WO2007061299A1

WO2007061299A1 - Method for manufacturing a building construction of curable material, building construction and kit of parts therefor

Info

Publication number: WO2007061299A1
Application number: PCT/NL2006/050153
Authority: WO
Inventors: Robert Marius Willibrord Van Hove
Original assignee: Individual
Current assignee: Individual
Priority date: 2005-06-29
Filing date: 2006-06-28
Publication date: 2007-05-31
Anticipated expiration: 2007-12-29
Also published as: NL1029368C2

Abstract

The invention relates to a method for manufacturing a building construction, wherein use is made of an inflatable body. The method according to the invention makes it possible to manufacture a building construction relatively quickly. The invention further relates to a building construction obtainable with such a method and a kit of parts for manufacturing such a building construction.

Description

Method for manufacturing a building construction of curable material, building construction and kit of parts therefor

The invention relates to a method for manufacturing a building construction. The invention further relates to a building construction obtainable with such a method. In addition, the invention provides a kit of parts for manufacturing such a building construction.

The manufacture of building constructions using an inflatable mould is known from for instance US 5918438. US 5918438 describes a method in which an inflatable mould in a semi-spherical shape is held in place by a network of cables, covered on the inside with an insulating foam from which is suspended a conventional reinforcement for the concrete shell. Conventional reinforcing cages are also suspended from the foam layer for the purpose of forming structural trusses. After curing of the insulating foam both the conventional reinforcement and the conventional reinforcing cages are embedded in concrete. Once the concrete has cured a self-supporting half-sphere is finally obtained in which a pattern of ribs has been created on the inner side of the sphere. The external cable network can be removed after curing of the concrete. A drawback of the method of US 5918438 is that the method is relatively labour-intensive. The freedom of design is moreover limited.

The present invention has for its object to provide an improved method for manufacturing a building construction.

The invention provides for this purpose a method for manufacturing a building construction of curable material, comprising the processing steps of: arranging tensioning wires between anchoring elements, positioning an inflatable body such that the extension of the inflatable body is defined by the tensioning wires, inflating the inflatable body, applying curable construction material to at least a part of the inflated body and curing of the construction material applied to the inflated body. A building construction of curable material can thus be obtained in simple manner. Furthermore, the method is less labour-intensive than known methods. The anchoring elements can for instance form part of a foundation. The tensioning wires can be for instance cables, belts, chains or assemblies thereof, optionally in combination with rigid elements. The desired construction can be manufactured with great freedom in design by combining positions of anchoring elements and tensioning wires of determined length. The tensioning wires deform the inflatable body locally and in fact form a mould in the inflated body for trusses in the building construction to be formed from construction material. The inflatable body is preferably adapted for co-action with the tensioning wires. Inflation of the inflatable body can for instance take place with an air compressor. It is also possible to use a preformed inflatable body adapted for co-action with at least one tensioning wire in a determined position. The tensioning line can thus be placed more rapidly and more reproducibly in the desired position. The curable construction material can for instance be concrete or a related composite material. After curing of the construction material the inflatable body is preferably removed. The inflatable body can optionally be reused in the manufacture of another building construction according to the invention. After curing of the construction material at least a number of the tensioning wires can also, if desired, be released and/or removed. The construction can then, if desired, be further finished, for instance by applying protective and/or decorative layers, and/or arranging functional recesses such as window and door openings.

It is advantageous if the method also comprises of embedding at least some of the tensioning wires in the construction material. A construction is thus obtained in which the tensioning wires are embedded as reinforcement, which gives the construction a higher dynamic load-bearing capacity after curing. The embedded tensioning cables are preferably provided with engaging members for an improved anchoring in the applied construction material. Embedding is for instance possible, after the manufacture of a first layer in which the tensioning cables lie on the surface of the building construction, by arranging a second layer of curable construction material over the cables in order to thus embed the cables.

