Wall structure and method for manufacturing a wall structure

(19)

(11)

EP 2 639 372 A1

(12)	EUROPEAN PATENT APPLICATION

(43)	Date of publication:
	18.09.2013 Bulletin 2013/38

(21)	Application number: 13158523.4

(22)	Date of filing: 11.03.2013

(51)

International Patent Classification (IPC):

E04B 1/61^(2006.01)
E04B 2/02^(2006.01)

E04B 2/08^(2006.01)

(84)	Designated Contracting States:
	AL AT BE BG CH CY CZ DE DK EE ES FI FR GB GR HR HU IE IS IT LI LT LU LV MC MK MT NL NO PL PT RO RS SE SI SK SM TR
	Designated Extension States:
	BA ME

(30)

Priority:

12.03.2012 FI 20125260

(71)	Applicant: Finnfoam Oy
	24100 Salo (FI)

(72)	Inventor:
	Nieminen, Henri 24130 Salo (FI)

(74)	Representative: Turun Patenttitoimisto Oy
	P.O. Box 99 20521 Turku 20521 Turku (FI)

(54)	Wall structure and method for manufacturing a wall structure

(57) A wall structure and a method for manufacturing a wall structure, which wall structure comprises load bearing frame beams (1, 1`), fixing profiles (2, 2`) that are essentially horizontal with respect to the frame beams (1, 1`) and fixed to the frame beams (1, 1`), and wall plates (3, 3`, 4, 4`), said wall plates comprise a first planar surface layer, a second planar surface layer and a heat insulating core layer between the surface layers. The wall plates (3, 3`, 4, 4`) in the wall structure are arranged in the structure in such a manner that the fixing profile (2, 2`) is in the joint between two wall plates (3, 3`, 4, 4`) arranged against one another one on top of the other.

Description

Object of the invention

[0001] An object of the invention is a wall structure and a method for manufacturing a wall structure as well as the use of a wall structure in industrial or storage halls according to the preambles of the enclosed independent claims.

Background of the invention

[0002] Typically storage halls, industrial halls and other similar hall constructions comprise a load bearing frame beam structure, into which wall elements have been attached. Frame beams are typically manufactured from steel, laminated timber or concrete. Wall elements are dimensioned to fit the frame structure, so that the elements can be attached to the frame beams of the frame structure. Such a structure requires designing and manufacturing elements that fit to the frame structure and the lifting of the elements into their place is usually laborious and requires lifting equipment at the construction site.

Object and description of the invention

[0003] An object of the present invention is to reduce or even eliminate the above-mentioned problems appearing in prior art.

[0004] An object of the present invention is to provide a wall structure that is quick and easy to build and to mount by using standard sized wall plates and standard sized horizontal fixing profiles.

[0005] A particular object of the invention is to present a wall structure for use in the outer walls of storage halls, industrial halls and other similar buildings with a frame beam structure.

[0006] To attain this purpose, the wall structure and method according to the invention is primarily characterised in what is presented in the characterising parts of the independent claims.

[0007] The other, dependent claims present some preferred embodiments of the invention.

[0008] A typical wall structure according to the invention comprises

load bearing frame beams, the height of which defines the height of the wall structure in the vertical direction,
fixing profiles which are attached to the frame beams, and which fixing profiles are essentially horizontal with respect to the height direction of the wall structure
wall plates forming the wall surface of the wall structure, which wall plates comprise a first planar surface layer, a second planar surface layer and a heat insulating core layer between the surface layers, wherein the compression strength of the core layer is at least 10 kPa,
and in which wall structure the wall plates have been arranged in the structure in such a manner that the fixing profile is in the joint between two wall plates arranged one on top of the other and the fixing profile is, in the horizontal direction of the wall structure, formed of one or more parts connected to each other, in such a manner that the fixing profile is uniform on the whole horizontal direction of the wall structure, from a first edge of the wall structure to a second edge of the wall structure.

