METHOD AND FORMWORK SYSTEM FOR PRODUCING A CONCRETE WALL

Description

[0001] The present invention relates to a method for producing a concrete wall extending from a first to a second existing wall using a first formwork for the front side of the concrete wall and a second formwork for the back side of the concrete wall.

[0002] Creating a concrete wall as a partition or dividing wall between two existing walls is a common task in concrete construction. For example, load-bearing walls are first constructed on each floor, and then a concrete wall is constructed between each pair of these walls, i.e., between the existing walls, to separate residential or commercial spaces. This is generally done using formwork that is fixed parallel to each other between the two existing walls. The resulting space between these walls and the existing walls is then filled with liquid concrete, allowing the liquid concrete to harden into the concrete wall.

[0003] The formwork is available in different widths and heights and can therefore be used directly for standard floor heights and distances between the existing walls. The formwork is each slightly smaller in width than the distance between the existing walls to allow for manipulation and fixing. To fix it to the existing walls, each formwork is generally brought to the designated location and clamped between the existing walls using wedges. From CN 112 962 831 A or KR 2012 / 0002152 A, it is known that the formwork can alternatively be fixed to the existing walls using metal brackets. The remaining gaps between the formwork and the existing wall are filled, for example, with fast-curing assembly foam to prevent seepage of liquid concrete. Depending on the dimensions of the concrete wall to be constructed, i.e.Depending on their width, height, and thickness, the formwork can be additionally supported on the ground with props before pouring, as known from CN 110 284 634 A, and / or anchored to one another with formwork anchors, as known from CN 110 409 801 A. DE 1 784 727 A1 describes the creation of a tile partition wall, in which the front sides of the space are closed with frames or T-irons in order to permanently integrate them into the tile partition wall. Finally, US 2020 / 0018082 A1 shows an extremely complex, multi-part formwork system for creating complexly structured coffered ceilings or vaults, whereby props that hold adjacent system components in position are covered with a flexible sealing film.

[0004] Fixing the formwork in place using wedges is relatively laborious. Since driving in the wedges often causes the formwork to shift, it is particularly difficult to maintain the intended position, i.e., position and alignment, of the formwork precisely during wedging. If this is not achieved, the concrete wall will not be produced in the intended position and / or thickness. Removing the expansion foam, wedges, and formwork is also laborious and time-consuming. Furthermore, if too much expansion foam is applied to the gap during sealing, it will also penetrate the space between the formwork and thereby weaken the concrete wall being constructed. Conversely, if too little expansion foam is applied, the risk of leaks increases, through which liquid concrete will seep out and have to be laboriously removed.

[0005] The invention aims to create a method for a formwork system which enables extremely precise production of the concrete wall in a particularly quick and simple manner.

[0006] This object is achieved according to claim 1 by a method of the type mentioned at the outset, which is characterized by the following steps, which are carried out in any order, unless otherwise stated: Mounting a first and a second angle profile on the first existing wall, wherein the first angle profile has a length corresponding to a height of the first formwork, and the second angle profile has a length corresponding to a height of the second formwork; mounting a third and a fourth angle profile on the second existing wall, wherein the third angle profile has a length corresponding to the height of the first formwork, and the fourth angle profile has a length corresponding to the height of the second formwork; after mounting the first and third angle profiles, attaching the first formwork to the first and third angle profiles; after mounting the second and fourth angle profiles, attaching the second formwork to the second and fourth angle profiles; after attaching the formwork, pouring the space formed by the formwork, the angle profiles, and the existing walls with liquid concrete and allowing it to harden into a concrete wall.

[0007] One leg of each angle profile is mounted to an existing wall; the respective formwork is attached to the other leg. These other legs of the first and third angle profiles thus represent a system for the first formwork, and those of the second and fourth angle profiles represent a system for the second formwork. The angle profiles are easily accessible before the formwork is attached and can therefore be easily mounted on the existing walls in exactly the intended position for the formwork, and any errors can be easily corrected. The formwork is precisely aligned on the angle profiles and can be easily attached to them. Moving the formwork or changing its position when attaching it to the angle profiles and therefore when fixing it – via the angle profiles – to the existing walls is impossible.Since each angle profile has a length corresponding to the height of the formwork that can be attached to the angle profile, the gaps between the formwork and the existing walls are already closed by the angle profiles, eliminating the need to fill them with expansion foam and subsequently remove it completely. This allows the concrete wall to be constructed quickly, easily, and with extreme precision in the desired position and thickness.

