WO2014086362A1

WO2014086362A1 - Mounting system for prefabricated wall elements

Info

Publication number: WO2014086362A1
Application number: PCT/DK2013/000085
Authority: WO
Inventors: Jorgen Christoffersen
Original assignee: Jorgen Christoffersen
Priority date: 2012-12-06
Filing date: 2013-12-02
Publication date: 2014-06-12
Also published as: DK177773B1

Abstract

A mounting system for prefabricated wall elements for mounting wall elements against a guide block, which is designed for attachment to a foundation in the wall element's longitudinal direction. The guide block includes an upper and an oppositely located lower surface having an installation against the foundation, as well as lateral faces, connecting the upper and lower surfaces. An element bottom plate designed for fastening to the wall element's lower bottom plate. The mounting system includes a bottom rail with a top part comprising an upper face which is designed to turn toward the wall element's bottom plate and cover this when the wall element is installed, and a lower surface, which is designed to face toward the guide block's upper surface. The bottom rail's side walls, which extend from its top part in direction towards the guide block's upper surface, are designed to cover the guide block's side walls.

Description

Mounting system for prefabricated wall elements

The invention relates to a fastening system for prefabricated wall elements for assembly of wall elements against a guide block, which in the wall element's longitudinal direction is designed for attachment to a foundation. The guide block includes an upper surface and an oppositely located lower surface facing against the foundation, as well as side surfaces, which connect the upper and lower surfaces. This fastening system includes an element bottom plate, which is designed to be secured to the wall element's bottom plate.

FR 2445871 describes a fastening system for wall elements. The system includes a bottom rail for fastening to a floor and the wall element's bottom surface is attached toward the upper surface. However, it may be difficult to keep the wall elements exactly in place, just as the stability of the assembly is not optimal. Moreover, the system does not allow for adjustment of the setup in the XY direction - horizontal direction - which is independent of an adjustment in the Z direction - vertical direction.

UK patent GB 2418438 describes a design, which obtains a fastening to the foundation by means of a geometric location. The system does not use hidden jointing techniques and does not provide sufficient options for finishing a prefabricated wall element to the required extent at the factory. The system makes it possible to assemble most of the wall elements at the construction site rather than having to fit them at the factory. In this respect, it should be noted that the authorities and insurance companies to an increasing extent require the building elements to be fitted while they are dry; for this reason a large proportion of building components, including completed wall elements, are prefabricated in a protected environment and that the implementation on the construction site is fast and secure. This is also reflected in the chosen material, which does not absorb moisture. It is also desirable to enable a quick and simple adjustment in the XY direction when mounting the wall elements, i.e. in the horizontal direction, which is independent of an adjustment in the vertical direction, i.e., in the Z-direction. This allows the rapid set-up and while also ensuring that the wall elements are set up in level. This will reduce the risk of damage to the building. This is not possible with any of the systems described by the above-mentioned patent.

Moreover, it should also be noted that the known rail systems, such as GYPROC steel profiles, are not intended for a hidden fastening technique in case the steel profiles for part of prefabricated wall elements. Instead, they are based on walls being constructed onsite. Neither the attachment to the foundation nor to the joint wall elements includes a hidden jointing technique, just as it is not possible to make an adjustment to wall elements in the XY direction independently of the adjustment in the Z-direction.

It is therefore the aim of this invention to provide a fastening system, which comprises an alternative to the known systems or which does not contain their disadvantages.

