ES2229833B1 - CONSTRUCTION METHOD OF WALLS AND FORGINGS OF HOUSES AND WALLS OF BUILDINGS USING STRUCTURAL PANELS. - Google Patents

Abstract

Construction method of walls and floors of houses and interior walls of buildings using structural panels; where the panels are partially prefabricated and coated with mortar at the final installation site. The prefabricated part consists of a three-dimensional structural reinforcement based on metal rods. A galvanized metal plate support element perforated and expanded by die is introduced into the structural reinforcement. The structural reinforcements are tied together by means of U-rods. The panels remain, after setting the mortar, joined together by "sharp keys" set "in situ" and forming part of the structure.

Description

Construction method of walls and slabs of houses and building walls using structural panels.

Object of the invention

The present invention relates to the design, development and implementation of a constructive method of walls and Forged houses and building walls using panels structural connected to form these walls and slabs of floors, in addition to stairs and other minor elements in buildings.

Background of the invention

The traditional construction method that currently employed is always based on the use of bricks, in their different classes, shapes and sizes, or blocks of lightened concrete in different thicknesses and sizes.

This construction method has numerous inconveniences, among them we can mention:

- Both the bricks and the blocks of concrete are manufactured in ceramics or plants located in points concrete of the national geography. This forces on the one hand collection of samples in the material stores to choose the as desired and commission it to the factory. On the other hand it has the inconvenience of the cost of transport material Until the work.

- The manipulation of the block and the brick, Although palletized, in the work, it is not simple. It must always be to hand, which brings with it an excess of labor needed to its manipulation

- They are fragile constructive elements, so that in its placement there is considerable waste.

- The process that involves the execution of a wall is slow, either formed with plaster or cement mortar, and it is necessary to wait a few days to continue working on she.

- For the execution of the facilities of plumbing, electricity, heating, telephony and sanitation; traditionally the use of rubbing on the walls is used, which weakens them, produces a lot of rubble, and it is necessary to cover the rubs; which is slow and facilitates the appearance of fissures or cracks in the finished wall.

- The final appearance of a brick wall or block, except those that we want to be seen, is not of finished wall, so it is necessary to plaster it with mortar cement or plaster cast due to its completion is enough.

- Brick and block are light elements by themselves, but the finished wall multiplies several times its initial weight; which brings with it the obligation to have it in account when calculating the structure.

- In a traditional construction, the block and brick are not used as load-bearing walls, they are dividing walls normally, so it is necessary to make a structure vertical and horizontal that supports the building.

- The cost of labor is high and every time There is greater shortage.

- The high demand for housing cannot be Complied with conventional construction.

- Severe weather conditions limit the season that can be built with systems conventional.

Description of the invention

The adoption of the constructive method based on partially prefabricated structural panels of the invention as normal or usual procedure in housing construction of social interest is a fundamental condition to industrialize Construction and lower costs.

Each panel consists of a structural reinforcement prefabricated three-dimensional metal which is placed on site joining it to others according to the layout of the work, to configure walls and slabs. In this armor a framework is arranged metallic that will provide support to the structural mortar that will apply later, after arranging the facilities. To the set the mortar you get the finished panel and the element constructive (wall or slab) desired.

Structural panels of different sizes, starting from a structural reinforcement size minimum or basic panels can be manufactured up to 2600 mm of net height, 2000 mm horizontal or wide length, and up to 150 mm thick, not including in this dimension the protruding rods side, and of course not counting the mortar layer that Applies on site

Thus the method of the invention comprises, not only the manufacture of the various structural panels dimensions, but also that of facilities and other materials, of sizes adapted to the dimensions of each panel, simplifying to the maximum the work of the technicians. Thus, the production results cheaper and work on site is done faster and easily.

As for the basic structural panel or module, It is established in two types: one for walls and one for slabs.

The dimensions that the panels can adopt Structural used in the invention are large enough to be able to adjust to the spaces that a project requires constructive anyone.

Similarly, the basic module is Small enough for your multiples to fit all the dimensions to be given to the different elements of the industrial range and to build a growth unit convenient, from one modular dimension to the next, so that modifications can be minimized; that's how they are defined Two basic modules: one for walls and one for slabs.