In a preferred embodiment the inflatable body is connected by at least one spacer to at least one tensioning wire prior to curing of the construction material. A better embedding of the tensioning wires in the construction material is thus achieved. The spacer is adapted to hold the tensioning wire at a distance from the surface of the inflatable body such that the construction material can also be arranged therebetween. The spacer can for instance be a profile part connecting to the cable, for instance a tube or ring.

At least two anchoring elements mutually connected by a tensioning wire are preferably also connected to each other by a tension-resistant element. Lateral forces (buckling forces) on the anchoring elements are hereby compensated. During inflation of the inflatable body the tensioning wire is formed into a curve, while the tension-resistant element continues to form a linear connection between at least two anchoring elements. The tension-resistant element is for instance a rod or cable, but can also be formed by a tension-resistant floor part on which the anchoring elements engage.

The tensile stress of the tensioning wires is preferably adjusted by tensioning means connected to the tensioning wires. It is thus possible to define the precise form of the lines of force. It is also possible to regulate the tension of each separate tensioning wire as desired. The tensioning means can for instance be arranged in an anchoring element or as intermediate part in the tensioning wire itself. The tensioning means can for instance be a turnbuckle.

In a preferred embodiment the tensile stress of the tensioning wires is adjusted by modifying the gas pressure inside the inflatable body. The desired form can thus be readily obtained, wherein it is advantageous if the length of the tensioning wires is predetermined. Control of the gas pressure can be automated and regulated in simple manner.

It is advantageous if at least one of the anchoring elements is arranged on an elevated element. A building construction with a large interior space can thus be obtained. The elevated element can for instance be a column or pillar. The form of the elevated element preferably corresponds to the lines of force formed by the tensioning wires connected to the elevated element.

In a preferred embodiment at least one anchoring element is connected to a plurality of tensioning wires. A plurality of trusses in the cured construction thus converge at one point so that optional reinforcement can be given a compact form. Anchoring elements are preferably mutually connected by tensioning wires via a connecting element connecting at least two tensioning wires. It is thus simpler to control the position of the tensioning wires during inflation of the inflatable body.

In one of the preferred embodiments at least four anchoring elements are positioned in a rectangular configuration, wherein at least the diagonally situated anchoring elements are mutually connected with tensioning wires. A cross vault can thus be constructed in simple manner. Such a construction is very labour-intensive in construction using known building methods. The formed cross vault has a great load-bearing capacity, wherein pressure forces are directed to the four corner points.

In another preferred embodiment at least one central anchoring element is connected to a plurality of tensioning wires, wherein the tensioning wires are also connected at the other outer end to a plurality of anchoring elements positioned fanning out relative to the central anchoring element. Shell-like and fan-shaped constructions can thus be readily obtained. Such constructions are particularly advantageous for applications in which acoustics take priority, such as in concert halls, conference hails and cinemas.

It is recommended that a foπnwork is also positioned for the purpose of forming the construction material in co-action with the inflatable body. A greater freedom of construction is thus obtained. The formwork can be any mould form which is suitable for the construction material to be used and which is preferably adapted for smooth fitting onto the inflatable body.

It is advantageous that at least some of the tensioning wires are positioned relative to the inflatable body using at least one guide element. It is thus simpler to position the tensioning wires in the desired direction. Damage to the inflatable body, in particular leakage, is also prevented. The guide element can for instance be a tube or channel. The guide element is preferably integrated into the inflatable element so that the tensioning wires can be positioned in rapid and reproducible manner.

The method preferably also comprises of arranging additional reinforcing material round the inflated body, whereafter the additional reinforcing material is embedded into the construction material. The load-bearing capacity of the building construction can thus be increased. The additional reinforcing material can for instance comprise a metal wire mesh. If tensioning wires are embedded in the construction material, it is a simple and advantageous solution to connect the additional reinforcement to at least one embedded tensioning wire.

In a preferred embodiment the inflatable body is positioned floating in water, wherein the inflatable body is stabilized by stabilizing means, wherein the construction material is arranged on at least a part of the inflatable body above the water surface, wherein the stabilizing means are removed after curing of the construction material. A floating object can thus be constructed in simple manner using the method according to the invention. The stabilizing means can for instance comprise a floating pier or a dock.

