WALL OF A BUILDING WITH A VERTICAL CONCRETE SUPPORT FORMING PART OF THE WALL AND METHOD FOR PRODUCEING SUCH A WALL

Description

[0001] The present invention relates to a wall of a building with a vertical concrete column forming part of the wall and to a method for producing such a wall.

[0002] By providing concrete columns in walls, the walls in question are given greater stability. Such concrete columns are used, for example, in the knee walls (jammers) of buildings. A knee wall is an exterior wall built above the bare ceiling of the attic, on which the roof structure rests and which is therefore subject to particularly large forces. The integration of vertical concrete columns into the wall forming the knee wall increases its stability and ensures that the knee wall is suitable for absorbing the large forces acting on it. However, concrete columns can also be provided in any other wall of a building. For example, they can also increase the stability of walls on the floors below the building. These can include, but are not limited to, storey-high corner columns provided in the corners of the building.

[0003] When constructing a wall containing concrete columns, the concrete columns are constructed first. For this purpose, a formwork, usually made of wood with built-in reinforcement, is first erected, and then the formwork is filled with liquid concrete. After the concrete has dried, the formwork is removed, and the remainder of the wall containing the concrete columns is constructed using masonry building blocks, such as bricks. Since the concrete columns are usually thinner than the rest of the wall, for example, with a cross-section of 22x25 cm, a subsequent thickness adjustment is usually carried out, for example, by placing appropriate leveling elements on the concrete column.

[0004] Depending on the wall, it may contain a considerable number of concrete supports. For example, a wall forming a knee wall may have a concrete support every 2 m. The above-mentioned work must be carried out for each of the concrete supports in the wall in question.

[0005] The construction of a wall containing concrete columns is therefore associated with considerable effort and is extremely time-consuming.

[0006] Further prior art is known from documents GB 689 143 A, CN 104 631 689 A, DE 23 29 339 A1, and EP 0 404 044 A1. WO 2005 / 093182 A1 discloses a wall made of masonry, non-load-bearing blocks made from renewable raw materials such as plant fibers, with the load-bearing capacity of the wall provided by the concrete column. The chamber blocks for the formwork do not correspond to the grid of the masonry block assembly.

[0007] US 5,404,685 shows a boundary wall or fence with non-load-bearing polystyrene elements. US 5,924,247 shows a wall without a masonry block bond.

[0008] The present invention is therefore based on the object of finding a wall containing concrete supports which can be produced particularly easily and quickly, but which is nevertheless well thermally insulated and has a high load-bearing capacity, as well as a method for producing such a wall.

[0009] This object is achieved according to the invention by the wall claimed in patent claim 1 or the method claimed in patent claim 12.

[0010] In the claimed wall or in the claimed method, the formwork blocks forming a formwork device are integrated into the masonry block assembly like normal masonry blocks for building a wall, i.e. like masonry blocks not formed by formwork blocks. Thus, in a first step, a coherent masonry block-formwork block assembly can be produced, with the wall sections containing the concrete supports being formed by the formwork blocks, and the wall sections not containing concrete supports being formed by the normal masonry blocks. The concrete supports can then be produced in a second step by pouring the vertical recesses of the formwork blocks. This completes the construction of the entire wall. The formwork blocks can remain in the wall after pouring.Preferably, the formwork blocks have at least the same height and width as the normal masonry blocks, so that any leveling and adjustment work can be eliminated.

[0011] Since the formwork blocks are also made of good thermal insulation material, more precisely foamed plastic, or foamed polystyrene, or foamed polyurethane, no special thermal insulation of the concrete supports is required.

[0012] Using formwork blocks, walls containing concrete columns can be constructed in fewer steps and much faster and easier than before. Such walls can ultimately be built like a wall without concrete columns. The only difference is that where concrete columns are required, the formwork blocks are integrated into the masonry block composite instead of the standard masonry blocks and later poured with liquid concrete. Since the formwork blocks can be the same size as the standard masonry blocks, integrating the formwork blocks into the masonry block composite is no problem. The processing is identical. It is only necessary to pay attention to which block should be used where.

