WO2018167725A1

WO2018167725A1 - Non-stress construction composite for building structural walls and ceilings, and a method of building structural walls and ceilings using bridgeless non-stress construction composites

Info

Publication number: WO2018167725A1
Application number: PCT/IB2018/051767
Authority: WO
Inventors: Aleksander PANEK
Original assignee: Climatic Sp. Z O.O. Sp. K.
Priority date: 2017-03-17
Filing date: 2018-03-16
Publication date: 2018-09-20
Also published as: PL420892A1

Abstract

The subject of the invention is a bridgeless structural composite for construction of walls and ceilings as well as the method of construction of walls and ceilings using bridgeless structural composites. The bridgeless composite, according to the invention, comprises external and internal profiles, battens connecting external and internal profiles and filling. The method of construction of walls and ceilings of buildings using bridgeless structural composites, according to the invention, consists in the fact that bridgeless structural composites are positioned at a certain axial distance from each other, and that construction is implemented in the following manner: bridgeless structural composites are attached to the building structure using connectors, the board intended for use inside the building is fixed directly to the bridgeless structural composites, the space between bridgeless structural composites is filled with a layer of thermal insulation, the board intended for use outside the building is fixed directly to the bridgeless structural composites, or a spacer structure between bridgeless structural composites and a board intended for use outside the building is used. The solution according to the invention has wide use in construction, in particular it can be advantageously used in modular construction.

Description

NON-STRESS CONSTRUCTION COMPOSITE FOR BUILDING STRUCTURAL WALLS AND CEILINGS, AND A METHOD OF BUILDING STRUCTURAL WALLS AND CEILINGS USING BRIDGELESS NON-STRESS CONSTRUCTION COMPOSITES

[1] The subject of the invention is non-stress construction composite for building structural walls and ceilings, and a method of building structural walls and ceilings in using non-stress construction composites The solution, according to the invention, is widely used in construction, has particular advantages in modular construction.

[2] Modular construction is characterized by reduced time of completion of erecting a building. It is connected with the necessity of making the construction process independent of weather conditions. For this reason, construction technology seeks building systems making it possible to manufacture as much of the lightweight structure as possible in the prefabrication plant. In modular construction, only foundations are laid at the building site. Prefabricated modules are set on the foundations, and work consists in assembling modules and connecting elements of installations running between modules. A significant problem is the need to build a significant part, or even the whole fagade at the construction site after assembling the modular building. The insulating and finishing layer of the fagade completed, for example, using the light wet method is susceptible to mechanical damage. The manufacturing such a fagade in the prefabrication plant involves the risk of damage during loading, transport and assembly. What it means in practice is a necessity of building the fagade at the construction site which is not possible, for example, in adverse weather conditions.

[3] Various systems of building walls and ceilings used in construction are known from prior art, such as: skeleton technology from dried and planed wood, solutions known from traditional construction, e.g. ceramic wall, SCS Scottsdale Construction Systems or similar systems based on thin-walled steel profiles and sandwich panels with polyurethane foam or Styrofoam core. These systems, apart from the need to make the insulation and finishing layers of the fagade only at the construction site, are also burdened with many other disadvantages preventing maximum reduction of construction time, crucial from the point of view of modular construction.

[4] The SCS system is known from prior art, in which the outer walls consist essentially of wood chip plasterboard, aluminium mat, SCS structure filled with glass wool, OSB Oriented Strand Board-3 i and an additional layer of heat insulation. The disadvantage of this type of solution is the need to build a double- layer wall to eliminate linear thermal bridges. Moreover, SCS profiles are made only in specific sizes of 90 mm and 140 mm, which is a significant limitation in the thickness profile of the first layer of the wall in which different types of installations are designed. In turn, flat roofs built in the SCS system consist of a roofing membrane, EPS (expanded polystyrene),ln turn, flat roofs built in the SCS system consist of a roofing membrane, EPS (expanded polystyrene), OSB-3 board, SCS structure filled with glass wool, aluminium mat and fibre-plaster board. These types of flat roofs also generate the necessity to ensure continuity of the outer insulation layer of the wall, attic and roof, in order to eliminate thermal bridges.

