WO2019012440A1

WO2019012440A1 - Non-stress construction composite for building structural walls and ceilings, and a method of building structural walls and ceilings using bridgeless non-stress construction composites

Info

Publication number: WO2019012440A1
Application number: PCT/IB2018/055101
Authority: WO
Inventors: Aleksander PANEK
Original assignee: Climatic Sp. Z O.O. Sp.K.
Priority date: 2017-07-11
Filing date: 2018-07-11
Publication date: 2019-01-17
Also published as: PL238485B1; PL422190A1

Abstract

The subject of the invention is a bridgeless structural composite for construction of walls and ceilings as well as the method of construction of walls and ceilings using bridgeless structural composites. The bridgeless composite, according to the invention, comprises freely shaped external and internal profiles and filling between external and internal profiles made of material with thermal properties. The method of construction of walls and ceilings of buildings using bridgeless structural composites, according to the invention, consists in the fact that bridgeless structural composites are positioned at a certain axial distance from each other, and that construction is implemented by the connection of bridgeless structural composites located in the wall and ceiling of the building, the space between bridgeless structural composites is filled with a layer of thermal insulation and fixing to the bridgeless structural composites of subsequent cladding layers.

Description

NON-STRESS CONSTRUCTION COMPOSITE FOR BUILDING STRUCTURAL WALLS AND CEILINGS, AND A METHOD OF BUILDING STRUCTURAL WALLS AND CEILINGS USING BRIDGELESS NON-STRESS CONSTRUCTION COMPOSITES

[1] The subject of the invention is non-stress construction composite for building structural walls and ceilings, and a method of building structural walls and ceilings in using non-stress construction composites. The solution, according to the invention, is widely used in construction, has particular advantages in housing and public utilities building.

[2] The development of modern construction, in particular housing and public utilities, generates the need to develop solutions that allow maximum acceleration in completion of erecting a building. It is connected with the necessity of making the construction process independent of weather conditions and for this reason, construction technology seeks building systems making it possible to manufacture as much of the building processes as possible in the prefabrication plant. In modular construction, only foundations are laid at the building site. Production of prefabricated modules in plants, creates favourable conditions for their prefabrication and allows to limit the construction site space, only to the place for assembly of prefabricated on size elements. Previous attempts to improve the construction work have been limited by the need to perform the insulation layer and finishing of the fagade only on the construction site, in order to eliminate the risk of damage during loading, transport or assembly. In practice, it forced the necessity of interrupting construction works during adverse weather conditions and, finally, deviations from the work schedule.

[3] Various systems of building walls and ceilings used in construction are known from prior art, such as: skeleton technology from dried and planed wood, solutions known from traditional construction, e.g. ceramic wall, SCS Scottsdale Construction Systems or similar systems based on thin-walled steel profiles and sandwich panels with polyurethane foam or Styrofoam core. These systems, apart from the need to make the insulation using traditional methods, only at the construction site, are also burdened with many other disadvantages preventing maximum reduction of construction time, crucial from the point of view of modern construction. Such defects include, for example, limited possibility of running the installation in the insulating layer, difficult installation of window and door joinery, the need to use a significant insulating layer to eliminate thermal bridges.

[4] The SCS system is known from prior art, in which the outer walls consist essentially of wood chip plasterboard, aluminium mat, SCS structure filled with glass wool, OSB Oriented Strand Board-3 and an additional layer of heat insulation. The disadvantage of this type of solution is the need to build a double- layer wall to eliminate linear thermal bridges. Moreover, SCS profiles are made only in specific sizes of 90 mm and 140 mm, which is a significant limitation in the thickness profile of the first layer of the wall in which different types of installations are designed. In turn, flat roofs built in the SCS system consist of a roofing membrane, EPS (expanded polystyrene), In turn, flat roofs built in the SCS system consist of a roofing membrane, EPS (expanded polystyrene), OSB-3 board, SCS structure filled with glass wool, aluminium mat and fibre-plaster board. These types of flat roofs also generate the necessity to ensure continuity of the outer insulation layer of the wall, attic and roof, in order to eliminate thermal bridges.

