WO2015067826A1

WO2015067826A1 - Method of producing building shuttering with concrete structure in situ

Info

Publication number: WO2015067826A1
Application number: PCT/ES2013/070763
Authority: WO
Inventors: Luis FORCANO OBÓN
Original assignee: Clever Inversiones Urbanisticas, S.L.
Priority date: 2013-11-06
Filing date: 2013-11-06
Publication date: 2015-05-14

Abstract

The invention concerns a method of producing building shuttering with a concrete structure in situ, the method employing self-supporting permanent shuttering in the walls and floor, with thermal insulation and soundproofing, the walls being formed by mutually opposite vertical and parallel shuttering panels (3) which are first connected so as to form the inner corners, the metal framework (6) being positioned, and then the outer shuttering panels. The prefabricated panels (4) which form the shuttering (2) are produced in situ on self-supporting polystyrene blocks (42), in which spaces are produced in order to from longitudinal channels (43) which, when concreted with a metal framework (44), form ribs (41) in the manner of small beams, connected by means of an expanded polystyrene part (42) at their bases and sides. These panels (4) are disposed above the vertical shuttering, supported on various props (5); the mesh of the compression layer (21) is then put in place and concrete is poured, at the same time over the compression layer (21) and in the vertical walls (1), in the space occupied by the structure (6) between the side panels (3).

Description

Procedure of realization of formwork of buildings, with concrete structure in situ.

Field of the Invention

The invention, as its own title indicates, refers to a method of making formwork for buildings, in which the concrete structure is placed in situ and which provide for the execution of load-bearing walls and forged with insulation and installations included, with minimum Struts, fast and economical execution.

The present invention encompasses within the field of structures, based on profitable (in time and money) the execution of buildings constructed with reinforced concrete, based on load and forged walls, both with thermal and acoustic insulation inserted in the lost formwork, as well as all building facilities. The method encompasses the manufacture and commissioning of these formwork, as well as the execution of exploded plans of armor to be placed on walls and floors.

Background of the invention

At the moment in construction the great majority of the structures executed "in situ" with formwork are realized, so much in walls, pillars, beams and slabs, that must be supported with props (to the ground or to the previous plant) and that once set the concrete must be removed to place them on another floor or in another work.

This carries an economic cost of rent (or purchase) and a cost, in time and money, to remove them, taking into account that, except for the formwork (not used in building but in civil works) they are not self-supporting, and must be secured with struts to the floor or the floor of the previous floor.

When leaving only the concrete between the formwork (exterior and interior), in order to comply with the regulations in force in each country in relation to thermal and acoustic insulation, panels of very different materials must be placed normally inside the structure, leaving between both normally an air chamber, which obviously increases the cost and the execution time. In the slabs, depending on the required value, thermally and acoustically between different floors, a false ceiling must be executed, that is, another skin similar to the walls.

All this presents an additional problem due to the time the concrete needs to harden (set) and be self-resistant; the placement of struts between plants and makes it unfeasible that, in 15, 21 or 28 days that must be placed, no other work can be performed inside the building.

Currently, there is some method that executes the walls with insulated formwork, but the slabs must be enclosed with struts, leaving the building for those 15, 21 or 28 business days to be able to perform other work internally, such as the placement of flooring, carpentry, facilities, etc.

Description of the invention

The invention relates to a method of executing structures, based on walls and reinforced concrete slabs in which it is only necessary to place two rows, of 3 or 4 struts, in each of the interior gaps, placed near the walls , in such a way that other subsequent works can be carried out in the building while the upper floor structure is being built. This formwork is self-supporting and buildings of as many floors as necessary may be executed, taking into account that the limit will be taken with the thicknesses and amounts of reinforcement to be placed in the structure, but never by the formwork. Both the slabs that make up the walls, as well as the floor, have the required thermal and acoustic insulation inserted, including all installations (water, electricity, telephony, gas, etc.) and are permanent formwork (since there is no need to remove formwork).

For the execution of this formwork it is necessary to have a series of elements; namely:

On the one hand a series of elements for the in situ manufacturing of the formwork that will form the walls of the building, consisting of a series of polystyrene panels (porexpan), on which externally a metal mesh is fixed, or fixed. Metal armor is also necessary structural, of the appropriate thickness and configuration to the wall to be built, which will be located between two formwork panels that define respectively the exterior and interior faces of the building walls. As indicated, this formwork is a lost formwork, since it becomes part of the wall itself by concreting the interior hollow.

On the other hand, elements for the fabrication of the floor slab are also necessary. For this purpose, a series of self-supporting blocks of porexpan will be available, about 2.40 m along the length of the span, in which longitudinal, parallel emptyings have been carried out. These blocks are arranged on the floor, or on horizontal tables, to form a mold in which the slab is concreted, previously placing the corresponding reinforcements in said gaps, forming a series of parallel ribs as joists joined by a piece of polystyrene expanded (porexpan) by its bases and flanks. These panels are forged in the place where they have been concreted and will be placed in the building during the formwork process; conforming the same as the walls a self-supporting and lost element since it happens to integrate the floor / ceiling of the building.

