EP2402525A1

EP2402525A1 - Method for erecting a building having a cast-in-place frame and decorative outer finish

Info

Publication number: EP2402525A1
Application number: EP10839866A
Authority: EP
Inventors: Dahir Kurmanbievich Semenov
Original assignee: Individual
Current assignee: Individual
Priority date: 2009-12-21
Filing date: 2010-11-17
Publication date: 2012-01-04
Also published as: EP2402525A4; RU2421580C1; WO2011078734A1

Abstract

The invention relates to the field of construction, and the technical result is a reduction in the amount of labor and time required to erect a building. The method for erection of the cast-frame building with decorative external finish comprises the foundation pouring, tying of the reinforcing construction of the first floor, pouring of walls of the first floor with the help of removable formworks, installation of the frame beam reinforcement and pouring of ceilings and frame beams. The method further comprises tying of the reinforcing construction of the second floor and subsequent floors with the wall pouring, installation frame beam reinforcements and pouring of ceilings and frame beams of subsequent floors and roof erection. Wall formworks are used, consisting of the hollow cap and pallet with the wall blank, which are located inside the pallet and made at the factory. This wall blank contains at least one decorative layer and at least one heat insulating layer. These layers are linked with each other by reinforcing elements and set with the decorative layer outside. Reinforcement of supporting concrete layer of the wall is installed in the hollow cap of the removable wall formwork. After removal of the removable wall formwork, beam formworks, which are adjacent to the wall blank, are set on supporting concrete layer of the wall in the upper zone, which is unfilled with concrete. Fixing elements for the roof framework are laid in the ceiling before the ceiling pouring of the last floor.

Description

DESCRIPTION OF THE INVENTION

The invention relates to the field of the construction, in particular to ways and methods of the erection and construction of cast-frame houses with a different number of floors and multilayer walls, which do not require the heat insulation, additional treatment and finish of internal and external surfaces.
There is the method of multilayer wall production, including the formation of a rigid spatial frame with constructional grids for the attachment of concrete layers and connecting elements, the installation of the heat insulation material slab in this frame. Also this method includes subsequent fixation of the frame on the foundation and the infliction of inner and outer concrete layers by the guniting. Herewith the formation of the frame is carried out in a horizontal position with a size of the floor, taking into account the thickness of the wall with a simultaneous placement of the heat insulation material inside the frame. And in the case of the frame formation the heat insulation material slab is amplified by connecting, as those used reinforcing bars, rigid spatial bracings, bar bracings, technological bars. Herewith reinforcing bars and rigid spatial bracings are placed in pre-made holes in the heat insulation material slab, bar bracings are passed through the heat insulation material at the angle of 45° to its plane and technological bars are installed and fixed on the surface of the heat insulation material with the formation of the thermoreinforcing package, used as a permanent formwork (see the invention patent RU Nº 2095526 , K
. E 04 B 2/86, published in 1997). This fairly widespread method of wall erection contains a large number of sequential labor-intensive operations, leading to a rise in the cost of a construction and waste of time for the erection of a building. Also it has a narrow range of applications and is not intended for the erection of buildings in earthquake zones.
Also there is the method of the manufacturing of multilayer construction product. This method includes operations of alternate layer stacking in the framework, and the concrete mixture is leveled in a horizontal plane flush with the first bead of the permanent formwork after the stacking of the first fine concrete layer in the permanent formwork. Then longitudinal reinforcement of the first layer is laid on the first bead, and the heat-insulated layer of the light-weight concrete is laid. This layer is located in a parallel plane with respect to the first layer. After the concrete mixture is leveled in a horizontal plane flush with the second bead of the permanent formwork, and the longitudinal reinforcement of the second layer is laid on the second bead, the second layer of the fine concrete is laid. Finally the concrete mixture is leveled in a horizontal plane flush with the shear of the permanent formwork, simultaneous vibroforming is produced for all layers, and everything is retained until mixture setting. Herewith the permanent formwork is enclosed in the hard jig (see the invention patent RU Nº 2307903 , K
. E 04 C 1/40, published in 2007). This method allows to improve heat insulation properties, increase the durability and reliability of construction panels, wall and buildings, which are made of them. However, this method is not suitable for monolithic housing and makes it impossible to erect buildings with high strength and aseismic stability.
