EP0074908A1 - Building element and its application - Google Patents

Abstract

1. A storey-high building element consisting of a rectangular coffering block formed of a core (1) of light insulating material coated with a shock- and weatherproof external facing (2) and with a ready-to-paint internal facing (3) and comprising, for the pouring of concrete, evenly spaced vertical channels (4) sunk within the insulating core and communicating with a trough (7) provided on the top edge, said vertical channels communicating together through horizontal slots (5), characterized in that the external face of the block continues over a certain height beyond its topmost section with an extension in the form of a projecting edge (9) which is itself ending with a raised ledge (10) located plumb with the external edge of the upper trough (7), the lower edge of said block being provided with a trough (8), the external rim of which is adapted for fitting over said raised ledge (10).

Description

The present invention relates to a construction element and to its implementation as well as to construction elements annexed to the basic element.

It is known to make constructions by means of prefabricated elements of storey height. Some of them fall under what is known as heavy prefabrication and have the disadvantage of being heavy, thereby requiring appropriate means and techniques of implementation; moreover, they are generally unsatisfactory from the point of view of thermal insulation; others are light but can only be used for the manufacture of partitions or linings, excluding the manufacture of load-bearing walls; still others are provided with vertical recesses allowing the pouring of concrete posts likely to give them a load-bearing role, while remaining portable by hand.

The invention relates to elements of this type and tends to remedy their drawbacks with regard to resistance to lateral forces, the production of joints and chaining, openings, adaptability to different installation problems, flexibility at the level of architect's plans, while remaining light, easy to handle by hand, usable by the greatest number and not requiring, on site, a specific technology, of a simple implementation, economical of hand d 'work and materials. The basic construction element according to the invention consists of a rectangular, multilayer, shuttering height block, formed of a core of light insulating material, coated with an external facing resistant to impact and weathering and of an internal facing intended to be painted or coated, and comprising recesses for the pouring of concrete, characterized in that said recesses have the form of a resile made up of internal, vertical and horizontal channels which are intertwined, embedded in the insulating core and regularly spaced, the vertical channels adjacent to the lateral banks communicating on the one hand with said lateral banks by the horizontal channels and on the other hand with gutters provided on the upper and lower banks.

Preferably, the thickness of light insulating material on either side of each channel recess is not less than 5 cm towards the outside and 4 cm towards the inside.

The block thus produced is light and easy to handle; after its installation, pouring the concrete into the mesh provides the building with both a vertical and horizontal framework which makes it load-bearing, ensures the connection and jointing between adjacent elements as well as the resistance of the assembly to lateral forces. On the other hand, the block can be easily cut to the right of the vertical or horizontal channels, which ensures great flexibility in dimensioning both in width and in height of the walls and openings, the framing of the latter being automatically ensured. In addition, this block solves the problem of thermal bridges both at the vertical junctions and at the horizontal junctions.

• a) Les tronçons de canaux horizontaux situés de part et d'autre d'un canal vertical sont borgnes et séparés de ce canal par une cloison mince, et facile à briser pour établir la communication entre canaux horizontaux et verticaux.
• b) La gouttière supérieure est séparée de certains au moins des canaux verticaux par une semblable cloison mince et destructible.
• c) Les rives latérales comportent des gouttières en forme de demi-canaux.
• d) En variante, les parements latéraux de l'âme d'un bloc ont un profil en section en forme de tenon et mortaise correspondants.
• e) Un bloc est composé de l'assemblage d'au moins une âme en matériau isolant léger de faible largeur à parements latéraux en tenon et mortaise, comportant un seul canal vertical et des tronçons de canaux horizontaux séparés du canal vertical par des cloisons minces, avec un parement externe commun résistant aux chocs et aux intempéries et un parement interne commun destiné à être peint et revêtu.
• f) Pour l'assemblage de deux blocs ou fractions de blocs adjacents latéralement, il est prévu, au droit de chaque canal (ou gouttière) vertical des gorges permettant l'introduction de clefs constituées par un profilé en matière plastique de section en I, tant sur la face interne que sur la face externe, entre canal et parement.
• g) Pour l'assemblage en partie haute, la face supérieure externe du bloc est prolongée, sur une certaine hauteur par un rebord lui-même terminé par un relevé situé à l'aplomb du bord externe de la gouttière supérieure.

