FRAMING SYSTEM AND METHOD FOR MAKING PREFAB FACADE ELEMENTS WITH AT¬ TACHED CONCRETE BEAM, ANDTHEREBY OBTAINED SELF-SUSTAINING FACADE SPAN ELEMENTS

The invention relates to a polyvalent framing kit for use in making faςade wall span elements in a simple prefab mode, simultaneously with a matching concrete beam, for windows, doors, gateways, balconies, projec¬ tions and the like. Said framing kit also allows the forming of concrete beams.

The framing kit comprises an adaptable base element and different connectable extension elements, allowing a plurality of different span shapes with annexed beam to be composed.

The extension elements may vary in dimension: the ver¬ tical as well as the horizontal dimension can be adap¬ ted or selected in accordance with the width or the construction depth of the walls, incl. the dimension or length of the faςade stucture, preferably stretcher brick masonry. The add-on framing kit can be made from different materials such as steel,aluminium, stainless steel, PVC, wood etc. The different elements are con¬ nectable to oneanother by means of clamp fasteners or bolt-nut connections, such that the desired span shape geometry can be readily assembled together. The invention pertains also to a method of making pre¬ fab building elements of the facade span type composed of a conrete beam bearing member with attached finish layer, in particular strecher rows of brick masonry or other facing elements, produced by using said add-on framing kit, and furthermore to the prefab building element itself obtained thereby. In order to make a strong and safe framework for a corbel span of a wall opening with a thickness of 300 mm, one needs a lot of material on the building spot:

e.g. 2 struts every metre of opening (with in total at least 4), at the exterior and interior side of the wall 2 wooden beams and traverses (e.g. rafters), a plate or board matching the facade wall depth whereup¬ on the stretcher bricks are laid, a plate (with fill- up) for cast molding the concrete, at the exterior of the wall a plate with wooden studs mounted with an angle of 45° to retain the concrete at the inner wall side. The board in the horizontal plane and also the board at the wall interior must be adapted (saw cut to size) to: a) the depth and length of the opening and b) the heigth of the beam. Such a construction requires a lot of material and ma¬ ny labour hours. Further there is a waste of material due to sawing.

With the add-on framing kit all these steps are eli¬ minated and there is no longer a need of complicated framework constructions. The width and the length of the stretcher and the beam are adjusted in very short time on the framing table. In case a framework has to made at a storey level, working becomes dangereous (in particular at corner openings) since mounting occurs outside the b <uilding plate. The present invention pro- vides a solution to these drawbacks arising on con¬ struction yards. For placement of a wall span with adjoining concrete beam, if made by the framing kit of the invention, one needs only 2 struts. Concrete beam casting no longer occurs on high levels but is carried out on a safe and regular working height. By utilizing the add-on framing kit one has now the possibility to manufacture, on the working floor or on the ground floor, facade spans with accompanying con¬ crete beam in a simple and quick prefab manner. In ad¬ dition the framing kit offers the possibility to make prefab concrete beams to desired size.

The proposed novel solution according to the invention is a framing system in the form of an extendable (add¬ on) framing kit as defined in main claim l. Preferred and particular embodiments of the invention are defin¬ ed by the technical features of the dependent claims.

The advantages accomplished with the present invention are directed to quality improvement, material-saving and saving of time. These comprise:

1) attachment of faςade span corbelling to matching beam in prefab, fabricated on the shop floor

2) simultaneous production of facade corbelling and concrete beam

3) work operations steadily carried out on ideal height, i.e. shop floor

4) more accurate work achievable by this method

5) the stretchers remain standing in the correct po¬ sition, no sagging or cracking

6) no use any more of galvanized angle steel plate 80x80x8mm, weight of 9,66 kg per running metre

7) preciser placement of insulation and waterproof materials on top of span corbelling

8) no need of framing materials such as timber beams, panels, struts etc.

9) saving of many man hours linked to framing work: timber sawing, frame mounting, shoring up etc.

