Patent Application
20220275639
The present disclosure generally relates to a structural wall; and more particularly relates to a structural wall having an exogenous structure with reticulated frame along its longitudinal axis in its interior to enable filling of the interior on-site through industrial procedures.
Construction systems of wood, metal or other material, which have pillars, stiffening diagonals, bottom plate, top plate and transversal firewalls in a same longitudinal axis, are widely known. These conventional construction systems use some form of padding such as expanded polystyrene, glass wool, polyurethane foam or other similar materials, which is usually placed between vertical walls to provide insulation, prior to closing or lining one of the wall faces. Such traditional walls of wood and earth have their structure in their longitudinal axis. Further, these traditional walls use concrete mixtures which are usually specified in terms of the dry-volume ratios of cement, sand, and coarse aggregates. Cement, however, is not an environmentally neutral material. In the manufacture of cement, carbon dioxide is released into the atmosphere, and cement kilns burn hazardous waste, being a source of dioxins and mercury emissions into the atmosphere. Cement also pollutes water, with wash water from ready-mix plants highly alkaline and containing toxic cement kiln dust.
US Patent Publication 20040237425A1 (Worrell et al.) discloses a construction overlay composition and wall structure whose interior is filled with after the placement of vertical slats, side mesh, insulation on both sides and horizontal reinforcing bars. The disclosed wall structure of Worrell et al. has a great complexity and variety of construction elements which makes it unsuitable for on-site filling. On the other hand, the structural wall of the present disclosure does have essential pillars to transmit the loads to the base of the wall and to be able to fix its coating, and can be built in thicknesses much smaller than those mentioned in Worrell et al., at least 40 centimeters. Moreover, the structural wall of the present disclosure is pre-fabricable, which is clearly not the case with the structural wall as disclosed in Worrell et al.
Chilean Patent Document No. 1416-92 (abandoned patent application from 1992) discloses a self-supporting panel to be placed on a radier, which is provided with a layer of expanded polystyrene and its metal mesh cladding and subsequent stucco. The self-supporting panel in this reference is not a resistant wall, neither have diagonal pillars (but rather boards that reinforce the panel in the middle), nor internal firebreak chains or transversals; and it does not mention the way in which the self-supporting panel is structured; and thus may not be construed to be a structural wall capable of receiving loads.
Chilean Patent Document No. 2010000682, of the inventor of the present disclosure (Bravo Valenzuela Ricardo) discloses a wooden structure with an expanded polystyrene foundation and concrete cylinders at its base, which is filled with branches or adobes. Although this reference may have some common elements that are used or applied in conjunction with the structural wall of the present disclosure, but the said reference does not incorporate lattice structure nor elimination of internal diagonal shapes, and is not suitable for massive or industrial filling as in the case of the structural wall of the present disclosure.
Each of the aforementioned references suffers from one or more disadvantages, as discussed above. Therefore, there is a need of construction technique providing a structural wall whose reticulated frame shapes connect spaces in its interior, and which has an exogenous structure along its longitudinal axis, in order to enable its interior filling on-site, through industrial procedures.
In an aspect of the present disclosure, a structural wall is provided. The structural wall comprises a load-bearing wall-beam. The load-bearing wall-beam comprises two or more pillars. The load-bearing wall-beam further comprises at least one pair of a bottom plate and a top plate fixed to the two or more pillars to define beams located horizontally above a foundation block, about halfway up the wall and proximal to tops of the two or more pillars. The load-bearing wall-beam further comprises pillar supplements fixed in a plane of diagonal stiffening elements and coupled to the pillar supplements and the pair of the bottom plate and the top plate to stiffen the load-bearing wall-beam. Herein, the load-bearing wall-beam has a longitudinal axis thereof being free of continuous structural elements, to be permeable to on-site pouring and distribution of a filling mixture therein.
In one or more embodiments, the load-bearing wall-beam at the longitudinal axis thereof is reticulated to be permeable to passage of the filling mixture inside thereof.
In one or more embodiments, the two or more pillars comprise diagonal stiffening elements on each side of the two or more pillars. The diagonal stiffening elements are fixed to the pair of the bottom plate and the top plate and to the pillar supplements, and the pillar supplements are fixed externally to the two or more pillars.
In one or more embodiments, the two or more pillars comprise articulated elements arranged between the pair of the bottom plate and the top plate. Herein, the articulated elements join the pair of the bottom plate and the top plate together
In one or more embodiments, the two or more pillars are joined together by top wall ties arranged at a same height thereof.
In one or more embodiments, each of the two or more pillars is provided with one or more ribs in case of a continuous load-bearing wall-beam.
In one or more embodiments, the bottom plate is located externally to a plane of the two or more pillars and above a level of the foundation block.
In one or more embodiments, the load-bearing wall-beam provides structural support required therefrom using one or more of: cladding, diagonal stiffening elements, ribs and reinforcements.
In one or more embodiments, the load-bearing wall-beam is made of folding modular blocks.
In one or more embodiments, the load-bearing wall-beam is a piece-assembled, foldable, modular and stackable structure.
