WALL MODULE FOR BUILDING A STRUCTURE, ASSOCIATED STRUCTURE AND CONNECTOR SYSTEM

Abstract

A wall module is configured as a concrete prefabricated building element for building a structure and can be connected to further wall modules to form a structure and is configured to withstand improbable extreme loads. The wall module has a wall body with multiple edges, a plurality of reinforcement rods which all together form a regular reinforcement grid, and each extend parallel to the edges, and which are cast into the wall body. The reinforcement rods each penetrate the wall body substantially from edge to edge, and provided at their ends with connecting elements configured to establish a connection with complementary connecting elements of an immediately adjacent wall element. Each of the connecting elements is connected with clearance to the associated reinforcement rod such that it can be moved in a plane which is perpendicular to the longitudinal direction on all sides by at least 2 mm.

Description

CROSS-REFERENCE TO RELATED APPLICATION

This is a continuation application, under 35 U.S.C. §120, of copending international application No. PCT/EP2012/000856, filed Feb. 28, 2012, which designated the United States; this application also claims the priority, under 35 U.S.C. §119, of German patent application Nos. 10 2011 014 179.0, filed Mar. 16, 2011 and 10 2012 001 167.9, filed Jan. 24, 2012; the prior applications are herewith incorporated by reference in their entireties.

BACKGROUND OF THE INVENTION

Field of the Invention

The invention relates to a wall module which is realized as a prefabricated concrete component for building a structure. It also relates to a structure, in particular an operating or installation building of a nuclear power station, which is produced by using wall modules of this type.

Safety-relevant buildings of nuclear installations, for example such buildings which house the emergency power units, have up to now been realized almost exclusively as concrete structures which are cast in-situ. The prefabricated method of construction tried and tested in conventional residential building construction has not been used in practice up to now.

The high level of safety demands and consideration of internal and external load cases (EVI and EVA) for nuclear installations usually result in a very high reinforcement density. For this reason, the majority of building structures of nuclear power stations or other installations relating to nuclear technology are carried out using the solid method of construction. In the case of the method of construction, the minimum wall thickness up to now has been approximately 0.85 m as a result of the large amounts of reinforcement.

The building/the structure must namely withstand all loads and load connections from the following events in categories H1-H4:

Normal operation (H1):

• • constant loads,
  • variable loads including loads caused by transport and installation, and combined loads.

Influences produced by events to persons caused externally (H2):

• • explosion,
  • plane crashes, and
  • fire in the external area.

Influences produced by internal unforeseen events (H3):

• • in-house fire,
  • collapse of internal design,
  • falling loads,
  • internal flooding, and
  • internal explosion.

Improbable events (H4):

• • earthquakes,
  • extreme winds,
  • extreme snow and formation of ice,
  • tornado loads, influence of tornado projectiles,
  • extreme external temperatures,
  • extreme flooding,
  • extreme precipitation,
  • physical protection,
  • explosive blast wave, and
  • explosive gas cloud.

The use of prefabricated components—although deemed to be completely desirable on account of the associated standardizing and the optimizing of the entire planning, construction and construction sequences—has up to now run into considerable difficulties in this context and consequently has not come about. This is due, in particular, to the connection techniques which have been used up to now in prefabricated construction and which either do not meet the demands made in the nuclear sector or are not capable of overcoming the admissible component tolerances which are as a rule to be met.

The fact that for every nuclear power station essentially the same buildings with the same functionality are planned from scratch, leads to the consideration as to how the planning and execution costs can be reduced.

Reduction is possible by using systems which enable the desired rooms and their occupation to be planned in a flexible manner using prefabricated modules.

The demands which are made on structures in the area of nuclear power stations correspond to the highest demands in structural and safety engineering. The planning and execution is consequently very expensive and cost-intensive.

The introduction of prefabricated building has up to now run into difficulties with reference to the friction-locking connection between the individual structural elements and with reference to overcoming the associated tolerances and dimensional inaccuracies as well as alignment inaccuracies during assembly.

