Wall construction system with drywall composite columns and method for wall construction

Abstract

Disclosed are a wall construction system with drywall composite columns and a method for constructing walls using thin sheet steel sections in concrete composite construction for erecting story-high walls with at least one-sided planking with building boards, in particular for residential buildings. Structural loads of solid ceilings and facade walls are absorbed via the composite columns arranged in a modular grid within the wall plane. The joining of the composite columns takes place at the column head over a concrete beam on which the ceiling rests. In-filling wall or facade elements may be arranged between the composite columns. The composite columns include a concrete composite column with a sheet metal reinforcement and a spatially offset thin-walled sheet steel section for mounting drywall thereto even after the metal reinforcement has been filled with concrete. The sheet metal reinforcement and the thin-walled sheet steel section may have different material qualities and thicknesses.

Claims

1. A system for constructing load-bearing walls, comprising: a plurality of story-high drywall composite columns which support ceilings and walls of a house, the drywall composite columns being arranged in a modular grid; and building boards planking at least one side of the drywall composite columns, wherein each of the drywall composite columns includes a first portion including a concrete composite column (2) with a sheet metal reinforcement (5) and a second portion which is spatially offset from the first portion and includes at least one thin-walled sheet steel section (3) having a flat drywall locating surface (4), wherein the sheet steel section (3) is connected to and extends parallel to the concrete composite column (2), and wherein the flat drywall locating surface (4) is arranged at a distance from the concrete composite column, and wherein the flat drywall locating surfaces of the drywall composite columns are arranged in a common plane which does not intersect the concrete composite columns, and wherein the building boards (9) are secured to the flat drywall locating surfaces of two or more adjacent ones of the drywall composite columns.

2. The system as in claim 1, further comprising installation openings (6) arranged in the sheet steel section (3) between the concrete composite column (2) and drywall locating surface (4).

3. The system as in claim 1, wherein the sheet metal reinforcement (5) the concrete composite column (2) and the corresponding sheet steel section (3) having the drywall locating surface (4) are manufactured from a single piece sheet metal strip semi-finished product.

4. The system as in claim 3, wherein the sheet metal strip semi-finished product has a uniform thickness and wherein the sheet metal reinforcement (5) has at least one local material concentration in form of meandering or multi-layered sheet metal folds.

5. The system as in claim 3, wherein the single piece sheet metal strip semi-finished product has different material thicknesses and/or different material qualities in the first portion and the second portion.

6. The system as in claim 1, wherein the sheet metal reinforcement (5) of the concrete composite column (2) has local sheet metal bends (6) over its entire length or height, which a) are suitable for their own positional fixation on a component or b) engage in an interlocking manner in wall elements (8) or c) anchor a tubular sheathing plate in the concrete or d) fix a position of additional setting profiles.

7. The system as in claim 1, wherein the sheet metal reinforcement (5) of the concrete composite column (2) is tubular and has local sheet metal bends in the form of punched material offsets on its entire length or height, through which concrete cannot pass.

8. The system as in claim 1, wherein the sheet metal reinforcement (5) of the concrete composite column (2) comprise expanded metal, wire mesh, or fiber fabric mesh (25) and is joined to the sheet steel section (3) or is engaged with the sheet steel section by concrete.

9. The system as in claim 1, wherein the sheet steel section (3) and the sheet metal reinforcement (5) of the concrete composite column (2) are separate story-high parts which are joined together by interlocking joining structures.

10. The system as in claim 9, wherein the sheet steel section (3) and the sheet metal reinforcement (5) have different material thicknesses and/or different material qualities.

11. The system as in claim 1, wherein a position of the drywall locating surface (4) is adjustable before the respective drywall composite column is filled with concrete.

12. The system as in claim 1, wherein at least one further drywall locating surface (4) is present within a wall between the drywall composite columns (1), a further flat locating surface of which is offset parallel to the common plane.

13. The system as in claim 1, wherein an outer peripheral surface of the sheet metal reinforcement (5) of the concrete composite column (2) is completely or partially sealingly enclosed with film (22) or fabric or a thick coating.

14. The system as in claim 1, wherein directly between adjacent ones of the drywall composite columns (1) an in-filling wall element (8) is inserted, the in-filling wall element comprising a factory-laminated building board covering at least one side thereof at least partially.

