Wall element and method for the placement of such wall elements

Abstract

In a multi-layer, prefabricated wall element (1) for the construction of a building, with at least one edged, vertically extending recess to be filled, a supporting layer (2) stabilising the wall element is firmly connected to a thermal insulation layer (3) and the recess passing through the wall element (1) over its entire height is arranged at least in sections in the thermal insulation layer (3).

Description

[0001]06- 12-2023-3S774501-Ham- O0 2 PCT / DE2023 / 000148 EW 418 / 23 PCT Wall element and method for setting such wall elements Description: The invention relates to a multi-layer, prefabricated wall element for the construction of a building, with at least one edged, vertically extending recess to be filled. The demand for highly efficient, ecologically and climate-friendly and at the same time highly thermally insulating construction systems is increasing. This is reflected, for example, in the continuously rising proportion of prefabricated houses in Germany. Today, prefabricated houses are generally built using timber construction methods. If prefabricated houses are built using solid construction methods, the factory application of an additional thermal insulation composite system made of polystyrene or another highly insulating material is typically required.Monolithic solid construction systems consisting of storey-high wall modules that encompass the entire wall structure and can be moved with high efficiency are not available. The main reason for this is that the load-bearing function of a solid wall system is traditionally the primary focus. Due to the low thermal insulation capacity of load-bearing solid building materials, an additional thermal insulation composite system made of other insulating materials must be added. The result is ecologically unfavorable combinations of mineral and mostly petrochemical substances. 0E-12-2023-3S774S01-HauPtPost-0013 PCT / DE2023 / 000148 Multi-layer wall elements are well-known and proven. For example, prefabricated house construction uses walls in which, for example, a thermal insulation layer made of foam plastic is enclosed by fiberboard. However, such walls often lack sufficient mechanical stability.In order to increase mechanical stability, wall elements have become known which are provided with vertical tubes or recesses which, if appropriate with reinforcement, are filled with concrete for example and which then form a load-bearing skeleton of a wall, as explained for example in WO 2012 / 158031 A1. The object of the invention is to transfer such a reinforced concrete skeleton construction to multi-layer, prefabricated wall elements. In the case of the wall element in question, this is achieved by the features of claim 1. Such wall elements can be designed to be storey high in a known manner and can be provided with doors or windows. Connection to ceilings and floors is achieved, for example, by grouting or a mortar bed. The invention presented here separates the creation of the room-enclosing wall function spatially and temporally from the static wall function.For this purpose, the currently common manufacturing process for solid, large-format wall elements is inverted: First, a large-format wall module is manufactured in the factory from a mineral or biogenic building material that is not structurally sound but offers good thermal insulation. Recesses are provided in the wall elements produced in this way, which are later filled with in-situ concrete on site. Together with the floors and ceilings, they then form the building's load-bearing structure in the form of a reinforced concrete skeleton. 013-12-2023-35774S01-HauPiPmst-0014 PCT / DE2023 / 000148 The vertical transfer of loads, for example from floor slabs, occurs through the filled recesses, which may also contain reinforcement, and hardly at all through the load-bearing layer. The subsequent filling of the recesses in the thermal insulation layer with in-situ concrete is therefore of particular importance.When filling the recesses, forces such as increased pressure and vibrations act on the non-load-bearing material of the insulation layer. To absorb this pressure, the recesses, particularly in the area of ​​the future posts of the supporting structure, are provided with specially designed internal formwork. If formwork is provided, this can be factory-fitted adjacent to the base layer and, if necessary, fixed to it. The base layer absorbs forces only insofar as it supports the thermal insulation layer, to which it is firmly attached, for example, for transport from the production site to the construction site. A base layer made of lightweight concrete and / or biogenic concrete such as wood concrete and / or carbon concrete, or a mixture thereof, can achieve this.The thermal insulation layer is particularly intended to be made of lightweight or infra-lightweight concrete, which can be provided with aggregates such as expanded glass, silicates or polystyrene, and / or biogenic concrete, for example hempcrete, hemp-lime or expanded clay concrete. This construction makes it possible to incorporate existing mineral building materials that are well-insulating and at the same time ecologically beneficial and more resource-saving into an efficient construction process. These OE- 1 -2023-337743 HauPtPazi-0013 PCT / DE2023 / 000148 building materials are generally moderately heavy and have only a low load-bearing capacity, which has so far hindered their widespread use as a wall system. The ecological balance of the wall element according to the invention is also further improved by these measures. For a secure connection between these different materials for the load-bearing layer and theThe thermal insulation layer can further be provided such that the base layer and the thermal insulation layer are positively and non-positively connected to one another by anchoring elements. Such anchoring elements are preferably initially introduced into one of the layers during production and then integrated into the second layer when it is applied. Such anchoring elements can also be formed in a simple manner by reinforcement in the base layer, which primarily serves to increase stability. In a further embodiment, it can be provided that the base layer has diffusion-open areas. The diffusion-open areas, which have a size between a porosity and open perforations, can into the CO2. 