SUMMARY OF THE INVENTION

Consequently, the object underlying the invention is to provide a wall module of the type mentioned in the introduction which can be put together and joined in a simple manner with further wall modules of this type to form a structure, especially a building or building complex, which is not only configured for conventional operating loads but over and beyond this also withstands improbable extreme loads—individually or even in combination—for instance flooding, earthquakes, incessant rain, ice loads, wind loads, whirlwinds, extreme ambient temperatures, projectile impact, plane crashes, etc..

Accordingly, provided is a wall module which is realized as a prefabricated concrete component for building a structure. The wall module has a wall body which has a regular, in particular rectangular base and several, in particular four, edges, and a plurality of reinforcement rods which, as a whole, form a regular reinforcement grid, preferably extend in each case parallel to the edges and which are sealed into the wall body. The reinforcement rods pass through the wall body in each case substantially from edge to edge and are provided on their ends with connecting elements which are realized for producing a connection to complementary connecting elements of a directly adjacent wall element and wherein the respective connecting element—in each case in the released state not connected to a complementary connecting element—is connected to the associated reinforcement rod with clearance or in a movable manner in such a manner that it is displaceable in a plane which is at right angles to the longitudinal direction of the reinforcement rod on all sides by at least 2 millimeters in relation to a provided central position. The mobility can be completely prevented in the tensioned, fixedly connected state.

It is particularly advantageous and sufficient for usual demands in the construction of nuclear power stations if displaceability by at least 5 millimeters, preferably by as far as up to 10 millimeters, is ensured.

The term wall module in this case is to be interpreted in a wide sense and includes along with the inside and outside wall portions (side walls) of a building in particular also floor and ceiling plates.

Level, flat wall modules, in particular with a rectangular base, are certainly preferred—however the wall modules can also be curved such that, for example, it is possible to construct a curved wall portion or a cylindrical building (reactor building, etc.).

As has been shown in a surprising manner, in this way not only is a flexible connection realized between the individual modules which makes it possible to bridge unavoidable component tolerances and alignment tolerances in the case of on-site assembly, but where there is suitable dimensioning, in spite of—or even precisely because of—the comparatively high level of flexibility of the individual connections, it is possible to realize heavy-duty bonds between wall modules which withstand high shearing forces and bending moments and ensure reliable load removal over the module boundaries into the respective anchoring points.

It is expedient when the connecting elements—in each case in a primary manner—are configured to be connected together in a friction-locking manner, in particular by a screw connection or clamping. Where applicable, form locking can also be provided additionally, in particular for securing screw connections produced beforehand.

In a preferred development, in each case at least two reinforcement rods which extend in parallel are combined to form one unit and are connected at the ends to the same connecting element.

As already indicated above, the respective wall module can be a component of a side wall or of a ceiling wall or a floor plate, therefore it is either vertically or horizontally aligned. Accordingly, both vertical and horizontal reinforcement rods with vertical or horizontal connecting elements connected thereto are provided in the installed or mounted state in order to connect both the side wall modules amongst themselves and ceiling wall modules amongst themselves and also together.

In an advantageous design, a wall module is provided where reinforcement rods which extend horizontally in the mounted state are fixedly connected, in particular welded, at the ends to a support element which has at least one holding plate. The respective holding plate is engaged around by a U-shaped saddle element with a base plate and two leg plates, and wherein the leg plates are fixedly connected, in particular welded, in turn, to an associated horizontal connecting element. In a preferred manner, the saddle element is realized in an integral manner.

In this case, in the mounted state the saddle element, in an expedient manner, abuts by way of its base face against an end face of the holding plate and is dimensioned in particular with regard to the distance between the leg plates in such a manner that the above-named flexible seat is realized. This means that in a preferred manner in this variant the required flexibility of the connection is realized by the displaceability of the saddle element in relation to the holding plate.

In a preferred variant, the respective support element consists of one single square holding plate which is fixedly connected, in particular welded, to a total of two reinforcement rods.

In an alternative variant, the respective support element includes two square holding plates which are connected together by two square cross plates. The support element is fixedly connected, in particular welded, to four associated reinforcement rods. Each of the two holding plates is engaged around by a saddle element which is connected to a horizontal connecting element. In this variant, a connecting unit which is located in the wall module therefore includes a total of four reinforcement rods which extend in parallel and which are each provided at the ends with a connecting unit which has two connecting elements.