[5] In the case of timber frame technology known from prior art, the outer walls of the wooden frame system are basically made of the following layers: Styrofoam/wool, mesh, plaster, MFP. (Multifunction Panel), wind proof foil, timber structure (at a distance of approx. 40 cm) mineral wool, vapour barrier foil, MFP and plasterboard. This technology also implies the need to make a double- layer wall, or make walls of considerable thickness to eliminate linear thermal bridges. This type of walls are not resistant to water or biological corrosion, and are heavier than those made in the technology of bridgeless structural composites. [6] One of the most well-known and widely used external wall construction systems is the traditional brick wall. In this system, masonry held external walls are generally made as two-layer: the supporting layer can be made of bricks, hollow blocks, cellular concrete blocks, silicates or expanded clay concrete. The thermal insulation layer is made from mineral wool or polystyrene with a thickness of approx. 12-20cm, fitted from the outer side of the wall. The most significant disadvantages of erecting walls in traditional technology is high volumetric weight and long construction time. For this reason, erecting a masonry wall is dependent on weather conditions and can not take place in the prefabrication plant, and find applications in modular technology.

[7] Wall and ceiling installation systems in the form of sandwich panels with a core of polyurethane foam or expanded polystyrene are also known from the state of art. Sandwich panels consist essentially of two claddings of steel sheet (external and internal) and a structural-insulating core between them. The disadvantage of this type of solutions is surface finishing limitations and placing installations in the insulating layer of the panel. In addition, sandwich panels make it impossible to put in windows and doors directly in the panels without using additional substructures.

[8] From description PL480892, a bridgeless structural composite for the construction of walls and ceilings of buildings is known, as well as the method of building walls and ceilings of buildings using such a composite. The solution disclosed therein eliminates the disadvantages of the systems described above, known from the prior art, e.g. such as: limited possibilities of making the finishing layer of the fagade in its entirety in the prefabrication plant, necessity of using a thick layer of insulation to eliminate thermal bridges, limited possibility of finishing the surface and running the installation in the insulating layer. However, said composite does not allow complete exclusion of the possibility of point thermal bridges. A significant disadvantage of the mentioned solution is also the limited freedom of shaping the geometry of the composite, resulting from the presence of lacings connecting the external and internal composite profiles. These technical features extend the process of manufacturing such composites, allowing only for the production of segments of limited length.

[9] The primary objective of the invention described in this document was to eliminate the drawbacks of the prior art used in construction.

[10] This goal has been achieved with a bridgeless structural composite for the construction of walls and ceilings, according to claim 1. The system of building walls and ceilings based on bridgeless structural composites, compared to the SCS system, is characterized by reduction of linear thermal bridges in single-layer barriers. This system also makes it possible to adjust the thickness of the partition, depending on the needs. In comparison to timber frame technology systems of building walls and ceilings, it is characterized by a lower volumetric weight, as well as better resistance to biological corrosion and moisture. Compared to traditional brick walls, it has a lower weight, and requires much shorter implementation time at the construction site. Moreover, it is possible to be completed at the prefabrication site. In addition, in contrast to sandwich panels with polyurethane foam or expanded polystyrene core, the wall and ceiling installation system based on bridgeless structural composites allows for air diffusion, placing installations inside the wall, and easy installation of window and doors. In addition to the bridgeless construction composite with battens according to PL480892, it eliminates not only linear thermal bridges, but also completely excludes the possibility of point thermal bridges, gives freedom in shaping the structure and its nodes, and also allows continuous production.

[11] The essence of the invention is a bridgeless structural composite intended for construction of walls and ceilings, which is characterized by the fact that it contains external and internal profiles and filling between external and internal profiles, made of a material with thermal insulation properties.

[12] Preferably, the external and internal profiles are made of sheet metal, preferably of galvanized, stainless or acid resistant steel.

[13] Preferably the filling is closed cell polyurethane foam or extruded polystyrene.

[14] Preferably, the bridged structural composite is in the form of a post or a beam.

[15] Preferably, the bridgeless structural composite is used in construction, preferably in in housing and public utilities building.

[16] According to the invention, any configuration of the external and internal composite profiles results in an increase in its stiffness.

[17] According to the invention, filling the composite between external and internal profiles allows for complete elimination of point and linear thermal bridges and reducing the heat transfer coefficient, both the structural composite and the entire partition, for the construction of which such composites were used.

[18] The filling used in the composite according to the invention, being a material with insulating properties, also ensures the cooperation of external and internal profiles during load transfer, increases the stiffness of the element as well as protects profiles against buckling and torsional buckling.

[19] The essence of the invention is also the method of construction of walls and ceilings of buildings using bridgeless structural composites, characterized by the fact that the bridgeless construction composites are placed at a certain axial distance from each other, and that it is realized by transverse connection of bridgeless structural composites located in the wall and ceiling of the building, filling the space between bridgeless structural composites with thermal insulation layer, fastening to bridgeless cladding composites of subsequent cladding layers.

