiment in which the building wall comprises liquid pipes, solar cell panels are positioned on or integrated into the outer surface of the building wall, i.e. on the outside of one of the major surfaces of the building wall. In a conventional manner the solar cell panels produce power. As is well-known during production of power from solar cells a relatively large amount of heat is produced, which lowers the amount of power produced by the solar cells. Thus, it is preferred that the liquid pipes are positioned behind the solar cell panels to provide cooling of a back side of the panels using circulation of the liquid within the piping. Preferably the channel and liquid pipe weave back and forth across the surface to provide a larger heating area. Inlet and outlet of the liquid pipe can be provided in the resultant building wall for connection with a solar heating system. When the liquid circulates outside the building wall, it is cooled for instance in the ground or in a solar heating system, e.g. for heating water for domestic use. Preferably the piping includes flexible tubes that can easily be positioned in the grooves before the injection step. The flexible tubes can be attached in different places to the wall core using temporary fastening means such as metal clips or the like that can be introduced into the wall core and be integrated into the coating. It is noted that in the embodiment with solar heating piping the piping can alternatively be positioned within the coating or on an outer surface of the coating. The latter may be optimal for cooling solar cell panels. However, the described embodiment in which the piping is positioned between the wall core and the coating provides an advantageous manner to include the piping in the building wall, which can be done at the factory. The building wall may comprise one or more solar heating pipes. The pipes may also be provided on the major surface of the building wall facing the inside of the building to be connected to a cooling or heating liquid source to heat or cool the building interior. Heat collected from the outside wall may be distributed at the inside wall.
In another embodiment the injection step also comprises similar coating of the other of said major surfaces of the wall core with the cementitious, fire-proof material forming an outer surface with a second outer surface of the building wall. One or both surfaces are preferably substantially fully covered by the coating to make the resultant wall fire-proof when installed in a building. All minor surfaces of the wall core (four minor surfaces in the case of a parallelepiped building wall) are also preferably coated, which provides a stable wall cassette, which is fire-proof on all sides and surfaces. However, if the building in which the building wall is positioned allows it, not all surfaces, especially one or more of the minor surfaces, need be coated.
In another embodiment the expanded plastic material essentially consists of polystyrene or polyurethane. It may also comprise additives or fillers such as cellulose and starch. Preferably more than 80 percent, more preferred more than 90, more preferred more than 95, more preferred more than 98 of the solid matter of the core plate is polystyrene or polyurethane. Thermal conductivity measured according to EN 12667 may range from 0.032 to 0.038 W/(m·K) depending on the density of the core plate. The density of the core plate may be 10 to 50 kg/m3, preferably 20 to 30 kg/m3. Adding fillers (graphites, aluminium, or carbons) may allow the thermal conductivity of the core plate to reach around 0.030-0.034 W/(m·K).
In another embodiment the core plate extends between the reinforcement structure and the coating so that the core plate at substantially all positions distances the coating from the reinforcement structure with at least 5 mm, preferably at least 10 mm, more preferred at least 15 mm. This provides improved insulating properties of the wall.
Another aspect of the invention provides a fire-proof and insulating prefabricated building wall manufactured according to the method of any one of the above embodiments. Such building walls may be characterized in that the core plate extends to substantially in all positions within the boundaries of the core plate be in contact with the reinforcement structure. This is achieved since the plastic material during expansion completely surrounds and encloses the reinforcement structure. If channels, cabling or piping is included in the wall core as explained above the core plate may similarly extend to substantially in all positions within the boundaries of the core plate be in contact with the channels, cabling or piping.
A further aspect of the invention provides a fire-proof and insulating prefabricated building wall, comprising
an interior load-bearing reinforcement structure comprising a number of reinforcing members,
a foamed core plate of a plate shape, the core plate being manufactured of an insulating expanded plastic material that encases the reinforcement structure, the core plate comprising outer surfaces of its plate shape including two major surfaces, the reinforcement structure extending through and being embedded in the core plate with substantially all surfaces of the reinforcement structure in contact with the core plate within said outer surfaces of the core plate,
the reinforcement structure and the foamed core plate forming an insulating wall core with two major surfaces substantially coinciding with said two major surfaces of the core plate, and
one of said major surfaces of the wall core being coated with a coating of cementitious, fire-proof material that forms a coating having an outer surface forming a first major surface of the building wall,
a solar heating liquid pipe being positioned in a channel extending between the wall core and the coating.