[0013] Advantageous developments of the invention can be found in the dependent claims, the following description, and the figures. It should be noted that only theFigures 6 to 9 relate to the invention.

[0014] The invention will be explained in more detail below using exemplary embodiments with reference to the figures. Figure 1 a wall in which the formwork device described in more detail below is integrated, Figure 2A a top view of one-piece formwork blocks of different sizes, Figure 2B two-part versions of the Figure 2A shown formwork blocks, Figure 2C the individual parts from which the Figure 2B shown formwork blocks are assembled, Figure 3A a plan view of a formwork block arrangement for the production of a concrete column to be placed in a corner of a building, Figure 3B a side view of the Figure 3A arrangement shown, Figure 4A a plan view of a formwork block arrangement for the production of a concrete column to be placed in a reveal, Figure 4Ba side view of the Figure 4A arrangement shown, Figure 5A a plan view of a formwork block arrangement for the production of a concrete column to be placed in a straight section of wall, Figure 5B a side view of the Figure 5A arrangement shown, Figure 6 a formwork block with a side cutout and the formwork block part cut out to form the cutout, Figure 7 the formwork block according to Figure 6 with a normal masonry block inserted into the cutout, Figure 8 a wall that the Figure 1 shown wall, but using the formwork blocks according to Figure 6 and normal masonry blocks inserted into the cutouts, and Figure 9 a formwork block that does not yet have a side cutout, but is prepared to create such a cutout.

[0015] The formwork device described in more detail below is a formwork device for producing concrete columns, in particular for producing vertical concrete columns forming parts of a wall.

[0016] The formwork device is formed by special formwork blocks which are designed and dimensioned in such a way that they can be used as masonry blocks for the construction of a wall consisting of masonry blocks, and can be combined with masonry blocks not formed by formwork blocks during wall construction and can be integrated into the masonry block composite like the masonry blocks not formed by formwork blocks.

[0017] An example of how the formwork blocks can be integrated into the masonry block composite is shown in Figure 1 illustrated.

[0018] The Figure 1 shows part of an unfinished outer wall of a building.

[0019] The reference symbol GD designates a floor of the building. A vertical wall M constructed of masonry blocks 1 and 2 is planned on the floor GD. In the example considered, the wall M will form a knee wall after its completion, but it could also be any other wall. At the location designated by the reference symbol BS, a concrete column is to be constructed that extends vertically upwards from the floor GD and is integrated into the wall M.

[0020] Wall M is constructed from masonry blocks 1 and 2 arranged in a masonry block pattern. In the example considered, the masonry block pattern consists of several stacked rows of masonry blocks, whose masonry blocks are selected and arranged such that the vertical joints between adjacent masonry blocks do not overlap.

[0021] The concrete column BS passes through the masonry blocks 1, which form the wall section traversed by the concrete column. As will be described in more detail later, the wall M is first constructed from the masonry blocks 1 and 2, and then the concrete column BS is created by pouring liquid concrete into a vertical recess in the wall. Thus, the concrete column is no longer constructed first and then the adjoining wall sections are erected; instead, the entire wall is constructed first and then the concrete column is created by pouring a vertical recess in the wall.

[0022] The wall M consists of two types of masonry blocks, namely the aforementioned formwork blocks 1 and regular masonry blocks 2, such as clay bricks or other masonry blocks. The formwork blocks 1 form the wall section traversed by the concrete column BS. More precisely, all masonry blocks traversed by the concrete column BS, and preferably only these masonry blocks, are formed by formwork blocks 1, whereas all other masonry blocks of the wall M are formed by regular masonry blocks 2.

[0023] The formwork blocks 1 have the same width as the normal masonry blocks 2 not formed by formwork blocks, which is usually approximately the same width as the wall thickness. The heights of the various masonry blocks 1 and 2 are also the same. The lengths of the various masonry blocks 1 and 2 can vary.

[0024] Each formwork block 1 is traversed by a vertical recess 11, which has a cross-section corresponding to the concrete column cross-section. In the example considered, this is a rectangular cross-section, but the cross-section can also have any other shape. In this case, the corners of the cross-section are rounded to increase the stability of the formwork blocks 1, but this is not a limitation.