[5] In the case of timber frame technology known from prior art, the outer walls of the wooden frame system are basically made of the following layers: Styrofoam/wool, mesh, plaster, MFP. (Multifunction Panel), wind proof foil, timber structure (at a distance of approx. 40 cm) mineral wool, vapour barrier foil, MFP and plasterboard. This technology also implies the need to make a double- layer wall, or make walls of considerable thickness to eliminate linear thermal bridges. This type of walls are not resistant to water or biological corrosion, and are heavier than those made in the technology of bridgeless structural composites. [6] One of the most well-known and widely used external wall construction systems is the traditional brick wall. In this system, masonry held external walls are generally made as two-layer: the supporting layer can be made of bricks, hollow blocks, cellular concrete blocks, silicates or expanded clay concrete. The thermal insulation layer is made from mineral wool or polystyrene with a thickness of approx. 12-20cm, fitted from the outer side of the wall. The most significant disadvantages of erecting walls in traditional technology is high volumetric weight and long construction time. For this reason, erecting a masonry wall is dependent on weather conditions and can not take place in the prefabrication plant, and find applications in modular technology.

[7] Wall and ceiling installation systems in the form of sandwich panels with a core of polyurethane foam or expanded polystyrene are also known. Sandwich panels consist essentially of two claddings of steel sheet (external and internal) and a structural-insulating core between them. The disadvantage of this type of solutions is the possibility of panel separation in the event of fire, surface finishing limitations and placing installations in the insulating layer of the panel. In addition, sandwich panels make it impossible to put in windows and doors directly in the panels without using additional substructures.

[8] The primary purpose of the invention described in this document was to eliminate the disadvantages of the prior solutions used in construction, in particular in modular construction.

[9] This goal has been achieved with a bridgeless structural composite for the construction of walls and ceilings, according to claim 1. The system of building walls and ceilings based on bridgeless structural composites, compared to the SCS system, is characterized by reduction of linear thermal bridges in single-layer barriers. This system also makes it possible to adjust the thickness of the partition, depending on the needs. In comparison to timber frame technology systems of building walls and ceilings, it is characterized by a lower volumetric weight, as well as better resistance to biological corrosion and moisture. Compared to traditional brick walls, it has a lower weight, and requires much shorter implementation time at the construction site. Moreover, it is possible to be completed at the prefabrication site. In addition, in contrast to sandwich panels with polyurethane foam or expanded polystyrene core, the wall and ceiling installation system based on bridgeless structural composites does not split during fire, allows for air diffusion, placing installations inside the wall, and easy installation of window and doors.

[10] The essence of the invention is a bridgeless structural composite intended for construction of walls and ceilings, which is characterized by the fact that it contains external and internal profiles, battens connecting external and internal profiles and filling.

[11] Preferably, the external and internal profiles are made of sheet metal, preferably of galvanized, stainless or acid resistant steel.

[12] Preferably, the battens are made of sheet metal, preferably of stainless steel or acid resistant sheet metal.

[13] Preferably, the filling is a material having insulating properties.

[14] Preferably, the filling is a closed cell polyurethane foam.

[15] Preferably, the battens are arranged alternately.

[16] Preferably, the battens have axial bends along the longer edge and/or their surface is perforated.

[17] Preferably, the bridged structural composite is in the form of a post or a beam.

[18] Preferably, the bridgeless structural composite is used in construction, preferably in modular construction. [19] The batten used in the composite, according to the invention, is a transverse connection between external and internal profiles, preventing their bending.

[20] The batten is characterized by increased stiffness (EJ). The use of an axial bending along the long edge of the batten causes an increase in the moment of inertia in the cross-section of the batten.

