A bricklaying method and an arrangement for the implementation thereof

Abstract

 Method for manufacturing a wall element (1) of bricks, blocks or the like masonry pieces (2,2a,2c) wherein mortar or the like binding material (4) is arranged between the essentially parallelepiped-shaped masonry pieces (2,2a,2c) in order to establish a monolithic construction, wherein said element (1) is assembled on a bearing structure. The lowermost structure (3) of the element is arranged per se so that it integrally with the other parts of the element constitutes the bearing structure of the element. Element (1) assembled by masonry of bricks, blocks or the like essentially parallelepiped-shaped masonry pieces (2,2a,2c) whereby the lowermost portion of the element (1) is arranged to constitute a strong unitary portion (3) of the structure distributing the forces directed against it towards the upper portions of the element.

Description

[0001] The present invention relates to a method of manufacturing a wall element of masonry pieces as defined in the introduction of claim 1. The present invention relates particularly to a method for manufacturing a wall element of bricks, blocks or the like masonry pieces by arranging mortar or the like binding material between essentially parallelepiped-shaped masonry pieces in order to form a monolithic structure wherein the element is assembled onto a bearing structure. The present invention relates also to a structure assembled by masonry of bricks, blocks or the like essentially parallelepiped-shaped masonry pieces.

[0002] Traditionally, a brick or block wall is made on site so that a mason is brought bricks or blocks or the like masonry pieces and mortar to bind these together. The mason arranges the mortar on at least one surface of the masonry piece and presses or knocks the loose piece to the already attached piece so that mortar remains in between the pieces and binds them together. As the height of the structure increases with advancing masonry work, a scaffolding or the like stand is lifted so that the mason can get at the object of labour fairly easily.

[0003] In order to facilitate the work described above and to improve its quality Finnish patent application No. 19991075 discloses an arrangement where mortar is brought through its own weight to a work object where it is spread on an already finished masonry structure. The arrangement in question makes working easier for the mason and masonry work considerably faster.

[0004] From patent specification CH-525 365 a method is known, which method permits actual masonry work to be done with the help of separate scaffolding equipped with a moving work base. In this method the mason remains in the same place all the time whereas the wall to be built moves past his work site in the form of an element supported by a supporting beam moving on said work base. The bricks are brought near the work site and mortar is pumped directly on the surface of the element. The publication also presents an apparatus comprising a supporting beam that can be moved past the mason's work site horizontally and a work site arranged in connection thereto, said work site being horizontally fixed, but vertically movable and further including equipment for feeding bricks and mortar. One of the problems with this arrangement is that the masonry structure assembled on the beam belonging to the apparatus easily breaks during transportation and assembly.

[0005] Element structures where a masonry wall is assembled in industrial conditions are also familiar in structural engineering. In said structures a masonry layer is affixed to the surface of a cast element for better looks and durability. In this case the masonry pieces are generally attached to said element when it is in an essentially horizontal position during the "masonry work". This kind of structure will endure transportation and assembly, but as the properties and functions of the cast wall do not correspond to the masonry structure made on site, the actual masonry portion is usually just a matter of looks without any structural significance or other advantages of a masonry wall.

[0006] One object according to the present invention defined in this application is to provide a more effective masonry arrangement where a masonry structure is manufactured in industrial conditions.

[0007] Another object is to provide an arrangement where an element essentially corresponding to the masonry structure made on site can be transported and assembled at its destination safely and without the risk of breaking.

[0008] One further object is to provide a masonry structure arrangement where a quick assembly and erection of the building frame is attained, still utilizing structures corresponding to an ordinary masonry wall.

[0009] These objects are achieved using arrangements according to the present invention, the characteristics of which are disclosed in the appended claims. Thus, the method according to the present invention is characterized in that the lowermost structure of the element as such is arranged so that it integrally with other parts of the element constitutes a bearing structure of the element. Correspondingly, a characteristic feature of the structure according to the present invention is that its lowermost portion is arranged to constitute a strong integral portion of the element distributing the forces directed against it towards the upper portions of the element.

