WO2017065716A1 - Concrete wall production method with on-site casting - Google Patents
Concrete wall production method with on-site casting Download PDFInfo
- Publication number
- WO2017065716A1 WO2017065716A1 PCT/TR2016/050384 TR2016050384W WO2017065716A1 WO 2017065716 A1 WO2017065716 A1 WO 2017065716A1 TR 2016050384 W TR2016050384 W TR 2016050384W WO 2017065716 A1 WO2017065716 A1 WO 2017065716A1
- Authority
- WO
- WIPO (PCT)
- Prior art keywords
- external
- sidings
- concrete
- mould
- facade
- Prior art date
Links
Classifications
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
- E04B2/00—Walls, e.g. partitions, for buildings; Wall construction with regard to insulation; Connections specially adapted to walls
- E04B2/84—Walls made by casting, pouring, or tamping in situ
- E04B2/86—Walls made by casting, pouring, or tamping in situ made in permanent forms
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
- E04B2/00—Walls, e.g. partitions, for buildings; Wall construction with regard to insulation; Connections specially adapted to walls
- E04B2/84—Walls made by casting, pouring, or tamping in situ
- E04B2/86—Walls made by casting, pouring, or tamping in situ made in permanent forms
- E04B2002/8682—Mixed technique using permanent and reusable forms
Abstract
This invention is related to a concrete wall production method with on-site casting The invention is particularly related to a method where the external facade of the building is formed together with the production of walls by placing the external facade siding into concrete mould that have been prepared for casting concrete during the on-site production of cast concrete walls. The aim of the invention is provide a method, which comprises the steps of preparing the moulds that shall be used in on-site cast concrete wall production, placing the external facade siding elements of buildings into the mould when the mould is being prepared, lifting the mould together with the external facade siding and carrying it to the area where the concrete will be poured therein, and pouring said concrete into said mould, and ensuring that the external facade sidings are fixed to the concrete while the concrete is setting.
Description
DESCRIPTION
CONCRETE WALL PRODUCTION METHOD WITH ON-SITE
CASTING
Technical Field
This invention is related to a concrete wall production method with on-site casting
The invention is particularly related to a method where the external facade of the building is formed together with the production of walls by placing the external facade siding into concrete mould that have been prepared for casting concrete during the on-site production of cast concrete walls.
Prior Art
Nowadays, the formation of walls from cast concrete in multi storey buildings are based on two main principles.
According to the first one of these principles the concrete block walls need to be prepared in advance (precast wall production) and to be lifted to the related floor and fixed in place. According to the other application, the moulds are prepared and concrete is poured into the moulds and the mould is disassembled (on-site casting) after the concrete sets.
In several applications the external facade siding, is applied after the cast concrete wall is formed outside the building. However this process, both leads to loss of time as time needs to pass for forming the cast concrete wall and for the concrete to set, and leads to increased costs due to high workmanship costs. Moreover, in high storey buildings as the siding of the external facade needs to be carried out
on said floor, this brings about workmanship costs, loss of time, safety expenses and many other aspects. Moreover problems regarding fine workmanship are also faced during the siding of the external facades of buildings when taking the siding materials up to the storey of the building in pieces.
According to the United States Patent document numbered US20050246983 of the known state of the art, the application of the external facade siding on a building facade by means of profiles that are inserted into channels that have been opened on the external facade siding materials is described.
According to the United States Patent document numbered US20090031652 of the known state of the art, the application of the external facade siding on a building facade by means of profiles that are inserted into channels that have been opened on the external facade siding materials is described.
According to the German Patent document numbered DE102005019977 of the known state of the art, a profile and connection system for an external siding is described. However in the applications of the patent documents mentioned above and in other similar applications, the external sidings need to be applied to the walls of buildings from outside the building after they have been produced. The above mentioned applications do not provide a solution to the problems regarding fine workmanship faced during the siding of the external facades of buildings when taking the siding materials up to the storey of the building in pieces, workmanship costs, loss of time, safety costs and the need to carry out applications on the floor of the building to which they need to be applied on.
In order to eliminate these problems, the external facade siding needs to be carried out simultaneously with cast concrete wall production
In order to reach this aim, in some applications the concrete mould is prepared, and is placed inside the external facade siding formed of a plurality of pieces, such as plates and is carried to the area where the concrete is cast, and concrete is poured into the mould and after the concrete is set the external facade siding is formed together with the wall.