15. The system as in claim 14, wherein the building board (21) is slightly smaller in area than the wall element and does not contact the drywall composite columns (1).

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) FIG. 1 shows portions of a vertical and horizontal cross-section through a house exterior wall.

(2) FIGS. 2a, 2b, 2c, and 2d show horizontal cross-sections through alternative embodiments of drywall composite columns.

(3) FIGS. 3a and 3b show horizontal cross-sections through further alternative embodiments of drywall composite columns.

(4) FIGS. 4a-4d show cross-sections through freestanding composite columns.

DETAILED DESCRIPTION

(5) FIG. 1 shows portions of a vertical and horizontal cross-section through a house exterior wall having a story-high drywall composite column (1) and in-filling wall elements (8). The drywall composite column (1) is set in a rail-like manner in a foot profile (16) anchored to the construction and axially secured thereto with a concrete connection anchor (19).

(6) The in-filling wall elements (8) in the form of dimensionally stable story-high insulation panels made of rigid foam have on both sides continuous lateral recesses as a permanent formwork (15) for receiving the sheet metal reinforcement (5) and the grouting concrete (23). At the column head, the sheet metal formwork (5) engages in a concrete beam (14) in order to achieve a structural clamping of the concrete composite column (2) to reduce the tendency to buckling.

(7) The drywall composite column (1) component includes two portions. A first portion is a concrete composite column (2) with an integrated sheet metal reinforcement (5) and grouting concrete (23). A second portion without concrete contact has a sheet steel section (3) and an integrated drywall locating surface (4). The columns aligned in the wall plane are planked on their respective drywall locating surfaces (4), predominantly with gypsum building boards (13) with joining means.

(8) The sheet metal reinforcement (5) of the concrete composite column (2) and the sheet steel section (3) with the drywall locating surface (4) are manufactured from the same galvanized Tailor Welded Coil as a sheet metal strip semi-finished product by roll forming, the sheet metal portions of which, however, have different thicknesses and qualities. The sheet metal reinforcement (5) is a welded rectangular hollow section of approx. 80125 mm having a wall thickness of 1.6 mm and a yield strength of approx. 600 N/mm2. The projecting sheet steel section (3) having the flat drywall locating surface (4) has a sheet metal thickness of only 0.6 mm and a yield strength of about 300 N/mm2.

(9) A free space of about 30 mm is available behind the locating surface (4) to receive joining means and installations. The sheet steel section (3) has punched out lateral openings (12) for horizontal routing of cables and lines of the house and to improve its elasticity. This profile flank is also manufactured at an angle of approx. 45 in order to couple the planking with even more elastically with regard to sound technology.

(10) The hollow section of the sheet metal reinforcement (5) has, over the entire length, continuous flag-like sheet metal bends (6) with corresponding openings in the profile, which can be well penetrated by the flowable concrete. These flag-like sheet metal bends (6) hold the sheet metal reinforcement (5) in an interlocking and positionally accurate manner in the in-filling wall elements (8) in the assembly process and serve to secure composite steel and concrete. The inner rib (10) with toothed strip also serves this functional connection.

(11) The structural loads of the in-filling wall elements can be absorbed and transmitted to the column with a dimensionable depth of engagement of the concrete in the lateral recesses.

(12) Depending on the stability and sound insulation requirements, the lightweight wall elements (8) can be additionally laminated on the inner side over the entire surface or only at the edges with an intermediate plate (21), as shown here. The intermediate plate (21) should be about 5 mm smaller so that, as an elastic vibration system, it also significantly improves the soundproofing of the lightweight wall, so that direct contact with the drywall composite column (1) is excluded.

(13) Depending on the stress on the facade and the stability of the wall element, additional constructive supports can be required as point facade anchors (17) or facade support strips (18) which are anchored directly to the drywall composite column (1) and are already secured to the sheet metal reinforcement (5) during assembly and structurally prior to concrete grouting.

(14) FIG. 2 shows further embodiments of drywall composite columns made of a thin-walled sheet steel strip having the same thickness for the two portions.