[0010] The invention will hereafter be described in more detail with reference to the appended drawings, wherein

Figure 1 discloses a general arrangement in accordance with a favourable embodiment of the present invention where the Figure shows a masonry element suspended in a lifting arrangement for transfer or assembly,

Figure 2 is a sectional side view disclosing how the element according to Figure 1 settles on a prefabricated footing and how a pre-cast floor slab can be fitted to the wall element,

Figure 3 is a sectional view from above disclosing a joint between two wall elements in a corner of the building, and

Figure 4 in a corresponding way discloses the attachment of a partitional wall, suitably an element in accordance with the present invention, to a wall built up of elements in accordance with the present invention.

[0011] A wall element in accordance with the present invention disclosed in Figure 1 under reference 1 comprises a wall structure composed of separate masonry pieces 2, 2a, 2b, 2c constituting an integral monolithic structure. In the favourable embodiment disclosed in Figure 1 the lowermost integral part of the structure is a separately formed supporting beam 3. Said beam distributes the forces directed to it especially during the handling process of the element towards the upper portions thereof. A layer of mortar 4a has been used to attach the lowest actual masonry piece layer 2c to said supporting beam 3 distributing the supporting strength evenly to the element structure.

[0012] Said masonry pieces 2, 2a, 2b and 2c of the element have, in a way known per se in traditional masonry, been joined together with a layer of mortar 4 laid between the pieces. The sectional projections 2, 3 and 4 disclose that the masonry structure as such has been favourably effected as a double structure with a layer of polyurethane or some other suitably rather hard insulation material 9 placed in between the masonry piece layers. Apart from having an insulating effect said layer 9 also acts to strengthen the structure at the same time.

[0013] Figure 1 discloses that a hoisting arrangement favourably is constructed so that lifting handles 5 have been brought down to the lowermost structure, suitably down to said supporting beam 3. These lifting handles favourably consist of bars, cables or chains fixed temporarily or in a detachable way and their upper end favourably brought through a lifting boom 6 extending over the length of structure 1 to a lifting loop 7. Figure 1 further discloses openings 8 made in the structure already in the masonry phase to provide windows, doors and the like.

[0014] Element 1 is suitably manufactured by applying the traditional masonry method where mortar is brought to the working site following the arrangement disclosed in Finnish patent application No. 19991075 so that mortar is induced to flow down to the object of work. However, the element per se is favourably manufactured elsewhere than on the building site, i.e. suitably in industrial conditions and can be delivered to the site dry and in first-class shape. Thus the arrangement in accordance with the present invention considerably decreases the storing of goods on the work site.

[0015] Figure 2 discloses that a lowest masonry structure 1a in accordance with the present invention favourably is assembled on a footing 10 known per se and established as the lowermost structure of a building. Guiding pins 11 facilitating the alignment of the element have suitably been cast on said footing 10. Said guiding pins 11 facilitate the assembly of the lowermost structure onto said footing 10 and ensure a right alignment. A layer of assembly mortar 4a made for example on the work site is spread in between the footing 10 and the structure 1a to fix the structure 1a to said footing 10. In some cases corresponding alignment arrangements have been effected also to facilitate the mutual alignment of two overlapping elements 1, 1a (not shown).

[0016] In the embodiment according to Figure 2 a beam or a beam block 12 at the top of each element 1, 1a is suitably fitted to the upper edge of the structure. Said beam or beam block 12 favourably comprises a structural casting 13 supporting e.g. a floor slab 14 or the roof structure of the building, which casting 13 is effected already at the plant. In addition, the attachment of the slab 14 to the wall structure can be ensured, if necessary, with a grouting 13a.

[0017] In accordance with Figure 2 one or several other structures 1 can be assembled on the lower element 1a. Elements 1, 1a, disclosed in Figure 2, have been effected as a double structure with insulation material 9 fitted in between the parallel masonry pieces 2a and 2b. This way the bearing beam structure 3a of the upper element 1 is also favourably effected as a double structure so that the beam 3a consists of two adjacent beam portions 3a' and 3a'' with insulation material 9 in between them in the same way as above. Suitably, adjacent beam portions 3 a' and 3 a'' have been joined together by stirrups 15 suitably made of stainless steel which stirrups 15 extend through the insulation material 9 and hold said portions 3a' and 3a'' of the bearing beam 3a in place.