2-balance. It can also be provided that the load-bearing layer has openings and / or recesses into which the insulation layer engages. For example, the load-bearing layer can form a framework or have a honeycomb structure. Strength can also be enhanced by the measure that, in a side view, the support layer forms an L-shaped foot on which the thermal insulation layer sits in situ. If the load-bearing layer is provided with thermal insulation layers -3g774S01-HauPiPost- PCT / DE2023 / 000148 on both sides, the foot will be T-shaped. Furthermore, such a foot prevents damage to the thermal insulation layer when a wall element according to the invention is installed and facilitates its alignment. Such a foot is also penetrated by the recess, so that, for example, continuous reinforcement between a floor and a floor slab is possible. The end faces of the load-bearing layer and the insulation layer can lie in a common plane.Wall elements are then placed butt-jointed together. Alternatively, if a joint is provided between the wall elements, this can be closed with a seal or mortar. It can also be considered that such a joint is provided only between the load-bearing layers or only between the insulation layers. In structural design, the load-bearing layer and the thermal insulation layer can be horizontally offset. When wall elements are placed, this results in overlaps between the load-bearing layer and the thermal insulation layer of adjacent wall elements. As a result of these measures, a straight construction connection joint is avoided in a building wall constructed with wall elements according to the invention. Furthermore, joints filled with mortar or seals can also be provided between the insulation layers and / or between the load-bearing layers.In a design of the wall element according to the invention, the thermal insulation layer has a corner recess on the upper side, facing the supporting layer. This measure creates a channel on the upper side of the adjoining wall elements. InA frame or a ring beam can be inserted into this channel. The advantage here is that reinforcement can be guided within the recesses or formwork right up to this frame. This connection achieves great mechanical stability. It can be provided that the thermal insulation layer projects above the load-bearing layer, in particular vertically, and that the channel between the insulation layer and the load-bearing layer is formed by the corner recess. This means that a ceiling connection can be created at the same time as filling the channel with in-situ concrete. Alternatively, if the insulation layer and the load-bearing layer are the same height, a ceiling can be easily placed on the wall element. It is also advantageous if at least one vertically extending transport anchor is provided in the load-bearing layer.It can be envisaged that a hook or eyelet protrudes from the top of the load-bearing layer for connecting a lifting device. An elegant option is for the transport anchor to be connected to the load-bearing layer at the top by a screw eyelet, into which a hook or eyelet can be screwed and unscrewed and is therefore reusable. Instead of or in addition to the above, the wall element can also be banded on which the element is suspended for transport and relocation. In a further embodiment of the wall element, it can be provided that a protective layer is applied to the thermal insulation layer and / or the load-bearing layer, particularly in the case of a wall element forming an external wall, to protect against the effects of the weather. With such a protective layer, it can also be provided that this and the load-bearing layer or the 0S-1 =2 'v='774S01-HauPiPosi-0018PCT / DE2023 / 000148 The thermal insulation layer may have a horizontal offset. This offset may correspond to the offset between the thermal insulation layer and the load-bearing layer, but may also deviate from it. In the case of such a deviation, the construction connection joint between the wall elements is angled four times. In a further embodiment of the wall element, it may be provided that a plaster or protective layer is applied to the thermal insulation layer and / or the load-bearing layer. Both the load-bearing and the thermal insulation layer can be located on the outside. Changing arrangements within a building are also possible. The construction of a building wall with wall elements according to the invention requires a high degree of precision in the positioning of the individual wall elements.This can be advantageously achieved by a lifting device placing a wall element into a mortar bed and ultimately aligning the wall element with wedges or blocks over a load-bearing foundation. Such a lifting device will act in particular on the transport anchor and / or the banding. By erecting a building wall and inserting a frame into the corner recesses of the thermal insulation layer, the recesses or formwork of the wall elements can also be filled with the same casting. A similar thing applies to creating a connection between a building wall with wall elements according to the invention and a ceiling. Thus, the recesses or formwork of the wall elements can be filled and / or the frame can be inserted while casting the ceiling. In this case, it may again be necessary to provide reinforcements 08-12-2023-3g77430 -HauP m i-0018 PCT / DE2023 / 000148 within the recesses or formwork in the frame orthe ceiling. To ensure the accuracy of the placement of the wall elements and, in particular, to ensure sufficient stability when casting the frame or creating a ceiling connection, it has proven useful to clamp the wall elements together, particularly permanently. This can be achieved by mechanical locking or by tensioning elements such as inserted clamps or spindle screws. In order to actuate these, recesses must then be provided in the layers if necessary. Alternatively, or if necessary additionally, wall elements arranged next to one another can have corresponding, vertically running recesses that form a common filling channel that preferably extends over the entire height of the wall element. Filled with, for example, in-situ concrete.This not only connects two wall elements to one another, but also increases the load-bearing capacity