These structural panels that are part of the invention are self-supporting due to structural reinforcement internal prefabricated, and therefore serve to build walls (or walls), floor slabs, stairs, etc., of buildings. The structural reinforcements are coated or "melted" with mortar cement and connect with each other using "shear keys" vertical and horizontal constituting together with the panels, the monolithic structure supporting the building. It is called in this writing "shear keys" to pilates and joists which are constituted according to the process of the invention between panel and panel, when setting the mortar that is applied in these zones.

The structural reinforcements of the panels of the invention are prefabricated in structural strength steel adequate, and they are self-supporting. They are transported to the construction site and placed in the appropriate location according to its rethinking, where they will be coated with structural mortar to form a wall or slab resistant to vertical building loads and Horizontal of a seismic event.

In the work the structural reinforcements make up the wall, joining by "shear keys" which also They constitute vertical stiffeners.

The walls built, join the beams of foundation and floor slabs formed by it system.

The method of the invention therefore tends to split or wake up the construction logically, depending on its functional and architectural divisions, so that it facilitate joints between panels, facilities and finishes

Structural reinforcements, in constructions for housing, offices, schools, hospitals, etc., present their exterior and interior faces, respectively prepared to receive the structural mortar, and its geometry has two main dimensions: in the case of one of them is the floor height according to the project, including with it the gaps for doors and windows; and another is the thickness determined according to the respective structural design.

The method foresees the prefabrication of the structural reinforcements of all panels for all walls  exterior and interior, floor slabs, stairs, etc., admitting as particular cases the variants by gaps of windows, doors, etc. to which you want to give a special design, for example in the case of facades.

The structure thus formed ensures the continuity and works as a monolithic set before gravity and earthquake actions.

The behavior of these structures, given the seismic actions, is in the elastic range with deformations little.

Thus the structural panels that form the walls (or walls) of the building, according to the specific design, they must essentially resist the forces in their plane due to vertical or lateral loads; in employment as slabs should resist normal forces to your plane by vertical loads and horizontal forces in its plane acting as rigid diaphragms before the lateral loads.

Buildings made according to the method of the invention lends itself to three-dimensional configurations that they are efficient to resist vertical loads by the lights reduced that are in buildings of social interest (housing) and to support lateral loads, by the density of walls (walls) in both directions. Regarding manufacturing and panel manipulation, the method of the invention consists of the prefabrication of structural reinforcements according to the dimensions necessary for the work in question, always at from a basic module of certain dimensions, of according to international specifications for the building.

As main advantages of the invention, it should be cite the following:

- Structural reinforcement is manageable, since it is  Lightweight, does not need any special handling and requires very Little labor for transport and placement.

- The construction process of walls and floors It is extremely fast and accurate since the armor is prefabricated structural, in which, once placed on site are placed in turn the electrical, plumbing, telephony, of heating and sanitary, embedded in this structural element, without having to touch any class in the work, without produce debris, and without weakening the walls made, to subsequently "melt" or apply the mortar.

- With the structural panel can be built walls of distribution of houses, trasdosado of cameras of air, walls of separation of housing and boxes of stairs; non-bearing façade enclosures and stair slabs; and walls of load of facade and interiors, and forged.

- The walls made are armed and are less susceptible than a wall made of brick or block of concrete to produce fissures or cracks on the surface.

- The walls made are much lighter than those made with brick or simple concrete block plastered. A wall m 2 executed with this Structural Panel It weighs 100 kg / m2 (plastered) finished with cement mortar. While one m2 of double hollow brick partition laid and plaster weighs 160 kg / m2. The difference in weight translates into a significant saving in the structure of tall buildings.

The structural reinforcement is constituted by a three-dimensional hollow drawer based on two side frames consisting of two parallel round cold corrugated steel, which are laterally related by rods of the same diameter bent in wavy or zigzag shape configuring trusses. All unions of these elements Metallic are made by spot welding in workshop, with an automatic process.