The frame-like support element in the variant can also be realized in an integral manner in a preferred development.

In a particularly preferred development, the female version of the respective horizontal connecting element includes a bushing which is provided with an internal thread and a complementary male version includes a threaded bolt which is provided with an external thread and has an associated locknut. The male connecting element and the female connecting element, when connected together, interact in the manner of a turnbuckle.

In this case, in an expedient manner, on the end which faces the support element, the respective bushing is screw-connected onto a threaded bolt which is provided for fastening on the saddle element.

In addition, a structure is advantageous where the leg plates of the respective saddle element are aligned parallel to the horizontally extending reinforcement rods and have receiving slots which extend parallel thereto and are defined by slot edges. The respective threaded bolt of the associated connecting element is pressed along the receiving slot between the leg plates and is fixedly connected, in particular welded, to the leg plates in the region of the slot edges.

The variants described up to now are suited particularly for horizontal reinforcement rods and horizontal connections. Variants which are suited particularly for vertical connections will be described below.

In an advantageous design a wall module is provided where reinforcement rods which extend vertically in the mounted state are fixedly connected, in particular welded, at their ends to a support element, which has a recess for the passage of a threaded bolt which is provided with an external thread and is active in interaction with two screwed-on anchor nuts and anchor plates, which are present if necessary and are penetrated by the threaded bolt as the vertical connecting element.

The above-specified flexibility of the vertical connections, in this case, is achieved in an expedient manner as a result of the threaded bolt having a somewhat smaller diameter than the seat which surrounds it and being realized in particular by an associated recess in the support element or by a corresponding recess in an anchor plate.

In this case, it is expedient when the respective support element includes four square frame plates which are connected together in the manner of a rectangular frame, wherein two frame plates which are located opposite one another are designed as holding plates and are fixedly connected, in particular welded, in each case to a reinforcement rod. In a preferred manner, therefore, one vertical connecting unit in the wall module has two reinforcement rods.

One design of the wall module is advantageous for all variants described up to now where the wall body, in the manner of a sandwich structure, has an outside shell, an inside shell and a core filling which lies between the two shells. The outside shell and the inside shell are connected together in a shear resistant manner by reinforcement elements which, along with the reinforcement rods of the connecting units, can also include further elements.

A structure which is composed of a plurality of wall modules of the named type which are connected together by the flexible connecting elements meets the demands named in the introduction in an excellent manner.

In an expedient manner, joints which are present between the wall modules for the construction of the building and, where applicable, recesses which are present in the region of the connecting elements are sealed in the respective wall body by way of concrete.

The system with prefabricated modules/wall profiles constructed in a modular manner proposed and explained up to now has a very high level of flexibility and at the same time results in standardization and optimization of the entire design, planning and construction sequence.

The system can be applied to all buildings which, as a result of their function in the installations, have to withstand the named external and internal events. This means that the system is able to be applied not only in nuclear power installations but it can also be used in chemical, military and other areas.

The element connections are configured such that the established reinforcement values can be transmitted in the form of a solid joint (100% force transmission). Each reinforcement rod is connected to the reinforcement of the following component in the case of such a design irrespective of whether the possible capacity to withstand stresses is reached.

Although different types of connectors for the wall elements, which up to now have also been designated as wall modules in the description, have already been described which meet the demands posed in an excellent manner, there is a requirement for further types and modifications to the existing types in order to provide flexible detailed solutions for the different cases in demand. In this case, attempts are made in particular as regards the design and the material requirements to produce simply retained, cost-efficient connectors or connector systems which can be connected simply and reliably to the reinforcement of the wall elements as well as joined to one another.

To this end, a connector system for a prefabricated part structure having a plurality of wall modules can be provided, wherein the connector system includes one or several components from the following group:

• a) a U-beam or a box which is arranged in the joint between two wall modules and by way of which the reinforcement rods (10) are screw-connected,
• b) a U-beam or a box which is arranged in the joint between two wall modules and in which the reinforcement rods engage in a positive-locking manner by means of screwed-on metal claws,
• c) a bond between two closure plates or boxes which are connected together by screw bolts, wherein each closure plate or each box is screw-connected to one of the reinforcement rods, and
• d) a double-headed anchor.