[0009] In a typical method for manufacturing a wall structure

the load bearing frame beams of the wall structure are arranged into place, which frame beams define the height of the wall structure in the vertical direction, and
wall plates forming the wall surface of the wall structure and fixing profiles are arranged into the wall structure in such a manner that the fixing profiles are attached to the frame beams in an essentially horizontal direction with respect to the height direction of the wall structure, whereby a uniform fixing profile in the horizontal direction of the wall structure is formed from a first edge of the wall structure to a second edge of the wall structure, and in such a manner that the fixing profile remains in the joint between two wall plates arranged against one another one on top of the other in the height direction of the wall structure.

[0010] The wall structure according to the invention allows building a wall surface on a frame beam structure from standard sized wall plates irrespective of the distance between the load bearing frame beams. In other words, the wall plates used in the wall structure do not need to be manufactured into the size defined by the distance of the frame beams, since the wall plates are not fixed to the frame beams, but the wall plates are securely fixed to the wall structure by fixing profiles that stiffen the structure. Therefore, a wall structure according to the invention may comprise, between the frame beams, several wall plates connected one after another. Typically in the wall structure according to the invention, standard sized sandwich-plate elements are used as wall plates, whereby for the wall structures there is no need to separately dimension and manufacture wall plates in different sizes. If need be, standard sized wall plates can be easily cut shorter on the construction site, if the dimensions of the wall structure so require.

[0011] The wall plates used in the wall structure according to the invention are typically so-called sandwich-plate elements that have the necessary stiffness, whereby they stand the wind load subjected to the wall structure.

[0012] Sandwich-plate elements comprising a first planar surface layer, a second planar surface layer and a core layer arranged between the surface layers are used in the wall structure according to the invention. In a wall structure according to the invention the core layer of the wall plates is any heat insulation material suitable for the purpose, which has a compression strength of at least 10 kPa (according to the standard EN 826), in order for the wall plate to have sufficient stiffness and strength properties.

[0013] In one embodiment of the invention, the core layer of the wall plate is made of foamed plastic, such as extruded polystyrene (XPS), expanded polystyrene (EPS) or polyurethane (PUR/PIR). The first and second planar surface layer is typically of sheet metal, sheet steel, concrete, foamed concrete, plywood, reinforced plastic or a combination of grout and reinforcing mesh.

[0014] In one preferred embodiment of the invention, the core layer of the wall plate is extruded polystyrene and the surface layers are made of a combination of grout and reinforcing mesh. Typically the surface layer is made of concrete grout that has been reinforced with a glass fiber mesh. Alternatively a carbon fiber mesh or other fiber mat or other similar material having a good tensile strength may be used with the concrete grout. The plate structure reinforcing glass fiber mesh or similar is arranged on essentially the whole surface area of the plate in at least one layer in such a manner that the mesh remains inside the concrete grout layer. Such coated XPS-plates are especially suitable for use as wall plates of a wall structure, since the water vapour resistance of XPS is larger than that of a glass fiber reinforced grout layer, whereby the largest water vapour resistance of the structure is at the heat insulating material, i.e. the cellular structure of the XPS functioning as the core layer has the largest water vapour resistance in the structure. The cellular structure of the XPS-plate is closed, so no water can pass through the plate. Moreover, a grout layer combined with a reinforcing mesh is an economical material and a good foundation for for example plastering.

[0015] The thickness of the wall plate used in a wall construction according to the invention is typically 50-500 mm, more typically 80-400 mm and most typically 100-250 mm.

[0016] The wall plate used in the wall structure usually has a rectangular shape, which comprises two parallel planar large surfaces, and a first and second parallel long side edge and parallel first and second short side edge, which are perpendicular to the long side edges, delimiting the surfaces. The length of the long side edge of the wall plate is typically 600 - 6000 mm, more typically 1200 - 4000 mm, and even more typically 1200 - 2600 mm. The length of the short side edge of the wall plate is typically 300 - 1500 mm, more typically 500 - 1300 mm, even more typically 600 - 1200 mm.

[0017] In one preferred embodiment of the invention, wall plates are used in which the length of the long side edges are 2400-2600 mm and the length of the short side edges is 600 mm.

[0018] The basic structure of a wall structure according to the invention is a load bearing frame beam structure, typically a frame structure of laminated timber, steel and concrete or steel. In one preferred embodiment of the invention, the wall structure is used in structures in which the distance between the load bearing frame beams is about 3-8 m.