[0018] Especially when the lowermost bearing beam 3, 3a per se is composed of masonry pieces, like favourably of lightweight aggregate concrete blocks or the like, a shoe 16 of e.g. profile steel extending all the way through the lower edge of the beam and suitably comprising portions 16a bent upward to increase bending rigidity, is favourably arranged to further strengthen the load-bearing capacity and rigidity of the beam 3, 3a or its portions 3a', 3a''. A reinforcement 17 is placed between the layers of brick, block or the like masonry pieces as such, especially in the mortar layer 4, in a way known per se. Furthermore, the bearing beam 3, 3a, at least, is usually equipped with an additional reinforcement 17a. As shown in Figure 2, the corresponding structure can also be applied in a case where the bearing lowermost beam 3, 3a is effected for example as concreting.

[0019] Figures 3 and 4 disclose how the masonry structures according to the present invention are favourably attached to each other in the corners of the building and, correspondingly, how a partitional wall or the like can be attached to the element according to the present invention. To enable the attachment protruding ribbed bar portions 18 have favourably been established on the edges of the structure. Thus, adjacent elements can provisionally be joined to each other by welding together these ribbed bar portions 18 and/or by using an upright reinforcement structure as defined below. The favourably protruding ribbed bar portions 18 consist of extensions 17 of the reinforcement of the wall, particularly favourably bent back to the mortar joint 4 between the masonry pieces 2 of each element to constitute the end of the protruding portion 18. This way a series of protruding loops 18a are effected on the edges of the element. For adjacent structures 1 and 1b, said loops 18 have, in the manufacturing phase, been arranged mutually to form a tunnel 19 in which a vertical reinforcement 20 can favourably be slipped.

[0020] In the corner portions of the element the joint is finished by arranging extensions 9a of the insulation 9 in such a way that the insulation 9 runs functionally continuing through the structure also at the corner portion. According to one embodiment of the present invention this is effected so that the insulator 9 of the actual element 1, 1b is left slightly retracted at the edge of the element, thus leaving a cleft wherein the suitably fairly hard insulation piece 9a can be pushed. This is disclosed in Figure 3 under reference number 9b. After this at least an outer casting mould piece 21 is fitted around the corner and suitably also an inner casting mould piece 21a pulled tight together using anchorage devices 22 and mould clamps (not shown) known per se. This kind of moulds 21, 21a can be kept ready at the work site, and when the mould 21, 21a has been assembled the upright cavities thus developed are filled on the work site e.g. by casting concrete or other hardening material into them. This is generally presented in the figure under reference number 23.

[0021] Figure 4 discloses how a partitional wall 1c suitably manufactured as an element according to the present invention can favourably be attached to the element in a way corresponding to a corner joint. Then a cavity 24 is favourably developed in the cross structure 1 already in the manufacturing phase and the attachment and cast can be effected in this cavity by following the above-presented principles.

[0022] The arrangement presented above provides many considerable advantages. For one thing, work done on the work site and thus in work site conditions is reduced when the walls of the building are delivered to the work site as ready-made elements. Thus quality is often improved, because a major part of the work can be done in industrial conditions. However, the nature and appearance of a masonry wall made on site, usually experienced as positive, are maintained. The assembly of the elements on a normal-sized work site of a one-family house takes place at the speed of one floor per day. Due to the construction of intermediate floors as well as brim and joint castings, the assembly of the next floor is usually not possible to perform immediately, but only approximately one week from the assembly of the previous floor. The installation of a normal-sized one-family house including intermediate floors from pedestal to rooftop is, however, possible in three weeks at such a working pace.

[0023] It is generally possible and appropriate to install doors and windows already at the plant and to design and finish the frames of the doors and windows at the same time. It is also possible to perform, for example, the smoothing of the walls already at the plant.

