A BUILDING WALL AND A METHOD FOR MANUFACTURE

Abstract

A method for manufacture of a fire-proof and insulating prefabricated building wall comprising a wall core of an expanded, foamed plastic material, such as EPS (expanded polystyrene), with an integrated reinforcement structure and a coating of a cementitious material.

Claims

1. A method for manufacture of a fire-proof and insulating prefabricated building wall, comprising the steps of positioning an interior load-bearing reinforcement structure with a number of reinforcing members into an expansion mould with a mould wall comprising interior mould surfaces enclosing a plate shaped volume, blowing beads of an insulating expandable plastic material into the expansion mould, expanding the beads in the expansion mould and allowing them to melt together to form a foamed core plate of a plate shape corresponding to the plate shape of said plate shaped volume, said plate shape of the core plate comprising plate surfaces including two major plate surfaces, the beads ultimately expanding to encase the reinforcement structure so that the reinforcement structure extends through and is embedded within the core plate with substantially all surfaces of the reinforcement structure that are positioned within said plate surfaces of the core plate being in contact with the core plate, the reinforcement structure and the foamed core plate thereby together forming a load-bearing, insulating wall core, which assumes the general plate shape of the core plate, positioning of the wall core in a formwork mould with a mould wall encasing the wall core, the mould wall comprising interior mould surfaces forming a plate shaped volume, at least one of the major surfaces of the wall core being positioned at a distance from the mould wall, injecting a fire-proof cementitious material into the formwork mould and allowing it to extend at least between the mould wall and said one major surface of the wall core, and allowing the cementitious material to at least partly cure, the cementitious material adhering to said one major surface to thereby provide coating of the one said major surface of the wall core with the cementitious material to form a coating having an outer surface forming a first major surface of the building wall.

2. A method according to claim 1, comprising previous to the blowing step the further step of positioning piping, channels and/or cabling in the expansion mould to fit to desired positions in the resultant building wall, the piping, channels and/or cabling being embedded in the wall core during the expansion step.

3. A method according to claim 1, further comprising previous to the blowing step the further step of positioning of a frame within the expansion mould, the frame extending between two parts of the mould wall, a frame volume enclosed within the frame being kept free of the plastic material during the blowing and expansion steps, said frame volume forming a door or window aperture in the wall core and the resultant building wall.

4. A method according to claim 1, wherein the expansion mould on a mould wall surface facing said one major surface of the wall core comprises at least one longitudinally extending projection that extends coplanarly with the mould wall surface so that the expanded wall core on said major surface thereby comprises an associated longitudinally extended groove shaped by the longitudinally extending projection, and previous to the injecting step further comprising the step of positioning at least one solar heating liquid pipe in the groove so that after the injecting step in the resultant building wall the liquid pipe extends between said one of the major surfaces of the wall core and the coating, a channel for the liquid pipe being provided by oppositely disposed grooves in the wall core and the coating, respectively, and preferably the step of positioning on an outside of said one of the major surfaces at least one solar cell panel.

5. A method according to claim 1, wherein the injection step also comprises similar coating of the other of said major surfaces of the wall core with the cementitious, fire-proof material forming an outer surface with a second outer surface of the building wall.

6. A method according to claim 1, wherein the expanded plastic material essentially consists of polystyrene or polyurethane.

7. A method according to claim 1, wherein the wall core extends between the reinforcement structure and the coating so that the wall core at substantially all positions distances the coating from the reinforcement structure with at least 5 mm.

8. A fire-proof and insulating prefabricated building wall manufactured according to the method of claim 1.

9. A fire-proof and insulating prefabricated building wall, comprising an interior load-bearing reinforcement structure comprising a number of reinforcing members, a foamed core plate of a plate shape, the core plate being manufactured of an insulating expanded plastic material that encases the reinforcement structure, the core plate comprising outer surfaces of its plate shape including two major surfaces, the reinforcement structure extending through and being embedded in the core plate with substantially all surfaces of the reinforcement structure in contact with the core plate within said outer surfaces of the core plate, the reinforcement structure and the foamed core plate forming an insulating wall core with two major surfaces substantially coinciding with said two major surfaces of the core plate, and one of said major surfaces of the wall core being coated with a coating of cementitious, fire-proof material that forms a coating having an outer surface forming a first major surface of the building wall, a solar heating liquid pipe being positioned in a channel extending between the wall core and the coating.

