Patent Application
20140013699
The invention relates to a wall module which is realized as a prefabricated concrete component for building a structure. It also relates to a structure, in particular an operating or installation building of a nuclear power station, which is produced by using wall modules of this type.
Safety-relevant buildings of nuclear installations, for example such buildings which house the emergency power units, have up to now been realized almost exclusively as concrete structures which are cast in-situ. The prefabricated method of construction tried and tested in conventional residential building construction has not been used in practice up to now.
The high level of safety demands and consideration of internal and external load cases (EVI and EVA) for nuclear installations usually result in a very high reinforcement density. For this reason, the majority of building structures of nuclear power stations or other installations relating to nuclear technology are carried out using the solid method of construction. In the case of the method of construction, the minimum wall thickness up to now has been approximately 0.85 m as a result of the large amounts of reinforcement.
The building/the structure must namely withstand all loads and load connections from the following events in categories H1-H4:
Normal operation (H1):
Influences produced by events to persons caused externally (H2):
Influences produced by internal unforeseen events (H3):
Improbable events (H4):
The use of prefabricated components—although deemed to be completely desirable on account of the associated standardizing and the optimizing of the entire planning, construction and construction sequences—has up to now run into considerable difficulties in this context and consequently has not come about. This is due, in particular, to the connection techniques which have been used up to now in prefabricated construction and which either do not meet the demands made in the nuclear sector or are not capable of overcoming the admissible component tolerances which are as a rule to be met.
The fact that for every nuclear power station essentially the same buildings with the same functionality are planned from scratch, leads to the consideration as to how the planning and execution costs can be reduced.
Reduction is possible by using systems which enable the desired rooms and their occupation to be planned in a flexible manner using prefabricated modules.
The demands which are made on structures in the area of nuclear power stations correspond to the highest demands in structural and safety engineering. The planning and execution is consequently very expensive and cost-intensive.
The introduction of prefabricated building has up to now run into difficulties with reference to the friction-locking connection between the individual structural elements and with reference to overcoming the associated tolerances and dimensional inaccuracies as well as alignment inaccuracies during assembly.
Consequently, the object underlying the invention is to provide a wall module of the type mentioned in the introduction which can be put together and joined in a simple manner with further wall modules of this type to form a structure, especially a building or building complex, which is not only configured for conventional operating loads but over and beyond this also withstands improbable extreme loads—individually or even in combination—for instance flooding, earthquakes, incessant rain, ice loads, wind loads, whirlwinds, extreme ambient temperatures, projectile impact, plane crashes, etc..
Accordingly, provided is a wall module which is realized as a prefabricated concrete component for building a structure. The wall module has a wall body which has a regular, in particular rectangular base and several, in particular four, edges, and a plurality of reinforcement rods which, as a whole, form a regular reinforcement grid, preferably extend in each case parallel to the edges and which are sealed into the wall body. The reinforcement rods pass through the wall body in each case substantially from edge to edge and are provided on their ends with connecting elements which are realized for producing a connection to complementary connecting elements of a directly adjacent wall element and wherein the respective connecting element—in each case in the released state not connected to a complementary connecting element—is connected to the associated reinforcement rod with clearance or in a movable manner in such a manner that it is displaceable in a plane which is at right angles to the longitudinal direction of the reinforcement rod on all sides by at least 2 millimeters in relation to a provided central position. The mobility can be completely prevented in the tensioned, fixedly connected state.
It is particularly advantageous and sufficient for usual demands in the construction of nuclear power stations if displaceability by at least 5 millimeters, preferably by as far as up to 10 millimeters, is ensured.
The term wall module in this case is to be interpreted in a wide sense and includes along with the inside and outside wall portions (side walls) of a building in particular also floor and ceiling plates.
Level, flat wall modules, in particular with a rectangular base, are certainly preferred—however the wall modules can also be curved such that, for example, it is possible to construct a curved wall portion or a cylindrical building (reactor building, etc.).
As has been shown in a surprising manner, in this way not only is a flexible connection realized between the individual modules which makes it possible to bridge unavoidable component tolerances and alignment tolerances in the case of on-site assembly, but where there is suitable dimensioning, in spite of—or even precisely because of—the comparatively high level of flexibility of the individual connections, it is possible to realize heavy-duty bonds between wall modules which withstand high shearing forces and bending moments and ensure reliable load removal over the module boundaries into the respective anchoring points.