However various problems are also faced during this application.
First of the entire external facade siding placed into the mould, is placed with high accuracy and when the mould is being carried, the siding should not move or slide. As the external facade siding shall be fixed to the concrete right after the concrete is set, in any kind of shifting or moving, it will be difficult for the siding to be removed from the concrete and to be corrected. Therefore, it should be ensured that such sidings are placed with high sensitivity that the materials that have been placed into the mould must keep their position when the mould is being lifted to the floor where the concrete will be poured, and that the sidings should not shift at all. Moreover, even if the moving or shifting of external facade sidings are prevented, any kind of workmanship failure that may occur during the initial placing of external facade sidings into the mould also needs to be prevented.
Another problem is that, when concrete is being poured into the mould, and the concrete is being set, the water of the concrete needs to be prevented from leaking onto the external facade sidings. Otherwise, if the water of the poured concrete leaks onto the external surfaces of the external facade sidings when the concrete is being poured or when the concrete is setting, the sidings need to be re-cleaned. Moreover this situation could even damage the structure of some of the materials that are used as external facade sidings. Another problem is that, insulation material needs to be adhered onto the external facade sidings and a ventilation opening cannot be formed between the external
facade sidings and the insulation material. Moreover it will be more difficult to place the water insulation layer to be placed right behind the external facade sidings.
Aims of the Invention
The aim of the invention is provide a method, which comprises the steps of preparing the moulds that shall be used in on-site cast concrete wall production, placing the external facade siding elements of buildings into the mould when the mould is being prepared, lifting the mould together with the external facade siding and carrying it to the area where the concrete will be poured therein, and pouring said concrete into said mould, and ensuring that the external facade sidings are fixed to the concrete while the concrete is setting.
Another aim of this invention is to provide a method which ensures that the external facade sidings do not move in any way inside the mould, while the mould is being carried. Another aim of this invention is to provide a method which ensures that the external facade sidings are placed into the mould such that they will not lead to any kind of workmanship errors.
Another aim of the invention is to provide a method where the water of the concrete does not leak onto the external surface of the external facade sidings when the concrete is being poured or when the concrete is setting.
Another aim of this invention is to provide a method where an air gap is formed between the external facade sidings and the insulation plates.
Detailed Description of the Invention
The parts that shall be used to carry out the method provided in order to reach the objects of the invention has been illustrated in the attached figures.
According to said figures;
Figure 1, is the perspective view of the metal plate that shall be used in order to form the external mould, which has been positioned to the ground such that it forms a certain angle. Figure 2, is the perspective view of a horizontal profile placed under the metal plate, where the siding material and vertical profiles are placed on the horizontal profiles.
Figure 3, is the perspective view of an embodiment of the horizontal profile.
Figure 4, is the perspective view of an embodiment of the vertical profile.
Figure 5 is the side section view of the external mould. Figure 6 is the top section view of the external mould.
Figure 7 is the side section view of the external mould where an insulation plate retaining apparatus has been attached to the horizontal profile. Figure 8 is the side section view of the external mould where the horizontal profile channels are angled to the external facade sidings.
Figure 9 is the side section view of the external mould without any air gaps, where an insulation plate retaining apparatus has been attached to the horizontal profile.
The parts in the figures have each been numbered and the references of each number have been provided below.
1. Metal plate
2. External facade siding
3. Horizontal Profile
4. Vertical Profile
5. Screw
6. Siding material channel
7. Horizontal Profile channel
8. Horizontal Profile channel tabs
9. Steel plate
10. Insulation plate
11. Water insulation cover
12. Insulation plate retaining apparatus
13. Air gap
14. Insulation plate retaining apparatus channel
15. Insulation plate retaining apparatus tab The method carried out in order to reach the aims of the invention comprises the steps of;
- Placing a smooth surfaced metal plate (1) to the bottom layer at a certain angle in order to form an external siding mould,
- Placing a horizontal profile (3), having the same length as the metal plate (1), at the bottom of the metal plate (1),
- Aligning the external facade sidings (2) side by side on the horizontal profile (3),
- Inserting vertical profiles (4) between the external sidings (2) when said external sidings (2) are aligned side by side,
- Placing the other horizontal profile (3) having the same length as the metal plate (1) over the external facade siding (2) and vertical profiles (4) after
the first layer is covered, such that it shall form a base for the upper layer by covering the top section of the external facade sidings aligned side by side on the first layer and the vertical profiles (4) located between said external facade sidings (2),
Continuing this process until all of the metal plate (1) is coated,
Ensuring that the external facade sidings (2) and the vertical profiles (4) are locked by means of screwing the horizontal profiles (3) to the external surface of the metal plate (1) by means of screws (5),
Fixing, steel plates (9) in order to ensure that the horizontal plates (3) are anchored to the surface of the concrete and in order to fix the external facade sidings (2) to the concrete.