This objective is achieved with a fastening system as specified in the introduction, and which also includes a bottom rail to the fastening system with a top-part including an upper surface that is designed to face toward the element bottom plate and be covered by this when the wall element is installed, and a lower surface, which is designed to face toward the guide block's upper surface. This bottom rail includes side walls outbound from the bottom rail's upper part towards the guide block's upper surface. These side walls are designed to cover the guide block's side walls. This will make it possible to make an adjustment to the walls in the Z-direction, i.e., in the vertical direction independently of a prior alignment in the XY direction, i.e., the horizontal direction. This XY-alignment is performed by means of the guide block. When assembling the prefabricated walls on top of the guide block, they will be set correctly in the XY direction, i.e. horizontally. The guide block is to be installed first and is attached directly to the foundation, which must be cleaned for impurities in advance. The guide block is a bar that is shaped as a rectangle or square in its cross-section. However, it can also be e.g. T-shaped, etc. In order to prevent the absorption of moisture from the foundation, it is recommended to start by installing a moisture barrier - a membrane - throughout the entire forthcoming wall's width. In case the foundation is very uneven, the membrane must be sealed underneath with a gasket-material, such as construction silicone to prevent future water ingress. The guide block is placed in the center of the point of the bottom rail's location. For additional protection against unwanted water ingress, particularly during the construction stage, it can be an advantage to place a membrane of foil on the guide block going all the way to the outside end of the foundation. Adjustment pieces can be placed on top of the guide block's upper surface to ensure a 100 percent horizontal base for the bottom rail. The adjustment pieces have to be level to the upper surface of these adjustment pieces is level. Leveling is mainly done by means of a laser. The bottom rail is now placed on top of the guide block and attached to the foundation. The bottom rail's upper surface is now 100 percent horizontal and provides a coherent and stable surface for lower surface of the prefabricated wall element's bottom plate. The profile of the bottom plate fits to the bottom rail and comes with several types and sizes depending on the thickness of the wall element and choice of materials and is mounted on the bottom of the wall element. The prefabricated wall elements are placed directly on the bottom rail. In the case of exterior walls, a thin line of sealing material, such as construction silicone, is applied in advance to both load-bearing flanges.

The system generates significant time savings by allowing assembly directly on the construction site compared to current techniques, thus minimizing unwanted moisture damage. Finally, an invisible anchoring of the wall element to the underlying rail system is also achieved, just as the above is demonstrates the fact that the setup of the wall element in XYZ direction is done in a more secure and simple manner. Pre-fabricated wall element means a wall module that comes with a preassembled wall's usual characteristics and features. An appropriate embodiment of the mounting system includes the feature of the side wall's height extension in vertical direction T1 being less than or equal to the thickness T2 of the guide block measured vertically between the upper and lower surface.

This ensures that the bottom rail's vertical flanges do not touch or otherwise conflict with burrs on the foundation regardless of whether wedges are placed between the guide block and bottom rail or not. A further appropriate embodiment of the mounting system includes that the upper surface of the bottom rail includes a first male/female means of control, and the element bottom plate includes another male/female means of control. These means of control are designed to interact with each other. The means of control ensure good stability between the wall elements and the bottom rail, as the first and second means of control are engaged.

A further appropriate embodiment of the mounting system includes the fact that the bottom rail's upper surface contains a conical lock element that comprises outward facing divergent surfaces parallel with the bottom rail's longitudinal direction of which the upper surface is facing toward the element bottom plate is designed to have abut against it by anchoring the wall element. The two parallel and consecutive edges of the conical lock element are moreover designed to have abutted against the element bottom plate's vertical side walls. This help stabilizing the wall elements during the mounting process.

A further embodiment of the mounting system includes the fact that it contains a bottom fastening bracket. This which bottom fastening bracket is a plate- element that contains a recess, which is designed to engage with the bottom rail and also includes fixing-parts for fixing of a wall element.

This will make it possible to stabilize the wall element, as the bracket via its recess is secured to the bottom rail's conical lock grip and subsequently slided against the wall element's gable end, which is fitted with a gable post, in which the bracket can be secured. Fixing systems can include simple fastening by means of screws through holes in the bracket, or a locking pin on the bracket side facing the gable post where the locking pin engages in a recess in the wall element's gable post. The recess typically includes a conical-shaped punched element so that the cone-shaped recess is congruent with the bottom rail's conical locking lever and attached to this. The bottom fastening bracket is mounted onto the conical top through slots in the bottom rail. Afterwards, the bottom fastening bracket is advanced towards the wall element's vertical wall post and clicked into place thus locking together the bottom rail and bottom fastening bracket. The bottom rail's built-in slots are typically made with a distance of 1 meter between them, so that the bottom fastening bracket can be attached to the bottom rail's middle conical locking lever. A further appropriate embodiment of the mounting system includes supporting flanges that run horizontally from the bottom rail's side panels.