In an advantageous variant, the prefabricated component system as claimed in the invention has a wall thickness of just 0.40 m and an optional shell facing with a thickness of approximately 0.10 m. This means that all the above-described loads and load connections are reliably accommodated.

The advantages obtained with the invention consist in particular in that by providing a “modular system” with prefabricated, standardized wall modules or wall profiles which are provided with high-quality and flexible connections or joins, the advantages which have always been known from conventional prefabricated construction with respect to planing and execution time as well as costs and efficiency can be transferred to the construction of buildings for nuclear power installations. However, the invention is naturally not limited to these types of applications but can also be used, for example, for non-nuclear industrial installations, military installations or even for conventional buildings, for instance in regions where there is a high risk of earthquakes.

Other features which are considered as characteristic for the invention are set forth in the appended claims.

Although the invention is illustrated and described herein as embodied in a wall module for building a structure and an associated structure, it is nevertheless not intended to be limited to the details shown, since various modifications and structural changes may be made therein without departing from the spirit of the invention and within the scope and range of equivalents of the claims.

The construction and method of operation of the invention, however, together with additional objects and advantages thereof will be best understood from the following description of specific embodiments when read in connection with the accompanying drawings.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING

FIG. 1 is a diagrammatic, partially sectioned perspective view of a building portion which is composed of several wall modules using a prefabricated modular method of construction at a moment of assembly (more precisely: briefly prior to pushing together and joining the wall modules) according to the invention;

FIG. 2 is a front view of the building portion according to FIG. 1;

FIG. 3 is an illustration of a detail from a central region of FIG. 2 with connecting elements between the wall modules picked out and enlarged;

FIG. 4 is a perspective view of a detail from FIG. 3;

FIG. 5 is a perspective view analogous to FIG. 4, an alternative type of horizontal connecting units being shown on the one hand and on the other hand the concrete shell of the wall modules having been left out from the drawing;

FIG. 6 is a perspective view of a first type of horizontal connecting unit;

FIG. 7 is a perspective view of a second type of horizontal connecting unit;

FIG. 8 is a perspective view of a vertical connecting unit;

FIG. 9 is an illustration of a simplified construction of different components of the connecting unit according to FIG. 6;

FIG. 10 is an illustration of a simplified construction of different components of the connecting unit according to FIG. 7;

FIG. 11 is an illustration of simplified construction of different components of the connecting unit according to FIG. 8;

FIG. 12 is a perspective view of a wall portion of a building which is composed of several wall modules using the prefabricated modular method of construction;

FIGS. 13 and 14 are perspective views of show a connector system for wall modules according to a first embodiment (U-beam);

FIGS. 15-18 are illustrations showing a connector system for wall modules according to a second embodiment (box);

FIGS. 19-25 are illustrations showing a connector system for wall modules according to a third embodiment (terminator);

FIGS. 26 and 27 are illustrations showing a connector system for wall modules according to a fourth embodiment (claw I);

FIGS. 28 and 29 are illustrations showing a connector system for wall modules according to a fifth embodiment (claw II); and

FIG. 30 is an illustration of a connector system for wall modules according to a sixth embodiment (double-headed anchor).

DETAILED DESCRIPTION OF THE INVENTION

Identical or identically acting parts are provided with the same references in all the figures.

Referring now to the figures of the drawings in detail and first, particularly to FIG. 1 thereof, there is shown wall modules 2 as claimed in the present invention and are realized as prefabricated concrete components with connecting units 4 which are partially sealed in the concrete, connecting elements 6 for connection to complementary connecting elements 6 of corresponding adjacent modules projecting or jutting out of the respective wall body 8.

