Set of permanent formwork blocks
The set of permanent formwork blocks with integrated insulation and reinforcement voids addresses the issues of slow construction and thermal loss in existing methods, providing efficient assembly and improved insulation and seismic resistance.
Patent Information
- Authority / Receiving Office
- RU · RU
- Patent Type
- Patents
- Current Assignee / Owner
- КОРАБЛЕВ СЕРГЕЙ ВАСИЛЬЕВИЧ
- Filing Date
- 2025-12-25
- Publication Date
- 2026-07-01
AI Technical Summary
Existing construction methods for precast-monolithic buildings face issues with low construction speed, thermal insulation, and seismic resistance due to the design of permanent concrete wall formwork blocks, which include chamfers and decorative layers that increase heat loss and require additional foundation supports.
A set of permanent formwork blocks comprising wall, corner, and foundation blocks with integrated insulation and voids for reinforcement and utility lines, using concrete elements connected by lintels and insulation plates, allowing for efficient assembly and improved thermal and seismic resistance.
The solution ensures high thermal and sound insulation, increased seismic resistance, and efficient construction process by integrating insulation and reinforcement within the blocks, enhancing structural stability and reducing construction time.
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Abstract
Description
[0001] FIELD OF TECHNOLOGY TO WHICH THE INVENTION RELATES
[0002] The invention relates to the field of construction and can be used in the construction of quickly erected precast-monolithic civil and industrial buildings of varying heights, seismically resistant buildings, as well as the laying of communications with insulation in one construction cycle of energy-saving buildings.
[0003] STATE OF THE ART
[0004] From the prior art, a permanent concrete wall formwork is known for erecting wall structures, comprising combined and connected: a row block, a corner block and an additional corner block, characterized in that the blocks are made of concrete, wherein the row block contains parallel outer front and rear longitudinal walls connected by two parallel partitions, wherein on the upper surface of the partition there are chamfers 15 mm high at an angle of 45 degrees, turning into a groove with a radius of 8 mm, on the side surface of the walls there is a connecting stepped surface;the corner block is an angular structure and contains first parallel outer front and back longitudinal walls, which are located at an angle of 90 degrees to the second parallel outer front and back longitudinal walls, wherein both the first and second outer front and back longitudinal walls, each, are connected by two parallel partitions, wherein on the upper surfaces of the partitions there are chamfers 15 mm high at an angle of 45 degrees, turning into a groove with a radius of 8 mm, on the side surface of the walls there is a connecting stepped surface;the corner extension block is a hollow cubic structure consisting of four walls, each located at an angle of 90 degrees to each other, where two of the walls are front and two are back, on the side surface of the front walls there are fastening connecting surfaces, and on the upper surface of the front walls there are chamfers 15 mm high at an angle of 45 degrees, turning into a groove with a radius of 8 mm. [RU2791088, E04G 11 / 06, E04B 2 / 86, published 02.03.2023].;
[0005] The disadvantage of the above-described technical solution is the relatively low speed of wall construction and construction in general, as well as thermal insulation due to the presence of a chamfer for joining blocks and the lack of insulation, respectively.
[0006] The closest technical solution is a known system of permanent formwork in the form of multi-layer wall elements with voids for pouring concrete and a decorative layer with recesses and grooves on the outside, including special foundation blocks made in the form of a parallelepiped, the upper part of which is provided with a symmetrically located groove with a depth of no more than one third of the height of the block, and the side ends are provided with vertical trapezoidal recesses, belt blocks with an outward protrusion of no more than 30 mm, row blocks with an overlap, having grooves and ridges made in the facing layer of blocks and with the combination of vertical openings made in the bearing layer of row blocks, an angular external block, the heat-insulating and facing layers of which are made L-shaped, and the bed side of the facing layer and one of the header sides of the facing layer are provided with a ridge, and the other bed side and the other the butt side is provided with a groove, and the corner inner block,made with an L-shaped load-bearing and heat-insulating layer, wherein the facing layer is located in a niche of the heat-insulating layer, wherein part of the bed side of the facing layer is made with a ridge interacting with the vertical longitudinal ridge of the header side, and the upper side of the remaining part of the facing layer is made with a width equal to the width of the facing layer, and the front side of the remaining part of the facing layer is provided with a vertical longitudinal groove, wherein the total length of the front part of the corner internal block, including the load-bearing, heat-insulating layers, and part of the facing layer with the vertical longitudinal groove is selected equal to the width of the row block, to form window and door openings, opening blocks are used, the facing layer of which is provided with extension protrusions that exclude the passage of cold and wind. [RU2583801, E04B 1 / 02, E04B 2 / 54, published 10.05.2016].,
[0007] The disadvantage of the above-described technical solution is the possible formation of heat loss from the base due to the peculiarity of the insulation fastening, as well as the presence of a decorative concrete layer with recesses and grooves on the outside, as well as the need to use a foundation support.