[0025] The formwork blocks 1 are integrated into the masonry block assembly in such a way that the vertical recesses 11 of the formwork blocks 1 arranged one above the other are aligned and lie exactly where the concrete column BS is to be created.

[0026] These overlapping recesses 11 form the aforementioned vertical recess in the wall M, which is filled with liquid concrete to create the concrete column BS. The liquid concrete poured into the recesses 11 forms the concrete column BS to be constructed after hardening.

[0027] To increase the load-bearing capacity of the concrete column BS, it is reinforced with reinforcement, for example, reinforcing steel. The recesses 11 of the formwork blocks 1 are therefore designed and dimensioned such that their vertical recesses 11 are suitable for accommodating reinforcement, i.e., they can be passed through by reinforcement, for example. These reinforcements are not shown in the figures.

[0028] As mentioned, the recess 11 is preferably only poured after the wall M has been completed, more precisely after the masonry block assembly has been pulled upwards as intended.

[0029] The formwork blocks 1 form a formwork device, i.e., the casting mold for the concrete column BS to be constructed. No additional formwork, support, stabilization, bracing, etc. are required. The formwork blocks 1 can be poured with liquid concrete as installed in the wall M and are designed to withstand all forces acting on them before, during, and after the wall construction / pouring.

[0030] The formwork blocks 1 remain in the wall after the completion of the concrete column BS, thus forming a so-called permanent formwork. Since the formwork blocks 1 are the same width as standard masonry blocks, no further work is required where the concrete column is located, in particular no filling or cladding of gaps, wall niches, or the like.

[0031] The formwork blocks 1 are preferably made of a material with good thermal insulation properties, so no additional thermal insulation measures are required. In the example considered, the formwork blocks 1 are made of foamed plastic, such as expanded polystyrene. However, other plastics, such as polyurethane foam, or completely different materials can also be used.

[0032] The formwork blocks 1 can be made in one piece or in several pieces.

[0033] The Figure 2Ashows two one-piece formwork blocks 1 in a top view. The formwork blocks 1 shown have different lengths. The formwork block 1 shown on the left is a short formwork block, and the formwork block 1 shown on the right is a long formwork block. Formwork blocks of different lengths are required to ensure the necessary and prescribed joint offset, i.e., the lateral offset of the vertical joints between adjacent masonry blocks in stacked masonry block rows.

[0034] The Figure 2Bshows two two-part formwork blocks in a state in which the individual parts are connected to each other as intended. Again, two formwork blocks 1 of different lengths are shown. The short formwork block 1 shown on the left consists of a first formwork block element 1-1 and a second formwork block element 1-2 connected to it. The long formwork block 1 shown on the right consists of the first formwork block element 1-1 and a third formwork block element 1-3 connected to it.

[0035] The Figure 2C shows the Figure 2B shown formwork blocks 1 in a state in which the formwork block elements 1-1 and 1-2 or 1-1 and 1-3 are not connected to one another.

[0036] The first formwork block element 1-1 of the short formwork block 1 and the first formwork block element 1-1 of the long formwork block 1 are identical. The second formwork block element 1-2 of the short formwork block 1 and the third formwork block element 1-3 of the long formwork block 1 differ from each other, with only the length of the respective formwork block elements differing.

[0037] The formwork block elements to be connected to each other are connected via projections 13 provided on one of the formwork block elements, which engage in complementary recesses 14 provided on the formwork block element to be connected. In the example considered, the projections 13 are provided on formwork block elements 1-2 and 1-3, and the recesses 14 are provided on formwork block elements 1-1. However, this could also be reversed. It could also be provided that each formwork block element has at least one projection 13 and at least one recess 14.

[0038] The projections 13 preferably extend vertically over the entire height of the formwork block element supporting them. In the example considered, they have a T-shaped cross-section. A different cross-section could also be provided, for example, a mushroom-shaped or dovetail-shaped cross-section, or another cross-section that prevents the connected formwork block elements from being separated from one another by a longitudinal tension.