Prior to arranging of curable construction material the inflated body is preferably deformed by at least one deforming element engaging on the inner side of the inflated body. A greater freedom of design is thus obtained. The deforming element is preferably adapted to exert a pushing force or pulling force at a predetermined position of the inflated body. A plurality of co-acting deforming elements can be used for simple realization of complex shapes. Deformations directed toward the inner side of the building construction can be obtained by pulling forces, while outward directed deformations can be realized by pushing forces. The deforming element is chosen subject to the desired deformation. A wire, cable, rod, beam or tube can for instance be used as deforming element. In order to enable a controlled positioning of the deforming element, the deforming element is preferably fixed to the inner side of the inflatable body by means of fixation means such as a hook and loop connection. The deforming element can also be connected to an anchoring element located inside the inflatable body or integrated with the inflatable body.

In a preferred embodiment a pulling force is exerted by the deforming element on the inner side of the inflated body. Protrusions directed toward the interior of the building construction are thus realized in simple manner.

In a preferred embodiment the deforming element exerts a pulling force at least at two positions lying at a mutual distance on the inner side of the inflated body. A complex deformation can thus be realized in simple manner. Furthermore, no further anchoring means are required inside the inflatable body.

The deforming element preferably comprises a cable. Cables are easy to arrange, can be stowed in compact manner and are particularly suitable for exerting pulling force. A cable is preferably attached to the inner side of the inflatable body by means of fastening means, such as with a hook and loop fastening.

It is advantageous if, after curing of the building construction, a hanging support surface is arranged inside the building construction, wherein the support surface connects at least two opposite sides of the building construction. The support surface absorbs tensile forces present between the opposite sides of the building construction as a result of the force of gravity. The cured building construction is stabilized by such a support surface, while a floor is also created which enhances the functionality of the building construction. The support surface is for instance a floor of reinforced concrete. Fixing anchors for the support surface are preferably arranged in the opposite sides of the building construction before or after curing of the building construction. It is recommended that a plurality of fixing anchors are arranged, wherein the fixing anchors are positioned such that they define the support surface in stable manner.

In a preferred embodiment the tensioning wires are retensioned after curing of the building construction. The thus obtained building construction has an improved stability. The thus obtained building construction is in particular better able to withstand wind load and earthquakes.

The invention also provides a building construction of curable material obtainable in accordance with the method according to the invention.

In a preferred embodiment the building construction is bounded on one side by a double-curved surface, wherein the intersecting line between the double-curved surface and a plane of section comprises at least two arcs separated by an intersection. Such a building construction has a good pressure load-bearing capacity. The intersecting line in fact forms a truss of an arch. It is advantageous if at least one tensioning wire is embedded substantially parallel to the intersecting line in the construction material. Such a construction has an enhanced dynamic load-bearing capacity. The tensioning wire is preferably under a tensile stress such that the dynamic load-bearing capacity of the building construction is increased. The invention also provides a kit of parts for manufacturing a building construction of curable material, comprising tensioning wires, and an inflatable body adapted for co- action with the tensioning wires. A desired building construction can be easily manufactured using such a set. The tensioning wires can for instance comprise steel or plastic cables, belts and/or chains.

The invention further provides an inflatable body adapted for use in the method according to the invention. The inflatable body can for instance comprise integrated channels or fastening means for the tensioning wires, whereby the tensioning wires can be positioned more rapidly and easily. The inflatable element will of course comprise at least one gas connection for inflating and/or emptying the inflatable body. It is advantageous if the inflatable body is manufactured on an outer layer from a substantially form-retaining material, and an inner layer connected to the outer layer is manufactured substantially from a resilient, substantially medium-tight plastic. The final form is thus determined by the outer layer, while the inner side distributes the gas pressure over the outer layer. The form-retaining material can for instance be a fibre- reinforced plastic such as PVC, polyurethane, polyethylene or polypropylene. A rubber- like material such as butyl foil can for instance be used for the inner layer. It is advantageous if the inflatable body is provided on the outer side with a water-repelling layer such as teflon. Such an outer layer is found to make the removal from the inflatable body of cured construction materials such as concrete especially easy.