[0008] The angle profiles define the positions of the formwork and thus the courses of those four edges which are to enclose the front and back of the concrete wall with the first and second existing walls during construction. The angle profiles can actually be mounted at any point on the existing walls and the position of the concrete wall can be determined by them. In general, however, the position of the concrete wall to be constructed will be predetermined, so that in a preferred embodiment the additional step of determining the courses of the aforementioned four edges is carried out before the angle profiles are mounted, with an angle profile being mounted along each determined course during assembly. These courses can be transferred from a building plan or similar to the existing walls, e.g. marked on them, so that a corresponding angle profile is simply mounted along each marked line.

[0009] It is advantageous if the first and second angle profiles are aligned during installation so that their profile legs adjacent to the first existing wall face away from each other, and the third and fourth angle profiles are aligned so that their profile legs adjacent to the second existing wall face away from each other. This allows the angle profiles to be removed quickly and easily after the concrete wall has hardened and the formwork has been removed.

[0010] Depending on the material, the angle profiles can be glued, welded, riveted, nailed, etc. when mounted to the existing wall. It is advantageous if the angle profiles are screwed to the existing wall during installation, as this results in a removable yet stable installation on the existing wall.

[0011] Likewise, the formwork can be attached to the respective angle profiles in a variety of ways. For the reasons mentioned above, it is advantageous if the first and second formwork are screwed to the respective angle profiles during installation. Alternatively or additionally, the first and / or second formwork can be pressed against the respective angle profiles with one or more supports during installation, and / or the two formworks can be anchored to each other with formwork anchors, thereby pressing them against the angle profiles.

[0012] In order to achieve a further improved fixation of the formwork, in an advantageous embodiment of the method the following additional steps are carried out before the attachment of the first and second formwork: mounting a fifth angle profile on the floor between the first and second existing walls along a cutting line with a surface spanned by the first and third angle profiles and mounting a sixth angle profile on the floor between the first and second existing walls along a cutting line with a surface spanned by the second and fourth angle profiles, wherein in the attachment steps the first formwork is further attached to the fifth angle profile and the second formwork is attached to the sixth angle profile.

[0013] To strengthen the concrete wall, it is also beneficial to carry out the following additional step before pouring: inserting reinforcement for the concrete wall into the space mentioned.

[0014] The first and second existing walls are usually, but not necessarily, parallel to each other; similarly, the concrete wall is usually, but not necessarily, constructed at right angles to the existing walls. For this purpose, the angle profiles are preferably rectangular to represent the right angles between the concrete wall to be constructed and the existing walls. Furthermore, in an advantageous embodiment, the angle profiles are isosceles and thus universally applicable. Alternatively, the angle profiles can also have different leg lengths.

[0015] It is understood that the concrete wall to be constructed may be curved and / or angular; however, the formwork is preferably flat, thereby producing a flat, straight concrete wall.

[0016] The invention is explained in more detail below with reference to examples shown in the accompanying drawings. In the drawings: Fig. 1 Angle profiles of a formwork system mounted on two existing walls for producing a concrete wall between the existing walls according to a method according to the invention in a sectional view from above; Fig. 2 and 3 an example of an angle profile of the formwork system from Fig. 1 each in cross-section; Fig. 4 the angle profiles mounted on the existing walls of Fig. 1 with a formwork of the formwork system attached to it in a sectional view from above; Fig. 5 the angle profiles mounted on the existing walls with attached formwork from Fig. 4 in a perspective sectional view from the left; Fig. 6 the angle profiles mounted on the existing walls of Fig. 1with two formworks of the formwork system attached in a sectional view from above; and Fig. 7 a concrete wall produced by the method according to the invention after dismantling the formwork system of the Fig. 1 to 6 in a perspective sectional view from the left.