It is expedient when the connecting elements—in each case in a primary manner—are configured to be connected together in a friction-locking manner, in particular by a screw connection or clamping. Where applicable, form locking can also be provided additionally, in particular for securing screw connections produced beforehand.
In a preferred development, in each case at least two reinforcement rods which extend in parallel are combined to form one unit and are connected at the ends to the same connecting element.
As already indicated above, the respective wall module can be a component of a side wall or of a ceiling wall or a floor plate, therefore it is either vertically or horizontally aligned. Accordingly, both vertical and horizontal reinforcement rods with vertical or horizontal connecting elements connected thereto are provided in the installed or mounted state in order to connect both the side wall modules amongst themselves and ceiling wall modules amongst themselves and also together.
In an advantageous design, a wall module is provided where reinforcement rods which extend horizontally in the mounted state are fixedly connected, in particular welded, at the ends to a support element which has at least one holding plate. The respective holding plate is engaged around by a U-shaped saddle element with a base plate and two leg plates, and wherein the leg plates are fixedly connected, in particular welded, in turn, to an associated horizontal connecting element. In a preferred manner, the saddle element is realized in an integral manner.
In this case, in the mounted state the saddle element, in an expedient manner, abuts by way of its base face against an end face of the holding plate and is dimensioned in particular with regard to the distance between the leg plates in such a manner that the above-named flexible seat is realized. This means that in a preferred manner in this variant the required flexibility of the connection is realized by the displaceability of the saddle element in relation to the holding plate.
In a preferred variant, the respective support element consists of one single square holding plate which is fixedly connected, in particular welded, to a total of two reinforcement rods.
In an alternative variant, the respective support element includes two square holding plates which are connected together by two square cross plates. The support element is fixedly connected, in particular welded, to four associated reinforcement rods. Each of the two holding plates is engaged around by a saddle element which is connected to a horizontal connecting element. In this variant, a connecting unit which is located in the wall module therefore includes a total of four reinforcement rods which extend in parallel and which are each provided at the ends with a connecting unit which has two connecting elements.
The frame-like support element in the variant can also be realized in an integral manner in a preferred development.
In a particularly preferred development, the female version of the respective horizontal connecting element includes a bushing which is provided with an internal thread and a complementary male version includes a threaded bolt which is provided with an external thread and has an associated locknut. The male connecting element and the female connecting element, when connected together, interact in the manner of a turnbuckle.
In this case, in an expedient manner, on the end which faces the support element, the respective bushing is screw-connected onto a threaded bolt which is provided for fastening on the saddle element.
In addition, a structure is advantageous where the leg plates of the respective saddle element are aligned parallel to the horizontally extending reinforcement rods and have receiving slots which extend parallel thereto and are defined by slot edges. The respective threaded bolt of the associated connecting element is pressed along the receiving slot between the leg plates and is fixedly connected, in particular welded, to the leg plates in the region of the slot edges.
The variants described up to now are suited particularly for horizontal reinforcement rods and horizontal connections. Variants which are suited particularly for vertical connections will be described below.
In an advantageous design a wall module is provided where reinforcement rods which extend vertically in the mounted state are fixedly connected, in particular welded, at their ends to a support element, which has a recess for the passage of a threaded bolt which is provided with an external thread and is active in interaction with two screwed-on anchor nuts and anchor plates, which are present if necessary and are penetrated by the threaded bolt as the vertical connecting element.
The above-specified flexibility of the vertical connections, in this case, is achieved in an expedient manner as a result of the threaded bolt having a somewhat smaller diameter than the seat which surrounds it and being realized in particular by an associated recess in the support element or by a corresponding recess in an anchor plate.
In this case, it is expedient when the respective support element includes four square frame plates which are connected together in the manner of a rectangular frame, wherein two frame plates which are located opposite one another are designed as holding plates and are fixedly connected, in particular welded, in each case to a reinforcement rod. In a preferred manner, therefore, one vertical connecting unit in the wall module has two reinforcement rods.
One design of the wall module is advantageous for all variants described up to now where the wall body, in the manner of a sandwich structure, has an outside shell, an inside shell and a core filling which lies between the two shells. The outside shell and the inside shell are connected together in a shear resistant manner by reinforcement elements which, along with the reinforcement rods of the connecting units, can also include further elements.
A structure which is composed of a plurality of wall modules of the named type which are connected together by the flexible connecting elements meets the demands named in the introduction in an excellent manner.
In an expedient manner, joints which are present between the wall modules for the construction of the building and, where applicable, recesses which are present in the region of the connecting elements are sealed in the respective wall body by way of concrete.