10)immediate finishing of faςade walls possible; less scaffolding to be left or moved

11)dangereous situations on elevated framing height are avoided; safer and less strenous for workers

12)the framing kit is readily usable by every worker; without skilled framing man it is also possible to make concrete beams, even when the facing stretcher is substituted for bearing concrete; the desired height of bearing concrete is easy to set up in a precise manner

13)the present invention brings along a time-saving in , labour hours of:

60% for rectilinear span corbelling 70% for angled or three-part spans

In Belgium the outer walls of most buildings generally have a width (thickness) between about 300 and 400 mm. The length of a facing brick is mostly 190 mm. Taking account of these data the invention has been worked out in detail as shown hereinbelow in the drawings. The invention is not restricted, however, to the embodiments described below, which are merely intended to illustrate the advantages of the inventive concept in a few frequently executed constructions of common size and shape.

First a survey is given of kit elements and thereafter follows a description of each framing element (fig. 1 to fig. 21). Then a detailed illustration is given, in two composite drawings, of a rectilinear span framing embodiment, fig. 22, and of an angled span at an exte¬ rior corner, fig, 23. After discussing the rectilinear and the corner spans, a general survey is given of the further possibilities achievable with the present add¬ on framing kit.

THe extendable framing kit, according to its technical realisation mode, usually comprises the following ele¬ ments:

A. the frame bench: fig. 1-2-3.

B. the stretcher holders: fig. 4-5-6-20-21.

C. the concrete holders: fig. 9-10-11.

Elements A, B and C are joinable together so as to constitute the basic element of the framing system in accordance with the present invention.

D. Attachments for the frame bench:

1. table square: fig. 7.

2. table triangle: fig. 8.

3. pull-out bench element: fig. 17-18.

4. bench square: fig. 19.

E. Attachments for sideward setting off:

1. cube: fig. 16

2. endplate concrete holder without holes: fig.12.

3. endplate concrete holder with holes: fig.13.

4. side plate for concrete: fig. 14.

5. triangle with raised edge: fig. 15.

A. The frame bench: schematic illustration in fig. 1, with 4 bench elements. The frame bench, with single or multiple elements, constitutes the bearing structure of the inventive framing system.

In fig. 2: element 2 = element 3 (middle elements). In fig. 3: element 1 and element 4 (end elements). The preferred frame bench for simple applications con¬ sists of 4 angle-section elements of for instance 560/ 250 with a length of for example 1500 mm, whereby ele¬ ment 1 and element 4 at their free outer side faces are chamfered with an angle of for instance 45° , at the raised vertical face as well as at the horizontal face, in order to enable realization of several not- rectilinear span members (for example angled to 45°, 90°, 135° etc.). The frame bench elements are provi¬ ded with the required slits for adjusting (with the stretcher holding elements) the width dimension of the walls. At their side faces the bench elements com¬ prise holes to allow assemblng them to a coherent sup¬ porting structure in accordance with the required si¬ ze and shape of the concrete beam with the attached stretcher brickwork.

B.The stretcher holders: schematized in fig. 4 to 6

for embodiment with 4 elements. Fig.4, 20, 21.

Fig. 5: element 2 = element 3.

Fig. 6: element 1 and element 4. Composed of 4 angled section plate elements of 160/ 200 with a length of 1500 mm, whereby element l and element 4 are chamfered vertically over 45° at the outer end face thereof. At the side face there is the provision of head platelets with one opening for con- nectively fixing the elements.

In the upright vertical face a slit opening is fore¬ seen for adjustment to the length of the stretcher brickwork to be laid.

In the lower side face of the stretcher holder there is also a slit opening to enable adjustment of the full width of the laid stretcher with adjoining con¬ crete beam.

In addition there are provided stretcher holders of 160/200 with a length ol 1000 mm in a left hand and right hand design version, cf. fig. 20 and stretcher holder elements in a left and right hand version of 1500 mm length, fig. 21. The stretcher holders in fig. 21 have a slit opening only in their horizontal part for their fixing onto the frame bench element. The stretcher holders in fig. 20 have a slit opening in the horizontal as well as in the vertical plane. These stretcher holders of fig.20 and fig.21 are used to make prefab elements of overhanging masonry with attached beam. The strecher is bricked up against the vertical face of the angled bench element and the slit in the vertical plane of the stretcher holder, fig.20, is employed for passing therethrough reinforcing bars which can be extended later, for instance into a peri¬ pheral beam structure of the building.