(15) FIG. 2a shows a wall cross-section having wall elements (8) and intermediate plates (21) adhered to the inside over the entire surface, for example, as cement composite panels. The sheet metal reinforcement (5) is anchored in the assembly process by a plurality of flag-like sheet metal bends (6) interlocking to the wall elements and intermediate plates in the undercut lateral recesses.

(16) By grouting the column, the concrete penetrates through the profile openings into the wall element (8) and also acts on the narrow side flanks of the intermediate plates (21) and thus clamps these in a pressure-resistant manner between the drywall composite columns (1) arranged in the modular grid. The intermediate plates (21) are also acted upon from above by the concrete of the beam. Thus, the bracing of the wall and the profile stiffening of the weak axis is guaranteed against buckling without further assembly steps, also improving the sound and fire protection of the wall.

(17) The sheet metal reinforcement (5) is manufactured as a hollow section with protruding drywall locating surface (4) made of a sheet metal strip of equal thickness by roll forming and has meandering folded material concentrations for structural reinforcement, which improve the carrying capacity of the column and the steel concrete functional connection as blocked and somewhat compressed ribs.

(18) FIG. 2b shows only the cross-section of a composite sheet of drywall composite column (1) made of thin-walled folded sheet metal reinforcement with all-round continuous openings and sheet steel anchors (7) in the form of bent sheet metal lips (passages) on the sheet openings to secure the interlocking functional connection over the entire profile length. The material concentration of the sheet is adapted to the load.

(19) In FIG. 2c, the sheet steel section (3) and the sheet metal reinforcement (5) of the drywall composite column is manufactured from the same sheet metal strip of 0.7 mm thick galvanized sheet steel. The spatial distance of the drywall locating surface (4) to the surface of the column concrete is achieved by an interlocking inserted volume stable lightweight material backfill (9). Even after the concrete filling, this lightweight material (9) can be penetrated by joining means and can also be broken through by installations through the lateral installation openings (12). The functional connection with the concrete is achieved by sheet steel anchors (7) in the form of a plurality of openings with passages. The lateral recesses secure the wall elements (8) to the concrete grouting on the concrete composite column and prevent detachment of the enclosing sheet steel reinforcement from the column concrete.

(20) FIG. 2d shows the cross-section of in-filling wall elements (8) of a drywall composite column (1) and a simple sheet metal reinforcement (5) in conjunction with high-strength concrete as a spread concrete composite column. Continuous openings are included as sheet steel anchors (7) in the sheet metal reinforcement (5) in both concrete zones and also flag-like sheet metal bends (6) for assembly locking. The wall element is the sole formwork for the grouting concrete (23) of the concrete composite column.

(21) FIG. 3a: Sheet steel section (3) and sheet metal reinforcement (5) are manufactured from the same thin-walled sheet metal strip semi-finished product. The sheet metal reinforcement (5) is over mutually bent flanks interlocking with the wall elements (8) as formwork and with a coarse mesh tubular fabric mesh (25). The coarse fabric consists of longitudinally reinforced carbon fibers, which can be penetrated well by the flowable concrete. The fabric mesh hose can be produced easily and in a load-adapted manner in many dimensions and without tooling costs, can be processed and assembled on site and is insensitive in corrosive environment. The lightweight material backfill (9) includes the spatial distance between drywall locating surface (4) and concrete surface.

(22) FIG. 3b shows a rectangular hollow section having 2 mm sheet metal thickness as a sheet metal reinforcement (5) having a plurality of local sheet steel anchors (7) in the form of openings with passages and a sheet steel section (3) with 0.6 mm sheet metal thickness having an outer drywall locating surface (4) and an inner wall drywall locating surface (4). The sheet steel section (3) is inserted in an interlocking manner into punched holes in the sheet metal reinforcement (5) in a precise position and permanently locked by the subsequent concrete grouting. The inner wall drywall locating surface (4) is used for additional planking with building boards (13) for structural stiffening of the wall or/and for improving sound and fire protection.

(23) To secure the position of the external smooth hollow section during assembly, separate small molded parts are inserted as a profile holder (20) in a few lateral openings, which molded parts hold the sheet metal reinforcement (5) in the undercut of the wall element (8) in an interlocking manner (tongue and groove principle). After grouting, the concrete interlocking bears weight.

(24) FIG. 4 shows a plurality of cross-sections of freestanding composite columns without in-filling wall element, as they are predominantly used in load-bearing inner walls.