The system with prefabricated modules/wall profiles constructed in a modular manner proposed and explained up to now has a very high level of flexibility and at the same time results in standardization and optimization of the entire design, planning and construction sequence.
The system can be applied to all buildings which, as a result of their function in the installations, have to withstand the named external and internal events. This means that the system is able to be applied not only in nuclear power installations but it can also be used in chemical, military and other areas.
The element connections are configured such that the established reinforcement values can be transmitted in the form of a solid joint (100% force transmission). Each reinforcement rod is connected to the reinforcement of the following component in the case of such a design irrespective of whether the possible capacity to withstand stresses is reached.
Although different types of connectors for the wall elements, which up to now have also been designated as wall modules in the description, have already been described which meet the demands posed in an excellent manner, there is a requirement for further types and modifications to the existing types in order to provide flexible detailed solutions for the different cases in demand. In this case, attempts are made in particular as regards the design and the material requirements to produce simply retained, cost-efficient connectors or connector systems which can be connected simply and reliably to the reinforcement of the wall elements as well as joined to one another.
To this end, a connector system for a prefabricated part structure having a plurality of wall modules can be provided, wherein the connector system includes one or several components from the following group:
In an advantageous variant, the prefabricated component system as claimed in the invention has a wall thickness of just 0.40 m and an optional shell facing with a thickness of approximately 0.10 m. This means that all the above-described loads and load connections are reliably accommodated.
The advantages obtained with the invention consist in particular in that by providing a “modular system” with prefabricated, standardized wall modules or wall profiles which are provided with high-quality and flexible connections or joins, the advantages which have always been known from conventional prefabricated construction with respect to planing and execution time as well as costs and efficiency can be transferred to the construction of buildings for nuclear power installations. However, the invention is naturally not limited to these types of applications but can also be used, for example, for non-nuclear industrial installations, military installations or even for conventional buildings, for instance in regions where there is a high risk of earthquakes.
Other features which are considered as characteristic for the invention are set forth in the appended claims.
Although the invention is illustrated and described herein as embodied in a wall module for building a structure and an associated structure, it is nevertheless not intended to be limited to the details shown, since various modifications and structural changes may be made therein without departing from the spirit of the invention and within the scope and range of equivalents of the claims.
The construction and method of operation of the invention, however, together with additional objects and advantages thereof will be best understood from the following description of specific embodiments when read in connection with the accompanying drawings.
Identical or identically acting parts are provided with the same references in all the figures.
Referring now to the figures of the drawings in detail and first, particularly to
A perspective representation of a first type of horizontal connecting unit 4 is shown in
By dimensioning the components in a corresponding manner, in particular the length and width of the base plate 16 of the respective saddle element 14 in relation to the length and width of the holding plate 12 of the holding plate 12 which is engaged around by the saddle element 14, certain lateral displaceability of the saddle element 14, and consequently also of the associated connecting element 6, is ensured in relation to the reinforcement rods 10 which are sealed fixedly in the wall body 8 of the wall module 2, in particular by at least 2 millimeters, preferably at least 5 millimeters in an arbitrary direction at right angles to the longitudinal direction of the reinforcement rods 10. The substantially square wall body 8 is provided in the region of the respective saddle element 14 with a corresponding recess such that displaceability is actually provided. In this way, where required, unavoidable component tolerances during the production of or during the clamping of the connections are able to be equalized.
As far as the method of operation is concerned, the second type of horizontal connecting unit 4 shown in
It is important, once again, for the vertical connection, just as the horizontal connection, to allow for certain flexibility at right angles to the longitudinal direction of the reinforcement rods 10 of at least 2 millimeters, preferably at least 5 millimeters adjustment clearance.
In all cases, thrust loads, tensile loads and shear loads are reliably removed and passed on by the reinforcement rods 10 which are sealed in the concrete of the wall body 8 all in all in the manner of a regular, rectangular grid.
All the elements and components, which in the figures are composed from individual components which are welded together (weld seams 42), are also able to be realized in an alternative design in an integral manner, for instance cast or produced by cold or hot forming.
The types of connectors described below can take the place of the connectors shown and described in FIGS. 1 to 11—called “connecting elements” there—and can replace these in part or completely or can also be combined with or interact with them in numerous ways.