[20] Preferably, the subsequent cladding layers are panels intended for use inside a building or a structural slab together with a floor finishing layer and a floor panel.

[21] Preferably, the subsequent cladding layers are boards intended for use outside the building or between bridgeless structural composites, and a board intended for use outside the building is provided with a spacing structure.

[22] Preferably, the subsequent cladding layers are a structural board together with expanded polystyrene insulation, an expanding layer made of expanded polystyrene, as well as undercoat and undercoat.

[23] Preferably, the construction board is an MFP board.

[24] The subject of the invention and the examples of implementation are shown in the drawings, in which:

Fig. 1. Presents first alternative of bridgeless structural composite in a side view. Fig. 2. Presents first alternative of bridgeless structural composite in the A-A cross- section.

Fig. 3. Presents first alternative profile of bridgeless structural composite profile in a side view.

Fig. 4. Presents first alternative profile of bridgeless structural composite profile in the B-B cross-section.

Fig. 5. Presents second alternative of the first alternative of the bridgeless structural composite, in the side view.

Fig. 6. Presents second alternative of the bridgeless structural composite, in the C- C cross-section.

Fig. 7. Presents second alternative profile of the bridgeless structural composite, in the side view.

Fig. 8. Presents second alternative profile of the bridgeless structural composite, in the D-D cross section.

Fig. 9. Presents the third alternative of the bridgeless structural composite, in the side view.

Fig. 10. Presents the third alternative of the bridgeless structural composite, in the E-E cross-section.

Fig. 11. Presents the third alternative profile of the bridgeless structural composite, in the side view.

Fig. 12. Presents the third alternative profile of the bridgeless structural composite, in the F-F cross-section.

Fig. 13. Presents the fourth alternative of the bridgeless structural composite, in the side view.

Fig. 14. Presents the fourth alternative of the bridgeless structural composite, in the G-G cross-section.

Fig. 15. Presents the fourth alternative profile of the bridgeless structural composite, in the side view.

Fig. 16. Presents the fourth alternative profile of the bridgeless structural composite, in the H-H cross-section.

Fig. 17. Presents the first alternative of a protection wall with bridgeless structural composite in the horizontal section.

Fig. 18. Presents the first alternative of a protection wall with bridgeless structural composite in the vertical l-l section.

Fig. 19. Presents the second alternative of a protection wall with bridgeless structural composite in the horizontal section.

Fig. 20. Presents the second alternative of a protection wall with bridgeless structural composite in the J-J vertical section.

Fig. 21. Presents the vertical section through the module containing: flat roof, external wall and floor. Embodiment No. 1

[25] Fig. 1, Fig. 2, Fig. 3 and Fig. 4, show first embodiment of a bridgeless structural composite 3, in the form of a post. Closed cell polyurethane foam is the filling 2 in the space between profiles. According to this embodiment the external and internal profiles 1 are made of stainless steel and have a characteristic shape similar in cross-section to an unfinished T-bar.

Embodiment No. 2

[26] In the second embodiment shown in Fig. 5, Fig. 6, Fig. 7, Fig. 8, of the bridgeless construction composite 3 in the form of beam, the external and internal profiles 1 are made of galvanized steel and have a characteristic cross-sectional shape, similar to an open rectangular.

Embodiment No. 3

[27] In the third embodiment shown in Fig. 9, Fig. 10, Fig. 11 and Fig. 12, of the bridgeless construction composite 3 in the form of post, the external and internal profiles 1 are made of stainless steel and have a characteristic shape, with visible cross-section of the recesses within the external and internal periphery of the profiles 1. The filling 2 according to this embodiment is closed cell polyurethane foam.

Embodiment No. 4

[28] Fig. 13, Fig. 14, Fig. 15 and Fig. 16 presents a fourth embodiment of the bridgeless construction composite 3 in the form of post. The Filling 2 spaces inside the profile, according to this embodiment, is extruded polystyrene. The external and internal profiles 1, according to this embodiment, are made of stainless steel and have an irregular, a characteristic shape with cross-bends visible in the cross- section to the inside of the external and internal profiles 1. Embodiment No. 5

[29] Fig. 17 and Fig.18 presents a first embodiment of a protection wall with a bridgeless construction composite 3. According to this embodiment, a bridgeless construction composite 3 is attached to the board intended for use inside the building 6. Bridgeless construction composites 3 are arranged in the wall spaced at axial distance of 60 cm. In this embodiment, the space between the bridgeless structural composites is filled with a mineral wool insulation layer 5 with a bulk density of at least 45 kg/m³. For external profiles 1 made of galvanized steel, bridgeless structural composites 3, a board is designed for use outside the building

4 with a thin-layer of fagade finish.