C. The concrete holders: schematically shown in fig.9 in analogy of A and B.

fig. 10: element 2 = element 3 fig. 11: element 1 and element 4 Consisting of 4 angled section elements of 160/200 with a length of 1500 mm. Element 2 and element 3 are identical. Elements 1 and 4 are chamfered to 45° at the outer end side. The side faces of the concrete holders contain head platelets with 1 opening for con¬ necting the holder elements together. In the upright vertical side plane there is provided a slit opening to fix the same to the end face plate for the concre¬ te holder.

D. Auxiliary attachments for the frame bench.

1. Table square plate cf. fig.7: a table element of 560 x 560 with 2 sides having the same holes as the side faces of the angled bench elements and with the upper side having 2 slit holes.

2. Table triangle cf. fig.8: a table element of 560 x 45° with 2 sides thereof having the same holes as in the ^" side faces of the bench angle element. With this it is possible to produce stretcher brickwork with attached concrete beam forming an angle of 135°, in the left hand as well as in the right hand version.

3. Pull-out bench element cf. fig.17,18: comprises 2 extension elements with a length of 300 mm or 400 mm which in combination with slid¬ ing elements, eventually joined with a bench element of 1500 mm, offer sufficient possibili¬ ties to set up any desired length of the middle portion of a stretcher comprising e.g. 3 faces.

4. The frame bench square plate, fig. 19: a square angled-section element of 560 x 560 with - 2 sides having a raised edge identical to that of a bench element - 2 sides having holes identical to those

in side faces of angled bench element.

E. Attachments for lateral setting-off. l.The cube, fig. 16: 160 x 160 with a height of 190 mm. The cubiform bodies have one bore hole in 3 vertical side faces for the purpose of: a. connection to oneanother; b. adjoining in desired length to vertically raised edge of the stretcher holders; c. fixation to end plate of concrete holders.

2. End plate without holes for concrete holder, cf. fig. 12: the end plates of concrete holders free of holes are available in a left and right hand version. The end plates are 400 mm of height and 300 mm of width. At the right hand side a corner portion of 160 x 210 is cut away for linking-up with concrete holder. In vertical direction two sides are with flange, i.e. 400 mm and 210 mm. The flanged side of 210 mm has a slitted hole by which the concrete holed can be fastened. The flange to the side face of 400 mm can be clamped to the vertical side of the bench element.

3. Concrete holder end plate with holes, fig. 13: the end plates are provided in a left hand and a right hand version. The flanges are the same as in concrete holder end plates of fig.12. The end plates are provided with 6 holes through which the reinforcing bars of the concrete beam are extending if it is aimed to make an attachment with a different concrete beam.

4. Side plate for concrete, fig. 14: the plate is flanged at 2 sides in vertical di¬ rection and its dimensions are 400 x 140. On one side the flange has a slit over a length of 240 mm. Said plate may be realised with or without holes. The plate is used if one wants to replace

the stretcher brickwork by bearing concrete upon which the masonry is later continued. 5. Triangle with upright edge of 40 mm, fig. 15: the right-angled triangle with sides of 280 and 320 mm and a raised edge of 40 mm has a width of 140 mm. The triangle with raised edge is placed against the end plate of the concrete holder if the stretcher with attached concrete beam has to positioned at an angle of 45°, i.e. in order to make the attached concrete, at the bearing end portion thereof, join onto the supporting wall of the facade opening to be spanned.

Fig.22 gives an overall picture of a straight corbel¬ ling span with attached concrete beam in a view from above. The laid stretcher masonry has a length of 2150 mm for a wall opening of 2175 mm.

One adjoins horizontally the two middle frame bench elements (1) of the basic kit. This gives a total length of 300 mm. On this bench element two stretcher holdera (2) mounted together upon the horizontal base plane of the bench element by means of a bolt-nut con¬ nection. The distance between the stretcher holder and the vertical plane of the bench element is the total with of the wall. The length of the stretcher is ob¬ tained by means of the cubes (4) . The cubes are placed apart to 2150 mm and screwed on the stretcher holder. Mostly two cubes are used at the outer ends of the stretcher so as to achieve a sufficient bearing sur¬ face of the concrete beam. At the end faces of the cubes the desired concrete holder end plates (5) , with or without holes, are mounted. In this way sufficient kit elements are connected to lay the stretcher mason¬ ry. After the stretcher is finished with facing bricks (6), one positions the concrete holder (3) on top of the stretcher bricks and of the cubes. The concrete