of the connection against forces acting perpendicular to the wall elements. The invention is explained in more detail with reference to the drawing, which only schematically shows exemplary embodiments. The drawing shows: Fig. 1: a section through the layers of a wall element, Fig. 2: a section through a formwork, Fig. 3: a plan view of two butted wall elements, OS- 12-2023-3S774S01 MatAi Pas PCT / DE2023 / 000148 Fig. 4: a plan view of two wall elements with a joint arranged between them, Fig. 5: a plan view of two wall elements placed against one another and braced, and Fig. 6: a plan view of two wall elements connected by a cast channel. Figures 1 and 2 show vertical sections through a wall element.The figure in particular shows the structure consisting of three layers: a load-bearing layer 2 on the inside of the building, a middle thermal insulation layer, and an external protective layer 4 that protects the thermal insulation layer from the effects of the weather. Not shown in the drawing are anchoring elements that enable a positive and non-positive connection between the load-bearing layer 2 and the thermal insulation layer. The in-situ representations of the wall element show an L-shaped design of the load-bearing layer 2. The thermal insulation layer sits on the foot formed thereby. On top, the thermal insulation layer projects beyond the load-bearing layer and has a corner recess towards the load-bearing layer. A frame is inserted on an insulation or pressure distribution layer, on which a ceiling rests. A transport anchor 10 is inserted into the load-bearing layer 2 in a pull-out-proof manner.On the top side, the lifting anchor 10 has a socket 11 with an internal thread, into which a hook or eyelet can be screwed. This allows the wall element to be easily lifted with a hoist and placed on a base 12. This setting takes place in a mortar bed 13, which may have a moisture barrier. Precise alignment of the wall element is achieved using wedges or blocks. To stiffen the wall element and in particular to absorb vertical loads, a tubular formwork 20 is embedded in the thermal insulation layer. This formwork may, for example, have reinforcement and a concrete filling. The tubular formwork 20 rests against the load-bearing layer 2 and, in the exemplary embodiment, has a diameter that corresponds to the depth of the corner recess.This enables such tubular formwork 20 of wall elements forming a building wall to be filled during the formation of the frame 8. In such a case, the tubular formwork 20 ends in the lower level of the corner recess 6. In order to fill such a tubular formwork 20 with the introduction of the frame, the insulation or pressure distribution layer provided here must be provided with corresponding openings. The figure shows a section through such a tubular formwork 20. The tubular formwork 20 is filled with concrete during the pouring of a ceiling 21. Therefore, the tubular formwork 20 can end at the top with the load-bearing layer. Due to the direct support of the ceiling 21 on the filled, load-bearing tubular formwork 20, a frame can then be dispensed with. It can be advantageous to provide common reinforcement for the tubular formwork, ceiling and, if applicable, the frame.Alternatively, however, a frame can also be cast with the slab 21 and the connection to the tubular formwork 20. 08-12-2023-33774501-HamPtPmst-0022 PCT / DE2023 / 000148 Not shown in the drawing is a possible reinforcement within such a tubular formwork 20, which merges into the frame or a slab 21, thus creating an extremely load-bearing connection. If the thermal insulation layer and the load-bearing layer are congruent, wall elements can be placed directly adjacent to one another. The then continuous construction connection joint can, if necessary, have a mortar layer or an insulating layer. An alternative is shown in Figure 1. There, two wall elements 25, 26 are shown in a plan view. The wall elements 25, 26 are of the same type. They each consist of a base layer 27, a thermal insulation layer 28 and a protective layer 29. A tubular formwork 30 is embedded in each thermal insulation layer 28, adjacent to the base layer 27.Furthermore, each support layer 27 has two support anchors 31, 32. The support layer 27, the thermal insulation layer 28, and the protective layer 29 have the same wall widths. The thermal insulation layer 28 is connected to the support layer 27 with a horizontal offset v. This means that the connecting joint 33 between the wall elements 25, 26 does not run in a straight line. The protective layer 29 is also connected to the thermal insulation layer 28 with a horizontal offset. This offset can, but does not have to, correspond to the offset v between the support layer 27 and the thermal insulation layer 28. Empty conduits for all types of installations can be provided in the thermal insulation layer 28 and / or the support layer 27, which are accessible through appropriately designed openings in the support layer 27 or in the protective layer 29. Wall modules 25, 26 according to the invention can also be provided with openings for windows, doors, or the like. Also shown in Fig.shows overlapping wall elements 35, 36, so that a continuous construction connection joint is avoided. However, the insulation layers 37, 38 and the load-bearing layers 39, 40 do not butt against each other, not directly, but the joints 41, 42 are filled, e.g. with a mortar, an insulating or adhesive layer. In Fig. 5, the thermal insulation layers 45, 46 of the wall elements 47, 48 butt against each other. In opposite recesses in the load-bearing layers 49, 50, a U-shaped profiled connecting element is inserted, which braces the wall elements 47, 48 together by means of screws 51, 52 or the like inserted into the load-bearing layers 49, 50. In this exemplary embodiment, too, with a spaced-apart wall elements 47, 48, the construction connection joint can be provided with a mortar, an insulating or adhesive layer. The joints shown in Fig.The connection shown between two wall elements 55, 56 is achieved by casting corresponding, vertically extending recesses 57, 58 in the thermal insulation layers 59, 60, which form a common filling channel 61. This filling channel 61 extends, in particular, over the entire height of the wall elements 55, 56 and adjoins the supporting layers 62, 63.