A perspective representation of a first type of horizontal connecting unit 4 is shown in FIG. 6. The connecting unit 4 includes two reinforcement rods 10, which extend in parallel, are the same length and are welded at their respective ends with the end faces of a square holding plate 12. The respective holding plate 12 is engaged around by a U-shaped saddle element 14 which has a base plate 16 and two leg plates 18. In a preferred manner, the respective saddle element 14 is realized in an integral manner (in this case, however, a variant which is composed of several individual parts is shown) and is aligned in such a manner that the leg plates 18 to a certain extent form an extension of the reinforcement rods 10 outwards which continues, in turn, outwards in the form of a connecting element 6 which is aligned parallel to the reinforcement rods 10. The respective connecting element 6 includes a threaded bolt 20 which is provided with an external thread, engages between a receiving slot 22 of the two associated leg plates 18 by way of its inner end and is welded to the leg plates 18 on slot edges 24. The outer end of the respective threaded bolt 20 is either a female version which is provided with a bushing 26 which has an internal thread or a male version which is provided with a locknut 28 such that between complementary connecting elements 6 of adjacent wall modules 2 a corresponding friction-locking connection in the manner of a turnbuckle connection can be produced.

By dimensioning the components in a corresponding manner, in particular the length and width of the base plate 16 of the respective saddle element 14 in relation to the length and width of the holding plate 12 of the holding plate 12 which is engaged around by the saddle element 14, certain lateral displaceability of the saddle element 14, and consequently also of the associated connecting element 6, is ensured in relation to the reinforcement rods 10 which are sealed fixedly in the wall body 8 of the wall module 2, in particular by at least 2 millimeters, preferably at least 5 millimeters in an arbitrary direction at right angles to the longitudinal direction of the reinforcement rods 10. The substantially square wall body 8 is provided in the region of the respective saddle element 14 with a corresponding recess such that displaceability is actually provided. In this way, where required, unavoidable component tolerances during the production of or during the clamping of the connections are able to be equalized.

As far as the method of operation is concerned, the second type of horizontal connecting unit 4 shown in FIG. 7 is constructed in a completely analogous manner, but has twice the number of connecting elements 6 and of reinforcement rods 10. Consequently, on each side there are two holding plates 12 provided which are engaged around in each case by a saddle element 14 with an associated connecting element 6, the holding plates 12 being connected together by cross plates 30. The frame which is formed from holding plates 12 and cross plates 30 can be realized in an integral manner. The reinforcement rods 10 are welded to the end faces of the holding plates 12, as an alternative to this they can be welded to the cross plates 30. In this way, to a certain extent a double turnbuckle connection, which has the above-described flexibility, can be realized on each side of the connecting unit 4.

FIG. 8 shows a vertical connecting unit 4 with a basically similar functional principle, but the design of the connecting elements 6 is different in detail. The two reinforcement rods 10, in this case, are namely welded at the ends with a rectangular frame which is formed from four frame plates 32. An anchor plate 36 which is provided with a central recess 34 is welded onto the frame plates 32 on the inside surface of the rectangular frame which faces the reinforcement rods 10. The diameter of the recess 34 is dimensioned in such a manner that a threaded bolt 38, also designated as an anchor bolt, is able to be inserted through with a certain amount of clearance, this means forming an annular gap. An anchor nut 40 serves for solidifying and fixing a connection which is produced by way of a counterpart of an adjacent wall module 2 and is fixed there also by a corresponding anchor plate 36 which is penetrated by the threaded bolt 38. Differentiating between male and female connection types, in this connection, is not absolutely necessary, but can naturally be provided in an alternative development. As an alternative to this, clamping bushes or the like can also be used here in order to connect together the opposite ends of the threaded bolts 38 of the adjacent wall module 2.

It is important, once again, for the vertical connection, just as the horizontal connection, to allow for certain flexibility at right angles to the longitudinal direction of the reinforcement rods 10 of at least 2 millimeters, preferably at least 5 millimeters adjustment clearance.

In all cases, thrust loads, tensile loads and shear loads are reliably removed and passed on by the reinforcement rods 10 which are sealed in the concrete of the wall body 8 all in all in the manner of a regular, rectangular grid.

All the elements and components, which in the figures are composed from individual components which are welded together (weld seams 42), are also able to be realized in an alternative design in an integral manner, for instance cast or produced by cold or hot forming.

The types of connectors described below can take the place of the connectors shown and described in FIGS. 1 to 11—called “connecting elements” there—and can replace these in part or completely or can also be combined with or interact with them in numerous ways.

Several exemplary embodiments of connector systems as claimed in the invention for wall modules using the reinforced concrete prefabricated method of construction are explained in more detail by way of drawings in FIGS. 12 to 30.