holder is fixed to concrete holder end plate (5). On the horizontal table plane of the frame bench one puts an insulation board (7) of 40 mm thickness as a filler-up of the opening between the two end plates(5) of the concrete holder. Said insulation board of 40 mm determines the window abutment. Thereafter ono applies a condensation-proof insulation board (8) of 20 mm on the horizontal (except the bearing part of the beam) as well as on the vertical faces. The vertical insula¬ tion board is adapted to the desired height of the concrete beam, section A-A in fig. 22, so that after casting the concrete reaches the same height as of the condensation-proof board.In the concrete plane one disposes the required reinforcing bars and a steel rod with two hook eyes which extend above the concrete beam, such that the overall structure can be later moved easily with a crane. After these operations the casting of the concrete (9) can start. To achieve a strong adhesion of the concrete with the facing bricks and the condensation-proof insulation the concrete is treated with a vibration needle. The cubes and the concrete holder ensure that their attachment to the facing bricks is minimised and further that the wall cavity remains open to a possibly completest extent so that cavity insulation and condensation-proof material are applicable in optimum conditions. After sufficient drying of the span corbelling masonry with attached concrete beam, the same can be lifted with a crane and built-in at the desired place.

Figure 23 gives an overall view from above of a span corbelling structure with attached concrete beam for an outward corner window of 90 ^° . The stretcher brick¬ work has a length of 1050 mm in both directions. One assembles the bench element: the two end elements of the basic kit together with the table square. The

stretcher holders are mounted on the horizontal base plane of the assembled frame bench element. One positions the stretcher holders (2) at the correct distance to the raised vertical side of the assembled frame bench in both directions and one let the two head faces of the stretcher holders contact each other on the table square plate. The length of the stretcher is obtained by setting the cubes (4) at the required distance of 1050 mm. The cubes are fixed to the stret¬ cher holder. To the outer side of the cubes one dispo¬ ses the desired concrete holder end plate (5) with ho¬ les or without holes. Now one can begin with laying the stretcher bricks (6). After finishing the stretch¬ er masonry one places the concrete holders (3) over the stretcher bricks and the cubes and one fixes the concrete holders to the edge of the concrete holder closing plate (5). On the horizontal base plane of the frame bench one places an insulation plate(7) of 40 mm thickness between the end plates of the concrete hold¬ ers. This insulation is only for the purpose of space- out filling and defines the window abutment. Subsequ¬ ently one disposes in horizontal (except for the bear¬ ing part of the beam) aslike in vertical direction a condensation-proof insulation board (8) of 20 mm. The vertical insulation plate has the same size as the height of the concrete beam. In the concrete area pla¬ ne the needed reinforcing bars are placed and also a steel rod with 4 hook eyes which are extending above the concrete beam, such that said beam may be lifted and moved easily to a desired place by means of a crane. Following these operations the concrete (9) can be cast-molded. The cast concrete may be treated with a vibration needle to make the concrete firmly attach to the facing bricks and the condensation-proof insu¬ lation. After sufficient drying of the stretcher faced

span with attached concrete beam the said structure can be lifted with a crane and built-in at the desired location.

Follows now a general outline of the possibilities af¬ forded by the framing kit system: 1. Frontal view: a. straight horizontal span

c. right hand span 45'

d. left hand angled span

e. right hand angled span f. left+right hand angled span 135' g. upwards angled span 90

2. View from above: a. left hand corner span

b. right hand corner span

c. left+right hand corner span

d. left hand corner span 135° e. right hand corner span 135°

f.

g.

The above-mentioned stretcher forms (viewed in front and from above) are also easy to combine with onean- other by means of the present add-on framing kit. In addition all kinds of bay-window projections in any form (except curved shapes) can be easily constructed in prefab with the kit of the present invention. Thus even concrete beam structures with attached faca¬ de facing elements including bearing portions that are not located in a same plane may be realised by means of the framing kit system of this invention. As an illustration of the versatility and adaptive ca¬ pability of the framing kit system according to the invention there is shown in figure 25 a combination (schematized, frame bench structure) consisting of a bench element Al, a table square T with raised edges, a εlidable bench element A2, a table triangle DI, a bench element A3, a table triangle D2 and therewith adjoining bench element A4. By this arrangement a span corbelling structure of trapezoid geometry (angles of 90°, 135° and 45°) is built.