[0008] The problem solved by the claimed invention is to create a set of permanent formwork blocks that eliminates the shortcomings inherent in the analogue and prototype.
[0009] DISCLOSURE OF THE INVENTION
[0010] The technical results that the invention is aimed at achieving are:
[0011] - ensuring the strength and reliability of the set of blocks;
[0012] - ensuring high thermal and sound insulation properties of the block set;
[0013] - ensuring the technological effectiveness of installation and construction works;
[0014] - increasing the seismic resistance of buildings and structures;
[0015] - increasing the space for placing mortgages.
[0016] The technical results are achieved in that a set of permanent formwork blocks is proposed, including blocks, including those with insulation, having an empty space for pouring concrete and made with the possibility of installation in a single permanent formwork, characterized in that the set consists of eight blocks, including a wall block with insulation, a corner wall block with insulation on the outer corner, a corner wall block with insulation on the inner corner, a wall load-bearing block, a partition block, a ventilation block, a foundation block and a corner foundation block, wherein the blocks contain a concrete element made in the form of external and internal slabs connected to each other, the edges of which are parallel to each other, and the slabs in the wall with insulation, wall load-bearing, partition and foundation blocks are connected by two jumpers,the slabs in the corner wall blocks and the corner foundation blocks are connected by three lintels to form an empty space for reinforcement in two rods and the placement of embedded parts for utility lines, wherein the lintels consist of three parts, one middle and two side parts, wherein the middle part is made in the form of a right parallelepiped and has grooves, and the two side parts are made in the form of truncated pyramids, wherein the larger bases of the truncated pyramids are adjacent to the inner and outer slabs, respectively, and the smaller bases of the truncated pyramids are adjacent to the middle part, and the empty space formed between adjacent lintels has the shape of an octagon in cross-section, the blocks with insulation have a slab of insulation having a groove, connected along the base to the inner slab of the concrete element to form a single block and made of foam plastic, and the slabs in the ventilation block are connected by means of a lintel in which a through hole is made,having a rectangular cross-section, and the lintel has grooves whose diameter is larger than the diameter of the grooves in the middle part of the lintel of the other blocks.
[0017] There is an option in which the concrete element is made of concrete on granite screenings.
[0018] There is an option in which the concrete element is made of concrete on expanded clay filling.
[0019] There is an option in which the insulation plate is connected to the base with the inner plate of the concrete element using dovetail grooves.
[0020] There is an option in which the insulation is made of foam plastic PPS-16 F or PSB-S25F.
[0021] BRIEF DESCRIPTION OF DRAWINGS
[0022] Fig. 1 shows a wall block with insulation in a particular embodiment of the invention.
[0023] Fig. 2 shows a wall block with insulation installed on the outer corner, in a particular embodiment of the invention.
[0024] Fig. 3 shows a wall block with insulation installed on an internal corner, in a particular embodiment of the invention.
[0025] Fig. 4 shows a wall load-bearing block.
[0026] Fig. 5 shows a partition block.
[0027] Fig. 6 shows the ventilation unit.
[0028] Fig. 7 shows the foundation block.
[0029] Fig. 8 shows a corner foundation block.
[0030] The blocks contain a concrete element 1, made in the form of interconnected outer 2 and inner 3 slabs, the edges of which are parallel to each other. Slabs 2 and 3 in the insulated wall, load-bearing wall, partition, and foundation blocks are connected by two lintels 4. Slabs in the corner wall blocks and corner foundation block are connected by three lintels 4, creating a void 5 for reinforcement with two rods and the placement of embedded parts for utility lines.
