Patent Application
20130284881
This invention pertains to a modular system for assembling a disposable shuttering mould used to cast a concrete surface, especially with regard to casting unidirectional, bi-directional, transpiring, ventilated and heat-insulation lofts, as well as monolith unidirectional and bi-directional, transpiring, ventilated and heat-insulation floors, and also unidirectional and bi-directional, transpiring, ventilated and heat-insulation slabs.
Such surfaces as lofts, floors or slabs are conventionally built, in the construction trade, by making use of ordinary materials, e.g. hollow flat blocks and hollow floor bricks made of tiles and/or built on a lightweight aggregates concrete base, combined with supporting structures such as, for instance, brick dwarf walls and pre-compressed joists. However, the building of these structures involve very high costs; moreover, it requires a long construction time and also involves making use of a large amount of materials that are, unfortunately, not homogeneous to one another and, above all, transmit moisture and also feature poor technical performance, the latter element being essential to be able to build structures complying with the increasingly stricter energy-saving standards worldwide. Furthermore, the structures of this kind will not make it possible to immediately make the coating concrete cast, since a wait time will be needed in order to wait for the consolidation of the brickwork structures themselves with the attached cross-pieces with very short centre distances for supporting the horizontal partition, i.e. the surface that requires the additional reinforced concrete cast. To remedy these problems in the course of time, the engineering techniques have proposed modular structures made of “disposable” formwork made from recycled plastics (referred to as “second life” formwork), which will guarantee simple, quick laying and also make it possible to cast the concrete soon after the formwork laying. These formworks will, after they are put together, define at the top a substantially uninterrupted plane that will form the base for the concrete casting: likewise, it is commonly known that the coating concrete layer is reinforced, in a large number of applications, by means of a reinforcing metal structure made up of a conventional electrowelded mesh and/or metal rods, in order to achieve the surface consolidation, such a reinforcing metal structure being laid on the place defined by the “disposable” plastic formworks and subsequently incorporated into the coating concrete casting, yet without guaranteeing the right distance of the electrowelded mesh itself to obtain an adequate bar cover as laid down by the Technical Construction Standards.
The requirement (defined as the conservation of the physical and mechanical features both of the materials and the structures) is an essential condition in order for the safety levels to be guaranteed during the entire works design service life.
In particular, as far as a reinforced concrete structure is concerned (e.g. a horizontal plane or partition), greatest importance should be attached, for the durability purposes, to the protection of metal reinforcements against corrosion.
For this reason, the following conditions should be met:
sufficient bar covering shall be made by making use of compact, high-quality, low-porosity and low-permeability concrete;
never exceed a crack limit state, which shall be commensurate to the environment conditions, the stress and the reinforcements' proneness to corrosion.
The need to provide an adequate bar cover is, in turn, essentially related to a number of significant reasons that involve several issues:
1) structural durability (as regards the reinforced concrete) guaranteed by adequate protection of reinforcement against oxidation—an essential condition to the proper stress transfer from steel to concrete, and vice versa;
2) concrete is able, due to its featuring a pH value of 12.5 to 13.5 (i.e. a basic one), to guarantee the reinforcement passivation, provided that the same is adequately protected;
3) the latter condition may, however, be altered by two different types of attack capable of nullifying the protection and triggering the corrosion, i.e. carbonation and chlorination. The spread of both of these phenomena into the concrete, as deep as the layer in which the reinforcement is placed, can be hampered by the very inclusion of an adequate concrete layer (that is to say, the bar cover itself);
4) appropriate fire resistance can be achieved also by adding some more non-structural covering layers (cf. UNI EN 1992-1-2).
In fact—and in particular—these structures pose a problem whereby, in case conventional rods are used to build the metal reinforcement, such rods cannot be secured firmly to the formwork and, therefore, will normally be secured to one another by carrying out conventional operations (i.e. tying by means of metal wires), in order to prevent them from being displaced off their original position during the completion cast (when the concrete is laid). All of this will give rise to problems in the correct use of the conventional “disposable” shuttering moulds/formwork made of recycled plastics.
Furthermore, the known modular systems of “disposable” shuttering moulds/formwork made of recycled plastics still pose serious transpiration problems, which may lead to building poorly efficient reinforced concrete structures (considering the remarks made above), indeed as far as civil buildings are concerned, which will give rise to the well-known causes of SBS (Sick Building Syndrome).
The aim of this invention is, therefore, to solve the above-mentioned problems intrinsic to the older technique, by providing a unique modular system for assembling a transpiring, “disposable” heat-insulation shuttering mould/formwork to protect the structural reinforcements, after casting a reinforced concrete surface that will make it possible both to easily and quickly lay the modular elements making up such transpiring, “disposable” heat-insulation and variable-geometry shuttering mould/formwork, and to easily and accurate position the elements acting as reinforcements for the coating concrete layer as well as the water, gas or electricity piping.