It is advantageous if the inflatable body is provided on the inner side with fixing means for at least one deforming element. The possibility of arranging deforming elements makes it possible to realize exceptionally complicated constructions in simple manner. Fixing is preferably possible at different positions, thus creating great flexibility in use.

The invention will now be elucidated with reference to the following non-limitative embodiments. Figures la-Id show one of the possible preferred embodiments of a method according to the invention.

Figures 2a-2b show details of a method according to the invention. Figures 3a-3c show an alternative variant of the method according to the invention. Figure 4 shows an inflatable body for use in the method according to the invention. Figure 5 shows a building construction obtainable with a method according to the invention.

Figure 6 shows a variant of the method according to the invention. Figures 7a and 7b likewise show a variant of the method according to the invention.

Figures Ia- Id show a preferred embodiment of a method according to the invention, applied in this case to manufacture a cross vault. Figure Ia shows a top view of four anchoring points 1 which are positioned at the corner points of a square ground surface and which are mutually connected by means of tensioning wires 2 via a connecting plate 3. Positioned in a non-inflated state lying centrally between anchoring points 1 of tensioning wires 2 is an inflatable body 4 such that this inflatable body 4 is bounded by tensioning wires 2 in the inflated state and thus places tensioning wires 2 under tensile stress. Anchoring points 1 can be fixed directly to a floor surface but can also be placed at a distance from the floor on an elevated element such as a column. The volume of inflatable body 4 can optionally be further bounded during inflation by placing formwork for co-action with tensioning wires 2, for instance as according to broken lines 5, for the purpose of forming side walls.

Figure Ib shows the arrangement of figure Ia with corresponding numbering, wherein inflatable body 4 is brought into the inflated state using a compressor, whereby tensioning wires 2 come under tensile stress. The tension on tensioning wires 2 and the position of connecting plate 3 can optionally be adjusted by cable tensioners (not shown) which are preferably positioned close to anchoring elements 1. By pressing into the inflatable body the tensioning wires 2 form a mould for the trasses of the cross vault. Through being inflated the inflatable body 4 forms protrusions 6 at locations where inflatable body 4 is not bounded by tensioning wires 2. A mould for a cross vault is obtained in this case due to the relative positioning of anchoring elements 1 and the tensioning wires. The protrusions 6 not essential for the manufacture of the cross vault can optionally be bounded by additional formwork as according to broken lines 5, so that the final volume of the inflated body 4 is smaller and can thus be produced more rapidly. Through the use of additional formwork as according to broken lines 5 the arrangement of construction material in a subsequent step can also be performed more simply and precisely.

Figure Ic shows in side view the covering of the form of figure Ib with construction material. In this case a concrete layer 7 is applied over the inflated body 6. Tensioning wires 2 and connecting plate 3 are herein at least partially embedded in the concrete. If desired, additional reinforcement can also be embedded in the concrete. The figure shows how anchoring elements 1 are anchored hi floor 9 using pins 8. Tensively strong connection 10 is optionally arranged between anchoring elements 1, whereby the lateral forces on anchoring elements 1 are absorbed in simple manner. After curing of concrete layer 7 the inflatable body and possible associated formwork can be removed, thereby leaving the building construction as shown in figure Id.

The cross vault 11 in figure Id manufactured according to the invention can then be finished, for instance by applying finishing layers and optionally arranging recesses for specific applications. It is of course possible to build a plurality of the shown cross vaults 11 joined to each other, wherein anchoring elements 1 are for instance used for a plurality of adjacent vaults 11. Connecting plate 3 can optionally be adapted as support point for an overlying construction, such as an upper storey or a roof. The cross vault built according to the invention can be realized in less labour-intensive and more rapid manner than by traditional building methods, and offers a great freedom of design.

Figures 2a-2b show details adapted for the co-action between an inflatable body and a tensioning wire according to the invention, as can for instance be used in the method of figures Ia- Id.