Besides that there is the method of the erection of the precast-monolithic framework of a multistory building, which includes floor-by-floor alignment axes installation of unconsoled reinforced concrete columns, placement of assembly bridges, mounted on supporting posts, in the spans between columns for the installation of prefabricated carrier bearing elements of precast-monolithic cross frame beams of the girth of unconsoled columns and the formwork for the formation of reinforced concrete monolithic spacer longitudinal linking frame beams of the girth. Also this method includes laying on carrier bearing parts of precast-monolithic cross frame beams in a design position for the formation of the discs of per floor ceiling of multihollow reinforced concrete slabs, installation of frame beam reinforcement, simultaneous laying of the high-strength concrete around the interfloor ceiling with the formation of longitudinal spacer frame beams and carrier precast-monolithic cross frame beams and dwelling units of floor-by-floor ceiling. These units forms discs and are rendered monolithic with frame beams into a coherent whole through concrete longitudinal joints. Dwelling units are adjacent and based on every carrier precast-monolithic cross frame beam of adjacent multihollow reinforced concrete slabs. With regard to the method, it also contains the exposure of laid high-strength concrete, stripping of floor-by-floor ceiling after the concrete will reach the design strength, and permutation of assemble bridges on the finished stripping floor-by-floor ceiling for their subsequent use in the erection of next floor-by-floor ceiling. Herewith the formation of every carrier precast-monolithic cross fame beam proceeds in two stages, the first of them is the setting of supporting elements in a design position with the bearing on posts of assembly bridges. As the supporting elements are used the prestressed vibropressed reinforce concrete girder with lateral stepped ledges, which are symmetrical to the longitudinal axis of the girder. This girder is prefabricated and overlaps the cross bay between adjacent unconsoled columns. And also the girder forms permanent formwork bottom of upper monolithic part of this cross frame beam. The second stage involves the implementation of vertical walls formation of mentioned permanent formwork and also the formation of concrete longitudinal seams and depressions for cross reinforced key slots of upper monolithic part of the cross frame beam of the girth. These seams and depressions have a common working cavity of the box with the permanent formwork. So mentioned seams and depressions are formed by means of the usage of this permanent formwork. This happens after the installation of one of interfloor ceiling discs of adjacent prestressed vibropressed multihollow reinforced concrete slabs in a design position on lateral stepped ledges of prestressed vibropressed reinforced concrete girder of generators. These slabs are in contact with each other and form the box of concrete longitudinal seams with symmetrical longitudinal shelves with upper profiled surfaces, which are situated in lower parts of their lateral surfaces. Slabs have longitudinal depressions on the upper surface of the permanent formwork ends of multihollow reinforced concrete slabs for the formation of cross reinforced key slots of the upper cast part of the mentioned cross frame beam during the concreting (see the invention patent RU Nº 2318099 , K
. E 04 B 1/20, published in 2008). So the well-known method of the monolithic housing involves the erection of monolithic building framework, consisting of posts and ceilings. The area between them is filled with blocks or bricks, or panels (they are not made monolithic with the frame work).
There is the method of multilayer wall formation, including the formation with the usage of the formwork of three vertical layers of monolithic reinforced concrete. These three layers are alternated by thermal insulation layers and sealed with each other by rigid jumpers, which are not located coaxially (see the invention patent RU Nº 2335604 , K
. E 04 B 2/84, published in 2008). This method allows the erection of monolithic walls of different thickness at a sufficiently high strength. But the method does not solve the problem of building durability. Walls require additional finishing and subsequent regular repair in the case of the erection, with the usage of this technology.