Another aim of this invention is to provide a fully modular system for assembling a transpiring, “disposable” heat-insulation and variable-geometry shuttering mould/formwork for casting a reinforced concrete surface, which will facilitate the laying and mutual hooking operations in a specular way among the various modular elements making up such heat-insulation construction system by building a solid structure, which will indeed be a transpiring and highly stable (from the structural viewpoint) monolith construction both during the additional casting phase (while guaranteeing the foot traffic thereon, with resulting worker safety) and during the entire service life of the construction, thanks to the adequate reinforcement bar covering.
Moreover, one further aim of this invention is to provide a fully modular system for assembling a transpiring, “disposable” heat-insulation shuttering mould/formwork for casting a reinforced concrete plane made up of dynamic constructions elements able to be assembled according to several configurations (even the most disparate ones).
The above and the other aims and advantages of the invention, as detailed in the description hereafter, will be obtained by means of a unique modular system for assembling a “disposable” shuttering mould/formwork for casting a reinforced concrete plane and, in particular, for casting unidirectional, bi-directional, transpiring, ventilated and heat-insulation lofts, as well as monolith unidirectional and bi-directional, transpiring, ventilated and heat-insulation floors, and also unidirectional and bi-directional, transpiring, ventilated and heat-insulation slabs, like the one described under claim 1. Preferred embodiment designs and original variants of this invention will be the object of the relevant claims.
It is obvious that a number of variants and modifications can be made to the described items (e.g. variants and modifications concerning the shape and dimensions, as well as the arrangements and the parts performing equivalent functions) without departing from the scope of protection of the invention, as referred to in the enclosed claims.
This invention will be best described by a few preferred forms of construction, which will be provided by way of example and with no limitation thereto, with reference to the enclosed drawings, where:
The description below will illustrate the unique features of the various elements making up the transpiring, heat-insulation modular system 1 in accordance with the present invention, by showing, in particular, a few possible assembling configurations for building shuttering moulds and formworks for which structural, transpiration and heat-insulation specifications shall be met: it is obvious to any one engineer expert in this field that these configurations are, due to the present invention being relative to a unique transpiring heat-insulation modular system, to be meant only as mere examples which somehow limit the nearly infinite possibilities of possible, different further configurations that the modular elements (which will be described hereafter) of the transpiring heat-insulation construction system referred to in this invention may feature depending on the required heat resistance, i.e. with reference to transmittance (it is expressed by U- and defines an element's insulating capacity, as well as by SL units) (cf. UNI EN ISO 6946), which can be measured as follows:
where indicates the temperature (expressed by K°); indeed, the insulating elements themselves may reach λ [W/m K] 0.10-0.08 (and above), according to the different shapes, geometry and methods of assembling the elements themselves by means of special adequately shaped dovetails and grooves/slots.
Thus, with reference to
With particular reference to
As an alternative—and by referring to
In addition, it can be anticipated that supports 7 will be connected with one another by means of transpiration ducts, so as to facilitate the transpiration process inside the transpiring, “disposable” heat-insulation shuttering mould/formwork.
Furthermore, it can be productively anticipated that each of said supports 7 can be positioned freely onto the upper surface 5 of supporting plane 3, so that more possible rod laying configuration modes will be available and able to be adapted to specific requirements, in order to obtain metal reinforcements of varied forms so as to comply with all of the laws and regulations in force in the building and construction trade. To this end, base 75 (or each of bases 93 of support 7) can be equipped with at least one hooking profile 79, for instance by means of elastic-strain opposed teeth, suited to engage a respective corresponding seat 9 made available on the upper surface 5 of supporting plane 3, such seat 9 belonging to a plurality of similar seats arranged in various manners on all of such surface 5, as shown by way of example in
In addition, as regards one further variant that has not been illustrated, such body can also be equipped, next to one of its upper vertexes, with at least one seat suited to accommodate a respective hooking profile 79 placed on the base of another body, in order to stabilize and make the multiple stacking thereof integral, with no limitations at all.
By referring, now—and in particular—to
The supporting plane 3 shall preferably feature two such score lines 11 arranged in a mutually perpendicular position, so that they will divide the surface of supporting plane 3 into four partitions 13 having equal dimensions.
Still with reference to
In order to guarantee the necessary, proper transpiration inside the transpiring, “disposable” heat-insulation shuttering mould/formwork 1, the surface of supporting plane 3 may feature a plurality of such through holes 17 and/or transpiration channels (not shown) that they will guarantee the creation of a real smooth transpiration grid, so as not to constrain the outflow of condensate and/or vapour inside the transpiring, “disposable” heat-insulation formwork 1 itself.
