OBJECT OF THE INVENTION
[0001] The invention can be included in the technical field of construction, specifically
in the field of construction systems and elements.
[0002] The object of the present invention relates to a constructive element which can be
manufactured in a particularly fast and efficient manner, and also provides precision
in its finishing.
BACKGROUND OF THE INVENTION
[0003] There are plenty of precedents in the field of construction systems and of the materials
used, as it is public knowledge that, in the most developed countries, activities
related to construction constitute the main engine of the economy.
[0004] In any case, the higher the degree of development of a country, the higher the scarcity
of labour force and, consequently, solutions which permit the saving of labour force
are welcome, whether by mechanizing the construction processes, or by improving the
performance of all the activities which take part in construction. Therefore, there
is the trend of referring certain processes to integral manufacturing plants for prefabricated
elements which can be easily and efficiently used in the civic work where they are
required. On the other hand, development itself further involves compliance with ever
more demanding regulations due to reasons of security, comfort and respect for nature.
[0005] Prefabricated elements nowadays play central roles in the construction of all buildings,
whether they be for the structural work or for the complementary formation works such
as roofs, retaining walls or partitions of all types.
[0006] This use of prefabricated elements normally requires complementary operations for
surface finishing or for the formation of grooves intended to house the usual water,
electricity, television wiring or other similar systems. In that sense, lightweight
material panels are known which have built-in pipes, cable trays, connection boxes
and other complements which facilitate the building work, as for example described
in
EP 0757137.
DESCRIPTION OF THE INVENTION
[0007] The object of the present invention is constituted by the provision of a constructive
element of the wall or partition type in accordance with claim 1, which can be built
with greater efficiency, speed and perfection in the finishing than those constructive
elements described in the state of the art.
[0008] Therefore a constructive element is described which comprises a construction setting
material arranged inside a permanent formwork, wherein said permanent formwork is
adapted in its geometry to remain solidly attached to the construction material during
the setting of said construction material.
[0009] The permanent formwork is constituted by a pair of semi-forms, equipped with fastening
protuberances and/or recesses to the construction material. The semi-forms are arranged
facing each other, and the construction setting material is poured between said semi-forms.
[0010] The protuberances and recesses define slots which comply with the favourable functions
of:
- Provide fastening during the setting of the construction material between said construction
material and the semi-forms, by holding said semi-forms together with the construction
material;
- Provide a means of holding and fastening for different coating elements used in each
case for finishing of the constructive element, by allowing the insertion of a respective
collaborating fitting in the inner space of each slot in the anchoring of said coating
elements;
- Permit the insertion of a wooden bar into said slots to achieve wooden, outer and
inner finishing, screwing or nailing coating elements to said bars;
- Permit the passage of systems such as electrical, plumbing, telephone, etc. systems;
- Permit the placement of anchor clips to attach the construction systems of ventilated
façades;
- All types of finishing, such as plaster sheets, door and window frames, etc., can
be screwed onto the semi-forms with self-tapping screws;
- Permit the anchoring, fastening, attaching, nailing or screwing of all types of surface
finishing elements on the outer part of the semi-forms, which a considerable saving
in time and labour force with respect to the conventional techniques;
- Additionally, the space provided by the recesses and the protuberances, regardless
of the cross-sectional configuration that they adopt, besides providing the aforementioned
effects, can be used as channelling to house any type of piping, duct, wiring or such
like, or any other element associated with those different services and supplies,
so that in addition to permitting an easy and quick installation of these types of
elements, it guarantees a suitable protection thereof.
[0011] The protuberances and recesses can have extremely varied cross-sections, both of
regular and irregular geometries, and can consequently be rectangular, circular, trapezoidal
or of any other shape, leaving an inner space large enough to allow the insertion
of the aforementioned anchoring fittings of coating elements, of the profile-type
or of any other configuration. The anchoring fittings can be solidly joined to respective
internal fittings with the assistance of pin bolts, screws or such like which, passing
through a frontal aperture, are nailed to the corresponding internal fitting.