[0039] The complementary recesses 14, as mentioned, extend vertically, like the projections 13, over the entire height of the formwork block element containing them. To connect the formwork block elements, the projections 13 are inserted from above into the corresponding recesses 14, and the formwork block elements are then shifted vertically relative to each other until they are at the same height.

[0040] The dividing line between the connected formwork block elements preferably runs through the vertical recess 11 running through the formwork block 1 when viewed from above. This facilitates the production of the vertical recess 1.

[0041] In the example considered, the length of the formwork block in question can be determined as desired by selecting the formwork block elements to be assembled to form formwork block 1.

[0042] By a suitable different division of the formwork block 1 into individual parts and by providing at least certain individual parts in different sizes, other external dimensions of the formwork block in question can be additionally or alternatively determined as desired or individually adapted to the given conditions by a suitable selection of the individual parts to be assembled to form a formwork block.

[0043] Preferably, of the mutually facing sides of superimposed formwork blocks 1, one side has projections, and the other side has complementary recesses. The projections and recesses are arranged such that, in the intended relative position of the formwork blocks 1, the projections lie within the recesses. These projections and recesses are not shown in the figures.

[0044] The provision of said projections and recesses proves advantageous in several respects. Firstly, the projections and recesses are designed and arranged in such a way that they can only engage with one another in the intended relative position of the respective formwork blocks 1, i.e., when the projections and recesses are engaged, the formwork blocks automatically assume their intended relative position. In this state, the vertical recesses 11 of the formwork blocks 1 are aligned, so that no checking or alignment of the position of the vertical recesses 11 is necessary. Secondly, said projections and recesses prevent relative movement in the horizontal direction of the formwork blocks that have been placed on top of one another as intended. Thirdly, this increases the stability of the formwork blocks. In particular, the formwork blocks can better withstand the forces acting on them when the vertical recess 11 is poured.

[0045] It may prove advantageous if a layer is applied to at least one side of the formwork blocks or a plate is placed on top, which consists of a different material than the rest of the formwork blocks. In particular, it can be provided that a brick shell or the like is attached to one side for facing during the manufacture of the formwork block 1. This can, for example, give the side of the formwork block 1 facing the building's exterior the appearance and / or surface properties of the normal masonry blocks not formed by the formwork blocks.

[0046] It can also be provided to provide at least one side of the formwork blocks with a mineral plaster primer. This facilitates the plastering of the respective formwork block sides. Independently of this, it can be provided that at least one side of the formwork blocks 1 is provided with foam or mortar pockets designed to absorb the assembly foam, adhesive, or mortar used during wall construction and thus improve the connection to adjacent masonry blocks.

[0047] The formwork blocks described above can be used to create concrete columns that are integrated into a wall at any point.

[0048] The Figures 3A and 3B illustrate the use of formwork blocks 1 to construct a concrete column intended for use in a corner of a building. Figure 3A shows the top view of the corner of the building, and Figure 3B a side view.

[0049] As can be seen from the figures, the building corner in the example considered is formed by one-piece long formwork blocks 1 (formwork blocks according to Figure 2A right), whereby the formwork blocks are each rotated by 90° (alternating clockwise and counterclockwise) relative to the formwork block below, as shown.

[0050] The Figures 4A and 4B illustrate the use of formwork blocks 1 for the production of a concrete column provided in a reveal. Figure 4A shows the plan view of the reveal from above, and Figure 4B a side view.

[0051] As can be seen from the figures, the reveal in the example considered is formed by alternating one-piece long formwork blocks 1 (formwork blocks according to Figure 2A right) and one-piece short formwork blocks 1 (formwork blocks according to Figure 2A left) are placed on top of each other.

[0052] The Figures 5A and 5BFinally, illustrate the use of formwork blocks 1 for the construction of a concrete column provided in a straight section of wall. Figure 5A shows the top view of the wall, and Figure 5B a side view. These are other representations of the already Figure 1 shown use case.

[0053] As can be seen from the figures, the wall section traversed by the concrete column in the example considered is formed by long formwork blocks 1 (formwork blocks according to Figure 2A right) are placed sideways offset from each other.