[0019] The wall plates are arranged to the wall structure via a fixing profile that stiffens the structure, which fixing profiles are fixed to the load bearing frame beams. The fixing profile according to the invention is a separate part used in the wall structure, into which the wall elements can be arranged. The fixing profile is fixed to the frame beams for example with glue or with separate fasteners, such as screws. The fixing profiles are essentially horizontal with respect to the height direction of the wall structure and they extend in the horizontal direction of the wall structure from a first edge of the wall structure to a second edge of the wall structure. In the height direction of the wall structure, fixing profiles are arranged in the horizontal joints of the wall plate layers in such a manner that the profiles extend essentially over the whole width of the wall structure. Fixing profiles are arranged in the horizontal joints between wall plate layers depending on the distance between the frame beams of the wall structure and the wind load subjected to the wall structure. A fixing profile is therefore not required in each horizontal joint, but instead a part of the wall plates can have been arranged tightly against one another only via a tongue and groove joint. A fixing profile is thus arranged either into a part or all of the horizontal joints of the wall plates.

[0020] The shape and size of the fixing profile can also vary depending on what kind of wind load the wall is designed for. Typically the fixing profile is of standard size and it can be extended, in other words, it does not need to fit the beam distribution of the frame structure. Typically, a single fixing profile is a 3000-6000 mm long longitudinal profiled piece, most typically about 4000 mm long standardized length profiles are used, that can be attached to each other mechanically or with glue. The fixing profile can have the shape of for example a Z-profile or U-profile. The longitudinal edges of the fixing profile may comprise turned flanges. In a wall structure according to the invention the fixing profile is, in the horizontal direction of the wall structure, formed of one or more pieces, which pieces are attached to each other to form a uniform fixing profile for the whole width of the wall structure. The uniform fixing profile according to the invention continues over the connection points of the plates, whereby the resistance of the connection structure of the wall plates against wind loads is enhanced and at the same time the whole wall structure is made strong. In one embodiment of the invention, in which two or more profiles are attached to each other to form a profile that has the width of the whole wall structure, the fixing profiles are fixed to each other via a connective element or alternatively two or more fixing profiles are arranged partly overlapping to form a longer, uniform fixing profile.

[0021] The fixing profile can be manufactured in any suitable material for this use. The fixing profile is typically manufactured of metal, such as sheet metal or stainless steel sheet. The thickness of the fixing profile is typically about 0.2-3 mm. In one embodiment of the invention, the fixing profile is a thermal break beam made of steel sheet that typically comprises side plate perforation.

[0022] In one embodiment of the invention, the side edges of the wall plates arranged in the vertical direction one on top of the other that are arranged against each other comprise tongues and grooves, or they are bevelled to fit each other, so that the side edges position tightly one against the other in the wall structure. The fixing profile remains inside the joint between the wall plates, when the plates are positioned tightly one against the other in the finished wall structure.

[0023] In one preferred embodiment of the invention, the long side edges of the wall plates are essentially horizontal with respect to the height direction of the wall structure. In this case, the long side edges of the wall plates arranged one on top of the other in the height direction of the wall structure comprise tongues and grooves arranged to fit one another or the edges are belevelled to fit one another in such a manner that the fixing profile is arrangeable inside the joint. Preferably the side edges of the wall plates that are horizontally positionable in the wall structure are half-grooved, that is, the side edge of the wall plate comprises a step-wise form, in which a tongue (male tongue) is formed on one side and a groove (female groove) is formed on the other side of the side edge, into which groove the tongue (male tongue) of the plate next to it is positioned, to form a tight joint.

[0024] In one embodiment of the invention, the wall plates are arranged, in the horizontal direction of the wall structure, in such a manner that the male groove arranged on the upper edge of a lower wall plate in the wall structure is against the frame beams. In this case the male groove arranged on the lower edge of the wall plate to be arranged on top of this plate is arranged on that edge of the plate that is on the outer surface side of the wall structure. Thereby the joint between wall plates that is on the side of the frame beams is higher that the joint between the wall plates that is on the outer surface side of the wall structure.