[0012] In accordance with another preferred embodiment, the recesses and the protuberances
are used to anchor external fittings with the aid of pin bolts or screws which pass
through the longitudinal apertures and whose heads, of a larger diameter than said
aperture, are housed inside.
[0013] According to another preferred embodiment, the recesses and the protuberances permit
the application of intermediate spacers which keep the separation between the semi-forms
of both faces constant, in accordance with the thickness planned for the wall or partition
to be built. If you move away from what is described, the use of semi-forms according
to the invention permits an improvement of the building of constructive elements,
such as walls and partitions simplifying the construction operations and considerably
reducing the time invested in such operations, while at the same time providing flat
surfaces, duly prepared to receive and fasten the coating and finishing elements provided
for to finish the building work.
[0014] According to the invention, the semi-forms are materialized in metal plates, such
as black plates, zinc-coated plates, galvanized plates, lacquered plates, plastic-coated
plates, or any other of similar nature, of a thickness which is preferably between
0.50 and 0.75 mm, shaped as is usual in this state of the art, for example by folding
or drawing. In this case, the protuberances and recesses are defined in the plate
by means of the shaping method itself, whether it is folding, drawing or any of those
known and usually used in the state of the art. Each metal plate is fitted with protuberances
projecting from one side of the metal plate towards the construction setting material,
and with slots defined in correspondence with said protuberances in the other side
of said metal plate, said slots housing auxiliary installations.
[0015] Preferably, in the case of semi-forms manufactured from metal plate, said semi-forms
can incorporate stiffening projections which, similar to the protuberances and the
recesses, can be shaped by drawing or folding, preferably, and which provide said
semi-forms with greater rigidity and strength. Preferably, the stiffening projections
feature rectangular forms or substantially smaller dimensions to those of the protuberances
and the recesses.
[0016] Furthermore, a method is described, which is not part of the claimed invention.
[0017] The method comprises three main stages, in addition to a preliminary production stage
of a construction project with its plans and details for the redesign. That defines
the measurement of the formwork to be used and the design of the systems which must
run through each one of the constructive elements.
[0018] In the first phase, the semi-forms positioned on the floor are comfortably worked
with so that the planned systems (electric, water, communications channelling, etc.)
can be placed in the corresponding slots, subsequently securing them by casting a
polyurethane foam filling or similar product. It is implied that said systems are
preferably vertical, even though it is possibly advisable to make a cut to place,
depending on dimensions, the cable box, mechanism box, or some horizontal or oblique
channelling of short length. That is based on the physical design of the semi-forms
which, as is known, have the slots in the vertical direction. In the upper or lower
part, as applicable, the appropriate instalments will be left for the subsequent connections
which will run through a false ceiling or floating floor.
[0019] To finish up this first phase the necessary fittings must be placed in the slots
which will eventually serve to reinforce the coating and finishing elements planned
in the project.
[0020] The first phase being completed, the second phase is carried out, which consists
of lifting the semi-forms with all of the systems and fittings built-in during the
first phase, until positioning them vertically and using them traditionally as permanent
formworks. The semi-forms are arranged in pairs to define both sides of the constructive
elements, supporting them on foundation bases, securing them vertically with braces,
or in whatever is considered advisable, and securing the distance between semi-forms
with spacing elements, with the purpose of the idea that filling them with the filling
material (concrete, lightweight mortar or plastic foams, for example) will maintain
both the verticality and the distance between the semi-forms, which are decisive in
the final finishing.
[0021] Lastly, once a necessary setting for the constructive element to acquire the suitable
consistency and strength has been produced, the third phase is started, which comprises,
in the first place, completing the electricity, water, communications or any other
type of systems and, following this, placing the coating elements planned for the
project, attaching them as specified in each case by means of nails, lag screws, screws/nuts,
etc.
[0022] This way of proceeding in the construction system has a series of advantages with
respect to other more traditional methods. The main advantage is the cheapening of
the final product stemming from the important reduction in labour force costs as a
consequence of the quickness with which the building is carried out.
[0023] Furthermore, the programming, the meticulous preparation of the work to be done and
the quickness of the construction have a direct impact on the improvement in efficiency,
on the overall performances and on the decrease in the financial costs.