Claims

0G-12-2023-3S774S01-HauPtPast-0025 PCT / DE2023 / 000148 EW 418 / 23 Wall element and method for setting such wall elements Claims: Multi-layer, prefabricated wall element ( for the construction of a building, with at least one edged, vertically extending recess to be filled, characterized in that a support layer ( 2 ) stabilizing the wall element is firmly connected to a thermal insulation layer ( and that the recess penetrating the wall element ( over its entire height is arranged at least in sections in the thermal insulation layer ( ).

2. Wall element according to claim 1, characterized in that the recess has a separately formed formwork ( 20 ).

3. Wall element according to one or more of the preceding claims, characterized in that the recess or the formwork ( 20 ) adjoins the support layer ( 2 ).

4. Wall element according to one or more the preceding claims.characterized in that the supporting layer (2) is formed from a lightweight concrete and / or a biogenic concrete and / or a carbon concrete and / or that the thermal insulation layer (is formed by an infra-lightweight concrete and / or a biogenic concrete.

5. Wall element according to one or more of the preceding claims, characterized in that the supporting layer (2) and the thermal insulation layer (are connected to one another in a form-fitting and force-fitting manner by anchoring elements. n8-12-2 23-33774301— a piPmsi-0028 PCT / DE2023 / 000148 are connected.

6. Wall element according to one or more of the preceding claims, characterized in that the supporting layer is provided with reinforcement.

7. Wall element according to one or more of the preceding claims, characterized in that the supporting layer has diffusion-open regions.

8. Wall element according to one or more of the preceding claims, characterized in that the supporting layer has openings and / or recesses into which the insulating layer engages.

9. Wall element according to one or more of the preceding claims, characterized in that, in a side view, the supporting layer (L-shaped or T-shaped) forms a foot (on which the thermal insulation layer (2) rests or the thermal insulation layers rest. 10.Wall element according to one or more of the preceding claims, characterized in that the support layer (27) and the thermal insulation layer (28) have a horizontal offset (v).

11. Wall element according to one or more of the preceding claims, characterized in that the thermal insulation layer (28) projects vertically beyond the support layer (2) and that the thermal insulation layer (28) has a corner recess (29) on the upper side towards the support layer (2).

12. Wall element according to one or more of the preceding claims, characterized in that at least one vertically extending... 0G-12-2023-3S774Sni-HauPtPasi-0027 PCT / DE2023 / 000148 extending transport anchor (10) is provided. Method for constructing a building wall with wall elements according to one or more of the preceding claims, characterized in that a wall element ( is placed into a mortar bed (13) by a lifting device connected to the transport anchor (10), and that the wall element is aligned with wedges or blocks. Method for constructing a building wall with wall elements according to one or more of the preceding claims, characterized in that a ring beam ( connecting the wall elements) is introduced into the corner recess ( of the thermal insulation layer ( ). Method according to claim 14, characterized in that the recesses or formwork (20) of the wall elements ( are filled with the casting of the ring beam (Method for creating a connection between a building wall with wall elements according to one or more of the preceding claims and a ceiling, characterized in that the recesses or the formwork (20) of the wall elements (are filled and / or the ring beam (is cast) when the ceiling (9, 21) is cast. Method for creating a building wall with wall elements according to one or more of the preceding claims, characterized in that adjacent wall elements are clamped together.

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