Again, such building walls may be characterized in that the core plate extends to substantially in all positions within the boundaries of the core plate be in contact with the reinforcement structure. This is achieved since the plastic material during expansion completely surrounds and encloses the reinforcement structure. If channels, cabling or piping is included in the wall core as explained above the core plate may similarly extend to substantially in all positions within the boundaries of the core plate be in contact with the channels, cabling or piping. The solar heating piping may be included in the wall in the manner as described in the above.
In an embodiment of this aspect the reinforcing members comprise bars extending longitudinally from one end to another in a direction extending substantially in a plane of the plate-shaped building wall with load-bearing properties sufficient to allow the building wall to carry both its own weight and a substantial part of the load of a roof construction above the building walls, the bars having a cross-sectional profile that allows the bars to function as load-bearing columns in a static system of the building.
In another aspect the invention comprises a building including one or more building walls according to the invention and/or manufactured according to the invention. Preferably the building comprises at least two such walls, more preferred at least four such walls that form the four outer walls of the building. In such a building the reinforcing members may be configured and dimensioned to carry substantially all loads in a downwards direction, i.e. so that further reinforcement structures are substantially not necessary at the outer surfaces of the building. In effect the reinforcing members thus are the only load-carrying parts of or at the building's outer walls.
The invention will be described in further detail in the following with reference to the examples of embodiments shown in the drawings in which
Referring to
In
As is shown in
The formwork mould 13 is closed by putting together the two parts 13a, 13b after which a vacuum is applied to the volume 18. Then a fire-proof cementitious material is pumped into the formwork mould 13 from beneath and is allowed to extend between the mould wall 12 and all surfaces of the wall core 12. The cementitious material (not shown) then at least partly cures, the cementitious material adhering to all surfaces of the wall core 12 to produce a coating 40 (not shown in
The building wall is thus manufactured in a factory consecutively in two moulds 3, 13. The building wall is removed from the formwork mould 13 and transported to a building site where it is lifted into position, e.g. using a crane. Thus a building with a fire-proof, insulating, load-bearing prefabricated building wall comprising a wall core with an insulating core is manufactured. Several similar building walls of differing sizes and shapes can be attached to each other using connecting or anchoring devices that may also be integrated in the plate-shaped building wall and extend outside the wall from the surfaces of the wall. One example, denoted 41, of such an anchoring device is shown best in
The building wall can also be used as a horizontal or inclined “wall”, e.g. roofing or flooring modules, in the building that similarly may be connected to each other and the outer walls of the building. The building wall may be used as outer walls forming part of the building's weather screen as well as interior walls.
The bars 2a, 2b usually are dimensioned to carry the load of the wall itself as well as other building parts. Thus, in the embodiment shown the bars 2a, 2b are U-beams, i.e. having a cross-sectional U-profile that allows the bars 2a, 2b to function as load-bearing columns in the static system of the building.
The two major surfaces 40a, 40b of the building wall may be painted. Wall panels 33, 34 are attached to the outer surface of the building wall at the factory. The cementitious fire-proof material comprises light-weight concrete.
Expansion of the plastic material can be accomplished using steam provided from a steam generator in the factory.
The major surfaces 40a, 40b of the building wall resulting from the method according to the invention may be painted at the factory or on the building site.
The wall core 12 is shaped substantially as a parallelepiped that is positioned with its major surfaces 10, 11 substantially perpendicular and horizontal during the injecting step in which concrete is injected or pumped into the formwork mould 13. Similarly, the resultant building wall is shaped as a parallelepiped. Accordingly, the interior volumes 6, 18 of the expansion mould 3 and the formwork mould 13 are each shaped as a parallelepiped. A lid plate (not shown) is positioned on top of the moulds 3, 13 in their closed positions to form the upper surface of the mould wall 17.
Coating of the bottom minor surface of the wall core 12 is achieved by positioning one or more spacer blocks 21 (
Before the injection step the formwork mould 13 is filled with an insulating filler material in the form of LECA perlit beads 22 around the wall core 12 between which the cementitious material is distributed during the injection step so that the beads 22 are integrated into the coating 40. The resultant coating 40 is fire-proof.