- Side frames are formed with round different diameters from 5 mm to 12 mm depending on your structural function; and its separation varies from 50 mm to 200 mm depending on the use to which each element is destined, partition walls, facades stairs, load-bearing walls or floors;

- Inside the armor or drawer structural structure described in this way is a fabricated metal framework with cold rolled steel sheet thickness 0.3 m / m, 0.4 m / m and 0.5 m / m, galvanized or not, die cut and expanded and with ribs intermediate reinforcement; dimensions depending on the basic measures of the panel, and of its multiples.

- The structural panel preferably uses the  thickness of 0.3 m / m in the fabric since its mission is not it is more than to support the cement mortar thrown. This metallic framework can have a paper attached to it. (depending on the panel in question) that prevents the camera of air fill the finishing mortar and produce bridges thermal unwanted. The framework is cut with a width of 560 mm for each face of a 600 mm structural module and fixed to the inner face of the structure formed by rounds and rods with welding.

- Also and for the formation of walls, depending on the type in question: separation between rooms, bearing facades, separations between houses and boxes of stairs; the inner chamber can, if required, be filled with any type of insulation, formaldehyde foam, rigid foam of polyurethane, or glass wool depending on the thickness of the chamber and insulation class that you want to achieve thermal or acoustic and thermal, always applicable in different thicknesses and densities

- For exterior or interior walls, or for divisions between houses, structural armor is placed vertically on the foundation beam reinforcement, and a once plumbed it is fixed to it by staples before applying and set, or "melt" the mortar on the foundation beam.

Each structural reinforcement is fixed laterally to the previous one by means of binches or knots based on units pre-folded at the factory, which are placed at regular intervals throughout the entire joint. Preferably they are nailed alternately on both sides or faces of the reinforcements. Once the Ues are placed fully and hugging the two rounds of each of the two adjacent panels, the two points of the U are folded at opposite angles, and it is necessary to be tied with galvanized wire to stabilize the Ues. In this way the structure of the wall or slab in question is formed, and then the structural steel of the cutting key is placed. Said structural steel, in a suitable size for the cutting key, also comes prefabricated with the structural reinforcement.

Once the armor is fixed to the ground and formed the wall is rethinking the facilities and placed in the inside the armor cutting the metal framework for introduce the ducts and fix the (electrical) mechanisms. Subsequently, and in those large holes they are fixed again with galvanized wire the pieces of fabric necessary to give continuity to the already placed.

Once the structural reinforcements of the different panels in work, as well as the framework and installations proceed to coat both sides of the armor or structural drawers according to the function they perform in the building: with cement mortar (for external facades and internal structural walls, separations between homes and stairwells) or with plaster mortar (for partitions not structural, trasdosados).

The minimum thickness to be used in the coating with cement mortar is 25 mm, projected with machine in two continuous layers and with a dosage capable of generating a average resistance of 40 kg / cm2, mortars can be used prepared or stabilized

For mortar finishing, the surface with aluminum rulers in order to achieve a perfect flatness of the finished wall.

For slabs proceed in the same way, placing the elements in horizontal position.

It has been found that, naturally, the mortar resistance, especially in the "keys of sharp ", is much greater than 40 Kg / cm2. It is noted that the resistance of the mortar, being a constructive detail, does not It is the subject of this patent.

Brief description of the drawings

Figure 1 shows a schematic view of a building carried out according to the method of the invention.

Figures 2, 3, 4 and 5 show respectively perspective, plan, side and elevation views of the armor structural of the invention.

Figures 6 and 7 show paths respectively  sections of a panel encounter of the invention in the configuration of a slab, where you can see the nerve that constitutes the "shear key" as well as a meeting of A slab with a wall.

Figure 8 shows a horizontal section of a wall facing joints appear between straight vertical panels (12), at an angle near the numerals (1) and in perpendicular or in T.

Figure 9 shows a detail of the meeting in perpendicular between partitions based on panels of the invention.

Description of a practical embodiment of the invention

The method of the invention materializes through of the on-site training of partially prefabricated panels. Each panel 1 consists of a three-dimensional structural reinforcement 2 metallic, which is the prefabricated element, which is placed in work joining it to others according to the staking of the work, to configure walls 3 and slabs 4. In this armor there is a metal framework 5 that will provide support to the structural mortar  6 to be applied later. By setting the mortar you get the finished panel and the construction element (wall or slab) wanted.