A more complete appreciation of this disclosure and many of the attendant advantages thereof will be readily obtained as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings, wherein:
The present disclosure refers to a structural wall which provides replacement of typical stiffening elements as used in traditional walls. In traditional walls, the structural elements including pillars, diagonals, bottom plate (and/or top plate) and chains or transversal firewalls are located usually along a longitudinal axis of the wall. Such arrangement prevents pouring or placement of filing on-site. The present structural wall with reticulated stiffening structural elements (defining a wall-beam structure) allows passage of the filling material inside the wall to its full width, length and height. Such pouring may be accomplished in construction along the longitudinal axis of the structural wall that transforms its lining into a stiffening structure. The present structural wall allows the filling or pouring of different types of mixtures inside the wall to obtain qualities of thermal and acoustic insulation, thermal inertia, and fire resistance. The mentioned properties are obtained at a minimum cost, through the use of mud with straw; however, the present disclosure enables the use of a multiplicity of filling such as concrete with expanded polystyrene beads, soil with expanded polystyrene beads, volcanic ash, sand, soil mixtures with cement, sawdust, wood chips, sand or any available material that provides the wall with the required characteristics.
The traditional walls of wood and earth have their structure in their longitudinal axis. The structural wall of the present disclosure has structural elements reticulated or exogenous to the longitudinal axis thereof, which allows the pouring in its interior on-site. The present structural wall makes it possible to industrialize the placement of filling on-site, thus making the process efficient and cost-effective. The teachings of the present disclosure are applicable to a large number of variants and alternatives of the structural wall (as disclosed), so that the present structural wall has the possibility of being built in an infinite number of thicknesses, shapes and forms as per the requirements. The present structural frees this longitudinal axis of the structure and transfers it to both sides of the wall, joining the structure of its internal and external vertical faces with structural elements that are permeable to the passage of the filling forming a wall-beam, through the structural function of the bottom plate, intermediate plate and top plate pairs and the diagonal stiffeners and/or clamping and separating piece braces that join these plates. This provide greater structural resistance, by increasing its resistant modulus and allows the four necessary or certified requirements of a wall to be separated into two groups: (a) Mechanical or seismic resistance, which is entrusted to this structure; and (b) (i) Resistance and thermal inertia; (ii) Acoustic resistance, and (iii) Fire resistance.
The structural wall of the present disclosure may be embodied as indeterminate number of wall types with a variety of materials. The present structural wall includes a load-bearing wall-beam which defines the physical structure therefor. Hereinafter, the “structural wall” has been interchangeably referred to as “load-bearing wall-beam” and sometimes simply “wall” without any limitations. Six different embodiments for the present structural have been detailed in the present disclosure; however, it may be contemplated by a person skilled in the art that other embodiments may be possible with minor design variations or structural changes or material changes, which are intended be incorporated herein by reference.
Referring to
In the Wall A, the distance between pillars (A3) is determined by the architectural needs and the structural calculation. Horizontally, at the base of the wall and between the pillars (A3), the Wall A may have a light foundation made up of a foundation block (A4) of, for example, expanded polystyrene, polyurethane or similar materials, whose purpose is to isolate the wall from the ground, preventing humidity from rising and also full filling the function of thermally insulating the construction, thus avoiding the thermal bridge. The measurements of this expanded polystyrene block (A4) are given by the width of the Wall A to be built, and further based on the height and the climatic characteristics of the area where the wall A is to be built.
As shown, the Wall A may include bottom plate (and/or top plate) (A5) and an intermediate bottom plate (and/or intermediate top plate) (A6) nailed horizontally and externally to the pillars (A3) at their upper and lower extremes and possibly in their middle part with respect to their height, on both sides of the wall. Further, the Wall A may include diagonal stiffening elements (A8) fixed diagonally to the pillars (A3), the bottom plate (and/or top plate) (A5), and the intermediate bottom plate (and/or intermediate top plate) (A6) and also to both sides of the wall. The diagonal stiffening elements (A8) fulfill the purpose of triangulating and stiffening the structure exogenously to the axis of the pillars (A3). Such diagonal stiffening elements (A8) may be nailed or fixed on both sides of the wall, to pillar supplements (A3a) which in turn are fixed on the pillars (A3) of the same thickness as the bottom plate (and/or top plate) (A5) and the intermediate bottom plate (and/or intermediate top plate) (A6). Further, the pillars (A3) are joined together by top wall ties (A5a) arranged (spaced) at same height thereat.
Further, in the interior space formed by the column structure defined by the pillars (A3), widths of each of the bottom plate (and/or top plate) (A5), the intermediate bottom plate (and/or intermediate top plate) (A6), and the diagonal stiffening elements (A8) depend on a length of a formwork separating element (A9). The formwork separating element (A9) (also sometimes referred to as “formwork spacer” or simply “spacer”) may also define a coating thickness of the diagonal stiffening elements (A8), and a filling mixture (A11) of materials which according to the present disclosure is poured on-site depending on insulation needs. This formwork spacer (A9) is an element sufficiently resistant to compression to withstand the tightening of bolts that join both faces of the formwork and that pass through the interior of tubes (A10) arranged next to the formwork spacer (A9). For purposes of the present disclosure, a good option for the formwork spacer (A9) is a wooden batten; however this may not be construed as limiting to the present disclosure in any manner. As shown, the formwork spacer (A9) may be nailed or fixed to the pillars (A3), the bottom plate (and/or top plate) (A5) and the intermediate bottom plate (and/or intermediate top plate) (A6), near the tubes (A10), which are of equal length, and through which the bolts may be passed to fix the formwork spacer (A9) of the filling in the Wall A.