[0054] According to the invention, the formwork blocks 1 have a cutout 15 in one of their side surfaces. This cutout is preferably provided on the formwork block side which, when the formwork block 1 is used as intended, is located on the wall side facing the building interior, i.e. on the formwork block side that forms part of the wall interior. This cutout can be created, for example, by cutting out a corresponding part 16 from the formwork block 1. Of course, the cutout 15 can also be created in any other way. A formwork block 1 having such a cutout 15 and the formwork block part 16 cut out to form the cutout 15 are shown in the Figure 6 illustrated.

[0055] In the example considered, the cutout 15 is cuboid-shaped. It is provided on one of the vertical edges of the formwork block 1, preferably on an edge that, when the formwork block 1 is used as intended, will be on the side of the wall facing the interior of the building. The cutout 15 extends across the entire height, but only over part of the width and part of the length of the formwork block 1. It does not extend into the vertical recess 11 of the formwork block 1.

[0056] In principle, the cutouts 15 can also have a different shape and / or a different position within the formwork block.

[0057] Preferably, the cutout 15 is large enough to accommodate a smaller masonry block 21, which may be a smaller clay brick, for example. This is Figure 7Preferably, the cutout 15 is shaped and dimensioned so that exactly one masonry block 21 with standardized dimensions fits into it. Figure 8 shows a wall constructed using formwork blocks 1 according to Figure 6 was built. The Figure 8 shows the wall side forming the inner wall. The Figure 8 The wall shown corresponds to the one in the Figure 1 shown wall, but the formwork blocks 1 are arranged according to Figure 6 were used and the cutouts 15 are filled with masonry blocks 21. To avoid misunderstandings, it should be noted that the masonry blocks 21 are preferably inserted into the cutout 15 only after the installation of a respective formwork block 1 in the wall and are fixed in the intended position with mortar or adhesive.

[0058] The provision of cutouts 15 and filling them with normal masonry blocks 21 has the positive effect of providing improved sound insulation and fire protection at these locations.

[0059] In the above statements regarding the formwork blocks 1 with cutout 15, it was assumed that the cutout 15 is already formed by the manufacturer of the formwork blocks 1. However, this does not have to be the case. It is also possible to carry out only preparatory work for the creation of the cutout 15 during the manufacture of the formwork blocks 1.

[0060] An example of this is in Figure 9shown. In the formwork block 1 shown there, the formwork block part 16 to be cut out to create the cutout 15 is only partially cut out and otherwise still firmly connected to the rest of the formwork block. To completely separate the formwork block part 16 to be cut out from the rest of the formwork block 1, a cut must be made along a dotted line 17. Such a cut can be easily performed on a construction site using a commercially available saw, at least with the material used in the example considered (foamed plastic).

[0061] In the example considered, there is even a further simplification. On the formwork block 1, there is a marking 18 that indicates to the responsible person where the cut should begin to properly cut out the formwork block part 16.

[0062] Preferably, the marking 18 consists of a small notch in the formwork block 1. This notch is designed for inserting the saw before the actual sawing begins. The subsequent sawing creates a cut that automatically starts at the correct location and runs in the correct direction. Faulty cuts are reliably eliminated, even by inexperienced operators.

[0063] This makes it possible to decide on the construction site whether to use formwork blocks with a 15-inch cutout or without. The production of formwork blocks with a 15-inch cutout is possible quickly and easily at any time if necessary. This also applies to formwork blocks with the 18-inch marking / cutout.