[21] According to the invention, external and internal profiles and battens having an axial bend along the long edge, the surface of which may have perforations, additionally cause a longer heat transfer path, which, in addition to completely eliminating linear thermal bridges, also significantly reduces point thermal bridges, reducing the heat transfer coefficient, both the structural composite and the entire partition, for the construction of which such composites were used.

[22] The essence of the invention is also the method of construction of walls and ceilings of buildings using bridgeless structural composites, characterized by the fact that the bridgeless construction composites are placed at a certain axial distance from each other, and that it is accomplished by the following: attaching bridgeless structural composites to the building structure using fasteners, attaching the board intended to be used inside the building directly to bridgeless structural composites, filling the space between bridgeless structural composites with a thermal insulation layer, fixing the board intended for use outside the building directly to bridgeless structural composites or using a spacer structure between bridgeless structural composites and the board intended for use outside the building.

[23] The use of the bridgeless construction composite in construction of walls and ceilings of buildings, according to the invention, makes it possible to obtain the following benefits: > Easy wall panel assembly using screws, including boards resistant to difficult transport conditions.

> Facilitating the preparation of the finishing layer of the fagade entirely in the prefabrication plant.

> Eliminating the need for an outer insulation layer of the partition thanks to reducing thermal bridges.

> Reducing the thickness of the external partition, in the case of modular construction, reducing dimensions of the module and, consequently, the weight of the modules.

> Eliminating the risk of damage to the fagade during loading, transport and assembly on site thanks to the use of boards resistant to difficult transport conditions.

> Increased resistance of the partition to fire in its advanced phase. Battens ensure that the partition is held together during a fire.

> Manufacturing the partition in many alternatives, sizes and standards.

o Adjusting the width of the bridgeless construction composite, and consequently the entire partition, allows for optimal adaptation of the thermal insulation coefficient,

o Changing the type of polyurethane foam and profile thickness determines the mechanical properties of the element,

o Changing the class of steel used to build the composite results in additional properties, e.g. increased corrosion resistance, o Adjusting the width, and the feasibility to make openings easily, creates room for various types of installations inside the walls

> Mounting windows and doors directly in the insulation layer, which eliminates linear thermal bridges.

[24] The subject of the invention and the examples of implementation are shown in the drawings, in which:

Fig. 1. Presents bridgeless structural composite in a side view. Fig. 2. Presents bridgeless structural composite in the A-A cross-section.

Fig. 3. Presents bridgeless structural composite profile in a side view.

Fig. 4. Presents bridgeless structural composite profile in the B-B cross-section.

Fig. 5. Presents the first alternative of the batten in the bridgeless structural composite, in the view.

Fig. 6. Presents the first alternative of the batten in the bridgeless structural composite, in the C-C cross-section.

Fig. 7. Presents the first alternative of the batten in the bridgeless structural composite, in the D-D cross-section.

Fig. 8. Presents the second alternative of the batten in the bridgeless structural composite, in the view.

Fig. 9. Presents the second alternative of the batten in the bridgeless structural composite, in the E-E cross-section.

Fig. 10. Presents the second alternative of the batten in the bridgeless structural composite, in the F-F cross-section.

Fig. 11. Presents the third alternative of the batten in the bridgeless structural composite, in the view.

Fig. 12. Presents the third alternative of the batten in the bridgeless structural composite, in the G-G cross-section.

Fig. 13. Presents the third alternative of the batten in the bridgeless structural composite, in the H-H cross-section.

Fig. 14. Presents the fourth alternative of the batten in the bridgeless structural composite, in the view.

Fig. 15. Presents the fourth alternative of the batten in the bridgeless structural composite, in the l-l cross-section.

Fig. 16. Presents the fourth alternative of the batten in the bridgeless structural composite, in the J-J cross-section.

Fig. 17. Presents the first alternative of a protection wall with bridgeless structural composite in the horizontal section.

Fig. 18. Presents the first alternative of a protection wall with bridgeless structural composite in the vertical K-K section.