Also, as per the present first embodiment, for lining of the Wall A, a cladding (as represented by A12) in the form of plastered or milled stucco with lime, or the like may be considered, on which the final wall finish (as represented by A13) for the Wall A is made, without any limitations to the present disclosure.
The present disclosure further details the process for the way to build the Wall A. Herein, in the excavations, the pillars (A3) may be installed at a depth on a thin cylinder of concrete for load distribution (A2), or on concrete (A1), plumbed and spaced according to architecture and structural calculation. It may be convenient to first place the pillars (A3) at the ends of the wall so that those, in turn, could be utilized to place the rest of the columns using construction tracing tools. The expanded polystyrene blocks (A4) are then arranged between the pillars (A3). Thereafter, the pair of lower plates (A5), which may be already prefabricated, are placed sliding downwards horizontally and externally to these same pillars at their upper end, with articulated elements (A7) (in the form of reinforcement diagonals), until reaching the upper level of the foundation block (A4), enclosing or containing thereof. Further, the said pair of lower plates (A5) may be fixed to the pillars using nails or screws (A7a) defined by the structural calculation. After this, the pair of intermediate plates (A6) slides, as well as the pair of lower plates which after being leveled, are fixed to the pillars (A3), to then proceed in the same way with the pair of top plates (A5), which have diagonals placed symmetrically and/or identical to those of the intermediate plate, to facilitate later compaction of the filling mixture (A11).
Further, in the present first embodiment, the pillar supplements (A3a) of the same thickness or thickness as the plates (A5 and A6) are fixed to the pillars (A3) between the pairs of lower, middle and upper plates. These pillar supplements (A3a) complements the foundation block (A4) and are necessary so that the diagonal stiffening elements (A8), which are later nailed and arranged diagonally facing both sides of the wall, may be fixed correctly and in the same vertical plane, not only to the plates (A5 and A6), but also to the pillars (A3), and in turn considerably reduce the buckling span of the pillars (A3), and allows for greater stiffness and final strength of the formed Wall A (which may act as a wall-beam), and also adequately contains the interior filling mixture (A11).
It may be understood that the diagonal stiffening elements (A8) may laterally cover the foundation (A2) and may reach the top or crown of the Wall A. Therefore, it is important to place the diagonal stiffening elements (A8) opposite to each other on both sides or ends of the Wall A, in order to obtain an adequate response to possible seismic forces (if any), in both directions. Also, depending on the specific structural calculation and the height of the Wall A, it may be necessary to place one or more pairs of intermediate plates (A6) to reduce the span or to separate between fixings of the diagonal stiffening elements (A8). Further, it may be convenient to place ties (A7a) between the diagonal stiffening elements (A8) on both sides of the Wall A, when the quality of the fastening of these diagonals stiffeners (A8) to the pillar supplements (A3a) of the pillars (A3) and the bottom plates, intermediate and top plates (A5 and A6), may not be guaranteed (for example, if the structural calculation may indicate such scenario). Furthermore, in some examples, it may also be convenient to place moorings (A7a) between bottom plates (and/or top plates) and the intermediate plates (A5 and A6), and on both sides of the wall, which makes their fixings act by shearing and not by friction, in contrast to fixings of the bottom, intermediate and top upper plates (A5 and A6) to the pillars (A3) against the forces that tend to detach the said plates (A5 and A6) from the column (A3). In addition, this blockage reduces the span or the distance between the fixing of the plates (A5 and A6) to the pillars (A3).
Further, in some examples, once the levels and plumbing have been checked, and the anchors and joints with other walls have also been made, the formwork (AM) is placed, which normally requires spacers (A9) and pipes (A10). The spacers (A9) are elements that are arranged perpendicular to the longitudinal axis of the wall, normally of the same material and section as the diagonal stiffening elements (A8) and are fixed to the pillars (A3), lower, intermediate and upper plates, to define the final width of the lining of the reinforcement elements of the diagonals (A8) and, consequently, also of the filling mixture (A11) of the Wall A.
Conveniently, strips of strips the formwork spacer (A9) are attached to the pillars (A3), to the plates (A5 and A6) and the articulated element (A7) in the form of diagonal stiffeners, together with the tubes (A10) through which fixing element of the formwork spacer (A9) passes. As would be understood, this may allow to join both sides of the formwork spacer (A9). Further, this anchoring element, which is normally a bolt, is removed once the filling mixture (A11) of the wall has been set.
Subsequently, with the formwork (A9) already arranged on the wall, the filling mixture (A11) is poured or filled inside the wall. Herein, in an example, the filling mixture (A11) may be a mixture of mud with straw or with additives or aggregates, such as expanded polystyrene beads, wood chips, sawdust, volcanic ash or the mixture of materials that provides the desired insulation and/or characteristics.