[0025] The long side edges of the wall plate are typically half-grooved so that the height of the tongue and groove is about 10 - 30 mm. The thickness of the tongue and groove can vary between 3 and 80 mm, depending on the thickness of the plate of the wall plate. The thicknesses and heights of the tongues and grooves are designed such that the fixing profiles can be arranged inside the joint between the plates, in such a manner that the tongues and grooves can still be positioned tightly one against the other.

[0026] In one embodiment of the invention the fixing profiles are attached to the frame beams with fasteners at the tongue and groove of the wall plates, whereby the fastener remains inside the tongue-and-groove joint between two wall plates in the finished wall structure. Thus the through-holes for the fasteners do not need to be separately sealed with sealing compound.

[0027] As has been described above, the edges of the wall plates to be positioned one against the other are shaped such that the fixing profile is arrangeable inside the joint formed. Moreover, a groove or grooves for the fixing profile can be cut in the core structure of the wall plates, if the form of the profile so requires. Therefore in one preferred embodiment of the invention a groove or grooves into which the fixing profile is arrangeable have/has been arranged in the core layer of the side edge of the wall plate that is horizontal in the wall structure. In other words, the lower side, in the height direction of the wall structure, of a fixing profile and the upper edge of a wall plate to be arranged against it are essentially identical in shape, and correspondingly the upper side of the fixing profile and the lower edge of a wall plate to be arranged against it are essentially identical in shape. Thereby the fixing profile arranged between the wall plates remains inside the tongue and groove joint in the finished wall structure and the form of the fixing profile enables the fixing into the profile of the lower edge of the wall plate layer arrrangeable on top of it.

[0028] In a wall structure according to the invention there are wall plates arranged in the vertical direction one on top of the other, which wall plates are at their edges arranged tightly one against the other. Stiffening fixing profiles that extend in the horizontal direction from a first edge to a second edge of the wall structure are arranged into at least a part of the horizontal joints between the wall plates in the height direction of the wall structure. In one preferred embodiment of the invention, the fixing profile is arranged in all horizontal joints of the wall plates. When building the wall structure, horizontal layers of wall plates and fixing profiles in the horizontal joints of the wall plates are arranged into the wall structure. A wall plate layer is formed by arranging wall plates having the same height one after the other tightly against each other over the whole width of the wall structure. A fixing profile extending over the whole width of the wall structure is arranged on the upper edge of the wall plate layer. The fixing profile is fixed to the load bearing frame beams with glue or with separate fasteners, such as screws. The fixing profile is typically fixed to the frame beams in such a manner that the fastener goes through the tongue and groove of the upper edge of wall plate below the fixing profile, which tongue and groove is positioned against the frame beam. Since the wall plates are attached to the frame beams with fasteners at the tongue and groove, also the fastener remains inside the tongue-and-groove joint between two wall plates in the finished wall structure. When the fixing profile is fixed to the frame beams, a new layer of wall plates is arranged over the fixing profile, over the whole width of the wall structure. The lower edge of these wall plates is arrangeable in a tight manner with the upper edge of the wall plate layer located underneath it in such a manner that the fixing profile remains inside the joint formed. A fixing profile is again arranged on the upper side of this wall plate layer and the forming of the wall structure is continued in this manner over the whole height of the wall structure.

[0029] The corners of the building can be easily made tight by for example forming the edges of the plates to be positioned against the edges of the wall structure according to the invention to fit one another. The edges of the plates can be sawn for example at an angle of 45 degrees, whereby when the wall plates are arranged against each other also the corner between two wall structures is made tight. In addition, for example a ready-made corner mesh piece may be used in the corner, if the wall surface is plastered.

[0030] In the horizontal direction of the wall structure according to the invention, the wall plates have been arranged consecutively in such a manner that the side edges of the wall plates have been arranged against one another. Typically the side edges of the wall plates are in contact with each other via a tongue and groove joint. Typically wall plates are arranged, in the horizontal direction, consecutively in such a manner that the short side edges of the wall plates are against one another.

[0031] In one embodiment of a wall structure according to the invention, a sealant has been arranged in the joint between the wall plates, such as a butyl compound or another similar sealant. The sealant can be arranged in both the horizontal and the vertical joints.