The invention also relates to the following provisions which, in combination with the preceding characteristics, give it the value of a complete construction system:

• a) The sections of horizontal channels located on either side of a vertical channel are blind and separated from this channel by a thin partition, and easy to break to establish communication between horizontal and vertical channels.
• b) The upper gutter is separated from at least some of the vertical channels by a similar thin and destructible partition.
• c) The lateral banks have gutters in the form of half-channels.
• d) As a variant, the lateral facings of the core of a block have a sectional profile in the shape of a corresponding tenon and mortise.
• e) A block is composed of the assembly of at least one core of light insulating material of small width with lateral tenon and mortise facing, comprising a single vertical channel and sections of horizontal channels separated from the vertical channel by thin partitions , with a common external facing resistant to impact and bad weather and a common internal facing intended to be painted and coated.
• f) For the assembly of two blocks or fractions of adjacent blocks laterally, there are provided, at the level of each vertical channel (or gutter) grooves allowing the introduction of keys constituted by a plastic section of I-section, both on the internal face and on the external face, between channel and facing.
• g) For the assembly in the upper part, the external upper face of the block is extended, over a certain height by a rim itself terminated by a raised line located directly above the external edge of the upper gutter.

So it is possible to place or pour a floor which will be connected to the upper chaining and will serve as a basis for laying an upper floor.

h) For the realization of the base, there is provided a sill block of the same constitution as the base block, but- of reduced height and preferably longer length.

This arrangement removes the thermal bridges that are usually found at this location.

i) The horizontal channels are of significantly smaller cross section than the vertical channels, preferably of at least half less cross section.

j) Vertical voids are provided in the core of the block on either side of the horizontal channels.

k) For the construction of building angles, corner blocks are provided consisting of a core in the general shape of a post of rectangular section, provided with a vertical channel, comprising two vertical facings with tenon and mortise profile on two adjacent sides communicating with the vertical channel by sections of horizontal channels corresponding to those of ordinary blocks, the other two facing themselves being adjacent, being coated with either the internal facing or the external facing.

These and other arrangements are described below with reference to the accompanying drawings, in which:

Figures 1, 2 and 3 are three sectional views of an exemplary embodiment of the base block, Figure 1 being a section along BB of Figure 2, Figure 2 a section along AA of Figure 1 and Figure 3 a section along CC of FIG. 2.

Figure 4 is a vertical section illustrating the connection of a basic block with a sill block and a slab of floor.

Figure 5 is a vertical section illustrating the establishment of a floor floor by superposition of blocks.

Figure 6 illustrates in partial horizontal section the detail of the sealing keys and grooves provided for their establishment.

Figure 7 illustrates in vertical section the block / parapet connection.

Figure 8 illustrates in vertical section the block connection / wooden frame.

Figure 9 illustrates in section the block / joinery connection.

Figure 10 illustrates in horizontal section a block / loggia.

Figure 11 illustrates in vertical section a block / balcony.

Figures 12, 13 and 14 are three sectional views of an alternative embodiment of the base block, Figure 12 being a section along BB of Figure 13, Figure 13 a section along AA of Figure 12 and Figure 14 a section along CC of FIG. 13.

Figures 15 and 16 illustrate, in horizontal section, an exterior corner block and an interior corner block.

FIG. 17 illustrates in partial horizontal section the detail of constitution of a block with multiple core, as well as the assembly of two adjacent blocks.

Figure 18 illustrates in horizontal section the production of a split.

Referring to Figures 1, 2 and 3, we see that the block or basic element of the invention has the shape of a rectangular panel consisting of a core 1 of insulating material (expanded polystyrene foam, polychloride of vinyl, formophenolic, or filled polyurethane or aerated concrete) coated with a resistant external facing 2 such as a layer or a film coating of cement reinforced with glass fibers, or aramid fibers, or carbon fibers and ribbed, and d '' an internal facing 3 identical to 2 or made of cardboard plaster. Such a block can have storey height dimensions, for a width of 1.20 m, a thickness of 0.25 m, the weight is of the order of 70 kg. All other width and thickness obviously varies the weight.

According to the invention, this rectangular block is provided with recesses consisting of vertical 4 and horizontal 5 channels, intersecting, embedded in the core 1, regularly spaced and forming an orthogonal mesh; the vertical channels 4a, 4b, which are closest to the lateral banks, communicate on the one hand with said lateral banks by the lateral sections of the horizontal channels 5 and they communicate on the other hand with the horizontal gutters 7, 8 provided on the upper and lower banks.