The structural reinforcement 2 is constituted by a  3-dimensional hollow drawer based on two side frames 8 consisting of round 9 cold corrugated steel, which is laterally related by rods 10 of the same diameter configuring trusses 11. All joints of these elements Metallic are made by spot welding in workshop, with an automatic process.

The method supports the following variants:

to. Load-bearing walls

- For load-bearing walls, that is, for walls of load, the configuration undergoes slight variations with respect to the of the rest of the non-structural walls.

- Its standard dimension is 600 mm wide by  a variable height equal to the total height of the wall of the projected building, including tile height and ceiling, that is from forged to forged if the building has More than one height. Its thickness is variable, according to the design of the project, connected with shear keys.

- For a single-storey house, every 600 mm of  width is formed a resistant vertical element 12 of 600 mm of horizontal width or length x the corresponding height; formed by the two side trusses 11 of the side trusses adjacent two adjacent panels. These trusses, being manufactured with 8mm diagonal corrugated rounds meet the Stirrups function of the armor.

- To form the shear key on each side of the 600 mm wide module, diagonal rods 13 that bracing frames 8 of armor 2 will have a extensions 14 from the edge truss 120 mm and alternatively. These rod ties will be attached to the panel contiguous, horizontally, using 0.8 mm galvanized wire thickness, not shown, leaving a separation between modules 100 mm

- This load wall or wall is necessary anchor it to the foundation, not shown, and tie it to it so that a knot is created capable of withstanding the loads to the compression transmitted by the upper floor. For this and each 600 mm, that is, where the strong support 12 is formed, the two round corrugated steel sides that form the trusses are they will extend 15 300 mm and their ends will bend forming a anchor stick; this armor will be anchored to the foundation,  being able to transmit the compressive efforts to which it is Subjected the load wall.

- Fixed the module to the foundation and formed the wall, we proceed to coat its two faces with the mortar of 40 kg / cm2 cement and support (foundation) with a 210 kg / cm2 strength concrete.

- To be able to concrete the support it is necessary place a board, not shown, on each outer face attached to the side trusses with wire and nails stuck in it, after 7 days the wires can be cut and the formwork

- In case you need more insulation acoustic and thermal than that achieved in the air chamber of the structural panel of the invention during the prefabrication of the structural reinforcement insulation sheets can be introduced into the internal hollow 16 of the panel, of the characteristics and thicknesses that are necessary.

b. Forged

- To use the armor designed in floor slabs, with lights up to 4.00 meters, the preferred embodiment is identical to that used in load-bearing walls, unless the elements are placed horizontally, and what in walls was the support resistant 12 in slabs is the joist 17 manufactured "in situ" , which is armed with the two longitudinal round 9 of the side trusses of the structural reinforcement of each panel as braces reinforced with the rods 14 which in the case of panels for Forged will come from the factory with lengths of 300 mm. These rods will bend in curves as it appears in figure 6. If the builder wishes, he can tie each panel of the slab sideways with the adjacent panels with the same rods 14 mentioned. In turn, the finishes of the two faces of the structure are different, the upper part is finished with the obligatory compression layer 18 of 50 mm thickness and the lower face with 20 mm of cement mortar 19
projected.

- In the compression layer and above the joists it will be necessary to place round steel not represented as negative, and of diameters depending on the light of the slab, according to a respective structural design, as well as a steel mesh, not represented, for temperatures and refractions. These rounds and mesh are not represented in the
drawings.

A structural design must be made for each  building project.

C. Complementary elements

- As complementary elements in the execution of the work it is necessary to use derived structures to fulfill the function of lintels 20 and window sills 21. The basic module used in the main structure has a height of 2600 mm, of which a height of 80 mm is reserved for floor finishing and installation of horizontal installations. In addition, the 20 mm of finish of the lower face of the element that makes up the
wrought.

- Therefore we have a free height of 2500 mm, which meets the specifications for housing of all kind.

- This free height, where the Window placement is divided into:

Lintel: 400 mm high.

Window hollow: 1200 meters high.