Several exemplary embodiments of connector systems as claimed in the invention for wall modules using the reinforced concrete prefabricated method of construction are explained in more detail by way of drawings in
The following applies to all the examples below. The building is realized as a solid structure produced from modular elements or prefabricated modules of reinforced concrete in the form of wall elements, ceiling elements, corner elements and the like, summarized in short below by the term “wall module”, the term “wall element” being synonymous. The connections between the prefabricated elements are managed by way of special connectors or connector systems based on screw-type connections. The prefabricated wall modules can be combined together in an almost arbitrary manner.
The screw-type connections meet the demands for cyclical alternating stresses in the event of earthquakes or in the case of comparable natural events as well as in the case of extraordinary loads, for example explosions or collision loads.
A perspective representation of a wall portion which is composed of three identical, rectangular wall modules 2 is shown as an example in
1. U-beam-Type Screw Connection
Continuous U-beams, i.e. which preferably extend over the entire edge length of one or several elements and are provided with incisions/elongated holes corresponding to the reinforcement intervals of the reinforcement grid, are arranged between the modular elements which are realized in particular as reinforced concrete elements. To equalize tolerances, they can be provided with oversize in relation to the screw-type connections of the reinforcement rods which are pushed through.
The thickness of the U-beams should be at least 20 mm, 25 mm is recommended. Attachment to the concrete elements is effected by way of nuts which are screw-connected onto the protruding reinforcement rods or bars which are provided on the ends with a corresponding thread.
As the elongated holes in the U-beams have to have considerable oversize in relation to the screw-type connections for equalizing tolerances, washers or screws/nuts with a machined-off collar are expedient in order to secure sufficient contact surface.
The U-beams are slipped under the connectors and are screwed-connected.
The method of connection is illustrated as an example in
In this connection,
The diameters of the bores/elongated holes in the legs 1006 of the U-beam 1004, through which the ends of the reinforcement rods 10 are guided, are generously dimensioned such that the reinforcement rods 10 have a corresponding clearance when the locknuts 1010 are loosened, preferably at least 5 mm in each direction.
In an advantageous manner, in each case the reinforcement rods 10 pass through the entire wall module 2 from edge to edge or from connection point to connection point. This means that the respective reinforcement rod 10 has on each of its two ends a connector of the above-described type which interacts with an associated connector of the adjoining wall module. In a preferred manner, the two connectors on the opposite ends of one reinforcement rod 10 are the same type and have the same dimensioning. The same also applies to the further connection models described further below.
In the case of a correspondingly realized reinforcement grid, both vertical and horizontal connections between adjoining wall modules can be produced in this manner.
2. Box-Type Screw Connection
The box-type screw connection described below is also suited for both horizontal and vertical connections.
The connection type is illustrated by way of
In this case, in its left-hand half,
On the side which faces the wall module 2, the respective box 1014 is connected and fixed to the end of a reinforcement rod 10. This is affected by a so-called LENTON screwed-gland 1016 or in a similar manner. To this end, the end of the reinforcement rod 10 which tapers conically and is provided with an external thread is screwed into a complementarily formed threaded sleeve 1018 or screw socket which forms an integral component of the box 1014.
The connection between the two similarly constructed boxes 1014 amongst themselves is effected by an inside connecting bolt 1020 which is provided in each case with an external thread on both ends and passes through an associated bolt channel 1022. The screwed-on locking nuts 1024 act in each case by an anchor plate 1026, which lies between the locking nuts, on the ring sleeve 1028 of the associated box 1014 which defines the bolt channel 1022 and thus fix the arrangement. In this case, the ring-shaped end face 1030 of the respective ring sleeve 1028 forms a contact face which acts as a stop for the anchor plate 1026 which is realized in the manner of a slotted washer. As a result, the ring sleeves 1028 of the two boxes 1014 and consequently the two boxes 1014 altogether are pressed fixedly against one another in the clamped state.
As, on the one hand, the inside diameter of the bolt channel 1022 is greater than the outside diameter of the connecting bolt 1020, on the other hand the respective anchor plate 1026 has sufficient space for movement inside the enclosure which is formed by the walls of the box 1014, and finally there is also still a sufficiently large axial gap between the respective locking nut 1024 and the threaded sleeve/screw socket 1018 located opposite it, a connection is created which is adaptable in an excellent manner. The space for movement in all three directions which is provided when the locking nuts 1024 are not yet tightened, in this case, is preferably at least 5 mm.