[0024] Additionally, the method stands out in that it reduces transportation costs, as one
only needs to stock up on the semi-forms, finishing materials and system fittings;
the construction material, such as mortar or such like, is supplied in cement mixers
and is pumped, which means that when fillings based on lightweight mortars and polyurethane
foams are used, the total loads are less than those of the traditional construction
systems.
[0025] The use of the semi-forms permits an accurate preparation of hollow spaces, windows
and doors which are perfectly built, including anchors, and avoiding the use of frames
in doors and windows.
[0026] As an added advantage, it must be pointed out that the semi-forms themselves provide
not only the waterproofing of the façades but also noticeable improvements from the
acoustic and thermal standpoints.
[0027] The use of radial systems is particularly interesting. In said radial electrical
systems, the main switchboard, as well as all of the wiring in the housing or, in
general, in the building, arrives in the workshop already prepared, the terminals
for the wires having been installed and duly numbered, so that the on site installation
can be carried out by the workers themselves, since the route and installation of
each wire is specified in a plan. This radial electrical installation system achieves
an improvement in quality of installation, as well as a savings in labour force and,
in general, in costs.
BRIEF DESCRIPTION OF THE DRAWINGS
[0028]
Figure 1 shows two semi-forms facing each other and arranged in vertical position
Figure 2 shows a perspective view of a semi-form manufactured from metal plate which
comprises stiffening projections inserted between the protuberances.
Figure 4 represents the general arrangement of the different elements which take part
in the forming and concreting process for the formation of a partition.
Figure 5 represents the final phase of the constructive method, wherein the auxiliary
structures are eliminated and the inner and outer surfaces are coated according to
the type of finishing chosen. In this case, coating tiles have been decided upon on
the outer and plaster on the inner.
PREFERRED EMBODIMENTS OF THE INVENTION
[0029] As has been previously mentioned, the detailed description of the forms of preferred
embodiment of the constructive element of the invention is going to be carried out
in the following with the help of the attached drawings, wherethrough these drawings
use the same numeric references to designate the equal or similar parts.
FIRST EMBODIMENT: SEMI-FORM PLATES
[0030] Referring in the first place to Figure 1, a schematic view can be observed, viewed
from an overhead perspective, of a permanent formwork (1) in accordance with the invention,
made up of two semi-forms (11, 11') manufactured from folded or drawn metal plate,
and which adopt a substantially flat configuration, wherefrom one of whose faces project
multiple protuberances (5) and recesses (2), built into the body of the semi-form
(11, 11'), extended in the longitudinal direction of said semi-form (11, 11'), equal
and parallel to each other, and in successively equidistant positions.
[0031] The protuberances (5) and the recesses (2) feature a profile whose cross-section
can adopt different alternative forms. The protuberances (5) are projected from one
side of the metal plate and slots (3) are defined in correspondence with said protuberances
(5) in the other side of the plate.
[0032] Figure 2 illustrates an embodiment wherein the semi-form (11, 11') additionally incorporates
stiffening projections (32) defined between the protuberances (5), which provide greater
rigidity and strength.
[0033] Figure 4 schematically shows a wall or such like under construction, whose external
faces are delimited by an array of semi-forms (11, 11') successively aligned by each
one of the sides of the wall, and separated by a pre-set distance which is going to
define the thickness of the wall or partition once it is filled with a construction
material (20). As can be observed (see figure 1), the protuberances (5) and the recesses
(2) constitute the means of maintaining said semi-forms (11, 11') in their position
fitting in the material (20) once said material (20) has set. On the external face,
the slots (3) are left uncovered to fasten an outer coating (7).
[0034] In figure 5, a schematic view can be observed wherein semi-forms (11, 11') appear
positioned vertically on both sides of a wall or such like under construction with
the use of mortar, concrete or other material (20), where the thickness of the wall
is precisely determined by the separation between the semi-forms (11, 11'). Thanks
to the configuration of the recesses (2) (see figure 1), a multiplicity of spacers
(13), which will be described below in greater detail, can be coupled.