The most efficient technical solution is the method of building erection, involving framework erection from reinforced concrete rendered monolithic precast elements. Part of these elements are made on the technological line, which contains the equipment for the concreting, systems for the feeding and installation of the reinforcement, formwork with the strand longitudinal molding cavity under the appropriate designs, produced at the same time, including molding surfaces and the pallet, which is installed on discrete bearings with the rigid fixation in the central part of the length. Also there is the possibility of directional slippage in both directions and the adjustment of pallet altitudinal position on bearings for the rest of the length. And the pallet is provided with mounting joints of the central board, which are placed along the longitudinal axis of the pallet. The board forms formwork molding surface. Also the pallet is provided with fixation joints, which are situated along longitudinal edges of the pallet, and opening joints of longitudinal exterior folding boards, forming other molding surfaces. Herewith the formwork is provided with cross molding cutting removable terminal membranes (see the invention patent RU Nº 2293822 , K
. E 04 B 1/18, published in 2007). This method of building erection is technically complex and requires a lot of additional operations and funds for the construction.
The present invention is directed to solve the technical problem of labor content reducing and terms of building erection, improving of design flexibility of building framework with monolithic walls, which do not require additional finishing and repair of internal and external surfaces, improving of building operating characteristic, simplifying of concrete pouring process during the erection of building walls, increasing of the reliability, durability and aseismic stability of the construction.
The solution of this technical problem lies in the fact that this method of the erection of the cast-frame building with decorative external finish involves foundation pouring, reinforcing construction tying of the first floor, wall pouring of the first floor, installation of frame beam reinforcement and pouring of ceilings and frame beams. Also this method includes reinforcing construction tying of the second floor and subsequent floors with the wall pouring, installation of frame beam reinforcement and pouring of ceilings and frame beams of subsequent floors and roof erection. Herewith reinforcing tabs, which are set vertically, and mounting lugs for formworks of walls are laid preliminary in the foundation during foundation pouring. Reinforcing tabs are tied to the reinforcement of lower floor walls, mounting lugs are set for the formwork of walls during ceiling pouring. Reinforcing construction of walls is tied to reinforcing tabs, leaving vertical apertures for windows and doors. Then wall formwork is put down vertically on the reinforcement, and wall formworks are used, consisting of a hollow cap and pallet. There is a wall blank in the pallet. This blank is made at the factory and contains at least one decorative and one heat insulating layers, related to each other by reinforcement elements, located with the decorative layer outside. Reinforcement of wall supporting layer is situated in the hollow cap of wall formwork. Then wall formworks are fixed in mounting lugs of the foundation by fixing extensions, and voids around the reinforcement are filled with concrete inside hollow caps of wall formworks, forming supporting concrete layer of building wall and leaving the upper zone of wall formwork unfilled with concrete. This zone is adjacent to the heat insulating layer of the wall blank. Herewith frame beam formworks are set in the upper zone, which are not filled with concrete, after taking off wall formworks on supporting concrete layer of the wall. These frame beam formworks are adjacent to the wall blank. Fixing elements for roof framework are pledged in the last floor before ceiling pouring of last floor. Angular zones are left free during building wall pouring, and then these zones are laid with bricks or blocks. Ceilings between floors are erected simultaneously with balconies, and the lathing of ceilings is mounted with the help of supporting legs outside of building walls before the pouring. Last floor ceiling is erected simultaneously with visors, and the lathing of ceilings is mounted with the help of supporting legs outside of building wall before the pouring. Void formers are used in the process of ceiling pouring. The formwork is installed on the foundation or ceiling of the regular floor. This formwork is adjusted vertically and horizontally by support-screw regulators and fixing extensions of the formwork.