Once the filling mixture (A11) is placed inside the wall (which requires less vibratory energy than that of the concrete and, therefore, the thrust on the formwork (A9) is less), the “disintegration” of the mixture takes place, which may result in a rise of water to upper surface of the wall; and in such cases, the water may be dried with a sponge or a cloth (as per conventional techniques known in the art, incorporated herein).
Further, once sufficient time period has been elapsed for the filling mixture (A11) to set and/or dry and it can be guaranteed that the filler is not exerting pressure on the formwork (A9), the formwork (A9) may be removed. Herein, the said time period varies depending on the thickness of the wall, the type of mix, humidity and ambient temperature conditions. After a couple of days of drying, with the wall still damp/wet, the cladding (A12), as coating, based on a mixture of cement, lime and sand is applied directly on it, that protects it from humidity and gives it a final finish.
For the purposes of the present disclosure, the recommended composition of the final plaster, which may be approximately one-centimeter-thick, is cement, hydraulic lime and sand in an approximate volume ratio of 1:1:6. Also, in the present examples, once dry, the cladding (A12) (herein, plaster) may be painted, wallpapered or given a final finish (A13), as desired or may be required.
Referring to
At the base of the Wall B, between the pillars (B3), provided is a traditional concrete foundation or a light foundation block (B4) made up of a block of expanded polystyrene, or another insulating and moisture-resistant material. The purpose of the foundation block (B4) is to isolate the wall from the ground, preventing humidity from rising and also fulfilling the function of thermally insulating the construction, thus avoiding thermal bridges. The measurements of the foundation block (B4) are given by the width of the wall to be built and by the climatic characteristics of the area where the wall has to be built.
As shown, fixed, horizontally, to the pillars (B3) and on the outside, the Wall B includes bottom plate (and/or top plate) (B5 and B6) on both sides of the wall at the bottom, top and middle, which have articulated elements (B7) (also referred to as diagonals or locks without any limitations) therebetween, stiffening the same and forming a kind of horizontal beam for the Wall B. Further, the Wall B may include extras (B3a), of equal thickness to the bottom plate (and/or top plate), are placed between the bottom plate (and/or top plate) (B5 and B6) and fixed to the pillars (B3), to allow nailing and fixing, in the same plumb, on both sides of the wall. Furthermore, in opposite direction, the Wall B may be provided with diagonal stiffening elements (B8) that stiffen the structure of this wall throughout its height and also serve to contain a filling mixture (B11), once it has been set.
Also, as shown, in the interior space formed by the structure of the Wall B, whose width may depend on the length of a formwork separating element (B9), the material filling is poured on-site and composition according to specification and insulation needs. Herein, the formwork spacer (B9) may also define the thickness of the covering of the stiffening elements. The formwork spacer (B9) is an element sufficiently resistant to compression to resist the tightening of bolts that join both faces of the formwork and that pass through the interior of tubes (B10) arranged next to the spacer (B9). A good choice for formwork spacer (B9) is a piece of slat. The spacer (B9) is nailed or fixed to the pillars (B3) and/or intermediate bottom plate (and/or intermediate top plate) (B6) or bottom plate (and/or top plate) (B5), near tubes (B10) of equal length, through which bolts that may tie the formwork spacer (B9) may pass. In an example, the formwork spacer (B9) may be nailed or fixed to the pillars (B3) near the tubes (B10) of equal length, through which the bolts that may secure the formwork (B9) (but which may not be part of the wall). The articulated elements (B7) (as with diagonal placement of the slats) join and separate the intermediate bottom plate (and/or intermediate top plate) (B6), and form a kind of beam that helps to resist earthquakes in the flexural stress of the Wall B. Further, the pillars (B3) are joined together by top wall ties (B5a) arranged (spaced) at same height thereat.
Also, as per the present second embodiment, for lining of the wall, a cladding (as represented by B12) in the form of plastered or milled stucco with lime, or the like may be considered, on which the final finish (as represented by B13) for the Wall B is made, without any limitations to the present disclosure.
The present disclosure further details the process for the way to build the Wall B. Herein, in the excavations, the pillars may be installed at a depth directly on its bottom and on a concrete cylinder (B2), or on a foundation or foundation plinth (B1). reticulated (B3), plumb and distanced according to architecture and structural calculation. It may be convenient to first place the pillars (B3) at the ends of the wall so that they serve to tie canvases and place the rest of the pillars (B3) plumb and according to this layout. Next, the rest of the intermediate pillars (B3) are placed with canvas, and then the foundation mortar (B1) is placed. Once the pillars are correctly aligned and plumb, the expanded polystyrene foundation block (plinth) (B4) is placed between the pillars (B3). This expanded polystyrene foundation block (B4) can be replaced by rocks, boulders, concrete or other insulating and moisture-resistant material. Then, through the upper end of the pillars (B3), the pair of lower bottom plate (and/or top plate) (B5) with the diagonals (B7) already in place, slide down to the upper level of the foundation block (B4). Once this set of lower bottom plate (and/or top plate) (B5) and diagonals (B7) have been leveled, these bottom plate (and/or top plate) (B5) are nailed to the pillars (B3) and then the pillars (B3a) are placed on both sides of the wall, which are nailed or fix to the pillars (B3) and, immediately, the set of intermediate bottom plate (and/or intermediate top plate) (B6) with the already prefabricated diagonals (B7) slides again, along the upper part of the pillars and outside them, until they run into the recently placed pillar envelope (B3a). Thereafter, this set of intermediate bottom plate (and/or intermediate top plate) (B6) and diagonals (B7) is leveled and nailed to the pillars and the procedure of placing and nailing the second set of pillars (B3a) to the pillars (B3) is repeated, to then place, similarly, the set of upper floors (B5).