[0024] Above, some favourable embodiments of the arrangement according to the present invention have been disclosed, but it is clear to a person skilled in the art that arrangements according to the present invention also can be effected in connection with other structures. For example balcony slabs, columns or breast-work elements can be effected correspondingly and also, e.g., whole bay window elements in which case these construction portions are assembled in connection with actual wall installations following the same procedures.

Claims

1. A method for manufacturing a wall element (1, 1a, 1b, 1c) of bricks, blocks or the like masonry pieces (2, 2a, 2b, 2c) wherein mortar or the like binding material (4) is arranged between the essentially parallelepiped-shaped masonry pieces (2, 2a, 2b, 2c) in order to form a monolithic construction, which element (1, 1a, 1b, 1c) is assembled to the bearing structure, characterized in that the lowermost structure (3, 3a) of the element is arranged, per se, so that it constitutes, integrally with the other parts of the element, the bearing structure of the element

2. A method according to claim 1, characterized in that the bearing structure (3, 3a) is arranged to comprise a supporting beam to which the lowest masonry pieces (2c) of the element are attached so that the element structure (1, 1a, 1b, 1c) assembled of the masonry pieces (2, 2a, 2b, 2c) on the beam (3, 3a) forms a uniform monolithic entity together with the supporting beam (3, 3a).

3. A method according to claim 1 or 2, characterized in that the supporting beam (3, 3a) is arranged to comprise two parallel beam portions (3a', 3a'') between which insulation material (9) has favourably been arranged, suitably so that there is a stirrup arrangement (15) between these beam portions (3a', 3a'') to secure the element (1, 1a, 1b, 1c) is held together.

4. A method according to one of claims 2 to 3, characterized in that lifting handles (5) are established in the supporting beam (3, 3a) for the lifting, transportation and assembly of the structure (1, 1a, 1b, 1c).

5. A method according to any one of claims 1 to 4, characterized in that a beam-like portion is established on the topmost edge of the structure (1, 1a, 1b, 1c) favourably by fitting a concrete beam (13) into a beam block (12) to support the bearing structures (14) of the next floor of the building.

6. A method according to any one of claims 1 to 5, characterized in that the element (1, 1a, 1b, 1c) is provided, already during the manufacturing process, with openings (8) required in the final wall structure for, e.g., doors and windows .

7. A method according to any one of claims 1 to 6, characterized in that horizontal steel structures (18) are fitted to the ends of the elements (1, 1a, 1b, 1c) in connection with masonry, which horizontal steel structures (18) are used for connecting the elements (1a, 1b) adjacent either straight or forming a corner, suitably by welding, which joining is favourably made on the work site by filling the joint portion with concrete or a corresponding hardening material (23), suitably so that the space (24) between the elements is defined by a special mould structure (21, 21a) particularly surrounding the horizontal steel structures, said mould structure being favourably kept in place using form lock and anchor arrangements (22) known per se at which protruding loops (18a) are fitted at the ends of said horizontal steel structures, which allows a guiding reinforcement (20) to be vertically slipped through said loops (18a) of overlapping horizontal steel structures (18) of the adjacent elements (1a, 1b) before casting, favourably so that the elements (1a, 1b) by these means temporarily are kept in their approximate position during the assembly phase.

8. An element (1, 1a, 1b, 1c) assembled by masonry of bricks, blocks or the like essentially parallelepiped-shaped masonry pieces (2, 2a, 2b, 2c), characterized in that the lowermost portion of said element (1, 1a, 1b, 1c) is arranged to constitute a strong unitary portion (3, 3a) of the element, distributing the forces directed to it towards the upper portions of the element.

9. An element according to claim 8, characterized in that the lowermost masonry piece row of the element (1, 1a, 1b, 1c) is replaced by a horizontally uniformly continuous supporting beam (3, 3a).

10. An element according to claim 8 or 9, characterized in that the supporting beam (3, 3a) comprises several portions so that two parallel beams (3a', 3a'') have been joined together by transversal stirrups (15).

Drawing