[0017] Based on the Fig. 1 to 7 A method is illustrated by which a concrete wall 1 ( Fig. 7 ) is constructed, which is intended to extend from a first existing wall 2 to a second existing wall 3. The existing walls 2, 3 can be made of wood, brick, hollow walls, or the like; however, the existing walls 2, 3 will usually also be concrete walls, constructed, for example, as load-bearing walls using concrete construction. The concrete wall 1 to be constructed is therefore, for example, a partition or dividing wall for separating residential or commercial spaces from one another.

[0018] According to the method illustrated here, a first and a second angle profile 4 1 , 4 2 are mounted on the first existing wall 2; likewise, a third and a fourth angle profile 4 3 , 4 4 are mounted on the second existing wall 3. The order of mounting is arbitrary.

[0019] In the examples of Fig. 2 and 3 are the angle profiles 4 1 , 4 2 , ..., generally 4 i , e.g. isosceles ( Fig. 2 ), ie they have two profile legs S 1 , S 2 of the same leg length SL of e.g. 40 mm, 60 mm, 80 mm etc.; or they are unequal-sided ( Fig. 3), ie the angle profiles 4 i have different leg lengths SL 1 , SL 2 of e.g. 40 mm and 60 mm or 60 mm and 80 mm etc. etc. The angle profiles 4 i have a corresponding thickness D of e.g. 2 mm, 4 mm, 6 mm etc. The angle profiles 4 i are e.g. made of steel, in particular galvanized steel, or another metal, in particular aluminum, of plastic, in particular fiber-reinforced plastic, or of wood etc. In the examples shown, the two profile legs S 1 , S 2 of the angle profiles 4 i enclose a right angle α, ie they are right-angled angle profiles 4 i ; in other cases the angle profiles 4 i can be acute or obtuse-angled, as explained in more detail below.

[0020] For installation, each angle profile 4 i - with one of its profile legs S 1 , S 2 - is placed on the respective existing wall 2, 3 and, depending on the material of the existing wall 2, 3, for example, glued, welded, riveted, nailed and / or screwed to it with screws or screw anchors, for example with three to four over the length PL 1 , PL 2 , ..., generally PL i , ( Fig. 5 ) of the angle profiles 4 i with screw anchors evenly distributed or with screw anchors that are distributed at a mutual distance of, for example, 400 mm or 440 mm over the lengths PL i of the angle profiles 4 i, i.e. symmetrically to their respective centers. The angle profiles 4 i can each be aligned such that the profile legs S 1 , S 2 of two angle profiles 4 i mounted on an existing wall 2, 3 face each other or - as in the examples shown - face away from each other.

[0021] The Fig. 4 and 5show the result of a further step of the method, which is carried out after the assembly of the first and third angle profiles 4 1 , 4 3 : In this step, a first formwork 5 1 is attached to the first and third angle profiles 4 1 , 4 3 .

[0022] The first and third angle profiles 4 1 , 4 3 thus jointly determine the position, ie the position and the alignment, of the first formwork 5 1 and subsequently the first formwork 5 1 determines the position of the front side 1 V ( Fig. 7) of the concrete wall 1 to be produced itself. Since this position relative to the existing walls 2, 3 is generally not arbitrary but precisely planned, an optional step can be carried out prior to the steps of mounting the angle profiles 4 i. In this prior step, the courses of those four edges K are determined which, during production, are to enclose the front and rear sides 1 V , 1 R of the concrete wall 1 with the first and second existing walls 2, 3, respectively, and of which two in Fig. 7 These four lines can optionally be marked or sketched on the existing walls 2, 3; in any case, during assembly, one of the angle profiles 4 i is mounted along each line, thereby ultimately ensuring the construction of the concrete wall 1 in the planned position.

[0023] Fig. 6shows the result of a further step of the method: After mounting the second and fourth angle profiles 4 2 , 4 4 , a second formwork 5 2 is attached to the second and fourth angle profiles 4 1 , 4 3 . It is understood that the second formwork 5 2 can be attached before, after, or at most simultaneously with the first formwork 5 1 .

[0024] The four angle profiles 4 i and the two formworks 5 1 , 5 2 , generally 5 j , together form a formwork system 6, which optionally comprises further components, as explained below.