Placing first of all the insulation material (10) and then the water insulation cover (11) over the inner surface of the external facade sidings (2), Fixing the steel mesh to the external mould,
Lifting this external mould to the place of instalment by means of a crane, Placing the internal mould and fixing the internal mould to the external mould,
Pouring the concrete into the cavity having steel mesh located between the internal mould and the external mould,
Removing the screws (5) located on the external surface of the metal plate (1) after the concrete has set, and removing the metal plate (1) from the external facade siding surface.
According to the method, first of all the metal plate (1) having the dimensions desired to prepare an external mould, preferably having the same size as the concrete cast wall is positioned to the ground to form a certain angle. Not only a support unit can be placed behind the metal plate (1) but also it can be enabled for the metal plate (1) to stand at a certain angle by directly fixing the rear support
legs onto the metal plate (1). (Figure 1), Moulds having windows, doors or corners can also be arranged.
Later on, a horizontal profile (3), having the same length as the metal plate (1), can be fixed at the bottom of the metal plate (1). Either a protrusion can be provided at the bottom of the metal plate (1) in order for the horizontal profile (3) to be attached or the bottom horizontal profile can be fixed to the metal plate (1) by means of screws. Later on, the external facade sidings (2) are aligned side by side on the top section of the horizontal profile (3). The external facade sidings (2) can be produced from any kind of materials such as, natural stones, artificial stones, porcelain, clay, aluminium, compressed plastic etc. Vertical profiles (4) are placed between the external sidings (2). The vertical profiles (4) ensure that the distance between the external facade sidings (2) aligned side by side are equal and have the desired width. (Figure 2) Moreover as they will sit on the horizontal profile (3) located under the vertical profiles (4) and the external facade sidings (2) along the whole row, the distances between the external facade sidings (2) that shall be placed on top of each other must also be equal and must have the desired width, must be coupled to each other and must be locked with each other. Different kind of profiles can be used in order to provide the desired joint width. When the placement of the first row is completed, again a horizontal profile (3) along the vertical profiles (4) located between the external facade sidings (2) is covered. On top of said horizontal profile (3) a second row of external facade siding (2) is placed and in between them, vertical profiles (4) are placed and when the second row is completed again a horizontal profile (3) is placed on top, and the process is continued until the whole metal plate (1) is covered. It is possible to carry out the process by using only the horizontal profiles (3) rather than the vertical profiles. In this case, it shall be suitable for the external facade sidings (2) to abut each other. However this may cause problems regarding the need for expansion.
Horizontal profile channels (7) are located under and over the horizontal profiles (3), preferably for the external facade sidings (2) to be fitted thereon. Preferably horizontal profile channel tabs (8) are provided on the ends of these horizontal profile channels (7). (Figure 3) These horizontal profile channel tabs (8) fit into the siding material channels (6) that have been opened on the top and bottom surfaces of the external facade sidings (2) and the tabs lock the external facade sidings (2) together with the vertical profiles (4). (Fig 5) The siding material channels (6) provided on the external facade sidings (2) can either be opened directly on the external facade sidings (2), or these siding material channels (6) can also be formed with channel shaped profiles that may be mounted on the external facade sidings (2). Moreover these horizontal profiles (3) can also be mounted on the external facade sidings (2) without any tabs. This type of mounting may be carried out with linking means or by screws. According to this application, the external facade sidings (2) whose edges have been cut at a certain angle, can be fitted, laid down, coupled to each other and locked into the horizontal profile channels (7) having grooves that have been arranged to correspond to the angular cutting of the external facade sidings. (Figure 8) The horizontal profiles (3) can be provided with a plurality of parts that can be fitted into each other and again the horizontal profiles (3) can be produced from any kind of highly durable material such as aluminium, hard plastic, and metal. The horizontal profiles (3) and vertical profiles (4) can be produced, having different designs. The profiles that have been designed to have a plurality of parts can also be produced in order to provide solutions for different problems. When the entire metal plate (1) is covered, the horizontal profiles (3) fitted on the external surface of the metal plate (1) by means of screws (5) and they are anchored to the metal plate (1). If it is desired, this retention can be carried out by screwing the vertical profiles (4). Together with this retention, the horizontal profiles (3) will be able to fix the external facade siding (2) and the vertical profiles (4). By this means, the parts are locked with each other such that they are flexible (flexible interlocking). This application shall both provide flexibility and
reduce the risk of the external facade sidings (2) from falling; therefore it is suitable to be used in seismic areas with high earthquake risk.