The invention is illustrated by drawings. Fig. 1 shows the building foundation with reinforcing tabs and mounting lugs for the formwork in isometry. Fig. 2 indicates the same with reinforcement for walls. Fig. 3 illustrates the same with formworks, which are poured with concrete. Fig. 4 indicates the same with taken formworks. Fig. 5 shows the same with installed formworks and the reinforcement of frame beams. Fig. 6 indicates the same with the ceiling lathing of the first floor. Fig. 7 illustrates the same with the substrate on the ceiling lathing. Fig. 8 shows the same with void formers, reinforcement and mounting lugs for the formwork. Fig. 9 indicates the same with ceilings, which are poured with concrete. Fig. 10 shows the same with the reinforcement for the formwork of the second floor. Fig. 11 illustrates the second floor formworks, which are poured with concrete. Fig. 12 shows the same with taken formworks. Fig. 13 illustrates the same with installed formworks and frame beam reinforcement of the second floor. Fig. 14 indicates the same with the lathing for the ceiling of the second floor. Fig. 15 shows the same with the substrate on the ceiling lathing of the second floor. Fig. 16 illustrates the same with void formers, reinforcement and mounting lugs for the roof framework. Fig. 17 indicates the same with second floor ceilings, which are poured with concrete. Fig. 18 shows the same with mounted roof framework. Fig. 19 illustrates the same with the roof lathing. Fig. 20 indicates the finished building. Fig. 21 shows the finished building with corners, laid with bricks. Fig. 22 illustrates the wall formwork with bilayer wall blank, made at the factory. Fig. 23 shows the wall formwork with multilayer wall blank, made at the factory.
The method of the erection of cast-frame building with decorative external finish is used for the construction of houses and buildings with the different number of floors and different types. Reinforcing tabs 2, exposed vertically, and mounting lugs 3 for removable wall formworks 4 are laid preliminary before the pouring of the foundation 1. The reinforcement 5 for walls 6 of the first floor is tied to reinforcing tabs 2 after the drying of the foundation. This reinforcement 5 is set at the some distance from each other (see fig. 1). These distances are due to the sizes of future windows and doors. Partially hollow removable wall formworks 4 include multilayer wall blanks, made at the factory, consisting of at least one decorative layer 7 and one heat insulating layer 8. Wall blanks are situated in the pallet 9 of the formwork 4, which are closed by the hollow cap 10 in the case of the assembled formwork. (see fig. 22 and fig. 23). Removable formworks 4 are put down vertically on the reinforcement 5. Wall blank is set with the decorative layer outside in that way, when the reinforcement is inside the hollow cap 10 of the formwork 4 (see fig. 3). The hollow part of the formwork 4 is limited to the heat insulating layer 8 of the wall blank, which is installed in the pallet 9 of the formwork 4, with the one side and the cap 10 of the formwork 4 with the other side. In the case of wall blank production in pallets 9 at the factory the decorative layer 7 and the heat insulating layer 8 are linked with each other by reinforcement elements 11 in that way, when reinforcement elements 11 protrude beyond the heat insulating layer 8 in the hollow zone of the formwork 4, which are formed by the cap 10. Formworks 4, installed on the reinforcement 5, are fixed in mounting lugs 3. The hollow part of the formwork 4 with the reinforcement 5 and reinforcement elements 11 are poured with concrete, forming supporting concrete layer 12 of the wall 6 of the building, leaving the upper zone 13 of the formwork 4 unfilled with concrete. Wall formworks 4 are taken off (see fig. 4), and frame beam formworks 14 are fixed in the upper zone 13 (see fig. 5) after concrete solidification. Then the wooden lathing 16 for the first floor ceiling 17 is mounted with the help of supporting legs 15, and the substrate 18, for example, laminated plywood is mounted on this lathing (see fig. 7). Void formers 19, the reinforcement of the first floor ceiling 20 and mounting lugs 21 for the formwork 4 are installed on the substrate 18, and then there is the concrete pouring for the ceiling formation 17. Walls 6, erected on the foundation 1, are located at the some distance from each other with the formation of apertures 22 for windows and doors (windows and doors are not illustrated in a figure). The internal surface of walls, poured immediately at the level of the floor with the help of the formwork 4, does not require the additional finish and plaster due to the quality production of the internal surface of the cap 10 of the formwork 4.