In order to guarantee the necessary heat insulation from the ground, the soil (cf. DE Passivhaus standard) or any other bearing surface, the supporting plane 3 can be made of any one plastic material, such as, for instance, polypropylene or polystyrene, suitable to the purpose. Furthermore, in order to make it possible to build a transpiring, ventilated and heat-insulation French drain (as shown, by way of example, in
By referring, instead, to
Furthermore, the heat-insulation hollow floor brick 30 may feature a lower surface adequately adapted and shaped to stick and fit into the corresponding upper profile of the supporting frame 21, so that the overlap of at least one (or several) of them will be simple, immediate and stable, without making use of any further fastening means to prevent reciprocal movements when the additional structural concrete is cast. Moreover, the upper surface of the heat-insulation hollow floor brick 30 may be adapted and shaped to correspond with the profile of the lower surface of supporting plane 3, so that a heat-insulation hollow floor brick 30 and a supporting plane 3 (or their partitions 13, 33) can be overlapped easily and firmly, for instance in order to enhance the insulation from the ground or make thermal transmittance passive. In order to guarantee the necessary, proper transpiration inside the transpiring, “disposable” heat-insulation shuttering mould/formwork 1, the surface of heat-insulation hollow floor brick 30 may feature a plurality of such through holes 37 and/or transpiration channels that they will guarantee the creation of a real transpiration grid inside the transpiring, “disposable” heat-insulation shuttering mould/formwork 1 itself. Such through holes 37 and/or transpiration channels shall preferably match with the similar holes and/or channels found on supporting plane 3, so that, in case of overlap between a supporting plane 3 and a heat-insulation hollow floor brick 30 (or between their partitions 13, 33), the availability of the transpiration grid inside the transpiring, “disposable” heat-insulation shuttering mould/formwork 1 will be ensured.
Please note that the heat-insulation hollow floor brick 30 can be used to build a loft and can also be hooked integrally to the thermo-acoustic panel placed vertically to form the loft or roof soffit, or resting directly onto the ground itself. The heat-insulation hollow floor brick 30 itself can be considered as an element to form a ventilated, integral thermal insulation coating (free from thermal bridges) and can be integrally hooked, in a “lock-in” fashion, to special profiles (not shown) made of steel or aluminum alloys or structural extruded profiles made of fibre glass (G.F.R.P.) or structural composite thermoplastic materials. The same profiles are integrally blocked, by means of dowels, into an existing wall made also of conventional materials.
By referring, in particular, to
The heat-insulation base 50 can also be equipped, on its perimeter, with lock-in profiles suited to accommodate the corresponding connection profile for any one spacing connector 16 of the type known in the relevant engineering field in order to allow perfect structural connection of heat-insulation base 50 with at least another heat-insulation hollow floor brick and/or at least one supporting plane 3 and/or at least one partition 13, 33 of the latter and/or another heat-insulation base 50: the lock-in profiles 53 will productively correspond with the lock-in profiles 15, 35 of a respective supporting plane 3 or heat-insulation hollow floor brick 30 when overlapping such heat-insulation base 50.
Furthermore, the heat-insulation base 50 may feature score lines 51 suited to allow modular partitioning of the same heat-insulation base 50 into bases featuring smaller dimensions and different shapes from the ones of the originally intact base 50, such dimensions and shapes being essentially the same as the ones of the above-mentioned partitions 13, 33. Similarly, in order to guarantee the full, unique modular design of the construction system of transpiring, “disposable” heat-insulation shuttering moulds and/or formworks referred to in the present invention, every single partition of the heat-insulation base 50 may feature, on its perimeter, lock-in profiles 53 so that these profiles will productively correspond with lock-in profiles 15, 35 even of individual partitions 13, 33 in case they are stacked on such partition of the heat-insulation base 50.
Each heat-insulation base 50 shall preferably feature such a section as a form essentially shaped like a “U” upside down, which defines an insulating channel 55. Grooves 57 shall preferably be found along the side walls of said insulating channel 55, which are suited to make it possible to insert insulating partitions (not shown) at varying distances, which are suited to prevent, if necessary, the penetration of concrete into the channel/hollow 55 at the time of casting the structural concrete and also enhance the insulation provided by the insulating base without the formation of convective air motions 50.
Here too, in order to guarantee the necessary heat insulation from the ground, the soil or any other bearing surface, both the heat-insulation hollow floor brick 30 and the insulating base 50 can be made of any one plastic material such as, for instance, polystyrene, and other materials featuring unique insulating and sound-proofing characteristics, as commensurate to the purpose.
Furthermore, the heat-insulation hollow floor brick 30 and, if necessary, the insulating base 50, may be made by means of vacuum techniques, in order for the same to feature top thermal and acoustic characteristics.
By referring, in particular, to
By referring, instead, to
Obviously, all of the elements described above (or some of them) relative to the modular construction system referred to in the present invention can be used both in conventional building works and, above all, in the sustainable environment-friendly building works, both to build, from the very beginning, unidirectional, bi-directional, transpiring, ventilated and heat-insulation lofts, as well as monolith unidirectional and bi-directional, transpiring, ventilated and heat-insulation floors, and also unidirectional and bi-directional, transpiring, ventilated and heat-insulation slabs, and also refurbish crumbling floors, lofts and slabs previously existing and not complying with the anti-seismic and thermo-acoustic requirements, and also build, for instance, micro-ventilated and macro-ventilated roofs, with provisions for being fitted to any one type of new or existing outer curve (though a crumbling one) failing to meet any one requirement referred to several times, that is to say, even a wooden one, with no applicability constraints.
| Number | Date | Country | Kind |
|---|---|---|---|
| TO2011A000013 | Jan 2011 | IT | national |
| Filing Document | Filing Date | Country | Kind | 371c Date |
|---|---|---|---|---|
| PCT/IT2012/000004 | 1/10/2012 | WO | 00 | 7/12/2013 |