As the horizontal profiles (3) are located between the external facade sidings (2) at a horizontal axis and the vertical profiles (4) are located between the external facade sidings (2) at a vertical axis, it is ensured that both the distance between the external facade sidings (2) are equal or at a desired distance, and that when the metal plate (1) is being carried, the moving or shifting of the external facade siding (2) is prevented. Together with this as the external facade siding (2) shall be in contact with the metal plate (1), there will be no shifting outwards in that axis either. As all kinds of workmanship shall be performed on-site, these processes will both be performed easier, and as the horizontal profile (3) and the vertical profiles (4) shall encase the external facade siding (2) completely, there will be no problems regarding alignment.
Later on the steel plates (9) are anchored to the horizontal profiles (3). These steel plates (9) remain inside the concrete that is to be poured and therefore the horizontal profiles (3), and in return the external facade sidings (2) that have been locked to the horizontal profiles (2) and the vertical profiles (4) are fixed to the concrete that shall be poured. (Figure 6) Steel rods can be used instead of steel plates (9) to show the same function.
Later on the insulation plate (10) is adhered behind the external facade sidings (2). By this means the insulation of the building is also provided.
Following the insulation plate (10) the water insulation cover (11) is adhered. The water insulation cover (11) not only prevents the water arriving externally to reach the building but also prevents the concrete water from reaching the front face of the external facade sidings (2). It is possible to change the application sequence of the water insulation cover (11) and the insulation plate (10). For example according to an embodiment of the invention, instead of adhering the insulation
plate (10), the light and slim insulation plate that is to be coupled to the horizontal profiles (3) or the vertical profiles (4) can be applied to the retaining apparatus (12) by arranging the insulation plates (10). According to this embodiment, an air gap (13) can be formed between the external facade sidings (2) and the insulation plate (10). According to this embodiment an insulation plate (10) retaining apparatus (12) is used having an insulation plate (10) retaining apparatus channel (14) and the insulation plate (10) retaining apparatus tab (15) which shall be placed between the insulation plate (10) and coupled to the horizontal profile (3). According to this embodiment, an air gap (13) shall be formed between the external facade sidings (2) and the insulation plate (10). (Figure 7) By this means a ventilated external facade siding (2) system is established which provides the highest comfort in external facade siding plating. According to this embodiment, it is also possible for the steel plates (9) or rods that shall remain inside the concrete to be coupled to this insulation plate (10) retaining apparatus (12). These insulation plate (10) retaining apparatus's (12) can be designed in different forms. According to a different embodiment, the insulation plate (10) can be placed between the external facade siding and the retaining apparatus channel (14) of the insulation plate (10) and therefore the arrangement will be; external facade siding (2), water insulation cover, insulation plate (10) and concrete and an air gap (13) will not be provided. (Figure 9)
Later on the steel meshes are fixed and the external mould is formed. This external mould is lifted to the place where the concrete will be poured and the external mould and the internal mould are coupled to each other. The wall is formed by pouring concrete between the space formed between the steel mesh or meshes and the moulds. When the concrete is set, the screws (5) on the metal plate (1) are removed and therefore the metal plate is separated from the horizontal profiles (3) and the external facade siding (2).
Claims
1.) The invention is an on-site cast concrete wall production method comprising the steps of,
- preparing the external moulds externally,
- lifting the external mould, to the floor where the concrete is to be poured and fixing the internal mould in front of said external mould,
- pouring the concrete between the external and internal mould,
- Characterized by fixing the external sidings (2) into the external mould, while the external mould is being formed externally,
- And by using horizontal profiles (3) that extend from one end to the other such that said profiles enable to couple and lock the external sidings (2) with each other and to align said external sidings (2) with each other.