[0031] The lintels consist of three parts, one middle 6 and two lateral 7. Part 6 is made in the form of a right parallelepiped and has grooves 8. Parts 7 are made in the form of truncated pyramids, with the larger bases of the truncated pyramids adjacent to slabs 3 and 2, respectively, and the smaller bases of the truncated pyramids adjacent to part 6. The space 5 formed between adjacent lintels has an octagonal cross-section.
[0032] Blocks with insulation have a plate 9 made of insulation, having a groove 10 and connected along the base with a plate 3 to form a single block.
[0033] Plates 2 and 3 in the ventilation block are connected by a crossbar 11, which contains a through-hole 12 with a rectangular cross-section. The crossbar has grooves 13, the diameter of which is greater than that of grooves 8.
[0034] In a particular embodiment of the invention, plate 11 is connected along the base to plate 3 by dovetail grooves 14.
[0035] IMPLEMENTATION OF THE INVENTION
[0036] The invention is illustrated by the following examples of implementation.
[0037] Example 1.
[0038] The permanent formwork block set consists of eight blocks, including wall block with insulation, corner wall block with insulation on the outside corner, corner wall block with insulation on the inside corner, wall load-bearing block, partition block, ventilation block, foundation block and corner foundation block.
[0039] The blocks contain a concrete element 1, made in the form of interconnected outer 2 and inner 3 slabs, the edges of which are parallel to each other. Slabs 2 and 3 in the insulated wall block, load-bearing wall block, partition block, and foundation block are connected by two lintels 4. Slabs 2 and 3 in the corner wall block and corner foundation block are connected by three lintels 4, creating a void 5 for reinforcement with two rods and the placement of embedded parts for utility lines.
[0040] The lintels consist of three parts: one central part (6) and two lateral parts (7). Part (6) is shaped like a right parallelepiped and has grooves (8) with a diameter of 8 mm. Parts (7) are shaped like truncated pyramids, with the larger bases of the truncated pyramids adjacent to plates (3) and (2), respectively, and the smaller bases (10) of the truncated pyramids adjacent to part (6). The space (5) formed between adjacent lintels has an octagonal cross-section.
[0041] The blocks with insulation have a plate 11 made of insulation, which has a groove 12 and is connected at the base with a plate 3 to form a single block.
[0042] Plates 2 and 3 in the ventilation block are connected by a crossbar 13, which contains a through-hole 14 with a rectangular cross-section. The crossbar has grooves 15 with a diameter of 16 mm.
[0043] The concrete elements are made of concrete on granite screenings, and PPS-16 F foam plastic was chosen as the insulation material.
[0044] Example 2.
[0045] The permanent formwork block set is constructed similarly to Example 1, with concrete elements 1 made of expanded clay concrete. Grooves 8 have a diameter of 10 mm, and grooves 20 mm. Slab 11 is connected to slab 3 at the base with dovetail grooves 16, and PSB-S25F foam plastic is selected as the insulation material.
[0046] Below is a description of how to assemble the blocks from the proposed kit into a single formwork. The first row of the foundation begins with corner foundation blocks. Corner foundation blocks can be used when laying both internal and external corners. The first row is installed on a cement-sand mortar of at least M 300, using horizontal and vertical joints to compensate for foundation imperfections. After installing the corner blocks, the space between them is filled with foundation blocks so that, if possible, any incomplete blocks are installed in the middle, no closer than the third block from the edge. While laying the foundation blocks, anchor them to the foundation base if (L)-shaped reinforcing bars have not been installed in advance to tie the structure together in the empty spaces (voids) of the block. After installing the first row of foundation blocks, horizontal reinforcement with two rods is applied, as well as in the corners and at the joints with other blocks.To create a T-shaped connection between foundation blocks, the top half of the block is cut off to accommodate the void of the block being joined. Subsequent rows of foundation blocks are assembled in the same sequence, and the corner blocks are installed upside down, thus creating a bond between the rows. Foundation blocks can be assembled for pouring concrete in 5 to 6 rows, ensuring reinforcement is placed every other row. After this, vertical reinforcement can be installed at the edge of the horizontal reinforcement. If the foundation wall is poured in several stages, rebar extensions are provided for subsequent bonding of the wall. When pouring the rows, the top foundation block is poured halfway to ensure a better bond between the two structures. It is then recommended to treat the foundation walls with hot mastic on both sides and with weld-on waterproofing on the outside to protect the foundation structure from moisture.A clamped foundation slab with beams can also be integrated into this system to complete the waterproofing circuit. To do this, the upper inner half of the upper blocks is cut off and L-shaped reinforcement is installed, which is connected to the slab. If economic feasibility and geology permits, a strip foundation can be constructed from these blocks for non-critical structures. After installing the first row of blocks, horizontal reinforcement is applied with stirrups corresponding to the number of voids in the blocks. Subsequent rows are then assembled with stirrups, and in the final row of blocks, reinforcement is installed at the top of the stirrup, creating a concrete beam with stirrups and upper and lower reinforcement.