The supporting flanges on each side of the bottom rail's center conical locking lever, ensuring an even pressure distribution and a better balance of the wall element.

A further appropriate embodiment of the mounting system is a conical-shaped locking element on the bottom rail's upper free surface for interaction with the bottom fastening bracket's recess.

This provides a stable connection between wall post and bottom rail.

A further appropriate embodiment of the mounting system is the fact that the mounting system also includes a top fastening bracket (13), which includes a plate part. This plate part is designed to be fastened to the wall element's (1 1) vertical gable post with a first part and a second part designed to be fastened to the rafters and/or a top plate. This ensures a total locking of the wall element. The upper attachment of the wall element could, however, also be done in other ways, for example by using an angle bracket, etc. Alternatively, attachment can take place from the top of the wall element, when the building setup is completed, and/or where ceilings are installed before the wall element is setup, where nails, screws, etc. can be screwed down through the ceiling and into the wall element.

Complete anchorage is achieved by the use of top fastening bracket and a bottom fastening bracket and the other components of the mounting system.

A further appropriate embodiment of the mounting system includes adjustment pieces between the upper surface of the guide block and the lower surface of the bottom rail. A further appropriate embodiment of the mounting system includes the fact that the guide block's side surfaces have a distance of S1 between them and that with regard to the distance between the bottom rail's inner side walls that are pointing toward each other, B1 is greater than or equal to S1. Thus, S1 is the guide block's width.

A further appropriate embodiment of the invention includes the fact that the bottom rail is a U-shaped profile the internal lateral faces of which have a significant press fit towards the guide block's lateral faces.

It is noted that the mounting system for prefabricated wall elements in general involves: A guide block in the wall element's longitudinal direction that is designed to be secured to a base/foundation with the option of horizontal levelling the foundation's uneven areas. A bottom rail with a lower surface in the form of a significant pressure-fit to the guide block with an upper part including vertical guide flanges to the wall element's bottom plate and a conical fastening element for fastening of the wall element. A bottom plate mounted at the bottom of the wall element and which is primarily congruent with the bottom rail's top- part and which together with the bottom plate each of which forming half of a male/female form. A bottom fastening bracket: a plate element which includes a recess that is congruent with the bottom rail's conical fastening element and also includes anchorage adapted to engage with the wall element's vertical gable post. The system also includes a top fastening bracket installed in the upper part of the wall element's vertical gable post and secured to top plate and rafter, thus ensuring both vertical stabilization of the wall element and the complete connection and anchoring of the common rafter to the foundation.

The invention will now be explained in detail with reference to the drawings, in which:

Fig. 1 shows the individual subcomponents that form part of the mounting system according to the invention, as well as related equipment and the system's relation to a wall element. Fig. 2 shows a prefabricated wall mounted with the mounting system using the items shown in fig. 1 and according to the invention.

Fig. 3 shows a prefabricated wall mounted together with the mounting system according to the invention and with alternative equipment for final attachment.

Fig. 4 shows a detailed view of a wall element steered into place.

Fig. 5 shows the X, Y, and Z directions for the mounting system. Fig. 1 shows a mounting system according to the invention which comprises a bottom rail (4) and an element bottom plate (7), and the mounting system's relationship with a guide block (1 ) and a wall element (1 1 ). In the example shown, the guide block (1 ) is a rectangular bar shown in cross-section comprising an upper flat surface (33), an opposite lower flat surface (34), as well as two consecutive lateral faces (35).

The Bottom rail (4) includes a top (6) consisting of an upper surface (36) and a lower surface (37) which face toward the guide block's (1 ) upper surface (33) during the assembly. The bottom rail top's (6) upper surface (36) contains a conical locking element (16) which is a part of a first means of control. The conical locking element (16) includes two conical profiles which are axis-parallel to the bottom rail and longitudinal; both of which have upper divergent lateral faces and an upper, level end surface, the two longitudinal profiles of which are separated by a longitudinal recess (15). The bottom of recess (15) contains holes enabling the bottom rail (4) to be mounted on the guide block (1 ) and attached by means of screws (27) and in special cases further attached to the foundation by mounting through the holes.