2.) A method according to claim 1, characterized in that, vertical profiles (4) are inserted between the external sidings (2) when said external sidings (2) are aligned side by side on a metal plate (1)
3. ) A method according to claim 2, characterized in that, the external sidings
(2) are inserted into the horizontal profile channel tabs (8) and horizontal profile channels (7) located under and on the horizontal profiles (3).
4. ) A method according to claim 3, characterized in that, the external facade sidings (2) whose edges have been cut at a certain angle, can be fitted, laid down, coupled to each other and locked into the horizontal profile channels (7) having grooves that have been arranged to correspond to the angular cutting of the external facade sidings.
5. ) A method according to claim 3 or 4, characterized in that, the horizontal profile channel tabs (8) located at the end of the horizontal profile channels (7) are fitted into the siding material channel (6) located on the external facade sidings (2) and therefore the horizontal profiles (3) are locked to the external facade sidings (2).
6. ) A method according to claim 5, characterized in that, steel plates (9) are fixed in order to ensure that the horizontal profiles (3) and/or vertical profiles (4) are anchored into the concrete to ensure that the external facade sidings (2) are anchored to the concrete.
7. ) A method according to claim 6, characterized in that, an insulation plate
(10) and water insulation cover (11) is placed over the internal surface of the external facade sidings (2).
8. ) A method according to claim 7, characterized in that, the insulation plate
(10) can be placed between the external facade siding and the retaining apparatus channel (14) of the insulation plate (10) and therefore the arrangement will be; external facade siding (2), water insulation cover, insulation plate (10) and concrete.
9. ) A method according to claim 8, characterized in that, the insulation plate
(10) is placed between the insulation plate (10) retaining apparatus channel (14) and the insulation plate (10) retaining apparatus tab (15) and therefore an air gap is formed between the insulation plate (10) and the external facade sidings (2).
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| TR2015/12914 | 2015-10-16 | ||
| TR201512914 | 2015-10-16 |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| WO2017065716A1 true WO2017065716A1 (en) | 2017-04-20 |
Family
ID=57406320
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| PCT/TR2016/050384 WO2017065716A1 (en) | 2015-10-16 | 2016-10-14 | Concrete wall production method with on-site casting |
Country Status (1)
| Country | Link |
|---|---|
| WO (1) | WO2017065716A1 (en) |
Citations (6)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US2465871A (en) * | 1946-12-03 | 1949-03-29 | Charles A Hardie | Faced monolithic building wall |
| FR2098021A5 (en) * | 1970-07-27 | 1972-03-03 | Steuler Industriewerke Gmbh | |
| WO2004088064A1 (en) * | 2003-04-01 | 2004-10-14 | Nuova Ceval S.R.L. | A method for making coating walls |
| US20050246983A1 (en) | 2004-04-26 | 2005-11-10 | Loyd Stephen N | Curtain wall system and method |
| DE102005019977A1 (en) | 2005-04-27 | 2006-11-09 | Deutsche Steinzeug Cremer & Breuer Ag | Building facade has support frame defining ventilation space for ceramic panels attached by fixings in grooves in rear panel faces |
| US20090031652A1 (en) | 2006-02-08 | 2009-02-05 | Frons Ventilo S.A. | Device for fixing thin elements to facades |
-
2016
- 2016-10-14 WO PCT/TR2016/050384 patent/WO2017065716A1/en active Application Filing
Patent Citations (6)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US2465871A (en) * | 1946-12-03 | 1949-03-29 | Charles A Hardie | Faced monolithic building wall |
| FR2098021A5 (en) * | 1970-07-27 | 1972-03-03 | Steuler Industriewerke Gmbh | |
| WO2004088064A1 (en) * | 2003-04-01 | 2004-10-14 | Nuova Ceval S.R.L. | A method for making coating walls |
| US20050246983A1 (en) | 2004-04-26 | 2005-11-10 | Loyd Stephen N | Curtain wall system and method |
| DE102005019977A1 (en) | 2005-04-27 | 2006-11-09 | Deutsche Steinzeug Cremer & Breuer Ag | Building facade has support frame defining ventilation space for ceramic panels attached by fixings in grooves in rear panel faces |
| US20090031652A1 (en) | 2006-02-08 | 2009-02-05 | Frons Ventilo S.A. | Device for fixing thin elements to facades |
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