[0035] Said coupling by means of spacers (13) immobilises a semi-form (11) from one side
of the wall with respect to the semi-form (11') of the opposite side of the wall,
thereby guaranteeing the maintenance of the uniformity of the thickness of the wall,
and these spacers (13) being buried by the material (20) of the wall, thereby helping
reinforce said wall after the setting of the material (20).
PRODUCTION METHOD
[0036] The construction method used in the production of walls or partitions using the semi-forms
(11, 11') previously described as permanent formwork (1) is described below again
with help of figure 1, 4 and 5. The method is carried out according to the following
three phases:
First phase.- (see figure 1)
Once the dimensions of an inner semi-form (11) and an outer semi-form (11') are known,
said semi-forms (11, 11') are placed horizontally or in the position which is considered
to be most comfortable and in the inner semi-form (11), flexible tubes for electrical
pipes (4), the junction boxes (24), the boxes for switches or plugs (25), the pipes
for the conduction of water (26) with their stopcocks (27) and outlet connectors for
pigtails (28), leaving instalments for the upper and lower part with the purpose of,
when it is time, to proceed to the splicing with the systems which run on a false
roof or under a floating floor. Once the placement of all the necessary elements on
the corresponding slots (3) has been finished, they are secured and immobilised in
their position with a foam polyurethane filling (29) or similar product.
The outer semi-form (11') is equipped with adapted fittings for the holding of coating
elements (7), such as wooden bars (40), hooks, blind plugs, special screws, etc.,
whose operation is very easy as all of these elements can be strengthened on slots
(3). In the case represented in figure 1, wooden bars (40) have been decided upon
which are perfectly fit into said slots (3) as their cross-section has been prepared
so that they can slide inside said slots (3) without the possibility of them coming
out when they have to work as support for the coating elements (7). Another possibility
is to fasten the bars (40) to the semi-forms (11, 11') by means of lag screws (not
represented).
Second phase.- (see figure 4)
In this second phase, the semi-forms (11, 11') are lifted with all of the elements
installed thereon which have been immobilised thanks to the foam filling (29) (see
figure 1) placed for this purpose. Then, said semi-forms (11, 11') are placed precisely
on the firm floor, or on the foundation (31) built for this purpose, fastening them
with provisional support structures (14), guaranteeing the uniform separation of the
semi-forms (11, 11') by means of spacers (13) which incorporate cladding (18), and
the solidity of the array with threaded bars (16) and nuts (17). Taking advantage
of the support structure (14), scaffolding boards (15) can be placed, as is normal
in constructions.
Lastly, the construction material (20), which can be concrete, mortar or the type
of mixture chosen for the project, is pumped, pouring it through a supply hose (19)
in the space between both semi-forms (11, 11') which, as has been indicated, act as
permanent formwork (1).
Once the setting period has passed, the support structure (14), scaffolding boards
(15) and the rest of the elements such as nuts (17) and threaded bars (16) are removed.
Third phase.- (see figure 5)
The finishing operations are performed in this phase:
- a) systems, making the correct connections from the installations which have remained
visible.
- b) inner facing, adding a layer of plaster (22) or any other type of finishing which
is considered by the project of the construction work.
- c) an outer facing, placing the coating tiles (7), which are nailed on the wooden
bars (30) (see figure 1).