[0047] Then the building walls are constructed using insulated wall blocks, using the same principle as for the foundation, but with some additions. In the first row of wall blocks, 100mm thick octagonal thermal inserts made of extruded polystyrene foam are inserted into the lower part of the block through the void to reduce heat loss and prevent freezing of the foundation. However, this does not completely eliminate freezing of the structure, especially due to the installation of structures or the presence of cabinets, which impede heating of the wall along the outer perimeter and contribute to the development of mold in these areas. To prevent this problem, a cross-linked polyethylene pipe with insulation is installed along the second row of blocks of the outer contour and connected to the underfloor heating system. The first row is assembled using mortar (not lower than M300) along the block bed, and the vertical and subsequent horizontal joints are laid with masonry mortar or foam block adhesive.Foam block adhesive is preferred because it creates a thinner joint, ensuring a tighter fit of the foam. The blocks are assembled on the foam using a small bead of foam adhesive along the bed, with the grooves provided in them being "foamed" at the ends. Reinforcement is applied starting from the first row, then every second horizontal row, corners, and block joints using two rods. To tie the structure together, corner blocks are installed with the bed facing up in odd rows and with the bed facing down in even rows, ensuring structural stability before and during concrete pouring. In this manner, walls are assembled to a height of 5-6 blocks for concrete pouring.
[0048] When connecting walls in a T-shape, the top half of the wall block is cut off at the connection point, down to the middle, to accommodate the void of the adjacent block. This allows for subsequent reinforcement with L-shaped reinforcing bars, achieving wall integrity. When connecting partition blocks to load-bearing walls, the block is cut at the connection point only for the L-shaped reinforcing bar. The blocks are filled with mortar as the walls are built, 2-3 rows at a time, compacting the mortar by ramming and using reinforcing bars. Window and door openings at the ends are covered with boards with lintels and braces to retain the concrete mix, after foaming any leaks around the perimeter to retain the cement laitance. Lintels for windows and doors are made as follows: reinforcement rods with clamps are laid along the top board of the boarded opening according to the number of voids in the lintel blocks, adding 2 clamps on each side.The first row of lintels is laid with the bed facing up, with the blocks interlocked, and stirrups are inserted into the vertical voids. The second row is installed with the bed facing down, and the reinforcement is inserted into the stirrups to tie the integrated beam together.
[0049] Pipes for concealed utility lines are installed according to the design in unoccupied voids, both vertically and horizontally, tying them to the edge of the block or to the reinforcement cage with binding wire. For this purpose, holes are pre-drilled in the block, if necessary, and the embedded pipes are inserted into them. It is best to use rigid installation pipes or a specialized installation system for monolithic walls. If the unoccupied voids do not correspond to the designed location, additional chasing is performed after concreting, which significantly simplifies subsequent installation of utility lines.
[0050] Concrete is poured layer by layer, followed by vibration. The height of the poured blocks directly depends on the density of the reinforcement and the number of utilities being installed.
[0051] A monolithic interfloor slab is constructed in the same way as an integrated clamped slab foundation, with the difference being that formwork and supports are installed underneath. Alternatively, prefabricated floor slabs can be used.
[0052] Horizontal reinforcement in two bars of foundation and wall blocks must be secured to prevent the bars from shifting from their designated positions during concreting. This can be done using spacers or by securing them with tying wire at the edges and every subsequent meter. Vertical reinforcement is installed before pouring, with subsequent extensions for further tying of the wall. The upper blocks are also poured halfway to ensure improved structural rigidity.
[0053] Ventilation units are installed in a load-bearing wall inside the house to improve ventilation. They are assembled using mortar of at least grade M300 and tied with two reinforcing bars in the unit's grooves with extensions of at least 400 mm and U-shaped bends at the ends for better bonding to the wall.