(25) FIG. 4a shows a drywall composite column (1) having a predominantly rectangular concrete cross-section and having arched envelope surfaces from 3-sided enclosing sheet metal reinforcement and two sheet steel section portions having drywall locating surfaces (4), which are manufactured from a thin-walled sheet metal strip semi-finished product having the same material thickness. On a side of the column, a dimensionally stable lightweight material backfill (9) is inserted, which closes off the column as formwork and simultaneously forms the free space for fastening connections behind the drywall locating surfaces (4). The profile legs are held together by means of a plurality of U-bolts on the column height.

(26) The composite effect is ensured, in addition to the U-bolts, primarily over several rows of sheet steel anchors (7) in the form of bridges as reshaping partial punching over the entire length or height of the column. The bridges are punched horizontally, so that the sharp-edged sheet bends allow for the stresses along the steel section anchor function on the concrete surface. If the bending out is only slightly more than the material thickness of the sheet steel, then the function as a concrete-tight formwork is still preserved.

(27) In the case of higher sheet-metal bridges, for example, an externally spreadable covering is necessary as a hardening thick coating (22) to ensure a sealed formwork in order to close the gaps in the sheet metal.

(28) For house installations, a cladding tube (24) has been inserted in the precisely prepared openings of the composite section before the concrete grouting. For this purpose, a plurality of openings is pre-punched on the sheet metal section, which can be broken off as required.

(29) FIG. 4b shows a column having a round concrete cross-section having two drywall locating surfaces (4) and having a plurality of sheet steel anchors (7) in the form of inner sharp-edged stamping over the entire column height to ensure the concrete composite. The sheet metal formwork cannot detach from the surface due to the strained confinement of the concrete core. Many individual sheet metal tabs engage in perforations of the opposite side at the central contact point of the sheet metal reinforcement (5) and are hooked by bending in such a way that a quasi-structurally stable tube is produced.

(30) For the functional connection, the embodiment FIG. 4c has continuously flag-like sheet metal bends (6) inwards (horizontal or vertical) in several rows with corresponding openings in the envelope surface of the sheet metal reinforcement (5). The bends have the shape of a trapezoidal surface and are anchored by the longer inner side in an interlocking manner and by the two-sided adhesive bond and in a force-fitting manner in the concrete of the column. Film or fabric (22) is wrapped tightly, around the circumference so that the concrete cannot escape through the openings in the formwork of the concrete composite column (2). At least one sheet steel section (3) having at least one drywall locating surface (4) is hooked or joined in an interlocking manner in precisely fitting openings through the film envelope. A position of the drywall locating surface (4) is adjustable before the respective drywall composite column is filled with concrete.

(31) Local incisions for selectively bendable or breakable profile zones can be present on the sheet metal reinforcement (5) of the concrete composite column (2) in order to be able to put diagonal braces or struts into the formwork from the outside. Likewise, flag-like sheet metal bends (6) can exist inward to firmly damp setting profiles precisely in position.

(32) FIG. 4d: The cross-section of the concrete composite column (2) shows a perforated steel tube having 1.5 mm sheet metal thickness and having a dense film wrapping (22). The perforations in the sheet metal reinforcement of about 30 mm in diameter are, in this case, sufficiently large to act as a sheet steel anchor (7).

(33) One or more thin-walled sheet steel sections (3) having 0.6 mm sheet metal thickness and flat bearing surface (4) are inserted or hooked on the concrete composite column (2) in an interlocking manner later on the site through the film by means of sharp and precisely fitting bends in the perforations and permanently joined by the later concrete grouting.

LIST OF REFERENCE NUMBERS

(34) 1 drywall composite column 2 concrete composite column 3 sheet steel section 4 drywall locating surface 5 sheet metal reinforcement 6 flag-like sheet metal bend 7 sheet steel anchors 8 wall element 9 lightweight material backfill 10 rib 11 gap 12 installation openings 13 building boards 14 concrete beam 15 permanent formwork 16 foot profile 17 facade anchors 18 facade support strips 19 concrete connection anchor 20 profile holder 21 intermediate plate 22 wrapping with film 21 concrete 24 cladding tube for installations 25 fabric mesh