[0064] Regardless of the details of its practical implementation, the formwork device described above proves to be advantageous in many ways. It allows the concrete columns of a wall containing concrete columns, and thus the entire wall, to be constructed particularly easily and quickly. LIST OF REFERENCE SYMBOLS:

[0065] 1Formwork block 1-1First formwork block element 1-2Second formwork block element 1-3Third formwork block element 2Normal masonry block 11Vertical recess in 1 13Protrusion on 1-2 and 1-3 14Recess in 1-1 15Cutout in 1 16Part cut out of 1 17Line of the cut to be made 18Marking / notch BSConcrete column GDFloor ceiling MMurr

Claims

1. A wall (M) of a building comprising a vertical concrete support (BS) forming part of the wall, and a plurality of masonry blocks (2) arranged in a masonry block composite, the wall further comprising a formwork device remaining therein for producing the concrete support, the formwork device being formed by formwork blocks (1) through which a vertical recess (11) passes, which has a cross-section corresponding to the concrete support cross-section and is filled with concrete, characterized in that the formwork blocks (1), like the masonry blocks (2) not formed by formwork blocks (1), are integrated into the masonry block composite, in that the formwork blocks (1) are made of foamed plastic, or of foamed polystyrene, or of foamed polyurethane, in that the formwork block (1) has a formwork block part (16) to be cut out in order to produce a cutout (15), which is only partially cut out and is otherwise firmly connected to the rest of the formwork block (1), and in that the cutout (15) is designed to receive a smaller masonry block (21).

2. The wall (M) according to claim 1, characterized in that - the formwork blocks (1) have the same height as the masonry blocks (2) not formed by formwork blocks, - the formwork blocks (1) have the same width as the masonry blocks (2) not formed by formwork blocks, and - the formwork blocks (1) have a width corresponding to the wall thickness.

3. The wall (M) according to one of the preceding claims, characterized in that only the wall section traversed by the concrete support (BS) is formed by the formwork blocks (1), and the other wall sections are formed by the masonry blocks (2) not formed by the formwork blocks.

4. The wall (M) according to one of the preceding claims, characterized in that the formwork blocks (1) are integrated into the masonry block composite in such a way that the vertical recesses (11) of the formwork blocks come to lie where the concrete support (BS) is located.

5. The wall (M) according to one of the preceding claims, characterized in that the vertical recesses (11) are filled with liquid concrete, which in the hardened state forms the concrete support (BS) to be produced.

6. The wall (M) according to one of the preceding claims, characterized in that the vertical recesses (11) of the formwork blocks (1) are traversed by reinforcement means.

7. The wall (M) according to one of the preceding claims, characterized in that the formwork blocks (1) are formed in one piece.

8. The wall (M) according to one of claims 1 to 6, characterized in that the formwork blocks (1) are each composed of several individual parts (1-1, 1-2, 1-3).

9. The wall (M) according to claim 8, characterized in that - in the top view from above - the dividing line between two individual parts (1-1, 1-2, 1-3) of a formwork block (1) runs through the vertical recess (11) of the same, so that the length and / or the width of a respective formwork block (1) can be determined as desired by a suitable selection of the individual parts (1-1, 1-2, 1-3) to be assembled to form the respective formwork block.

10. The wall (M) according to one of the preceding claims, characterized in that one side of the mutually facing sides of formwork blocks (1) arranged one above the other has projections (13), and the other side has complementary indentations (14), the projections and the indentations being designed and arranged in such a way that they can only engage with one another in the intended relative position of the formwork blocks.

11. The wall (M) according to one of the preceding claims, characterized in that the cutout (15) is provided on the formwork block side which, when the formwork block (1) is used as intended, comes to lie on the wall side facing the interior of the building.

12. A method for producing a wall (M) of a building with a vertical concrete support (BS) forming part of the wall, and with a plurality of masonry blocks (2) arranged in a masonry block composite, wherein a formwork device remaining in the wall after the concrete support production is used to produce the concrete support, wherein the formwork device is composed of a plurality of formwork blocks (1), each of which is traversed by a vertical recess (11) which has a cross-section corresponding to the concrete support cross-section, characterized in that the formwork blocks are integrated into the masonry block composite in the same way as the masonry blocks (2) not formed by the formwork blocks, in that formwork blocks made of foamed plastic, or of foamed polystyrene, or of foamed polyurethane are used, in that the formwork block (1) has a formwork block part (16) to be cut out to produce a cutout (15), which is only partially cut out and is otherwise firmly connected to the rest of the formwork block (1), and in that the cutout (15) is designed to receive a smaller masonry block (21).