The following applies to all the examples below. The building is realized as a solid structure produced from modular elements or prefabricated modules of reinforced concrete in the form of wall elements, ceiling elements, corner elements and the like, summarized in short below by the term “wall module”, the term “wall element” being synonymous. The connections between the prefabricated elements are managed by way of special connectors or connector systems based on screw-type connections. The prefabricated wall modules can be combined together in an almost arbitrary manner.

The screw-type connections meet the demands for cyclical alternating stresses in the event of earthquakes or in the case of comparable natural events as well as in the case of extraordinary loads, for example explosions or collision loads.

A perspective representation of a wall portion which is composed of three identical, rectangular wall modules 2 is shown as an example in FIG. 12.

1. U-beam-Type Screw Connection

Continuous U-beams, i.e. which preferably extend over the entire edge length of one or several elements and are provided with incisions/elongated holes corresponding to the reinforcement intervals of the reinforcement grid, are arranged between the modular elements which are realized in particular as reinforced concrete elements. To equalize tolerances, they can be provided with oversize in relation to the screw-type connections of the reinforcement rods which are pushed through.

The thickness of the U-beams should be at least 20 mm, 25 mm is recommended. Attachment to the concrete elements is effected by way of nuts which are screw-connected onto the protruding reinforcement rods or bars which are provided on the ends with a corresponding thread.

As the elongated holes in the U-beams have to have considerable oversize in relation to the screw-type connections for equalizing tolerances, washers or screws/nuts with a machined-off collar are expedient in order to secure sufficient contact surface.

The U-beams are slipped under the connectors and are screwed-connected.

The method of connection is illustrated as an example in FIG. 13 and FIG. 14.

In this connection, FIG. 13 shows a section through a vertically aligned wall module 2, in this case with an associated shell facing 1003. The U-beams 1004 can be seen on the top edge and the bottom edge of the wall module 2, by which U-beams the connection to the adjacent wall modules (not shown here) is realized. The U-beams 1004 in each case abut against the edge faces of the associated wall modules by way of their legs 1006 and to a certain extent form spacers between adjacent wall modules. For a secure connection between the U-beam 1004 and the wall module 2, the ends (screw-type connections) of the reinforcement rods 10, which project out of the wall element and are provided there with an external thread, are guided through associated elongated holes in the leg of the U-beam and are in each case secured by a locknut 1010 which is screwed on from the outside.

The diameters of the bores/elongated holes in the legs 1006 of the U-beam 1004, through which the ends of the reinforcement rods 10 are guided, are generously dimensioned such that the reinforcement rods 10 have a corresponding clearance when the locknuts 1010 are loosened, preferably at least 5 mm in each direction.

In an advantageous manner, in each case the reinforcement rods 10 pass through the entire wall module 2 from edge to edge or from connection point to connection point. This means that the respective reinforcement rod 10 has on each of its two ends a connector of the above-described type which interacts with an associated connector of the adjoining wall module. In a preferred manner, the two connectors on the opposite ends of one reinforcement rod 10 are the same type and have the same dimensioning. The same also applies to the further connection models described further below.

FIG. 14 shows a top view of the connection between two wall modules produced in this manner. Only the horizontal reinforcement rods 10 can be seen of the wall modules themselves in this simplified representation.

In the case of a correspondingly realized reinforcement grid, both vertical and horizontal connections between adjoining wall modules can be produced in this manner.

2. Box-Type Screw Connection

The box-type screw connection described below is also suited for both horizontal and vertical connections.

The connection type is illustrated by way of FIGS. 15 to 18.

In this case, in its left-hand half, FIG. 15 shows a perspective view of the reinforcement grid 1012 of a rectangular wall module 2 with boxes 1014 which are connected in each case to the ends of the reinforcement rods 10. In the right-hand half of the figure, the wall module 2 is shown in the delivery state with applied concrete compound. Each of the boxes 1014 is connected to an associated box 1014 of the adjacent wall module 2 by means of a screw-type connection when the wall modules 2 are joined together.

FIG. 16 shows a longitudinal section through a box-box combination which is connected together in such a manner at the connection point between two wall modules 2.