Second floor and subsequent floors are erected in the same manner as the first floor, starting from the tying of the reinforcement 5 for the installation of second floor formworks 4 to the ceiling formation 23 of next floor. Herewith reinforcement elements, linking the decorative layer 7, heat insulating layer 8 and supporting concrete layer 12, tightly bind wall blanks with the construction of the wall 6. And the construction of the wall is linked with the foundation 1, ceilings 17 and 23, building frame beams 24 and 25 by the reinforcement 5. Tabs 26 for the fixation of the framework 27 of the half dome roof 28 are set on the ceiling 23 of the last floor before the process of concrete pouring (see fig. 16). The framework 27 of the half dome roof 28 is welded to tabs 26 on the ceiling 23 after the process of concrete solidification. Then this framework is sheathed, for example, by boards 29 and cut by roofing materials 30.
This method provides the possibility of the erection of house walls 5 with corners 31, which are free from concrete constructions. This fact allows using corners of the different geometry. In this case corners 31 of the building are laid by bricks or blocks after roof erection 28. Windows and doors are set in apertures 22 between walls (windows and doors are not illustrated in a figure). Also the method provides the balcony erection 32 simultaneously with the ceiling erection 17. For these purposes the lathing 16 of ceiling 17 are mounted beyond walls 6 of the building with the help of supporting legs 15, which are situated on console parts of the ceiling 17, during the process of the mounting (see fig. 10). Supporting legs 33 are used for the erection of the visor lathing 34, which is made of the roofing material. The lathing 16 of ceilings 23 are mounted with the help of supporting legs 33 beyond walls of the building before the process of the concrete pouring (see fig. 19-20). Due to the above properties of this method, there is the possibility of the varying of the building appearance, number of floors, position and performance of windows, doors, balconies, loggia, and also internal planning, saving advantages of the monolithic construction of the low-rise building with the wall blank, which are made at the factory.
The use of void formers 19 and 35 in the case of the ceiling erection 17 and 23 gives the opportunity to reduce the weight of the construction and costs of materials without loss of the strength of the ceiling construction 17 and 23. As this method provides the erection of the building framework, using reinforced concrete monolithic walls 6, which are tightly linked by means of the concrete and reinforcement 5 with the foundation 1, ceilings 17 and 23, then strong seismic resistant construction, forming unified spatial monolith, is obtained as a result of the process of the construction. There is high accuracy level of walls, erected by means of simple devices, due to the fact that wall formworks 4, which are stringed on the reinforcement 5, installed on the foundation 1 or the ceiling of the regular floor, regulated vertically and horizontally by fixing extensions 36 and support-screw regulators (this is not shown in figure). The erection of the half dome roof 28 on the metallic framework 27 improves properties of the strength and seismic resistance of the building by loads, which are distributed along a curved path. The metallic framework 27 is linked with the reinforcement 5 of walls 6 and ceilings 23 of the building. The use of removable wall formwork 4 with the wall blank, which is made preliminary at the factory, allows increasing the strength of the cast-frame construction of the building, because all vertical and horizontal elements are tightly linked with each other. The wall blank consists of the decorative layer 7 and heat insulating layer 8, linked by reinforcing elements 11, loop ends of which protrude beyond the heat insulating layer 8. The use of removable wall formwork also allows erection of the building, which does not require the heat and noise insulation, additional internal and external finishing works and has decorative form.