Before filling the beads into the formwork mould 13 a steel wire mesh 23 is positioned in the formwork mould 13 between the wall core 12 and the mould wall 17 extending along the major surfaces of the wall core 12. The wire mesh 23 is positioned to be substantially co-planar with the major surfaces 40a, 40b and is positioned approximately half-way between the major surfaces 10, 40a and 11, 40b, respectively. The wire mesh 23 is then moulded into the coating 40 during the injection step, which provides improved structural integrity and flexural strength of the coating 40 so that the coating 40 is able to carry its own weight, but is otherwise not load-bearing.
An acrylic wire mesh 24 is also positioned close to the mould wall 17 at each of the major surfaces 10, 11 of the wall core 12 before the injection step so as to be integrated into the coating 40 during the injection step.
The method may be repeated to produce one or more further, similar building walls using the same equipment.
Previous to the blowing step a pipe 25 and a power cable 26 are positioned in the mould 13 to fit to desired positions in the resultant building wall, the pipe 25 and cable 26 being embedded in the wall core 12 during the expansion step. At the factory the pipe 25 and cable 26 are thus positioned in exact locations in the building wall, and cutting in the building wall at the building site is completely avoided. The plastic material within the surfaces of the wall core 12 are everywhere in contact with outer surfaces of the pipe 25 and cable 26 since the plastic material is expanded to enclose these. The pipe 25 and cable 26 at respective ends project out of the wall core and the building wall to allow for connection. Further cabling, conduits, piping plumbing etc. may be included depending on the needs.
Previous to the blowing step a frame 27 is also positioned within the expansion mould 3, the frame 27 extending between the two major surfaces of the mould wall. Hereby, a frame volume 28 enclosed within the frame 27 is during the blowing and expansion steps step kept free of the plastic material, the frame volume 28 forming a door or window aperture in the wall core 12 and the resultant building wall. The frame comprises four side surfaces that function as formwork for the side surfaces of the aperture. Hereby, in a cheap and easy manner a window aperture is also included in the wall core 12 without the need to cut out apertures in the wall core 12 after manufacture. Similarly, a like frame 29 is included in the formwork mould 13 in the same position to ensure that the coating 40 also does not extend to the window aperture.
The expansion mould 3 on a mould wall surface facing the major surface 10 of the wall core 12 comprises a projection (not shown) that extends coplanarly with the mould wall surface 10 so that the expanded wall core 12 on the major surface 10 thereby comprises an associated longitudinally extended groove 30 shaped by the longitudinally extending projection. The projection and thus the groove 30 weave back and forth across the surface as shown to provide a larger collecting area. Previous to the injecting step a flexible solar heating liquid pipe 31 is positioned in the groove 30 so that after the injecting step in the resultant building wall the liquid pipe 31 extends between the major surface 10 of the wall core 12 and the coating 40, a channel for the liquid pipe 31 being provided by oppositely disposed grooves in the wall core 12 and the coating 40, respectively. Hereby, at the factory the liquid pipe 31 can be readily included in the building wall close to the major surface 40a of the building wall and at the outer side of the insulating wall core 12. The liquid pipe 31 is thus able to collect and store heat energy from the coating 40 as previously explained.
Three solar cell panels 32, each comprising a number of solar cells, are positioned on the surface of the building wall on the outside of the major surface 40a of the building wall. Specifically, each panel 32 is positioned in suitable shaped depressions in a wall cover 33, which is attached to the surface of the coating 40 and extends to enclose the surface 40a. In a conventional manner the solar cell panels 32 produce power that via not shown conduits may be transferred from the panels 32. The liquid pipe 31 is thus positioned behind the solar cell panels 32 to provide cooling of a back side of the panels 32 using circulation of the liquid within the pipe 31. Inlet and outlet of the liquid pipe 31 are connected with a solar heating system (not shown).
A like wall panel 34 is positioned to enclose the opposite major surface 40b of the building wall.
The flexible liquid pipe 31 is attached in different places to the wall core 12 wall using temporary fastening means such as metal clips or the like that can be introduced into the wall core 12 and be integrated into the coating 40.
Referring to
| Number | Date | Country | Kind |
|---|---|---|---|
| 2014 70567 | Sep 2014 | PA | national |
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/DK2015/050273 | 9/15/2015 | WO | 00 |