[0054] When forming the inner corner of a house, it is necessary to trim the insulation on the wall block with a hacksaw due to the design features, while the blocks themselves are cut with a grinder or a hacksaw for foam blocks if they are made using expanded clay.
[0055] After the walls are erected and poured, the foam joints are pierced with a foam gun every 100 mm of the insulation thickness and filled with foam adhesive to ensure the insulation is solid. The "wet façade" process is then applied.
[0056] A set of permanent formwork blocks according to the embodiment examples of the invention can satisfy many architectural planning and engineering solutions with insulation in one construction cycle.
[0057] The internal structure of the blocks, thanks to the empty space for reinforcement in two rods and the placement of embedded parts for utility lines in the shape of an octagon, ensures good load distribution during concreting of walls and the stability of the entire structure.
[0058] The simplicity of the technological process using the proposed kit is achieved due to the lack of need for complex technical equipment, as well as the availability of consumables, which in turn ensures the technological efficiency of installation and construction work.
[0059] The presence of blocks with insulation in the kit simplifies construction by combining several operations in one technological cycle, and also ensures the thermal insulation and soundproofing properties of the proposed kit due to the use of foam plastic as an insulating material, selected taking into account the climatic zones and possible heat loss of the building.
[0060] The lintel is made in three parts, namely two side and one middle, so that the two side parts of the lintel are made in the form of truncated pyramids, the bases of which are adjacent to the inner and outer plates, respectively, and the middle part of the lintel is made in the form of a right parallelepiped, and the truncated tops of the side parts of the lintels are adjacent to the middle part, which allows for an increase in the space for placing embedded parts while maintaining high strength characteristics.
[0061] The diameter of the ventilation block grooves must be larger than the diameter of the other compact blocks to allow for reinforcement with the wall using thicker rebar. The concrete fill of the ventilation block is minimal, yet the entire ventilation shaft is significant and subject to various loads. Therefore, to compensate for the loads and the resulting stresses, it is necessary to use larger diameter rebar.
[0062] The use of dovetail grooves in a particular embodiment of the invention further increases the strength, reliability and wear resistance of the connection due to the special trapezoidal shape, which ensures maximum adhesion and tight fit of the outer and inner plates to each other.
[0063] The proposed set of blocks, technologically easy to assemble, has sufficient strength, heat and sound insulation properties, which allows it to be used in the construction of various buildings and structures.
Claims
1. A set of permanent formwork blocks comprising blocks, including blocks with insulation, having an empty space for pouring concrete and made with the possibility of installation in a single permanent formwork, characterized in that the set consists of eight blocks, including a wall block with insulation, a corner wall block with insulation on the outer corner, a corner wall block with insulation on the inner corner, a wall load-bearing block, a partition block, a ventilation block, a foundation block and a corner foundation block, wherein the blocks contain a concrete element made in the form of interconnected outer and inner slabs, the edges of which are parallel to each other, and the slabs in the wall with insulation, wall load-bearing, partition and foundation blocks are connected by two lintels, the slabs in the corner wall and corner foundation blocks are connected by three lintels to form an empty space for reinforcement in two rods and the placement of embedded parts for utility lines,wherein the lintels consist of three parts, one middle and two side parts, wherein the middle part is made in the form of a right parallelepiped and has grooves, and the two side parts are made in the form of truncated pyramids, wherein the large bases of the truncated pyramids are adjacent to the inner and outer slabs, respectively, and the smaller bases of the truncated pyramids are adjacent to the middle part, and the empty space formed between adjacent lintels has the shape of an octagon in cross-section, the blocks with insulation have a slab of insulation having a groove, connected along the base to the inner slab of the concrete element to form a single block and made of foam plastic, and the slabs in the ventilation block are connected by means of a lintel in which a through hole is made, having the shape of a rectangle in cross-section, wherein the lintel has grooves, the diameter of which is greater than the diameter of the grooves of the middle part of the lintel of the remaining blocks.
2. A set according to paragraph 1, characterized in that the concrete element is made of concrete on granite screenings.
3. A set according to paragraph 1, characterized in that the concrete element is made of concrete with expanded clay filling.
4. A set according to paragraph 1, characterized in that the insulation plate is connected to the base with the inner plate of the concrete element by dovetail grooves.
5. The kit according to paragraph 1, characterized in that the insulation is made of foam plastic PPS-16 F or PSB-S25F.