3. Terminator-Type Screw Connection
A further connection type, also suited for both horizontal and vertical connections, is illustrated in
In this case, one single connector is shown in perspective in
In the case of this type of connection, the respective reinforcement rod 10 of the wall module 2 is anchored at its ends in a closure plate 1034 which is also designated as a terminator. This can be effected in particular by means of screw-connection, for instance using a LENTON screwed-gland or the like, the threaded sleeve 1036 or screw socket being inserted and fixed in a positive-locking manner in a corresponding bore through the closure plate 1034 (see
The connection between two closure plates 1034 is effected, in turn, by screw bolts 1038 which penetrate the associated bores through the closure plates 1034 and are secured by means of nuts 1040. Correspondingly bored steel plates 1042 between the nuts 1040 and the closure plates 1034 act to some extent as washers.
Two screw bolts 1038 which are arranged symmetrically and parallel to the center axis of the reinforcement rod 10 are provided in the exemplary embodiment.
Once again also important here is the excellent adjustability of the connection for adapting to unavoidable production tolerances or dimension inaccuracies as well as alignment inaccuracies during assembly. For this reason, the inside diameter of the bores penetrated by the screw bolts 1038 in the closure plates 1034 is greater than the outside diameter of the respective screw bolt 1038 such that, when the nuts 1040 are released or loosened, the desired freedom of movement (say: clearance) of preferably more than 5 mm in all directions is realized. This can be seen, for example, from
In an expedient manner, the length of the screw bolts 1038 is dimensioned in such a manner that in the mounted state a significant gap remains between the two interconnected closure plates 1034. When finishing the building which is composed of the wall modules 2, these types of gaps are advantageously sealed with a filling compound, for instance fine-grained concrete or mortar. This also applies analogously to gaps, joints and spaces at the joint points between adjacent wall modules in the case of the other types of connections described here.
The distance between adjacent, parallel reinforcement rods 10 of the reinforcement grid 1012 which can be seen in
4. Claw-Type I Screw Connection
The connection has a certain similarity to the U-beam-type screw connection. The screw connection of the reinforcement rods is not managed with sockets, but rather metal claws are screwed onto the ends of the reinforcement rods which ensure the solid joint. In addition, a metal plate, which completes the support profile to form the closed rectangular ring, is screwed onto the U-beam. In an expedient manner, the joint between the wall modules is sealed again.
This is shown as an example in perspective in
In
In a manner similar to the U-beam-type connection, the box, which is arranged between the two interconnected wall modules 2, preferably extends over the entire edge length thereof.
5. Claw-Type II Screw Connection
In the case of the type of connection, in an analogous manner to the claw-type I screw connection the reinforcement rod 10 is provided on its ends with screwed-on metal claws 1060. Deviating from this, however, the U-clamp 1062 does not extend over several or all the connections of a side edge of the respective wall module 2, but only over the connector itself. Fixing is effected by screws 1064 which extend at right angles to the longitudinal axis of the reinforcement rods 10, as shown in perspective in
6. Double-Headed Anchor Connection
Finally, as an alternative to or in addition to the types of connections described up to now, it is possible to use as connecting means so-called double-headed anchors which are admitted into corresponding recesses in the wall modules. The possibility for transmitting the tensile force of the corresponding wall joint is ensured as a result.
The connector system is illustrated as an example in
Each double-headed anchor 1070 has two thickened, radially protruding heads 1074 which are integrally formed on the end of an anchor rod 1076 and which are fixed in a positive-locking manner in corresponding recesses or grooves of the associated wall module 2 in each case. In an expedient manner the recesses are sealed with a filling compound, for instance mortar or lightweight concrete, after assembly.
A form-locking (positive) connection is one that connects two elements together due to the shape of the elements themselves (e.g. ball and socket), as opposed to a force-locking connection, which locks the elements together by force external to the elements (e.g. screw).
| Number | Date | Country | Kind |
|---|---|---|---|
| 102011014179.0 | Mar 2011 | DE | national |
| 102012001167.9 | Jan 2012 | DE | national |
This is a continuation application, under 35 U.S.C. §120, of copending international application No. PCT/EP2012/000856, filed Feb. 28, 2012, which designated the United States; this application also claims the priority, under 35 U.S.C. §119, of German patent application Nos. 10 2011 014 179.0, filed Mar. 16, 2011 and 10 2012 001 167.9, filed Jan. 24, 2012; the prior applications are herewith incorporated by reference in their entireties.
| Number | Date | Country | |
|---|---|---|---|
| Parent | PCT/EP2012/000856 | Feb 2012 | US |
| Child | 14027717 | US |