Figure 2a shows an assembly of the outer surface of an inflatable body 20 under gas pressure, a channel 21 arranged on the outer surface 20, spacers 22 engaging on the channel and adapted for co-action with a guiding tube 23 through which a tensioning wire 24 runs under tensile stress. For the sake of clarity the components are shown in exploded view. The plastic or metal channel 21 serves to distribute the pressure of tensioning wire 24 over surface 20 so as to thus prevent damage to inflatable body 20 and to guide tensioning wire 24 in the desired direction. The channel can be arranged on inflatable body 20 or be integrated into a preformed inflatable body 20. Spacers 22 enable a better embedding of the tensioning cable in the construction material to be applied, as will be shown hereinbelow. A plurality of spacers 22 are placed distributed at mutual distances along the length of the tensioning wire. The optionally placed guide tube 23 can for instance have a U-shaped or circular profile, wherein it is recommended to give the interior of the tube a form accessible to liquid construction material. Figure 2b shows the device of figure 2a in cross-section with corresponding numbering. A layer of concrete 25 in liquid form is herein arranged on inflatable body 20, wherein the concrete 25 has also penetrated into openings of spacer 22 and around tube 23 round tensioning cable 24. The inflatable body 20 deformed by tensile stress on the cable forms a mould for two curved surfaces in the concrete 25 separated by a truss. Due to spacer 22 the tensioning cable 24 is well embedded in the concrete. Spacer 22 and tube 23 moreover serve as engaging members on the concrete, whereby a strong construction is obtained. After curing of concrete 25 the inflatable body 20 and optionally channel 21 can be removed.

Figures 3a-3c show a variant of the method according to the invention, wherein a watertight inflatable body 30 floating in water 31 is stabilized on either side by floats 32 to which are fixed anchoring points 33 provided with tensioning wires 34. Tensioning wires 34 are embedded in construction material 35, for instance concrete, plastic or a composite material. After curing of the material the anchoring points 33 are removed, whereafter the top-heavy part of inflatable body 30 covered with construction material 35 tilts downward, thereby creating the situation as in figure 3b. The inflatable body can then be removed, so creating a hollow floating shell as shown in figure 3c. In this way a floating shell 36 can be manufactured quickly and easily with great freedom of design. Shell 36 can for instance be used as vessel or as anchored floating object. It is then possible to realize a building structure on the floating object, for instance a houseboat.

Figure 4 shows a shell-like mould 44 for manufacturing a shell-like vault, wherein from at least one central multiple anchor plate 41 a plurality of tensioning lines 42 are connected to a plurality of single anchor elements 43 placed fanned-out relative to central anchor plate 41. Tensioning lines 42 are under tensile stress by an inflatable body 44 inflated under tensioning lines 42. The tensile stress of each tensioning line 42 can be individually controlled by tensioning means in anchor elements 43 and/or the central anchor plate 41. It is further possible to vary the gas pressure inside inflatable body 44 using the compressor and venting means (not shown). Preformed channels are arranged in inflatable body 44 for co-action with tensioning lines 42, whereby the tensioning lines can be positioned more easily. In order to prevent lateral slipping the tensioning wires 42 are also mutually connected by means of transverse connections 45 arranged over the curvature of the inflatable body. In addition to aesthetic advantages, the building constructions which can be manufactured with such a mould 40 also have particularly favourable acoustic and light-diffusing properties, and can be obtained quickly and easily by the method according to the invention.

Figure 5a shows a building structure 50 in which a plurality of cross vaults 51, comparable to that of figure Id, are built together. Cross vaults 51 are anchored to columns 52, thereby creating a large space under cross faults 51. The cross vaults support a framework of support beams 53 on which floor slabs 54 are then placed. The surface formed by floor slabs 54 can subsequently be used as basis for a following layer in the building structure. Such a construction is for instance particularly suitable as underground parking garage, which can be realized quickly and easily with the method according to the invention.

Figure 5b shows the building structure 50 of figure 5a in top view, wherein the cables 55 embedded in the vaults can be seen. Fixing means 56 for the support means are arranged at the central points of cross vaults 51.