Fig. 19. Presents the second alternative of a protection wall with bridgeless structural composite in the horizontal section.

Fig. 20. Presents the second alternative of a protection wall with bridgeless structural composite in the L-L vertical section.

Fig. 21. Presents the third alternative of a protection wall with bridgeless structural composite in the horizontal section.

Fig. 22. Presents the third alternative of a protection wall with bridgeless structural composite in the M-M vertical section.

Fig. 23. Presents a vertical section through the module.

Embodiment No. 1

[25] Fig. 1 and Fig. 2, show an embodiment of a bridgeless structural composite in the form of a post. Battens 2, made of stainless steel, are arranged alternately. Battens 2, in this embodiment, connect the external and internal profiles 1, which in this example of implementation are made from galvanized steel. Closed cell polyurethane foam is The filling 3 in the space between profiles and battens. The shape of battens 2 connected to the outer and inner profiles 1, in this embodiment resembles an I-beam

Embodiment No. 2

[26] In the embodiment shown in Fig. 3 and Fig. 4, the outer and inner profiles 1 are made of galvanized steel and in the cross-section resemble an T-beam.

Embodiment No. 3

[27] Fig. 5, Fig. 6 and Fig. 7 show an embodiment of batten 2 in stainless steel. Batten 2 in this embodiment has an axial bending 18 along the long edge. The batten alternative in this embodiment is characterized by increased stiffness (EJ) and increased moment of inertia C-C resulting from axial bending.

Embodiment No. 4

[28] Fig. 8, Fig. 9, Fig. 10 show an embodiment of batten 2 in stainless steel. In this embodiment, batten 2 has an axial bending 18 along the long edge and perforations 19 on the surface. In this embodiment, perforations 19 have a shape resembling a circle. Perforations 19 result in a longer heat path through batten 2. The batten alternative in this embodiment is characterized by lower stiffness (EJ) with respect to the embodiment of the batten in the third embodiment.

Embodiment No. 5

[29] Fig. 11, Fig. 12 and Fig. 13 show an embodiment of batten 2 in stainless steel. In this embodiment, batten 2 has an axial bending 18 along the long edge and perforations 19 on the surface. According to this embodiment of batten 2, perforations 19 have a smaller diameter than the batten perforations in the fourth embodiment. The batten alternative described in this embodiment is characterized by a lower stiffness (EJ) with respect to the embodiment of the batten described in the third embodiment.

Embodiment No. 6

[30] Fig. 14, Fig. 15 and Fig. 16, show the embodiment of a batten 2 in stainless steel. In this embodiment, batten 2 has an axial bending 18 along the long edge and perforations 19 on the surface. Perforations 19 resemble an elliptical shape. The batten alternative described in this embodiment is characterized by a lower stiffness (EJ) with respect to the embodiment of the batten described in the third embodiment. Embodiment No. 7

[31] Fig. 17 and Fig. 18 present the embodiment of the protection wall with bridgeless structural composite 4. According to this embodiment, bridgeless structural composites 4 are fastened to the wall 8 in the form of a post. Bridgeless construction composites 4 are spaced at axial distance of 60 cm. In this embodiment, the space between the bridgeless structural composites 4 is filled with a mineral wool insulation layer 6 with a bulk density of at least 45 kg/m³. The board designed for use outside the building 5, with a thin-layer of fagade finish, is attached to bridgeless structural composites 4 external profiles 1 made of galvanized steel.

Embodiment No. 8

[32] Fig. 19 and Fig. 20 show an embodiment of protection wall with bridgeless structural composite 4. According to this embodiment, post-shaped bridgeless structural composite 4 is fitted to the board intended for use inside the building 7. Bridgeless structural composites 4 are spaced in the wall at axial distance of 60 cm. In this embodiment, the space between the bridgeless composites is filled with a layer of mineral wool insulation 6 with a bulk density of at least 45 kg/m³. The board designed for use outside the building 5, with a thin-layer of fagade finish, is attached to bridgeless structural composites 4 external profiles 1 made of galvanized steel.