Next, the pipe of the required electrical installation is placed on the bottom plate of the internal side of the wall and then the diagonal stiffening elements (B8) are placed at an angle of approximately 45% with respect to the vertical and at a distance of about 12 centimeters from the bottom plates to the top plates. Further, the diagonal stiffening elements (B8) are nailed to the intermediate bottom plate (and/or intermediate top plate) (B6) to the supplements of the pillars (B3a), confining the foundation between these diagonals, in order to contain and affirm the subsequent filling of the structure.
Further, for plastering the wall, the formwork spacers (B9) are placed, nailed to the pillars (B3) and to the bottom plate (and/or top plate) (B5 and B6), in such a way that they extend about 3 centimeters beyond the exterior and interior lead of the wall. Then, on canvas, between these spacers (B9) at the ends of the wall, the intermediate spacers are placed and nail together with having, closely, tubes (B10) through which to cross the bolts or ties that may help to maintain the formwork (BM) as temporarily required for the wall on both sides to receive and contain the filling mixture (B11). In this way, a constant thickness, a parallelism between its opposite faces and a perfect verticality of the Wall B is ensured. It may be appreciated that, herein, the length of the spacers (B9) may define the thickness of the Wall B.
Now, with the formwork arranged on the wall definitively, the filling mixture (B11) may be poured manually or industrially (with machinery) inside the wall. In the present examples, the filling mixture (B11) may include, but not limited to, a mixture of mud with straw, or with aggregates such as: expanded polystyrene beads, wood chips, sawdust, volcanic ash or the mixture of materials that provides insulation and/or desired features.
Once sufficient time period has elapsed for the filling mixture (B11) to set or dry, and it can be guaranteed that the filling mixture (B11) may no longer exerts pressure on the formwork (BM), the formwork (BM) can be removed. Herein, the said time period varies according to the thickness of the wall, the type of mixture, the humidity conditions, and the ambient temperature. After a couple of days of drying, and with the wall still damp/wet, a thin layer of coating, i.e. cladding (B12) which may be based on lime, cement and sand may be applied directly on the wall, which protects the wall from humidity and gives the wall a definitive finish.
For the purposes of the present disclosure, the recommended composition of the final cladding (B12) (herein, plaster), which may be approximately half a centimeter thick, is cement, hydraulic lime and sand, in an approximate ratio of 1:2:8 by volume. Also, in the present examples, once dry, the cladding (B12) may be painted, wallpapered or given any final finish (B13), as desired or may be required.
Referring to
As shown, the Wall C also has reticulated intermediate bottom plate (and/or intermediate top plate) (or intermediate plate) (C6) between the pillars (C3) and at the base and crown of the wall, and possibly another (according to calculation needs) halfway up the wall. This allows for the free passage of the building material, i.e., the filling mixture (C11), inside the wall. In some examples, the bottom plate (and/or top plate) (C5), in the case of prefabrication of this wall, constitute the main joining element of the sections or segments of this wall. Further, the pillars (C3) are joined together by top wall ties (C5a) arranged (spaced) at same height thereat.
The present disclosure further details the process for the way to build the Wall C. For purposes of the present disclosure, the distance between pillars (C3), in a single piece or lattice with the articulated elements (C7), is determined by the structural calculation. Horizontally, at the base of the wall, a pair of slats (C15) is contained under the bottom reticulated plate (C5) between the pillars (C3). The Wall C has a lightweight foundation block (C4), made up of a block of expanded polystyrene, polyurethane foam or similar, whose purpose is to isolate the wall from the ground, preventing humidity from rising and also fulfilling the function of thermally insulating the construction, also avoiding thermal bridges. The width of the said foundation block (C4) of expanded polystyrene is given by the thickness of the filling mixture (C11) used in the wall to be built and its height, as may be determined by the climatic characteristics of the area where the wall has to be built.
In some examples, a polyethylene film or other waterproof material (C17) is attached to the formed structure between structure and exterior cladding by means of brackets or glue as a moisture barrier, which may prevent staining of the coating and/or swelling of the wood. The polyethylene film (C17) may be fixed by means of nails, screws or another type of appropriate cladding fixing system (C16). A cladding (C12) in the form of a coating is applied on the outside and inside of the wall. These can be plates (which give great rigidity to the wall) or wooden boards that are placed diagonally to the pillars (C3), thus generating an excellent triangulation that lends great rigidity. Both coatings stiffen the wall exogenously to the plane of the pillars (C3) avoiding the placement of interior diagonals in order to allow the filling mixture (C11) to be poured on-site. As shown, the Wall C may further include reinforcements, for example, in the form of a wall to pavement union piece (C18), and also a wall to pavement anchoring system (C19), as may be contemplated by a person having ordinary skilled in the art and thus has not been described in detail for brevity of the present disclosure.