FIG. 17 and FIG. 18 show two cross sections marked correspondingly with roman numerals in FIG. 16.

On the side which faces the wall module 2, the respective box 1014 is connected and fixed to the end of a reinforcement rod 10. This is affected by a so-called LENTON screwed-gland 1016 or in a similar manner. To this end, the end of the reinforcement rod 10 which tapers conically and is provided with an external thread is screwed into a complementarily formed threaded sleeve 1018 or screw socket which forms an integral component of the box 1014.

The connection between the two similarly constructed boxes 1014 amongst themselves is effected by an inside connecting bolt 1020 which is provided in each case with an external thread on both ends and passes through an associated bolt channel 1022. The screwed-on locking nuts 1024 act in each case by an anchor plate 1026, which lies between the locking nuts, on the ring sleeve 1028 of the associated box 1014 which defines the bolt channel 1022 and thus fix the arrangement. In this case, the ring-shaped end face 1030 of the respective ring sleeve 1028 forms a contact face which acts as a stop for the anchor plate 1026 which is realized in the manner of a slotted washer. As a result, the ring sleeves 1028 of the two boxes 1014 and consequently the two boxes 1014 altogether are pressed fixedly against one another in the clamped state.

As, on the one hand, the inside diameter of the bolt channel 1022 is greater than the outside diameter of the connecting bolt 1020, on the other hand the respective anchor plate 1026 has sufficient space for movement inside the enclosure which is formed by the walls of the box 1014, and finally there is also still a sufficiently large axial gap between the respective locking nut 1024 and the threaded sleeve/screw socket 1018 located opposite it, a connection is created which is adaptable in an excellent manner. The space for movement in all three directions which is provided when the locking nuts 1024 are not yet tightened, in this case, is preferably at least 5 mm.

3. Terminator-Type Screw Connection

A further connection type, also suited for both horizontal and vertical connections, is illustrated in FIG. 19 to FIG. 25.

In this case, one single connector is shown in perspective in FIG. 21 and in a top view in FIG. 22. FIG. 23 to FIG. 25 show different sections through individual components of the connector.

In the case of this type of connection, the respective reinforcement rod 10 of the wall module 2 is anchored at its ends in a closure plate 1034 which is also designated as a terminator. This can be effected in particular by means of screw-connection, for instance using a LENTON screwed-gland or the like, the threaded sleeve 1036 or screw socket being inserted and fixed in a positive-locking manner in a corresponding bore through the closure plate 1034 (see FIG. 24).

The connection between two closure plates 1034 is effected, in turn, by screw bolts 1038 which penetrate the associated bores through the closure plates 1034 and are secured by means of nuts 1040. Correspondingly bored steel plates 1042 between the nuts 1040 and the closure plates 1034 act to some extent as washers.

Two screw bolts 1038 which are arranged symmetrically and parallel to the center axis of the reinforcement rod 10 are provided in the exemplary embodiment.

Once again also important here is the excellent adjustability of the connection for adapting to unavoidable production tolerances or dimension inaccuracies as well as alignment inaccuracies during assembly. For this reason, the inside diameter of the bores penetrated by the screw bolts 1038 in the closure plates 1034 is greater than the outside diameter of the respective screw bolt 1038 such that, when the nuts 1040 are released or loosened, the desired freedom of movement (say: clearance) of preferably more than 5 mm in all directions is realized. This can be seen, for example, from FIG. 24 and FIG. 25.

In an expedient manner, the length of the screw bolts 1038 is dimensioned in such a manner that in the mounted state a significant gap remains between the two interconnected closure plates 1034. When finishing the building which is composed of the wall modules 2, these types of gaps are advantageously sealed with a filling compound, for instance fine-grained concrete or mortar. This also applies analogously to gaps, joints and spaces at the joint points between adjacent wall modules in the case of the other types of connections described here.

The distance between adjacent, parallel reinforcement rods 10 of the reinforcement grid 1012 which can be seen in FIG. 20 is typically in the order of 200 mm. The value can also underlie for instance the other connection variants described here, considerable variations obviously being possible in dependence on the application. A typical value for the diameter of the screw bolts 1038 is in the order of 20 mm or more.