The bottom rail (4) includes vertically consecutive side walls (38), which point in the direction of the guide block (1) and opposite the conical locking element. The sidewalls (38) are appropriately equipped with flanges (41 ), as the side- walls (38) are bent at an angle of 90 degrees away from each other to provide room for the flanges (41 ) and subsequently back at an angle of 90 degrees and facing down toward the guide block (1 ). The sidewall (38) provides installations against the guide block's sidewalls. Below the flanges (41 ) is possible to place an additional component such as a list or sealant that can break the thermal bridge. The width S1 of the guide block measured between the lateral faces (35) is less than or equal to the width of the minimum distance B1 between the bottom rail's (4) lateral faces. Between the guide block's (1 ) upper surface (33) and the bottom rail's lower surface (37) it is possible to embed adjustment pieces (2), whereby the bottom rail (4) can be corrected in level in relation to a foundation. The thickness of the guide block (1 ) T2 is therefore greater than or equal to the distance T1 between the bottom rail's (4) lower surface and its abut against sidewalls towards the foundation, when the bottom rail (4) is located on top of the guide block (1 ). The bottom rail (4) thus encloses the guide block (1 ) and appropriate pvc-foil can be placed between the two elements in addition the described adjustment pieces (2). In addition, the sidewalls at the bottom rail (4) be appropriately clamped to the guide block's lateral faces in order to provide a good abut against this for a proper fit. It should be noted that the flanges (41 ) do not clamp onto the guide block as these flanges are used to finish the rail- system against the foundation for sealing against accidental ingress of water and air.

The element bottom plate (7) is thus mounted between the wall elements (1 1 ) bottom surface (21 ) and the bottom rail's (4) upper surface (36). The element bottom plate (4) is shaped with an upper surface which is essentially congruent with the wall element's (1 1 ) button surface (21 ). The bottom plate's (7) lower surface (8) that faces towards the bottom rail (4), is also essentially congruent with this, so that when the element bottom plate (7) is positioned against the bottom rail (4) a stable joint is created between the two parts. The element bottom plate (7) is formed with a turned-up U-shaped part which encloses the locking element (16) of the bottom rail (4). This ensures that the element bottom plate is stable against the bottom rail (4) precisely balanced. In addition, the element bottom plate (7) includes upper vertical outer surfaces (14) which appropriately latch onto the wall element's (1 1 ) outer surface.

The upper surface (36) of the bottom rail (4) thus includes - in principle - a male/female means of control, a first means of control, which in this case is the conical locking element (16) and the element bottom plate (7) thus comprising a second male/female means of control (40) in relation thereto, which is in principle to the lower surface of the element bottom plate that encloses parts of the bottom rail (4) in a stabilizing manner. The shape of the element bottom plate (7) corresponds to the bottom rail (4) as a male/female form located on top of the bottom rail. In addition, there is a means of control which ensures that the wall element is placed correctly in the XY plane.

The system also includes auxiliary bracket's containing a bottom fastening bracket (12) and a top fastening bracket (13). These brackets are designed to secure the wall element (1 1 ) with greater stability in relation to the foundation and in relation to rafters. The bottom fastening bracket (12) in this example is shaped like a plate part, where the upper plate part includes means of anchorage for the wall element's gable wall, which is appropriately is fitted with a wall post and where this plate part is stapled to it either by using the locking pins (19), which in Fig. 1 is shown in a sectional view, or by using the screws, which anchors the bracket to the gable post. The bottom fastening bracket's (12) lower part includes a conical recess (17), the delimiting lateral faces of which converge in the direction of the guide block (1 ) when the bracket (12) is installed. This conical shape is essentially congruent with the conical locking element's (16) outer lateral faces. This ensures an appropriate locking of the prefabricated wall element to the mounting system.