[0025] For attachment, the two formworks 5 j can be screwed, riveted, nailed, or similarly connected to the respective angle profiles 4 i. Alternatively or additionally, one or both formworks 5 j can be pressed against the angle profiles 4 i with (here: one or) more supports 7 and / or both formworks 5 j can be anchored to one another using formwork anchors 8 and thus also pressed against the angle profiles 4 i.

[0026] In a final step after the formwork 5j has been attached, the space 9 formed by the formwork 5j, the angle profiles 4i and the existing walls 2, 3 is poured with liquid concrete and allowed to harden into the concrete wall 1.

[0027] In the example shown, connecting reinforcements 10 ( Fig. 1) to be cast into the concrete wall 1 during pouring and to provide a firm connection to the existing walls 2, 3. In an optional further step, additional reinforcement (not shown) for the concrete wall 1 is introduced into the aforementioned space 9 before pouring.

[0028] In the embodiments of the Fig. 4 to 6 the formwork system 6 optionally comprises one or two further angle profiles 4 i , ie a fifth and / or a sixth angle profile 4 5 , 4 6 , of which the one shown in Fig. 4 left (and in Fig. 5front) sixth angle profile 4 6 is shown in dashed lines. Before the first or second formwork 5 1 , 5 2 is attached, the fifth angle profile 4 5 is mounted along an intersection line with an area spanned by the first and third angle profiles 4 1 , 4 3 - i.e., as it were, between the first and third angle profiles 4 1 , 4 3 - on the floor 11 between the two existing walls 2, 3; in a similar way, the sixth angle profile 4 6 is mounted along an intersection line with an area spanned by the second and fourth angle profiles 4 2 , 4 4 - i.e., as it were, between the second and fourth angle profiles 4 2 , 4 4 - on the floor 11 between the two existing walls 2, 3. In the steps of attachment, the first formwork 5 1 is attached to the fifth angle profile 4 5 and the second formwork 5 2 is attached to the sixth angle profile 4 6.

[0029] Formwork 5 j for concrete walls 1 are available in several different widths BS ( Fig. 4), e.g. 2.4 m, 2.8 m, 3.2 m etc., and heights HS ( Fig. 5 ), e.g. 2.7 m, 3.3 m etc., The widths BS are each adapted to the mutual distances A between adjacent load-bearing walls (here: existing walls 2, 3) that are customary in concrete construction; the widths BS of the formwork 5 j are slightly smaller than the distances A, which are e.g. 2.45 m, 2.85 m, 3.25 m etc., in order to be able to easily insert the formwork 5 j between the existing walls 2, 3. For the same reasons, the heights HS of the formwork 5 j are adapted to typical storey heights G of e.g. 2.75 m, 3.35 m etc., i.e. again slightly smaller.

[0030] The first, second, third and fourth angle profiles 4 1 , 4 2 , 4 3 , 4 4 each have a length PL 1 , PL 2 , PL 3 , PL 4 , which corresponds to a height HS 1 , HS 2 of the formwork 5 1 , 5 2 to be attached to them. In this way, no gaps remain between the existing walls 2, 3 and the formwork 5 j attached to them via the angle profiles 4 i. If angle profiles 4 5 , 4 6 are also mounted on the floor 11, for the same reason they preferably each have a length PL 5 , PL 6 which corresponds to the width BS of the formwork 5 j to be attached to them.

[0031] At the same time, all angle profiles 4 i each have leg lengths SL, which result in a sufficient overlap of, for example, 20 mm or more with the formwork 5 j attached to them. For example, angle profiles 4 i with a longer leg length SL of at least one leg S 1 , S 2 can be used if one of the existing walls 2, 3 or the floor 11 is uneven or inclined.

[0032] After the liquid concrete has hardened, Fig. 7 The optional supports 7 and / or formwork anchors 6 are removed, the formwork 5 j is removed, and optionally the angle profiles 4 i are unscrewed or loosened and, if necessary, tapped with a hammer. The formwork system 6 can then be reused.

[0033] In all of the examples shown, the two existing walls 2, 3 are parallel to one another. It goes without saying that this is not necessary; instead, the two existing walls 2, 3 could alternatively form an acute angle α with one another, for example. Likewise, the concrete wall 1 is shown at a right angle to the two existing walls 2, 3. This is also not mandatory; instead, the concrete wall 1 could extend diagonally to the existing walls 2, 3 from the first to the second existing wall 2, 3. In such cases, the angle profiles 4 i are optionally not right-angled; instead, their two legs S 1 , S 2 preferably form an angle α which corresponds to the respective angle of the edges K between the concrete wall 1 to be constructed and the existing walls 2, 3.