10. A building comprising a building wall according to claim 9, wherein the reinforcing members comprise bars extending longitudinally from one end to another in a direction extending substantially in a plane of the plate-shaped building wall with load-bearing properties sufficient to allow the building wall to carry both its own weight and a substantial part of the load of a roof construction above the building walls, the bars having a cross-sectional profile that allows the bars to function as load-bearing columns in a static system of the building.

Description

[0049] The invention will be described in further detail in the following with reference to the examples of embodiments shown in the drawings in which

[0050] FIG. 1 shows parts of an expansion mould used in an embodiment of the method according to the invention and a reinforcement structure of an embodiment of a building wall according to the invention.

[0051] FIG. 2 shows the expansion mould of FIG. 1 with the reinforcement structure inserted.

[0052] FIG. 3 shows the expansion mould of FIG. 1 in a closed position.

[0053] FIG. 4 shows a wall core of the building wall being extracted from the expansion mould.

[0054] FIG. 5 shows parts of a formwork mould used in the method.

[0055] FIG. 6 shows the wall core positioned in the formwork mould of FIG. 5.

[0056] FIG. 7 shows an exploded view of the building wall with some parts removed.

[0057] FIG. 8 shows a perspective view of the building wall of FIG. 7 with some parts removed.

[0058] FIG. 9 shows a perspective view of the building wall of FIG. 7.

[0059] FIG. 10 shows a schematic side view of the building wall of FIG. 7 taken along the line X-X of FIG. 11.

[0060] FIG. 11 shows a schematic sectional view of a detail of the building wall of FIG. 7 taken along the line II-II of FIG. 10.

[0061] FIGS. 1 to 6 illustrate different steps of an embodiment of the method according to the invention for manufacturing a fire-proof and insulating prefabricated building wall according to the invention as illustrated in FIGS. 7 to 11.

[0062] Referring to FIGS. 1 to 4 a load-bearing reinforcement structure 1 with six reinforcing members in the form of two horizontal steel beams 2a and four vertical steel beams 2b, which may be welded together or otherwise attached to each other at relevant positions, is positioned into an expansion mould 3 in two parts 3a and 3b with a mould wall 4 comprising interior mould surfaces 5 enclosing a plate shaped volume 6.

[0063] In FIG. 1 the expansion mould 3 is shown in an open position ready for receiving the reinforcement structure 1. In FIG. 2 the reinforcement structure 1 is positioned inside the expansion mould 3. In FIG. 3 the expansion mould 3 is shown in the closed position in which the two mould parts 3a and 3b are put together to form the volume 6 in which the reinforcement structure 1 is positioned. In the position of FIG. 3 beads of an insulating expandable plastic material (not shown) are blown into the expansion mould 3 via channels 7 and are expanded inside the volume 6 using heated steam that is also blown into the volume 6. The expanded plastic material consists essentially of EPS. Steam and gas can leave the volume 6 via channels 8. Inside the volume 6 the beads hereby melt together to form a foamed core plate 9 of a plate shape corresponding to the plate shape of the volume 6. The plate shape of the core plate 9 comprises plate surfaces including two major plate surfaces 10, 11. The beads ultimately expand to encase the reinforcement structure 1 so that the reinforcement structure 1 extends through and is embedded within the core plate 9 with substantially all surfaces of the reinforcement structure 1 that are positioned within the plate surfaces of the core plate 9 being in contact with the core plate 9. The reinforcement structure 1 and the foamed core plate 9 thereby together form a load-bearing, insulating wall core 12, which assumes the general plate shape of the core plate 9.

[0064] As is shown in FIG. 4 the wall core 12 is extracted from the expansion mould part 3a using members 14 that push a back part 14a of the mould surface 14 towards one major wall 11 of the wall core 12, the mould part 3b having been detracted to open the expansion mould 3. The members 14 as well as similar members 15 at a side part of the mould surface 14 and similar members 16 at a top part of the mould surface 14 can be used to adjust the three spatial dimensions of the plate shape of the volume 6 so that a large variance of sizes of the wall core 12 can be manufactured. The members 14, 15, 16 can be steel bars that are manually or automatically adjustable in their longitudinal directions.