When in use, once the adjacent blocks are brought together, the concrete pouring into the upper gutter 7 fills the lateral vertical channels, sections of horizontal channels joining two adjacent blocks as well as the lower gutter 8. top chaining and bottom chaining connected by concrete ladders spanning two adjacent blocks.

In the example of FIGS. 1 to 3, all the vertical and horizontal channels are filled with concrete, which gives a heavier framework than in the preferred variant of FIGS. 12, 13 and 14, in which the framework is constituted by the top and bottom chaining resulting from gutters 7 and 8, said chaining being connected by concrete ladders above, while the vertical and horizontal median channels remain empty, which leads to significant savings, a reduction in construction and an increase in insulation.

Preferably, the center distance of the channels will be 30 cm and a base block will have four frames in width for seven frames in height plus two adaptation spaces, as shown.

The dimensions in section of the channels and gutters are preferably determined so that a minimum thickness of 5 cm of insulating material remains between them and the outer wall, and 4 cm between them and the inner wall.

When several blocks are aligned side by side, the pouring of concrete into the recesses (after introduction of the steels required by the calculation) provides a framework, both vertical and horizontal, ensuring the load-bearing or self-supporting character of the assembly, the horizontal connection and jointing of the blocks as well as resistance to lateral forces.

The basic block according to the invention thus constitutes a component for construction, meeting the objectives sought.

In addition, this block can easily be cut to the right of the axis of channels 4 and 5, which allows, if the frame is 30 cm, to achieve all dimensions of multiple walls of 0.30 m, which gives a great flexibility in the system.

In the case of vertical cutting, there is no fall, the sections being able to be all used, each cutting transforming a channel 4 into two identical side gutters 6.

In the case of horizontal cutting, the lower part constitutes a fall; indeed, the invention provides that the external face of the block is extended at the top by a rim 9 of the order of 15 to 20 cm high and over a thickness of the order of 5 cm, this rim being itself even terminated by a rim 10 perpendicular to the outer edge of the gutter 7; it follows, in the case of horizontal cutting, that only the upper block fraction is provided with this arrangement intended to allow the production of floor or ceiling tiles.

This embodiment is shown in Figures 4 and 5. In these figures, we see a base block 11 superimposed on a sill block (Figure 4) or another base block (Figure 5).

The sill block 12 of FIG. 4 has the same constitution as the basic block of FIGS. 1 to 3 but a limited height, corresponding for example to a frame of 30 cm, and a length at least equal to that of a block of based. It may for example be a sectioned base block, but according to the invention, a sill block of ten frames (3 meters) or more is preferably provided, in order to provide a better seat.

During construction, an ordinary masonry at 13 will be prepared, on which the sill block 12 will rest so that its upper part is above the natural terrain 14. The slab 15 is poured in one piece with the chaining 16 which s inserts into the upper gutter 7 of the sill block 12. The base block 11 comes to rest on the slab 15 and the sill block 12, the statement 10 coming to be inserted in the gutter 8 of the block 11 with interposition of a seal d sealing 17. The reinforcement 18 provides the connection between base masonry 13, sill block 12, slab 15, chaining 16 and block 11.

A similar arrangement is found in Figure 5 for the production of an intermediate floor, which can be consisting of two layers, a slab or a slab 19 and a complementary concrete 20,

Note that sawing the inner lip 37 of the gutter 8 increases the thickness of the floor by several centimeters.

FIG. 6 illustrates the lateral connection between two contiguous blocks. This connection is obtained by keys 21, plastic profiles of I-section, which are threaded in grooves or recesses 22 provided in the core 1 behind the neighborhoods of the internal and external facings 2 and 3. The keys 21 provide the alignment, sealing and prevent concrete from entering the joints during pouring.

Grooves 22 are provided to the right of each vertical channel 4, as on the edges of the gutters 6.

Preferably, a mark 23 such as a groove or rib, makes it possible to identify from the outside the location of the axis of a channel 6 and to guide any cutting.

The external facing 2 is ribbed at 24 in line with the axis of a channel 4 as at the edges 25, so that after cutting, each block fraction is provided on its edges, with the same ribs and grooves as a basic block. A rib of the same type is provided on each horizontal frame.