Embodiment No. 6

[30] Fig. 19 and Fig. 20 presents an embodiment of protection wall with bridgeless structural composite 3. According to this embodiment, post-shaped bridgeless structural composite 3 is fitted to the board, finished with PCV flooring, intended for use inside the building 6. Bridgeless structural composites 3 are spaced in the wall at axial distance of 60 cm. In this embodiment, the space between the bridgeless composites is filled with a layer of mineral wool insulation

5 with a bulk density of at least 45 kg/m³. According to this embodiment, between the external steel profile 1 of the bridgeless structural composites 3 and the board intended for use outside the building 4, there is a spacer structure 7. The external steel profiles of 1 bridgeless structural composites, placed in the wall, are connected with a board 4 with a finishing layer intended for outdoor use.

Embodiment No. 7

[31] Fig. 23. presents an embodiment of the module with bridgeless structural composites 3 in the form of a post and a beam. According to this embodiment, the protection wall of the building comprises a board intended to be used inside the building 6, to which the bridgeless structural composites 3 3 in the shape of a post are attached. According to this embodiment, the bridgeless construction composites 3 in the protection wall are attached to ceiling beams with bridgeless construction composites 3 and floor beams with bridgeless construction composites 3. The floor roof of the building, according to this embodiment, consists of undercoat and underlay membrane 8, EPS foam drop layer 9, expanded polystyrene 10, MFP construction board 11, space between bridgeless structural composites 3 filled with thermal insulation 5 and boards for use inside building 6. According to this embodiment, the bottom structural element of the building, comprises a space between bridgeless structural composites 3 filled with thermal insulation 5, a MFP construction board 11, a floor finishing layer 12 and a floor board 13.

[32]

Reference list:

1- External and internal profiles

2- Filling

3- Bridgeless structural composite

4- The board designed for use outside the building

5- Thermal insulation

6- The board designed for use inside the building

7- Spacing structure

8- Surface roofing paper + undercoat

9- EPS foam drop layer

10- Expanded polystyrene insulation

11- Construction board

12- Floor finishing

13- Floor board

Claims

1. Bridgeless structural composite (4) for the construction of walls and ceilings, characterized in that, it contains:

a. Freely shaped external and internal profiles (1),

b. Filling (2) between external and internal profiles (1), made of material with thermal insulation properties.

2. Bridgeless structural composite (3), according to claim 1, characterized in that, the external and internal profiles (1) are made of sheet metal, preferably of galvanized, stainless or acid resistant steel.

3. Bridgeless structural composite (3), according to claim 1, characterized in that, the filling (2) is a closed cell polyurethane foam or expanded polystyrene.

4. Bridgeless structural composite (3), according to claim 1, characterized in that, the composite is in the form of a post or beam.

5. Bridgeless structural composite (3), according to any of the claims 1 to 4, characterized in that, the composite (3) is used in construction, preferably in housing and public utilities building

6. The method of building walls and ceilings of buildings, using bridgeless structural composites (3), according to any of the claims 1 to 5, characterized in that the bridgeless construction composites are placed at a defined axial distance from each other and in that the following is involved in construction:

a. transverse connection of bridgeless structural composites (3) located in the wall and ceiling of the building,

b. the space between bridgeless structural composites (3) is filled with thermal insulation layer (5).

c. attachment to bridgeless structural composites (3) subsequent cladding layers.

7. A method for constructing walls and ceilings of buildings, according to claim 6, characterized in that, the subsequent cladding layers are preferably boards intended for use inside a building (6) or a structural board (11) together with a floor finishing layer (12) and a floor panel (13).

8. A method for constructing walls and ceilings of buildings, according to any one of claims 6 or 7, characterized in that, the further cladding layers are preferably boards intended for use outside the building (4) or between bridgeless structural composites (3) and a board intended for use on outside the building (4) a spacing structure (7) is used.

9. A method for constructing walls and ceilings of buildings, according to any one of claims 6, 7 or 8, characterized in that, the subsequent cladding layers are a structural board (11) with expanded polystyrene insulation (10), an EPS foam drop layer (9) and surface roofing paper and undercoat (8).

10. A method for constructing walls and ceilings of buildings, according to any one of claims 7 or 9, characterized in that, the construction board (11) is preferably an MFP board.