[0065] FIG. 5 shows a formwork mould 13 in two parts 13a, 13b. In FIG. 6 the wall core 12 has been inserted into the formwork mould part 13a, the mould's interior wall 17 encasing the wall core 12. Similar to the expansion mould 3 the mould wall 17 comprises interior mould surfaces 17a defining a plate shaped volume 18, all surfaces, including major surfaces 10, 11, of the wall core 12 being positioned at a distance from the mould wall 17. The size and shape of the formwork mould 13 is specifically designed to the building wall produced, but could be adjustable similar to the expansion mould 3 as described above.

[0066] The formwork mould 13 is closed by putting together the two parts 13a, 13b after which a vacuum is applied to the volume 18. Then a fire-proof cementitious material is pumped into the formwork mould 13 from beneath and is allowed to extend between the mould wall 12 and all surfaces of the wall core 12. The cementitious material (not shown) then at least partly cures, the cementitious material adhering to all surfaces of the wall core 12 to produce a coating 40 (not shown in FIGS. 7 and 8, but shown in FIGS. 9, 10 and 11) of these surfaces with the cementitious material. The two major outer surfaces 40a, 40b of the coating 40 form the two major surfaces of the resultant building wall shown in FIGS. 7 to 11. The wall core 12 is standing upright, i.e. in a substantially vertically extending position, during moulding.

[0067] The building wall is thus manufactured in a factory consecutively in two moulds 3, 13. The building wall is removed from the formwork mould 13 and transported to a building site where it is lifted into position, e.g. using a crane. Thus a building with a fire-proof, insulating, load-bearing prefabricated building wall comprising a wall core with an insulating core is manufactured. Several similar building walls of differing sizes and shapes can be attached to each other using connecting or anchoring devices that may also be integrated in the plate-shaped building wall and extend outside the wall from the surfaces of the wall. One example, denoted 41, of such an anchoring device is shown best in FIG. 9. As is the case with the anchoring device 41, see FIGS. 1 and 2, the anchoring devices are generally attached to the reinforcement structure 1, e.g. using bolts. Usually it is relevant to include an array of like devices in relevant positions at the exterior surfaces of the building wall.

[0068] The building wall can also be used as a horizontal or inclined “wall”, e.g. roofing or flooring modules, in the building that similarly may be connected to each other and the outer walls of the building. The building wall may be used as outer walls forming part of the building's weather screen as well as interior walls.

[0069] The bars 2a, 2b usually are dimensioned to carry the load of the wall itself as well as other building parts. Thus, in the embodiment shown the bars 2a, 2b are U-beams, i.e. having a cross-sectional U-profile that allows the bars 2a, 2b to function as load-bearing columns in the static system of the building.

[0070] The two major surfaces 40a, 40b of the building wall may be painted. Wall panels 33, 34 are attached to the outer surface of the building wall at the factory. The cementitious fire-proof material comprises light-weight concrete.

[0071] Expansion of the plastic material can be accomplished using steam provided from a steam generator in the factory.

[0072] The major surfaces 40a, 40b of the building wall resulting from the method according to the invention may be painted at the factory or on the building site.

[0073] The wall core 12 is shaped substantially as a parallelepiped that is positioned with its major surfaces 10, 11 substantially perpendicular and horizontal during the injecting step in which concrete is injected or pumped into the formwork mould 13. Similarly, the resultant building wall is shaped as a parallelepiped. Accordingly, the interior volumes 6, 18 of the expansion mould 3 and the formwork mould 13 are each shaped as a parallelepiped. A lid plate (not shown) is positioned on top of the moulds 3, 13 in their closed positions to form the upper surface of the mould wall 17.

[0074] Coating of the bottom minor surface of the wall core 12 is achieved by positioning one or more spacer blocks 21 (FIG. 10) beneath the wall core 12 to space the wall core from a bottom mould surface of the formwork mould. The spacer blocks 21 are manufactured from light-weight concrete and are moulded into the coating 40 during the injection step.

[0075] Before the injection step the formwork mould 13 is filled with an insulating filler material in the form of LECA perlit beads 22 around the wall core 12 between which the cementitious material is distributed during the injection step so that the beads 22 are integrated into the coating 40. The resultant coating 40 is fire-proof.