Referring to
The placement of the filling mixture (D11) inside the wall is done manually, mechanically, or by means of concrete trucks. The wall is provided with interior and/or exterior cladding (D12); at its base and at its crown, which may have small holes that allow excess water to escape from the filling mixture (D11) of the wall. It is important to consider that while the filling mixture (D11) is fresh, the pressure on the walls can deform it, so it may be required to complete this process in multiple (two or more) stages, depending on the height and the type of filling mixture (D11) being utilized. Eventually, the placement of “temporary shoring and/or formwork” is recommended, which may be completed using known state-of-the-art solutions. Herein, final wall finish (D13) in the case of the described alternative may include a layer of paint over filling wallpaper, or another, since it may not, necessarily, require a cementitious stucco, with limiting the present disclosure in any manner.
Referring to
In the present examples, the modules of the Wall E may have different vertical fixing systems between adjoining sections, known from the state of the art. The Wall E is provided with a foundation, which has a block of expanded polystyrene, polyurethane or the like (E4), and whose purpose is to isolate the wall from the ground, preventing humidity from rising and also fulfilling the function of thermally insulating the construction, thus avoiding thermal bridge. The measurements of the foundation (E4) are given by the width of the wall to be built, and its height depending on the climatic characteristics of the area in which the wall has to be built. In some examples, the Wall E may also include reinforcements or ribs (E18) in its lower and upper part to anchor the pavement and receiving loads from the roof, prior to pouring the filling mixture (E11) inside the wall.
The present disclosure further details the process for the way to build the Wall E. Herein, the Wall E may be made of prefabricated modules in the form of folding modular blocks (E21) which may be unfolded on radier or foundation (E1), and then articulated locks (E20) nay be fixed between the parallel faces of the wall in their final position. Next, the folding modular blocks (E21) is placed at the base of the wall, which may have the necessary reinforcement (E18) and the joining elements to the pavement (E19) (and the insulating foundation (E4)) incorporated therewith.
Next, the wall is placed in its final position according to a defined layout and its base is fixed to the foundation (E1) by means of anchor bolts, plugs as part of the floor anchoring system (E19), which may be adopted on each occasion as per the requirements. Once a section of wall is installed, it continues to be joined vertically with the one that follows it by means of fixing clips (in form of pins or another element) (E22) that takes the adjoining vertical faces of a next folding modular block.
Further, once the walls to be filled on-site have been erected, a fixed or sliding temporary formwork is placed (as in the case of the Wall A), which has the function of preventing the deformation of the walls or vertical walls during the emptying of the filling mixture (E11) to the interior of the wall. Such temporary formwork may not be removed until the filling mixture (E11) of the wall sets and acquires a resistance and cohesion that ensures that it may not deform or affect the verticality and straightness of the surface vertical cladding (E12) of the wall. Once the sufficient cohesion of the wall filling is certain (E11), the temporary formwork is removed, and the wall is ready to receive its final wall finish (E13). In the present examples, the filling mixture (E11) may be poured into the wall by manual or mechanized means without any limitations. Herein, the filling mixture (E11) may include, but not limited to, a mixture of soil with the additive and/or aggregate that is stipulated and that may typically be mud with straw or is selected according to the desired performance characteristics from the Wall E.
Referring to
In the present examples, the Wall F is made up of lateral blocks (F21) of natural or synthetic materials that have sufficient and appropriate resistance and durability conditions for this use. These blocks (F21) are formed, in addition to their vertical walls, by articulated elements (F20) that join them. These blocks (F21) have reinforcements (F23) that allow the placement of tensors, which join a crowning plate (F5) with the middle plate and a base of a foundation (F1) and/or lower crowning plate (F5). These blocks (F21) also have an insulating foundation (F4) and formwork spacer tubes (F10) that, in addition to defining the final width of the wall, allow the passage of mooring bolts for formwork. It may be appreciated that since these blocks (F21) may be assembled by pieces, which are foldable, modular and stackable, and its interior can be filled on-site; thus this helps with saving space, facilitates storage and saves transportation costs.
The present disclosure further details the process for the way to build the Wall F. Herein, the wall is typically built on the foundation (F1), which may be in the form of traditional pavement or slab. Once the walls on the foundation (F1) have been defined and drawn, a reinforced connecting element as part of a floor anchoring system (F19) is attached to it (that acts as a slab), by means of anchor bolts, screws or another fixing element. Next, an insulating foundation block (F4) is placed at the base of the wall. The “assemble it yourself” or “assembled by pieces” type walls open and unfold to their final position, immobilizing the articulated elements (joint lock) (F20) between the walls, as located between the interior and exterior walls of the wall. Once a section of wall is installed, it continues to be joined vertically with the one that follows it by means of fixing clips (F22), in the form of pins, clips or another vertical element, that takes the adjoining vertical walls, and further joins horizontally at its upper end by means of a crowning plate (F5) which acts as reinforcements and/or horizontal folds, and which fulfill the function of plates at the base and crown of the wall, to anchor it to the pavement and receive loads from the roof, in addition to joining sections or segments of the wall, at its crown, and also receives and transmits the efforts through the ribs and reinforcements (F23), to the foundation.