- A mesh is also necessary to place in the compression layer of the slab and some other metal reinforcements, to join the corners of the panels that form the formwork of the walls and the corners of the walls with the slab. friction, according to this invention, comprises the following steps:

Execution of the foundation footsteps or simply a hearth (depending on the efficiency to be built) to support the walls, where some waits are left, with the length of overlap depending on the diameter of the reinforcement, to connect the vertical ground floor walls , which will join both once the second ones have been concreted.

- Placement on the brace or solera of the internal formwork of the vertical panels, starting with those that form a corner so that they are self-supporting, joining with the perpendicular contiguous by means of a "L" shaped armor, to give rigidity to the set. Once the corner panels are tied, all the interior vertical formwork is placed in the gaps that remain between corners.

- Placement of the structural metal reinforcement, parallel to the internal formwork of the hollow, held by separators that said structure has for this purpose. These consist of transverse rods that cross the porexpan and are conveniently attached to the formwork mesh, so that the mesh is positioned in the desired place and that both form a set.

Once the structural mesh has been placed and tied on the internal formwork, the external formwork is placed by inserting the separators, and joining them in the same way as in the internal formwork.

- Placement of prefabricated panels that make up the building slab on the vertical formwork, supported by wooden boards supported by 3 or 4 struts separated about 60 cm from the enclosure, which allows its upper surface to be able to execute on Her compression layer.

- On the slab formwork, the mesh of the compression layer is placed and, according to the structural calculation of the building, the negatives that the slab bears between openings supporting them directly on the mesh and tying them to it.

- The concrete is poured, simultaneously on the compression layer and on the vertical walls in the space occupied by the mesh between the side panels, taking care to pour them over by introducing the end of the pouring element into each of they as low as possible, to avoid segregation of the concrete during its fall and thus avoid the coke that would form if the pouring is done from the floor. In all vertical panels, all existing holes in them (windows, doors, etc.), as well as a pre-installation to place all the facilities of the building, will be left before pouring concrete. In the same way, in all the slabs the necessary elements will be left inserted to place all the installations inside.

Description of the figures

To complement the description that is being made and in order to facilitate the understanding of the characteristics of the invention, a set of drawings is attached to the present specification in which, for illustrative and non-limiting purposes, the following has been represented:

Figure 1 shows a section of a building made with lost formwork object of the invention.

Figure 2 shows a vertical section view of a panel (3) constituting the vertical formwork, with the frame (6) that will structure that wall.

Figure 3 is a perspective view of the joint in a corner between two panels (3), in this case interiors.

Figure 4 is a view equivalent to Figure 2, once the two panels (3) are placed with the frame (6) between them, conveniently located and fixed.

Figures 5 and 6 represent a section in different vertical planes, of the assembly of the formwork of a wall and of the slab (2) before pouring the concrete into the space between panels (3) and in the compression layer above the slab.

Figure 7 shows two views in vertical and lateral section of a wall formwork.

Figures 8 and 9 show respectively a side view and a vertical section of a floor of a building, once the gaps between panels (3) have been concreted to form the vertical walls (1) and the compression layer (21) above the floor (2). Figures 10, 1 1 and 12 show different details of the installation of pipes (10) in the walls (1) and ducts (45) in the slab, both with the mission of subsequently including the building facilities.

Figures 13 and 14 show in a vertical section two phases of the manufacturing process of the panels (4) that will form the building slab (2).

Detailed description of one embodiment

Depending on the geotechnical study of the land where the building is to be located, the geometry and reinforcement of the foundation braces (7), the basis of the entire structure, will be excavated and executed on a 10 cm concrete bed. In these braces some waits (71) will be left, with the length of overlap depending on the diameter of the reinforcement (6), to connect the vertical walls (1) of ground floor, which will join both once the second ones have been concreted.

The inner formwork of the vertical panels (3) are placed on the brace, starting with those that form a corner so that they are self-supporting. Each formwork located in a corner, joins with the perpendicular adjoining by means of an L-shaped armor (8), to give rigidity to the whole. Once tied, all the vertical forms of each of the holes are placed. (Fig. 3).

Each vertical panel (3) has a porexpan plate (32), which on the outside face fixed a metal mesh (31), which will support the coating that receives the wall (1) when it is finished based on cement, plaster, or any other material impregnated or projected by that face.

Once all the internal formwork of a hole is placed, the structural mesh (6) is placed, attached to it, separated by the spacers (33) that the mesh carries for this purpose. This mesh (6) will have transverse rounds (61) that cross the porexpan (32) which, conveniently attached to the formwork mesh, will serve to position them exactly and to form a whole set between them. (Fig. 2). Once tied, the outer formwork (3) will be placed by inserting the porexpan (32) into the spacers (61), and joining them in the same way as in the interior formwork. (Fig. 4). The slab formwork is manufactured directly on the floor, or on horizontal tables arranged for this purpose, providing blocks of 2.40 m for the length of the porexpan plate span (42), in which longitudinal channels have been practiced ( 43), inside which the reinforcement (44) and then the concrete that will give rise to the ribs (41), which will form a kind of joists, separated between them and below by the insulating material (42), is conveniently inserted.