In the example of FIGS. 12, 13 and 14, the lateral edges do not include gutters 6 in the form of vertical half-channels 4 (FIGS. 1, 2, 3) but solid profiles in tenon 6a and mortise 6b of corresponding shapes .

In addition, the horizontal channel sections 5 are separated from the vertical channels 4 by partitions 11 which are sufficiently thin to be easily destructible, but sufficient to resist the thrust of the concrete during casting, and the upper gutter 7 is separated from the vertical channels 4 by a thin and destructible partition 12, of the type of partitions 11.

In FIG. 12 this partition is shown maintained on the median vertical channels and destroyed above the lateral vertical channels, just as the partitions separating the lateral vertical channels 4a, 4b from the lateral banks are shown as destroyed.

If constructive reasons make it useful or necessary to fill a median channel, either horizontal or vertical, it suffices to destroy the corresponding partitions 11 or 12 at the time of assembly or before casting for this filling to be ensured.

Such occurrences will arise for example for the production of lintels or openings.

As can be seen in the drawing, it is no longer provided, for the alignment of adjacent blocks, grooves in which to thread keys, due to the alignment by tenon and mortise 6a, 6b.

According to another arrangement of the invention, shown in FIG. 17, the core 1 of a block as shown in FIG. 12 results from the assembly of one or more elementary cores with a single vertical channel, with the facings 2 and 3. It is thus possible to produce blocks of different widths, whole multiples of the width of the elementary core.

The external facings of a block will have ribs 25 on their bottom vertical and horizontal edges and ribs 24 in line with the channels 5 and the joint between two elementary cores with a mark or external ribs 23 for locating, which makes it possible to cut a large block into sub multiples; the vertical cutting of a block in submultiples is therefore done at the right of the separations between elementary souls adjacent and not to the right of the vertical channels.

The cross section of the horizontal channels 5 is much smaller than that of the vertical channels. In the example shown, their ratio is of the order of 1/4 which on the one hand saves material and on the other hand makes it possible to provide for the manufacture of blind vertical channels 26, on both sides horizontal channels 5, the channels 26 never being filled.

For the construction of building angles, blocks of angles are provided formed of an elementary core 1 with a single vertical channel 4 carrying the lateral tenon and mortise facing 6a, 6b on adjacent faces and carrying either the facing external 2 or the internal facing 3, on the two other adjacent faces (FIG. 15).

For re-entrant angles, it is preferred, for better sealing, to provide a larger core 1 allowing a re-entrant angle coated with external facing 2 (FIG. 16).

The prefabricated system and block according to the invention adapt very easily to the installation of a prefabricated acroterion, as shown in FIG. 7, which illustrates the detail thereof. The acrotère 28 is placed on the slab 19, 20 overlapping the raised 10, with plastic seal 17. It is fixed by the keying steel 29 for which a reserve 30 is provided in the acrotère 28.

The connection to a wooden frame is illustrated in Figure 8. The upper edge 9 of the blocks (Figure 1) will for example be cut, and the frame will rest on the top chaining 31 poured into the gutter 7. Legs 32 anchored in the channels 4 and 6 will secure the farm 33. A ceiling 34 may be suspended from the frame.

The openings will be made by cutting the blocks, preferably, but not necessarily, along the frame of the channels 4 and 5. The flexibility of the system is, in this respect, total. Metal frames 35 (Figure 9) of current type, complementary to the joinery 36, will dress the openings and will serve as formwork for pouring concrete into the channels.

For the realization of a loggia, an awning, a staircase, etc ... it is often necessary to provide sections of wall coming in spike towards the outside. To this end, the invention provides loggia blocks (FIG. 10) provided with the external facing 2 on its two main faces and on one edge, the other edge being provided with a gutter 6 as a basic element.

The balconies can be made with such an element or preferably with a special element (Figure 11) of decreasing thickness and with reinforced upper facing. It should be noted that only the balcony requires concrete pouring prior to its installation and handling by crane.

The realization of a balcony by a block according to the invention avoids the formation of thermal bridge,

Figure 18 illustrates the construction of a cross wall, for example between two apartments. It is obtained by opening inward, with a saw, a channel 4 and by placing a splitting block provided on each face with an internal facing 3. This operation can be carried out both at the level of a joint between two blocks. that in front of a channel 4 as shown in Figure 14. With such a split block, the acoustic and thermal protection between two apartments is equal to that towards the outside of the building.