Herein, tensioners (F24) for the diagonal bracing of the wall are transmitted through vertical and diagonal ribs and reinforcements (F23) located in the bottom of the folding block (F4) and top crowning plates (F5). Once the walls to be filled have been erected, a temporary shoring and formwork is placed which has the function of preventing the deformation of the walls or vertical walls during the emptying of filling mixture (F11) inside the wall. These may not be removed until this filling mixture (F11) of the wall acquires a setting, resistance and/or cohesion that ensures that it will not deform or affect the verticality of the surface of the vertical exterior and/or interior cladding (F12). In the present examples, the said interior cladding (F12) may be composed of lime plaster or other material that provides a certain impermeability or resistance to rain.
Further, once there is certainty of sufficient cohesion and/or drying and setting of the wall filling mixture (F11), the temporary shoring and formwork (FM) is removed, and the wall is ready to receive its final wall finish (F13). Herein, the filling mixture (F11) may be poured into the wall manually or mechanically (as known). The filling mixture (F11) may include, but is not limited to, a mixture of soil with the additive that is stipulated and that may typically be mud with straw, or as defined according to the specification. The filling mixture (F11) may be made in poured in layers, to avoid deformations and, in addition, depending on the type of filling to be used, to obtain a good cohesion of the filling mixture. Further, vibration and/or compaction is applied, using techniques known from the state of the art.
It may be appreciated that in the described cases of Wall A and Wall B or others with the application of the present disclosure, it is possible, to suitably reinforce the corresponding formwork, to utilize composition including rammed earth (known in the state of the art), in the compacted form or layered form, as the filling in the formwork. This may allow, in some places with little rain, to save the final coating as the cladding (Al2 and B12) and remove the formwork (AM and BM) immediately.
Herein, the pair of bottom plate and top plate (A5, A6, B5, B6, C5, C6) are fixed to the two or more pillars (A3, B3, C3, D3, E3, F3) on both sides of the wall, and joined horizontally by the articulated elements (A7, B7, C7, E20, F20) to convert the pair of the bottom plate and the top plate (A5, A6, B5, B6, C5, C6) into beams located horizontally above the foundation block (A4, B4, C4, D4, E4, F4), about halfway up the wall and proximal to tops of the two or more pillars (A3, B3, C3, D3, E3, F3).
The present disclosure provides a load-bearing structural wall with an exogenous structure along its longitudinal axis that does not have pillars, diagonals or chains or transversal stiffening firebreaks in its longitudinal axis or, failing that, its structure is reticulated, articulated and/or permeable to the passage of the filling mixture inside the wall, which allows its construction with soil from the same place of the work. This exoskeletal structure, partially hollow and structurally resistant, can be filled internally with different materials that give this wall habitability and comfort benefits, such as thermal insulation, thermal inertia, acoustic insulation and fire resistance, through the use of cheap fillings, such as soil from the same construction-site or simple mixtures such as mud with straw, clay with expanded polystyrene, lightweight concrete, soil with wood chips, soil and volcanic ash, sand and lime or even the use of industrial waste such as chopped tires or other elements (some of which are difficult to recycle), that is a wide range of fillings, depending on the specific need. The placement of the filling mixture on-site allows considerable savings in freight and industrial materials and ostensibly improves, in a simple, fast and economical way, the habitability, comfort and safety features of the walls, making it easy to prefabricate and industrialize, and with a significant variety of applications in homes and various types of buildings.
The structural wall of the present disclosure supports any structural requirement or effort, freeing the filling from any type of mechanical contribution. The simple fact of separating these requirements, due to the possibility of filling on-site, a homogeneous and calculable structure with any material, makes possible, for example, the use of earth with straw, as an extraordinary material to give a wall and of course, to the buildings that are built with it, the three remaining requirements or necessary certifications of a wall, jointly. No better material is known to provide the second group of resistances required of any wall and at a low cost; this, in other words, means that the ancient quest of humanity to build safely, with local materials, today already has a solution and this is simple, economical, structurally more resistant with the same amount of materials, ecological and easy to learn to build among many other advantages, to use in millions of houses that are built annually with mud and straw throughout the world; without structural calculation or industrialization, and at a higher cost.
The structural wall is characterized by having its longitudinal axis free of continuous structural elements or these are reticulated, forming a load-bearing wall-beam that allows its internal filling on-site, which is not possible in most traditional construction systems, and because its longitudinal axis or its interior is free of structure or is permeable to the passage of the filling mixture through the inside the wall; its structural components are made up of simple pillars or double pillars, joined by fastening and separation pieces; pairs of bottom plate/top plate that are fixed to the pillars on both sides of the wall joined horizontally by diagonal stiffening elements that converts these bottom plate/top plate or intermediate plate pairs into beams and which are located horizontally above the foundation level, halfway up the wall and also near the end or top of the pillars; pillar supplements of the same thickness as the bottom and top plates, or the intermediate plate to allow the fixing, in the same plane, of diagonal reinforcement elements, which are nailed to the supplements of the pillars and lower plate/upper plate or intermediate plate diagonally and opposite each side of the wall, to the lower plate/top plate and column shims and that constitute the required stiffening and triangulation for the structural wall.