[0032] In one preferred embodiment of the invention, the joints between the wall plates in the vertical direction are arranged at essentially different positions in the layers arranged one on top of the other.

[0033] The wall structure according to the invention is suitable for different frame structures, since the combination of fixing profiles and wall plates is easily positionable into the frame beams irrespective of the distance between the frame beams. This lowers the foundation costs of the building.

[0034] Suitable uses for the wall structure according to the invention are, i.a., different industrial and storage halls.

[0035] The wall structure according to the invention can be used in new builds or in renovations, when it is required to form a new wall surface on an existing frame structure.

Short description of the drawings

[0036] In the following, the invention will be described in more detail with reference to the appended drawings, in which

Figure 1: illustrates a wall structure according to the invention,
Figure 2: illustrates, as a side view, a wall structure according to the invention and an enlargement of fixing of the wall plates to the frame beam with a fixing profile,
Figure 3: illustrates, as side views, some alternative structures of the fixing profiles used in the wall structure according to the invention, and
Figures 4 and 5: illustrate some ways of attaching two different fixing profiles to each other.

Detailed description of the invention

[0037] Figure 1 illustrates a wall structure according to a preferred embodiment of the invention, which comprises load bearing frame beams 1, 1' and wall plates 3, 3', 4, 4' forming the wall surface of the wall structure. In the Figure, the long side edges of the wall plates 3, 3', 4, 4' are positioned essentially horizontally with respect to the height direction of the wall structure. In the horizontal direction of the wall structure, several wall plates are arranged consecutively and in the height direction of the wall structure, wall plates are arranged one on top of the other.

[0038] Figure 2 illustrates, as a side view, a wall structure according to the invention, which has wall plates 3, 3', 4, 4' arranged one on top of the other in the height direction of the wall structure. Fixing profiles 2, 2' that are fixed to the frame beam 1 have been arranged in the joints between wall plates in the height direction of the wall structure. As can be seen in the enlargement of the Figure, the fixing profile 2 arranged in the joint between wall plates 3, 4 arranged one on top of the other remains inside the tongue and groove joint between the wall plates, and the fixing profile 2 is fixed to the frame beam 1 with a fastener 6.

[0039] Figure 3 illustrates examples of fixing profiles 2 that can be used in a wall structure according to the invention. The side edges of the wall plates 3, 4 to be arranged one on top of the other comprise tongues and grooves that fit each other and that position tightly one against the other. If need be, additionally a groove or grooves 7, 7' into which the fixing profile 2 can be arranged, can be formed on the side edges of the wall plates. As is shown in Figure 3, the fixing profile can have the shape of for example a Z-profile or U-profile.

[0040] In one embodiment of the invention, the option C of the fixing profile is used, since in this option the profile 2 is as simple in form as possible and requires only grooves 7, 7' on the second side edge of the wall plates for positioning the fixing profile 2. Grooves 7, 7' are formed in the core layer of the wall plate.

[0041] Figures 4 and 5 illustrate some ways of attaching two different fixing profiles to each other, in order to form a uniform fixing profile on the whole width of the wall structure. In Figure 4, the fixing profiles 2, 2' are attached to each other by a separate extension element 8, typically an extension plate. In the structure illustrated in Figure 5, the fixing profiles 2, 2' are arranged to partly overlap, whereby a longer uniform fixing profile is obtained from two or more fixing profiles.

[0042] The invention is not intended to be limited to the above-presented exemplary embodiments, but the intention is to apply the invention widely within the inventive idea defined by the claims defined below.

Claims

1. A wall structure comprising

- load bearing frame beams (1, 1'), the height of which defines the height of the wall structure in the vertical direction,

- fixing profiles (2, 2') which are attached to the frame beams (1, 1'), and which fixing profiles (2, 2') are essentially horizontal with respect to the height direction of the wall structure,

- wall plates (3, 3', 4, 4') forming the wall surface of the wall structure, which wall plates comprise a first planar surface layer, a second planar surface layer and a heat insulating core layer between the surface layers, wherein the compression strength of the core layer is at least 10 kPa,
and in which wall structure the wall plates (3, 3', 4, 4') have been arranged in the structure in such a manner that the fixing profile (2) is in the joint between two wall plates (3, 4) arranged one on top of the other and the fixing profile (2, 2') is, in the horizontal direction of the wall structure, formed of one or more parts connected to each other, in such a manner that the fixing profile is uniform on the whole horizontal direction of the wall structure, from a first edge of the wall structure to a second edge of the wall structure.