Each formwork plate (4), once set, is lifted and placed on the vertical formwork, but supporting it on two wooden boards (9), 12 mm thick, supported by 3 or 4 struts (5) separated 50- 60 cm of the enclosure, which makes its upper surface capable of executing the compression layer (21) on it. Figures 5 and 6.

On the slab formwork, only the mesh of the compression layer (21) must be placed and, according to the structural calculation of the building, the negatives that the slab bears between openings supporting them directly on the mesh and tying them to it. In the same way that in the vertical corners formed by two formwork elements of vertical panels, L-shaped squares of 06 cm 20 will be placed horizontally joining the upper part of the vertical panels and the contour of the slab formwork, tied to the meshes of both.

Next, the concrete will be poured at the same time on the compression layer (21) and on the vertical walls (1), being careful to pour them over by introducing the end of the pouring element into each of them, the most as low as possible, to avoid segregation of the concrete during its fall and thus avoid the coke that would form if the pouring is done from the slab. Fig. 8 and 9.

All this will be executed in each of the holes that the plant has in execution, and, once its roof has been concreted (floor of the upper one), the cycle will be repeated with each of the plants that the building consists of.

In all the vertical panels, all the existing gaps in them (windows, doors, etc.) will be left, as well as a pre-installation (10) to place all the building facilities. In the same way, all floors will be left inserted the necessary elements or conduits (45) to place all the installations inside. Fig. 10, 1 1 and 12.

Once the nature of the invention has been sufficiently described, as well as a preferred embodiment, it is stated for the appropriate purposes that the materials, shape, size and arrangement of the described elements may be modified, provided that this does not imply an alteration. of the essential features of the invention claimed below:

Claims

1 .- Procedure for carrying out building formwork, with concrete structure in situ, which uses lost and self-supporting formwork, both on the walls and on the floor, which have the required thermal and acoustic insulation inserted, for whose execution a series of formwork panels (3) that will form the walls (1) of the building by placing two panels facing each other, vertically and parallel, each of which comprises a spaced polystyrene core (32) that is located towards the inside face of the wall (1), on which externally it has a metal mesh (31); leaving for the construction of the foundation braces (7) on which the walls (1) will rest, on which some waits are left, with the length of overlap depending on the diameter of the reinforcement, to connect the vertical walls of ground floor, said procedure comprising the following phases:

- placing the internal formwork (3) on the brace (7), starting with those that form a corner, in which they join the perpendicular adjoining by means of an "L" shaped reinforcement (8), then placing the remaining formwork vertical interiors in the gaps that remain between corners;

- placement of the structural metal reinforcement (6), parallel to the internal formwork of the recess (3), held by separators that said structure leads to such effect, consisting of transverse rods (61) that cross the porexpan (32) and are conveniently tie to the mesh (31) of the formwork (3);

- placing the external formwork (3) by inserting the porexpan (32) the spacers (61), joining them in the same way as in the internal formwork;

- placement of prefabricated panels (4) that will form the formwork (2) of the building, above the vertical formwork, supported by boards or sheets ((9) supported by several struts (5);

- on the slab formwork (2), the mesh of the compression layer (21) is placed, and in the vertical corners they place, horizontally, L-shaped squares, joining the upper part of the vertical panels and the contour of the slab formwork, and finally,

- the concrete is poured, simultaneously on the compression layer (21) and on the vertical walls (1) in the space occupied by the structure (6) between the side panels (3).

2. - Procedure for carrying out building formwork, according to claim 1, characterized in that the fabrication of the slab is carried out on site, by arranging on the floor, or on horizontal tables, a series of self-supporting polystyrene blocks (42), of the length of the opening, in which emptyings have been made that form longitudinal channels (43) in which a metal reinforcement (44) is available which, when concreting said channels (43), forms a series of ribs (41), parallel, as a joist, joined by a piece of expanded polystyrene (42) by its bases and flanks.

3. - Procedure of realization of formwork of buildings, according to claim 1, characterized in that in all vertical panels are left, prior to the pouring of the concrete, all the gaps existing in them, destined to the windows and doors, placing the pre-frame corresponding in said gaps and between both panels (3).

4. - Procedure of realization of formwork of buildings, according to claim 1, characterized in that between both vertical panels (3) channels are placed or channels are made between the insulator (32) that serve to channel the building facilities.

5. - Procedure for carrying out building formwork, according to claim 1, characterized in that in the polystyrene layer (42) that forms the base of the slabs (2) channels (45) are made or gutters are installed to place in inside all building facilities.