[0076] Before filling the beads into the formwork mould 13 a steel wire mesh 23 is positioned in the formwork mould 13 between the wall core 12 and the mould wall 17 extending along the major surfaces of the wall core 12. The wire mesh 23 is positioned to be substantially co-planar with the major surfaces 40a, 40b and is positioned approximately half-way between the major surfaces 10, 40a and 11, 40b, respectively. The wire mesh 23 is then moulded into the coating 40 during the injection step, which provides improved structural integrity and flexural strength of the coating 40 so that the coating 40 is able to carry its own weight, but is otherwise not load-bearing.

[0077] An acrylic wire mesh 24 is also positioned close to the mould wall 17 at each of the major surfaces 10, 11 of the wall core 12 before the injection step so as to be integrated into the coating 40 during the injection step.

[0078] The method may be repeated to produce one or more further, similar building walls using the same equipment.

[0079] Previous to the blowing step a pipe 25 and a power cable 26 are positioned in the mould 13 to fit to desired positions in the resultant building wall, the pipe 25 and cable 26 being embedded in the wall core 12 during the expansion step. At the factory the pipe 25 and cable 26 are thus positioned in exact locations in the building wall, and cutting in the building wall at the building site is completely avoided. The plastic material within the surfaces of the wall core 12 are everywhere in contact with outer surfaces of the pipe 25 and cable 26 since the plastic material is expanded to enclose these. The pipe 25 and cable 26 at respective ends project out of the wall core and the building wall to allow for connection. Further cabling, conduits, piping plumbing etc. may be included depending on the needs.

[0080] Previous to the blowing step a frame 27 is also positioned within the expansion mould 3, the frame 27 extending between the two major surfaces of the mould wall. Hereby, a frame volume 28 enclosed within the frame 27 is during the blowing and expansion steps step kept free of the plastic material, the frame volume 28 forming a door or window aperture in the wall core 12 and the resultant building wall. The frame comprises four side surfaces that function as formwork for the side surfaces of the aperture. Hereby, in a cheap and easy manner a window aperture is also included in the wall core 12 without the need to cut out apertures in the wall core 12 after manufacture. Similarly, a like frame 29 is included in the formwork mould 13 in the same position to ensure that the coating 40 also does not extend to the window aperture.

[0081] The expansion mould 3 on a mould wall surface facing the major surface 10 of the wall core 12 comprises a projection (not shown) that extends coplanarly with the mould wall surface 10 so that the expanded wall core 12 on the major surface 10 thereby comprises an associated longitudinally extended groove 30 shaped by the longitudinally extending projection. The projection and thus the groove 30 weave back and forth across the surface as shown to provide a larger collecting area. Previous to the injecting step a flexible solar heating liquid pipe 31 is positioned in the groove 30 so that after the injecting step in the resultant building wall the liquid pipe 31 extends between the major surface 10 of the wall core 12 and the coating 40, a channel for the liquid pipe 31 being provided by oppositely disposed grooves in the wall core 12 and the coating 40, respectively. Hereby, at the factory the liquid pipe 31 can be readily included in the building wall close to the major surface 40a of the building wall and at the outer side of the insulating wall core 12. The liquid pipe 31 is thus able to collect and store heat energy from the coating 40 as previously explained.

[0082] Three solar cell panels 32, each comprising a number of solar cells, are positioned on the surface of the building wall on the outside of the major surface 40a of the building wall. Specifically, each panel 32 is positioned in suitable shaped depressions in a wall cover 33, which is attached to the surface of the coating 40 and extends to enclose the surface 40a. In a conventional manner the solar cell panels 32 produce power that via not shown conduits may be transferred from the panels 32. The liquid pipe 31 is thus positioned behind the solar cell panels 32 to provide cooling of a back side of the panels 32 using circulation of the liquid within the pipe 31. Inlet and outlet of the liquid pipe 31 are connected with a solar heating system (not shown).

[0083] A like wall panel 34 is positioned to enclose the opposite major surface 40b of the building wall.

[0084] The flexible liquid pipe 31 is attached in different places to the wall core 12 wall using temporary fastening means such as metal clips or the like that can be introduced into the wall core 12 and be integrated into the coating 40.

[0085] Referring to FIGS. 10 and 11 the core plate 9 extends between the reinforcement structure 1 and the coating 40 so that the core plate 9 at all positions distances the coating 40 from the reinforcement structure. The minimum distance D is shown in FIGS. 10 and 11 and is approximately 15 mm. This provides improved insulating properties of the building wall since thermal bridges are avoided. Note that the solar panels 32 and the wall covers 33, 34 are not shown in FIGS. 10 and 11.