[0034] Furthermore, in the examples shown, the formwork 5 j is each flat. This is also not mandatory. For example, at least one of the formwork 5 j could be curved and / or, particularly when viewed from above, have an angular shape. In this case, the angle profiles 4 1 , 4 2 , 4 3 , 4 4 are not all mounted parallel and perpendicular to one another, but rather adapted to the required position of the formwork 5 j on the existing walls 2, 3. The same applies to the optional angle profiles 4 5 , 4 6 , which are mounted accordingly on the floor 11.

[0035] The invention is not limited to the illustrated embodiments, but includes those variants, modifications and combinations thereof that fall within the scope of the appended claims.

Claims

1. A method for constructing a concrete wall (1) extending from a first to a second existing wall (2, 3) using a first formwork (51) for the front side (1V) of the concrete wall (1) and a second formwork (52) for the rear side (1R) of the concrete wall (1), comprising the following steps in any order unless otherwise specified: mounting a first and a second angle profile (41, 42) on the first existing wall (2), wherein the first angle profile (41) has a length (PL1) corresponding to a height (HS) of the first formwork (51), and the second angle profile (42) has a length (PL2) corresponding to a height (HS) of the second formwork (52) ; mounting a third and a fourth angle profile (43, 44) on the second existing wall (3), wherein the third angle profile (43) has a length (PL3) corresponding to the height (HS) of the first formwork (51), and the fourth angle profile (44) has a length (PL4) corresponding to the height (HS) of the second formwork (52); after mounting the first and the third angle profile (41, 43), attaching the first formwork (51) to the first and the third angle profile (41, 43); after mounting the second and the fourth angle profile (42, 44), attaching the second formwork (52) to the second and the fourth angle profile (42, 44); after attaching the formworks (5j), filling the space (9) formed by the formworks (5j), the angle profiles (4i), and the existing walls (2, 3) with liquid concrete and letting it cure to form the concrete wall (1).

2. The method according to claim 1, characterized by the additional step performed before mounting the angle profiles (4i): determining the courses of the four edges (K) which the front and rear sides (1V, 1R) of the concrete wall (1) shall enclose with the first and second existing walls (2, 3) during constructing, wherein an angle profile (4i) is mounted along each determined course during mounting.

3. The method according to claim 1 or 2, characterized in that the first and second angle profiles (41, 42) are oriented during mounting in a way that their profile legs (S1, S2) resting on the first existing wall (2) are facing away from each other, and the third and fourth profiles (43, 44) are oriented in a way that their profile legs (S1, S2) resting on the second existing wall (3) are facing away from each other.

4. The method according to any one of the claims 1 to 3, characterized in that the angle profiles (4i) are screwed to the respective existing wall (2, 3) during mounting.

5. The method according to any one of the claims 1 to 4, characterized in that the first and second formworks (51, 52) are screwed to the respective angle profiles (4i) during attaching.

6. The method according to any one of the claims 1 to 5, characterized in that, during attaching, the first and / or the second formwork (51, 52) are pressed against the respective angle profiles (4i) using one or more supports (7) and / or the two formworks (5j) are anchored to each other by formwork anchors (8) .

7. The method according to any one of the claims 1 to 6, characterized by the additional steps performed before attaching the first and second formworks (51, 52) : mounting a fifth angle profile (45) on the ground (11) between the first and second existing walls (2, 3) along an intersection line with a plane spanned by the first and third angle profiles (41, 43), and mounting a sixth angle profile (46) on the ground (11) between the first and second existing walls (2, 3) along an intersection line with a plane spanned by the second and fourth angle profiles (42, 44), wherein, during the steps of attaching, the first formwork (51) is also attached to the fifth angle profile (45) and the second formwork (52) is also attached to the sixth angle profile (46).

8. The method according to any one of the claims 1 to 7, characterized by the step performed before filling: placing a reinforcement for the concrete wall (1) in said space (9).