The production of the wall blank in the pallet 9 at the factory provides high quality of the decorative layer 7, which forms the external surface of the pallet after the process of building erection. The decorative layer 7 are made of the fibrous concrete, which contains mineral, steel, polymer fibers or made of other similar materials, which allow getting of beautiful relief drawing of the external surface of the building, which does not require the finish and repair. The heat insulating layer 8 can be made of lightweight concrete such as foam concrete, aerated concrete, foam polystyrene concrete, pumice concrete or other materials, which provide high properties of noise and heat insulation. The use of multilayer wall blank of removable formwork 4 is illustrated in fig. 23. The wall blank can contain at least one additional decorative layer 37, intended for hardening of the main decorative layer. Also this blank includes at least one additional heat insulating layer 38, intended for improvement of heat and noise insulation properties of building walls.
Thus, the technical result, achieved with the use of the claimed invention, includes the reducing of the labor content and building erection terms, the increasing of the construction flexibility of the building framework with monolithic walls and the improving of building operating characteristics, which do not require additional finish and repair of internal and external wall surface. Also this technical result provides the simplification of the concrete pouring during the process of building wall erection, the enhancing of the reliability, durability and aseismic stability of the construction.

Claims

Method of the erection of the cast-frame building with decorative external finish, which comprises the foundation pouring, tying of the reinforcing construction of the first floor, pouring of walls of the first floor with the help of removable formworks, installation of the frame beam reinforcement and pouring of ceilings and frame beams, tying of the reinforcing construction of the second floor and subsequent floors with the wall pouring, installation frame beam reinforcements and pouring of ceilings and frame beams of subsequent floors and roof erection, whereby reinforcing tabs, which are installed vertically, and mounting lugs for removable wall formworks are laid preliminary in the foundation during the process of the foundation pouring, whereby reinforcing tabs are tied to the reinforcement of walls of the lower floor and mounting lugs for removable wall formworks are laid and during the process of the ceiling pouring, whereby the reinforcing construction of walls is tied to reinforcing tabs, leaving vertical apertures for windows and doors, then removable wall formworks are put down on the reinforcing construction of walls, said removable wall formworks consist of the hollow cap and the pallet with the wall blank, which is situated inside the pallet and made at the factory, said wall blank includes at least one decorative layer and at least one heat insulating layer, said layers are linked with each other by reinforcing elements and are placed outside together with the decorative layer, and the reinforcing construction of the supporting layer of walls is set in the hollow cap of removable wall formwork, then said removable wall formworks are fixed in mounting lugs of the foundation by fixing extensions, and voids around the reinforcement inside hollow caps of removable wall formwork are poured with concrete, forming supporting concrete layer of the building wall and leaving the upper zone of removable wall formwork unfilled with concrete, said zone is adjacent to the heat insulating layer of the wall blank, whereby after removable wall formworks are taken off frame beam formworks, which are adjacent to the wall blank, are set on supporting concrete layer of the wall in the upper zone, which is unfilled with concrete, whereby fixing elements for the roof framework are laid in the ceiling before the ceiling pouring of the last floor.
Method of the erection of the cast-frame building with decorative external finish on p. 1, characterized by the fact that angular zones are left free in the process of the wall pouring of the building, and then these zones are laid with bricks or blocks.
Method of the erection of the cast-frame building with decorative external finish on p. 1, characterized by the fact that ceilings between floors are erected simultaneously with balconies, so the lathing of ceilings is mounted by means of supporting legs beyond walls of the building before the pouring.
Method of the erection of the cast-frame building with decorative external finish on p. 1, characterized by the fact that the ceiling of the last floor is erected simultaneously with visors, so the lathing of ceilings is mounted by means of supporting legs beyond walls of the building before the pouring.
Method of the erection of the cast-frame building with decorative external finish on p. 1, characterized by the fact that void formers are used in the case of the ceiling pouring.
Method of the erection of the cast-frame building with decorative external finish on p. 1, characterized by the fact that the removable wall formwork, installed on the foundation or ceiling of the regular floor, is regulated vertically and horizontally by support-screw regulators and fixing extensions of the formwork.