Railing: 1000 mm high (920 mm high free)

- Lintel : Therefore the lintel conforms to a structural reinforcement 600 mm wide by 400 mm high, with the same characteristics as the structural reinforcement used in the exterior walls, bearing or not, exclusively varying the ends of the upper trusses and lower. So that the round ends of these, 6 or 8 m / m protrude from the end of the truss 150 mm, in order to be able to be embedded in the lateral elements of the wall serving as loading docks.

- Parapet: The window sill is formed with a main frame 600 mm wide by 1000 mm high, 920 mm leaving free after finishing the floor and placed horizontal installations. It has the same characteristics as the structural reinforcement used in the external bearing walls or not, exclusively varying the ends of the upper truss, so that the round ends of this 6 or 8 mm protrude from the end of the truss 150 mm, in order of being able to be embedded in the lateral elements of the wall, avoiding its overturning and giving continuity to the structure.

- Windows : the window openings can be modulated in width from the base module of 600 mm, in 1200 mm and 1800 mm, always maintaining the height of 1200 mm.

In this way for bathrooms and kitchens you can use the module 600x1200 mm; for bedrooms the module 1200x1200 mm and for living rooms and lounges the 1800x1200 module mm

d. Compliance with regulations on building

- The panel system of the invention complies with current standards for building materials in Spain.

- The main armor is composed of 5.8 and 10 mm cold corrugated steel rounds depending on the element in question and the height of it.

This type of round is normally used in the reinforcement of the beams manufactured " in situ " for floor slabs superior to those used with this module.

- Reinforcement reinforcements, negatives and reinforcements in load and support wall supports are made of steel hot corrugated, quality B-400 or B-800, in accordance with the Concrete Instruction Structural and normally used in concrete structures.

- The metal framework manufactured with sheet metal cold rolled steel die-cut and expanded with ribs intermediate reinforcement, is manufactured in Spain under German patent with a certain trade name; It is also patented in many other countries.

It can be galvanized or not depending on the situation of the structural module, in partitions or dividing walls, or on facades or load-bearing walls. Manufacturing thicknesses Standard are 0.3mm, 0.4mm and 0.5mm.

The one we use normally is 0.3 mm.

At the same time, it may or may not have a paper attached its later that will prevent the access of the mortar by the part internal panel. Depending on your situation, normally and for interior partition walls and partition walls in homes carry.

- The mortars used are normal market specially manufactured to be projected, homologated in the Spanish market, certified by AENOR and with quality seal IINCE.

- Alternatively, a type of plaster with greater acoustic and thermal power may be used, consisting of a mixture of perlite and plaster, with properties superior to normal plaster in terms of thermal and acoustic insulation and protection against
fire.

- The concretes used both in the finishing of vertical walls and in compression layers comply with the Concrete Instruction
Structural, in terms of its components, gravel, sand and cement and its dosage.

Claims (5)

1. Construction method of walls and floors of houses and interior walls of buildings using structural panels; characterized in that the panels are partially prefabricated and coated with mortar at the final installation site; the prefabricated part consists of a three-dimensional structural reinforcement based on metal rods of various thicknesses; a galvanized metal plate support element perforated and expanded by die is introduced into the structural reinforcement; the structural reinforcements are tied together by means of U-bent rods that embrace the lateral rounds of the adjacent trusses of two adjacent panels; the panels remain, after setting the mortar joined together by "sharp keys"
" in situ " and forming part of the structure. 2. Construction method of walls and floors of houses and interior walls of buildings using structural panels according to claim 1 characterized in that the panels are insulated by filling their interior with the appropriate insulation at the factory. 3. Construction method of walls and floors of houses and interior walls of buildings using structural panels according to claim 1 characterized in that the installation of electrical, telephone, drinking water, sewage and other facilities conduits is carried out before the application of the mortar, No need to break the walls. 4. Construction method of walls and floors of houses and interior walls of buildings using structural panels according to claim 1 characterized in that the mortar used is of the dry mortar type, covering on site with two continuous layers and regulating to achieve the necessary regularity of the flat surface of the walls and floors. 5. Construction method of walls and floor slabs of houses and interior walls of buildings using structural panels according to claim 1 characterized in that said panels are capable of becoming load-bearing walls.