1. Konstruktives Element, das Folgendes umfasst:
eine permanente Schalung (1) einschließlich eines Paares getrennter Halbformen (11,
11'), Folgendes umfassend:
eine erste Halbform (11) einschließlich einer ersten Metallplatte und
eine zweite Halbform einschließlich einer zweiten Metallplatte, wobei die besagten
Metallplatten eine Innenseite und eine Außenseite besitzen, wobei die Innenseiten
des Paares von Halbformen (11, 11') einander gegenüberliegen und dazwischen einen
Hohlraum definieren,
ein Bau-Setzungsmaterial (20), das innerhalb des besagten Hohlraums angeordnet ist,
Hilfsinstallationen,
eine Vielzahl von Protuberanzen (2), die in der ersten Metallplatte definiert sind
und sich von deren Innenseite in Richtung des Bau-Setzungsmaterials (20) erstrecken,
und
eine Vielzahl von Längsschlitzen (3), die an der Außenseite der ersten Metallplatte
in Übereinstimmung mit den besagten Protuberanzen (2) definiert sind, wobei die besagten
Längsschlitze die Hilfsinstallationen aufnehmen,
dadurch gekennzeichnet, dass
die erste und zweite Halbform (11, 11') jeweils nur aus der besagten ersten und zweiten
Metallplatte bestehen, wobei die zweite Metallplatte ähnlich der ersten Metallplatte
ist und eine Vielzahl von Protuberanzen (2) besitzt, die in der Platte definiert sind
und sich von der Innenseite der besagten Metallplatte in Richtung des Bau-Setzungsmaterials
(20) erstrecken, und über eine Vielzahl von Längsschlitzen (3) verfügt, die an der
Außenseite der besagten Metallplatte in Übereinstimmung mit den besagten Protuberanzen
(2) definiert sind und die Hilfsinstallationen aufnehmen, und
dass das konstruktive Element weiterhin Beschichtungselemente (7) und Befestigungsmittel
für die besagten Beschichtungselemente (7) umfasst, wobei sich die Befestigungsmittel
in den Längsschlitzen (3) der ersten und zweiten Metallplatte befinden.
2. Konstruktives Element nach Anspruch 1, bei dem jede Metallplatte mit Versteifungsvorsprüngen
(32) ausgestattet ist, die sich zwischen den Protuberanzen (2) befinden.
3. Konstruktives Element nach Anspruch 1, bei dem es sich bei den Hilfsinstallationen
um Wasser- und/oder Strom- und/oder Glasfaseroptikinstallationen handelt.
4. Konstruktives Element nach Anspruch 1, bei dem es sich bei dem Beschichtungselement
(7) um ein Putzbeschichtungselement handelt.
1. Élément de construction qui comprend :
un coffrage permanent (1) comportant une paire de semi-coffrages séparés (11, 11')
comprenant :
un premier semi-coffrage (11) comportant une première plaque en métal et
un second semi-coffrage comportant une seconde plaque en métal,
lesdites plaques en métal possédant un côté interne et un côté externe, le côté interne
de la paire de semi-coffrages (11, 11') se faisant face et définissant un espace creux
entre eux,
un matériel de pose pour construction (20) disposé à l'intérieur dudit espace creux,
des installations auxiliaires,
une pluralité de protubérances (2) définies dans la première plaque en métal se projetant
depuis son côté interne en direction du matériel de pose pour construction (20), et
une pluralité de fentes longitudinales (3) définies sur le côté externe e la première
plaque en métal en correspondance avec lesdites protubérances (2), lesdites fentes
longitudinales logeant les installations auxiliaires,
caractérisé en ce que
le premier et le second semi-coffrages (11, 11') sont uniquement constitués desdites
première et seconde plaque en métal respectivement, la seconde plaque en métal étant
similaire à la première plaque en métal, possédant une pluralité de protubérance (2)
définies dans sa plaque, se projetant depuis le côté interne de ladite plaque en métal
en direction du matériel de pose pour construction (20), et possédant une pluralité
de fentes longitudinales (3) définies sur le côté externe de ladite plaque en métal
en correspondance avec lesdites protubérances (2) logeant les installations auxiliaires,
et
en ce que l'élément de construction comprend en outre des éléments de revêtement (7) et des
moyens de fixation pour lesdits éléments de revêtement (7), les éléments de fixation
étant situés dans les fentes longitudinales (3) des première et seconde plaques en
métal.
2. Élément de construction selon la revendication 1, dans lequel chaque plaque en métal
est ajustée avec des projections de raidissement (32) situées entre les protubérances
(2).
3. Élément de construction selon la revendication 1, dans lequel les installations auxiliaires
sont des installations à eau et/ou à électricité et/ou à fibres optiques.
4. Élément de construction selon la revendication 1, dans lequel l'élément de revêtement
(7) est un élément de revêtement en plâtre.