Embodiment No. 9

[33] Fig. 21 and Fig. 22, show an embodiment of the protection wall with bridgeless structural composite 4. According to this embodiment, post-shaped bridgeless structural composite 5 is attached to the board to be used inside the building 7, finished with a PCV liner. Bridgeless structural composites are spaced in the wall at the distance of 60 cm. In this embodiment, the space between the bridgeless composites is filled with a layer of mineral wool insulation 6 with a bulk density of at least 45 kg/m³. According to this embodiment, a spacer structure 9 is provided between the outer steel profile 1 of the bridgeless structural composites 4 and the board to be used outside the building 5. The bridgeless structural composites external steel profiles of 1, placed in the wall, are connected with the board 5 intended for outdoor use with a finishing layer.

Embodiment No. 10

[34] Fig. 23. shows an embodiment of the module with bridgeless structural composites 4 in the form of a post. According to this embodiment, post-shaped bridgeless construction composites 4 are attached to the board intended for use inside the building 7. According to this embodiment, the bridgeless construction composites 4 are attached to the structure of the building 15 by means of connectors 20. The roof of the module, according to this embodiment, consists of a combination of surface and underlay roofing felt 10, a drop layer made of EPS 11, the insulation of EPS, PUR foam fillings 14 and board intended for interior use 7. According to this embodiment, lower construction element of the module, contains PUR foam fillings 14 MFP board 13 floor finishing 16 layer and floor board 17.

[35]

Reference list :

1- profile

2- batten

3- filling

4- bridgeless structural composite

5- the board designed for use outside the building

6- thermal insulation

7- the board designed for use inside the building

8- the wall - spacing structure0- surface roofing paper + undercoat1- EPS foam drop layer

2- EPS foam insulation

3- MFP board

4- PUR foam

5- design of the building

6- floor finishing

7- floor board

8- axial bending

9- perforations

0- connector

Claims

1. Bridgeless structural composite (4) for the construction of walls and ceilings, characterized in that it contains:

a. external and internal profiles (1),

b. battens (2), connecting external and internal profiles (1),

c. filling (3).

2. Bridgeless structural composite (4), according to claim 1, characterized in that the external and internal profiles (1) are made of sheet metal, preferably of galvanized, stainless or acid resistant steel.

3. Bridgeless structural composite (4), according to claim 1 or 2, characterized in that the battens (2) are made of sheet metal, preferably of galvanized, stainless or acid resistant steel.

4. Bridgeless structural composite (4), according to claim 1, characterized in that the filling (3) is a material with insulating properties.

5. Bridgeless structural composite (4), according to claim 4, characterized in that the filling (3) is a closed cell polyurethane foam.

6. Bridgeless structural composite (4), according to claim 1 or 3, characterized in that the battens (2) are arranged alternately.

7. Bridgeless structural composite (4), according to claim 1 or 3 or 6, characterized in that the battens (2) have an axial bending (18) along the long edge and/or their surface is perforated (19).

8. Bridgeless structural composite (4), according to claim 1, characterized in that the composite (4) is in the form of a post or beam.

9. Bridgeless structural composite (4), according to any of the claims 1 to 8, characterized in that the composite (4) is used in construction, preferably in modular construction.

10. The method of building walls and ceilings of buildings, using bridgeless structural composites (4), according to any of the claims 1 to 9, characterized in that the bridgeless construction composites (4) are placed at a defined axial distance from each other and in that the following is involved in construction:

a. the bridgeless structural composites (4) are fixed to the building structure (15) by means of connectors (20),

b. the board intended for indoor use (7) is fixed directly to the bridgeless structural composites (4),

c. the space between bridgeless structural composites (4) is filled with thermal insulation layer (6),

d. the board intended for outdoor use (5) Is fixed directly to the bridgeless structural composites (4) or spacer structure (9) is used between bridgeless construction composites (4), and the board intended for outdoor use (5).