The upper part of the wall element must be mounted as mentioned by means of an upper top fastening bracket (13). It includes a plate part, where the lower part of it can also contain locking pins (19) that engage with the gable post's (9) prefabricated fastener elements or can be installed by using the screws. This bracket also includes a threaded rod (25) which is used to secure and ensure the top-plate and/or rafter (10), as shown in Fig. 1. Fasten the threaded rod by means of a nut (30) and washer (31 ).

The bottom rail (4) contains built-in slots, approximately every meter, so that the bottom fastening bracket (12) can slide in at the bottom rail's middle, conical locking lever (16). If the bottom fastening bracket's (12) position should prove to be exactly at the bottom rail's slots, the bottom fastening bracket (12) can instead be attach in place with a number of self-tapping screws to the bottom rail (4). The wall post which is prepared for the construction can be fitted with items such as recesses, which allow the top fastening bracket and bottom fastening bracket to click into place. When all the wall elements (1 1 ) are in place, the element top plate (10) is ready to be placed on top of these, which is designed to guide the wall elements into each other and form a firm anchor for securing the rafter. Fig. 2 shows the same elements as in Fig. 1 , but where a wall element (1 1 ) is mounted to the foundation (3) using the mounting system according to the invention. The guide block (1 ) is attached to the foundation (3) by means of screws and the bottom rail (4) is placed on the guide block (1 ), between which adjustment pieces (2) are placed to level the bottom rail's (4) upper surface. The wall element (1 1 ) here is equipped with the element bottom plate (7), whose upper surface is congruent with the wall element's lower surface (21 ). The element bottom plate's (7) surface (8) that faces towards the bottom rail's (4) upper surface (36) is shaped to ensure a wide contact against this. This provides stability, also in the lateral direction, just as the conical locking element (16), in addition to locking the bottom fastening bracket (12) thereto, will provide a stability perpendicular to the wall element in the longitudinal direction. The reference numbers used in Fig. 1 therefore also apply to Fig. 2.

Fig. 3 shows an auxiliary bracket shaped in another manner than those shown in figures 1 and 2. The bottom fastening bracket (12) and the top fastening bracket (13) are both perforated plates firmly nailed against the wall element's vertical gable post instead of being clicked into place as shown in Figs. 1 and 2.

In addition, the construction is identical to the one in provided in Figs. 1 and 2.

Fig. 3 shows, as mentioned earlier, that the bottom fastening bracket (12) has been designed without the locking pin and instead being fitted with a perforated nail plate and fastened with ribbed nails or bracket screws. The top fastening bracket ( 3) is anchored in the same way. The bottom rail (4) is essentially a U-shaped profile with internal side faces that have a pressure-fit against the guide block's side faces. The bottom rail's (4) upper surface includes the locking element (16) which interacts with the element bottom plate (7), but also helps to secure the bottom fastening bracket (12).

The system according to the invention is thus a vertical anchorage between foundation and rafter and a horizontal slide protector, whereby the rail-system can be included in buildings' calculations for stability. The vertical wall post forms, together with the element bottom plate and the element top plate, the framework for the wall element in interaction with the mounting system. The mounting system includes the element bottom plate and the bottom rail in interaction with the guide block. It should be noted here that the conical locking element in the examples shown is shown with side faces, which diverge upwards. The conical locking element can, however, have other designs. For example, the side faces can instead include the appropriate recesses and gaps, so that there is an adequate opportunity for securing the brackets and so that there is a good surface joint and surface-area between the element bottom plate (7) and bottom rail (4).

Fig. 4 shows a detailed view of a wall element guided into place and where the reference figures are the same as those applied to the other drawings. The element bottom plate (7) includes vertically consecutive side walls (42), the internal surfaces of which contain installations against the conical elements corner, i.e., in the range between the locking element's outward diverging surfaces (39) and its top-plate. This acts as a means of control. The bottom rail rests against an adjustment piece (2), but could also rest against the guide block's upper surface while the bottom rail's walls and flanges do not have installations towards the foundation. Instead, it should be sealed

with appropriate joint fillers.