It appears from the above description that the block according to the invention and its accessories, special blocks and keys, makes it possible to produce a coherent construction system, simple to implement, by very economical means for very remarkable resistance and insulation results.

Claims (18)

Floor-level building element consisting of a rectangular shuttering block formed of a core (1) of light insulating material coated with an external facing (2) resistant to impact and weather and an internal facing ready to paint (3) and comprising recesses allowing the pouring of concrete, characterized in that the said recesses form a mesh consisting of vertical (4) and horizontal (5) channels intersecting, embedded in the insulating core (1), regularly spaced, the vertical channels (4a, 4b) adjacent to the lateral banks communicating on the one hand with said lateral banks by the horizontal channels and on the other hand with gutters (7, 8) provided on the upper and lower banks. 2. Element according to claim 1, characterized in that the sections of horizontal channels located on either side of a vertical channel (4) are blind and separated from this channel by a thin partition (11), easy to break to establish communication between horizontal and vertical channels when needed. 3. Element according to any one of claims 1 and 2, characterized in that the upper gutter (7) is separated from at least some of the vertical channels by one. similar thin and destructible partition (12). 4. Building element according to any one of the preceding claims, characterized in that the vertical lateral facing of the core of a block have profiles (6a, 6b) with a cross section in the shape of a tenon and corresponding mortise. 5. Building element according to any one of the preceding claims, characterized in that a block is composed of the assembly of at least one core (1) of material lightweight insulator of small width with lateral tenon and mortise facing (6a, 6b), comprising a single vertical channel (4) and sections of horizontal channels (5) separated from the vertical channel by thin partitions (11), with a facing common external (2) impact and weather resistant and a common internal facing (3) intended to be painted or coated. 6. Element according to any one of the preceding claims, characterized in that for the assembly of two blocks or fractions of adjacent blocks laterally, there is provided, at the level of each channel or half-channel of the grooves (22) allowing the introduction of keys (21) constituted by I-shaped plastic sections of length equal to the height of the element, said grooves (22) being placed in the core (1) in the vicinity of both external facing (2) and internal (3). 7. Element according to any one of the preceding claims, characterized in that its height is that of a stage and for assembly in the upper part, the external upper face of the block is extended over a certain height by a flange (9 ) itself terminated by a lift (10) located directly above the outer edge of the upper gutter (7). 8. Element according to any one of the preceding claims, characterized in that the distance between the channels or frame is 30 cm. 9. Element according to any one of the preceding claims, characterized in that the external facing has two internal ribs (24) serving as stiffeners, in line with the vertical channels (4) and on either side of its axis, thus that ribs (25) on the lateral edges and on each horizontal frame. 10. Construction element according to any one of the preceding claims, characterized in that the horizontal channels (4) are of significantly smaller section than the vertical channels (5), preferably of section at least half less. 11. Construction element according to any one of the preceding claims, characterized in that vertical voids (26) are provided in the core of the block on either side of the horizontal channels. 12. Element according to any one of the preceding claims, characterized in that, for the production of the base, sill blocks (12) are provided with the same constitution as the base block but of reduced height and of length greater than that of the basic block. 13. Building element according to any one of the preceding claims, characterized in that the corner blocks consist of a core (1) in the general shape of a post of rectangular section has a vertical channel (4), comprising two vertical facings (6a, 6b) with tenon and mortise profile on two adjacent sides communicating with the vertical channel (4) by horizontal channels (5) corresponding to those of ordinary blocks, the other two facings, themselves adjacent, being covered with either internal facing (2) or external facing (3). 14. Element according to any one of the preceding claims, characterized in that for the production of sections of external walls, there are provided blocks of the same constitution as the base block but provided with the external facing (2) on their two faces. and a vertical section. 15. Element according to any one of the preceding claims, characterized in that for the production of balconies, there is provided a block according to claim 11, of decreasing thickness and with reinforced facing (2). 16. Element according to any one of the preceding claims, characterized in that for the production of splits, there are provided blocks of the same constitution as the base block but provided with the internal facing (3) on their two faces. 17. Method of implementing elements according to any one of the preceding claims, consisting in placing the blocks according to the invention side by side on a base, optionally in introducing keys (21) into the grooves (22), and placing reinforcing steels, then pouring concrete into the channels (4 to 8). 18. Method of implementation according to claim 17, wherein the floor slabs are poured at the same time as the framework of the channels (4 to 8) and the chaining (16).

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