2. A wall structure according to claim 2, characterised in that in the wall plate (3, 3', 4, 4')

- the core layer is extruded polystyrene (XPS), expanded polystyrene (EPS) or polyurethane (PUR/PIR), and

- the first and second planar surface layer is of sheet metal, concrete, foamed concrete, plywood, reinforced plastic or a combination of grout and reinforcing mesh.

3. A wall structure according to claim 1 or 2, characterised in that the core layer of the wall plates (3, 3', 4, 4') is extruded polystyrene and the surface layers are made of a combination of grout and reinforcing mesh.

4. A wall structure according to any of the preceding claims, characterised in that the side edges of the wall plates (3, 3', 4, 4') arranged in the vertical direction one on top of the other that are arranged against each other comprise tongues and grooves, which tongues and grooves are arranged to each other and inside which tongue and groove joint the fixing profile (2, 2') is arrangeable in such a manner that the wall plates (3, 3', 4, 4') are tightly against each other.

5. A wall structure according to any of the preceding claims, characterised in that a groove or grooves (7, 7') into which the fixing profile is arrangeable have/has been arranged in the core layer of the side edge of the wall plate that is horizontal in the wall structure.

6. A wall structure according to any of the preceding claims, characterised in that the long side edges of the wall plates (3, 3', 4, 4') are essentially horizontal in direction with respect to the height direction of the wall structure.

7. A wall structure according to any of the preceding claims, characterised in that the fixing profile (2, 2') is made of metal, such as of sheet metal having a thickness of 0.2-3 mm.

8. A wall structure according to any of the preceding claims, characterised in that in the wall plates have been arranged consecutively in the horizontal direction of the wall structure in such a manner that the side edges of the wall plates have been arranged against one another.

9. The wall structure according to any of the preceding claims, characterised in that a sealant has been arranged in the joint between the wall plates.

10. A method for manufacturing a wall structure, characterised in that in the method

- the load bearing frame beams (1, 1') of the wall structure are arranged into place, which frame beams define the height of the wall structure in the vertical direction, and

- wall plates (3, 3', 4, 4') forming the wall surface of the wall structure and fixing profiles (2, 2') are arranged into the wall structure in such a manner that the fixing profiles (2, 2') are attached to the frame beams in an essentially horizontal direction with respect to the height direction of the wall structure, whereby a uniform fixing profile in the horizontal direction of the wall structure is formed from a first edge of the wall structure to a second edge of the wall structure, and in such a manner that the fixing profile (2) remains in the joint between two wall plates (3, 4) arranged against one another one on top of the other in the height direction of the wall structure.

11. A method according to claim 10, characterised in that the side edges of the wall plates (3, 3', 4, 4') arranged against each other comprise tongues and grooves, which tongues and grooves are arranged to each other and inside which tongue and groove joint the fixing profile (2, 2') is arrangeable in such a manner that the plates are tightly against each other.

12. A method according to any of the preceding claims 10 or 11, characterised in that wall plates (3, 3', 4, 4') are arranged into the wall structure, which wall plates comprise

- a first and a second planar surface layer, which surface layers are made of a combination of grout and reinforcing mesh, and

- a core layer between the surface layers, made of extruded polystyrene (XPS).

13. A method according to any of the preceding claims 10-12, characterised in that the long side edges of the wall plates (3, 3', 4, 4') are arranged essentially in the horizontal direction with respect to the height direction of the wall structure.

14. A method according to any of the preceding claims 10-13, characterised in that joint material is arranged in the joints between the wall plates (3, 3', 4, 4').

15. An industrial or storage hall, the walls of which comprise a wall structure according to any of the claims 1-9.

Drawing

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