Fig. 5 shows X, Y, and Z directions for the mounting system. Reference List

1 Guide block

2 Adjustment pieces

3 The foundation

4 Bottom rail

6 Bottom rail's top

7 Element bottom plate 8 Element bottom plate's plate part facing the bottom rail's top

9 Vertical wall post

10 Element top plate

11 Wall element

12 Bottom fastening bracket

3 Top fastening bracket

14 Vertical external surfaces of the element bottom plate 15 Recess

16 Conical locking element

17 Recess of 12

19 Locking pin

21 Wall element's bottom plate

25 Threaded rod 30 Nut

31 Washer

33 Guide block- upper surface

34 Guide block- lower surface

35 Guide block- lateral face

36 Bottom rail- upper surface

37 Bottom rail- lower surface

38 Bottom rail- side walls

39 Locking element's out-divergent surface

40 Second male/female means of control

41 Flanges

42 Element bottom plate's vertical side walls

Claims

Patent claims

1. Mounting system for prefabricated wall elements (11) for installing the wall element (11) against a guide block (1), which in the wall element's (1 1) longitudinal direction is designed for attachment against a foundation ( 3), and where the guide block (1) includes an upper (33) and oppositely placed lower surface (34) with the installations against the foundation (3), as well as lateral faces (35), which connect the upper and lower surfaces (33,34), in which the mounting system includes an element bottom plate (7), designed for fastening beneath the wall element's bottom plate (21), characterized by the mounting system also including a bottom rail (4) with a top-part (6) that includes an upper surface (36), which is designed to face towards the element bottom plate (7) and is hidden by this when the wall element's (11) is mounted, and a lower surface (37), which is designed to face the guide block's upper surface (33), and where the bottom rail (4) includes side walls (38) outbound from the bottom rail's top part (6) in the direction of the guide block's upper surface (33), the side walls of which (38) are designed to cover the guide block's side (35).

2. Mounting system according to claim 1 , characterized by the side walls' (38) height-extension in vertical direction T1 being less than or equal to the thickness T2 of the guide block (1) measured vertically between the upper and lower surface (33, 34).

3. Mounting system according to any of the previous claims, characterized by the upper surface (36) of the bottom rail (4) comprising a first male/female means of control and that the element bottom plate (7) comprises a second male/female means of control (40), and these first and second means are designed to interact with each other.

4. Mounting system according to any of the previous claims, characterized by the bottom rail's upper surface (36) comprising a conical locking element containing an out-divergent faces (39) parallel with bottom rails in the longitudinal direction, the upper surface of which are facing toward the element bottom plate's (7) internal surface which is designed to have an edge facing towards this by fastening the wall element (1 1) as well as two parallel extending edges of the conical locking element which are designed to having abutted against the elements' bottom plates' vertical side walls (42).

5. Mounting system according to any of the previous claims, characterized by including a bottom fastening bracket (12), which is a plate element containing a recess, which is designed to engage with the bottom rail (4) and further more includes means of anchorage for fastening a wall element (1 1 ).

6. Mounting system according to any of the previous claims, characterized by the bottom rail's side walls (38) extends horizontally on supporting flanges.

7. Mounting system according to claims 5-6, characterized by the bottom rail's upper free surface (36) comprises a conical-shaped locking-element (16) which interacts with the bottom fastening bracket's (12) recess.

8. Mounting system according to any of the previous claims, characterized by the mounting system also including a top fastening bracket (13), which (13) includes a plate part that is designed to be fastened to the wall element's ( 1) vertical gable post with a first part and a second part designed to be fastened to the rafters and/or a top plate.

9. Mounting system according to any of the previous claims, characterized by adjustment pieces (2) between the guide block's (1) upper surface (33) and the bottom rail's (4) lower surface (37).

10. Mounting system according to any of the previous claims, characterized by the guide block's side walls (35) having a distance of S1 between themselves and that the distance between the bottom rail's side walls' (38) internal surface pointing toward each other B1 is greater than or equal to S1 .