Figure 6 shows an alternative variant of the method according to the invention. On the inner side of an inflatable body 68 a cable 61 is fastened to a fastening point 64 which is connected to an anchor 62. Tensioning wires and anchoring wires arranged round the inflatable body are applied analogously to the foregoing embodiments, and for the sake of clarity are not shown. In co-action with the gas pressure inside the inflatable body there is created an inward directed deformation 63 in inflatable body 60. Another deformation 65 in inflatable body 60 is induced by a second cable 66 which connects two positions 67, 68. The deformed inflatable body 60 is subsequently covered with concrete, wherein deformations 63, 65 become manifest in the obtained building construction. 53

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72 by means of anchorings 73. Figure 7b shows the same construction in top view. A storey is thus realized in simple manner inside the building construction which also contributes toward the stability of the construction. The construction has particularly an improved resistance to wind load and earthquakes.

It will be apparent that the above stated embodiments are non-limitative, and that many advantageous preferred embodiments and variants of the method according to the invention can still be envisaged by the skilled person.

Claims

1. Method for manufacturing a building construction of curable material, comprising the processing steps of: - arranging tensioning wires between anchoring elements,

- positioning an inflatable body such that the extension of the inflatable body is defined by the tensioning wires,

- inflating the inflatable body,

- applying curable construction material to at least a part of the inflated body, and - curing of the construction material applied to the inflated body.

2. Method as claimed in claim 1 , characterized in that the inflatable body is connected by at least one spacer to at least one tensioning wire prior to curing of the construction material.

3. Method as claimed in either of the foregoing claims, characterized in that at least two anchoring elements mutually connected by a tensioning wire are also connected to each other by a tension-resistant element.

4. Method as claimed in any of the foregoing claims, characterized in that the tensile stress of the tensioning wires is adjusted by tensioning means connected to the tensioning wires.

5. Method as claimed in any of the foregoing claims, characterized in that at least one of the anchoring elements is arranged on an elevated element.

6. Method as claimed in any of the foregoing claims, characterized in that at least one anchoring element is connected to a plurality of tensioning wires.

7. Method as claimed in any of the foregoing claims, characterized in that anchoring elements are mutually connected by tensioning wires via a connecting element connecting at least two tensioning wires.

8. Method as claimed in any of the foregoing claims, characterized in that at least four anchoring elements are positioned in a rectangular configuration, wherein at least the diagonally situated anchoring elements are mutually connected with tensioning wires,

9. Method as claimed in any of the foregoing claims, characterized in that at least one central anchoring element is connected to a plurality of tensioning wires, wherein the tensioning wires are also connected at the other outer end to a plurality of anchoring elements positioned fanning out relative to the central anchoring element.

10. Method as claimed in any of the foregoing claims, characterized in that at least some of the tensioning wires are positioned relative to the inflatable body using at least one guide element.

11. Method as claimed in any of the foregoing claims, characterized in mat prior to arranging of curable construction material the inflated body is deformed by at least one deforming element engaging on the inner side of the inflated body.

12. Method as claimed in claim 11 , characterized in that a pulling force is exerted by the deforming element on the inner side of the inflated body.

13. Method as claimed in claim 12, characterized in that the deforming element exerts a pulling force at least at two positions lying at a mutual distance on the inner side of the inflated body.

14. Method as claimed in any of the foregoing claims 11-13, characterized in that the deforming element comprises a cable.

15. Method as claimed in any of the foregoing claims, characterized in that, after curing of the building construction, a hanging support surface is arranged inside the building construction, wherein the support surface connects at least two opposite sides of the building construction.

16. Method as claimed in any of the foregoing claims, characterized in that the tensioning wires are retensioned after curing of the building construction.

17. Building construction of curable material obtainable in accordance with the method as claimed in any of the foregoing claims.

18. Inflatable body adapted for use in the method as claimed in any of the foregoing claims 1-16.

19. Inflatable body as claimed in claim 18, characterized in that the inflatable body is provided on the inner side with fixing means for at least one deforming element.