The present structural wall is further characterized because of it having single, double or multiple pillars, reticulated in the transverse axis of the wall; it uses diagonal and horizontal strips to structure the double pillars, whose separation allows the distribution of the filling mixture inside the wall. It also has diagonal stiffeners opposite each side of the wall, which are fixed to the lower plates, intermediate plates and upper plates and to the pillar supplements, which in turn are fixed externally to the pillars. It also has fixing and separation pieces between the bottom, intermediate and top plates that join them, crossing the wall and also between pairs of columns and that transform pairs of columns and plates pairs into beams. In addition, it has the traditional elements of other walls, such as formwork spacer strips and tubes for the passage of bolts or braces that temporarily support the formwork.
The present structural wall is further characterized by being composed of double pillars or multiple reticulated pillars, permeable to the passage of the filling mixture inside the wall, joined by locks and/or ties between bottom plate/top plate spaced at the same height of the wall and between lattice pillars. The structural wall further includes pairs of reticulated screeds or plates joined by clamping and separating piece and intermediate plate also reticulated and permeable to the passage of the interior filling mixture of the wall. The structural wall also has an over solera to receive the beams. The structural wall further includes an external reinforcement and a filler according to specific insulation needs (thermal, acoustic or fire resistance), which is applied or poured on-site. The structural wall further includes an exterior plinth of fiber cement or other moisture-resistant material, slightly higher than the height of the foundation.
The present structural wall is further characterized by having a rib or reinforcement of the pillar in the case of a continuous wall, or a single reticulated or perforated pillar permeable to the passage of a filling of mud with straw, without or with additives, depending on the specific need and that is applied or poured inside the wall, in the same place of construction, manually or with machinery because its interior and/or exterior cladding; at its base and at its crown, has small holes that allow excess water to escape from the filling of the wall, made of mud with straw, mud with expanded polystyrene and/or other components depending on need for insulation; because at its base and at its upper end it has a reinforcement or fold where it is anchored to the pavement and where it supports the beams and/or higher loads.
The present structural wall is further characterized in that its structural construction elements are reticulated and/or permeable to the passage of the filling inside and the rest of the structural elements are outside the longitudinal axis of the wall, allowing the pouring of its filling on-site.
The present structural wall is further characterized in that its lower horizontal structuring element or plate is located externally to the plane of the pillars and above the level of the plinth or on the foundation, to prevent its putrefaction as a result of the rise of humidity The present structural wall is further characterized in that its lower horizontal structuring element or plate is located externally to the plane of the pillars and above the level of the plinth or on the foundation, to prevent its putrefaction as a result of the rise of humidity (that can rise from the foundations).
The present structural wall is further characterized because it can be prefabricated and its filling poured on-site; because its structure is external to the axis or plane of the longitudinal axis of this wall, delegating structural functions to its cladding and to its ribs and reinforcements, structures that, together with its other elements, make up a calculable and load-bearing structure.
The present structural wall is further characterized by, at least the Wall E and Wall F, is a piece-assembled, foldable, modular and stackable type.
The present structural wall is further characterized by being made up of folding modular blocks formed by parallel vertical side walls joined with articulated joint locks between them, which complement the elements necessary to form a wall-beam and allow its folding.
The present structural wall is also characterized because its application in type D walls, Wall E and Wall F, is made up of elements, such as: a single reticulated or perforated pillar, ribs or reinforcements of the pillar in the case of a continuous wall, rib vertical structural reinforcement, reinforcements, and/or folds at the base and crown of the wall, for anchoring to the pavement; internal or external structural coating composed, mainly but not exclusively, of metal, plastic, PVC or polycarbonate, which is covered, optionally, with board, wood plate, fiber cement, wood plaster or metal mesh with expanded polystyrene; folding modular block; vertical and diagonal ribs and reinforcements of the folding block; tensioners for diagonal bracing; simple lattice or perforated column; articulated joint locks between walls designed and connected in such a way that the Wall D, Wall E and Wall F are structurally calculable to resist the mechanical stresses to which a construction is subjected
The present structural wall is further characterized because it is built with folding modular blocks, stackable, assembled in parts, formed by parallel rigid side surfaces joined by articulated elements that, in addition to allowing or facilitate its folding and unfolding and define the final thickness of the wall, together with the lateral vertical faces, they form a wall-beam when the wall is unfolded, by the formation of a triangulation and stiffening, with the elements described.
The structural wall of the present disclosure aims to solve the problems associated with prior-art and further provide advantages over traditional construction techniques, as listed in the following:
| Number | Date | Country | Kind |
|---|---|---|---|
| 1619-2015 | Jun 2015 | CL | national |
| Number | Date | Country | |
|---|---|---|---|
| Parent | 15578087 | Nov 2017 | US |
| Child | 17745153 | US |