4. Claw-Type I Screw Connection

The connection has a certain similarity to the U-beam-type screw connection. The screw connection of the reinforcement rods is not managed with sockets, but rather metal claws are screwed onto the ends of the reinforcement rods which ensure the solid joint. In addition, a metal plate, which completes the support profile to form the closed rectangular ring, is screwed onto the U-beam. In an expedient manner, the joint between the wall modules is sealed again.

This is shown as an example in perspective in FIG. 26 and in section in FIG. 27.

In FIG. 27 it is possible to see the metal claw 1046 which is connected to the respective reinforcement rod 10. It is realized in an integral manner and has a threaded sleeve 1048 which is screwed onto the reinforcement rod 10 and a holding leg 1050 which is arranged at right angles thereto and stands out laterally. The end of the reinforcement rod 10 with the threaded sleeve 1048 is guided through a bore provided with significant clearance in the leg 1052 of the U-beam 1054 such that the holding leg 1050 of the metal claw 1046 is held fixedly in the interior of the U-beam 1054. The metal plate 1058 which is screwed onto the U-beam 1054 closes the U-profile to form a box.

In a manner similar to the U-beam-type connection, the box, which is arranged between the two interconnected wall modules 2, preferably extends over the entire edge length thereof.

5. Claw-Type II Screw Connection

In the case of the type of connection, in an analogous manner to the claw-type I screw connection the reinforcement rod 10 is provided on its ends with screwed-on metal claws 1060. Deviating from this, however, the U-clamp 1062 does not extend over several or all the connections of a side edge of the respective wall module 2, but only over the connector itself. Fixing is effected by screws 1064 which extend at right angles to the longitudinal axis of the reinforcement rods 10, as shown in perspective in FIG. 28 and in section in FIG. 29.

6. Double-Headed Anchor Connection

Finally, as an alternative to or in addition to the types of connections described up to now, it is possible to use as connecting means so-called double-headed anchors which are admitted into corresponding recesses in the wall modules. The possibility for transmitting the tensile force of the corresponding wall joint is ensured as a result.

The connector system is illustrated as an example in FIG. 30 by way of a section through two interconnected wall modules 2. In the example, two doubled-headed anchors 1070 which are arranged at right angles to one another are combined to form one anchor cross 1072. In particular, the two double-headed anchors 1070 can be fixedly connected together at the point of intersection of the anchor cross 1072. The anchor cross 1072 can also be cast in an integral manner. As an alternative to this, it is also obviously possible to use single double-headed anchors 1070.

Each double-headed anchor 1070 has two thickened, radially protruding heads 1074 which are integrally formed on the end of an anchor rod 1076 and which are fixed in a positive-locking manner in corresponding recesses or grooves of the associated wall module 2 in each case. In an expedient manner the recesses are sealed with a filling compound, for instance mortar or lightweight concrete, after assembly.

A form-locking (positive) connection is one that connects two elements together due to the shape of the elements themselves (e.g. ball and socket), as opposed to a force-locking connection, which locks the elements together by force external to the elements (e.g. screw).

Claims

1. A wall module being a prefabricated concrete component for building a structure, the wall module comprising:

a wall body having a regular base and a number of edges;

a plurality of reinforcement rods which, as a whole, form a regular reinforcement grid and being sealed into said wall body, said reinforcement rods passing through said wall body in each case substantially from edge to edge; and

connecting elements provided on ends of said reinforcement rods, said connecting elements producing a connection to complementary ones of said connecting elements of a directly adjacent wall module and a respective one of said connecting elements connected to an associated one of said reinforcement rods with clearance such that said respective connecting element is displaceable in a plane which is at right angles to a longitudinal direction of said associated reinforcement rod on all sides by at least 2 millimeters in relation to a provided central position.

2. The wall module according to claim 1, wherein said reinforcement rods extend in each case parallel to said edges of said wall body.

3. The wall module according to claim 1, wherein displaceability of said connecting elements by at least 5 millimeters is ensured.

4. The wall module according to claim 1, wherein said connecting elements are configured to be connected together in a friction-locking manner.

5. The wall module according to claim 1, wherein in each case at least two of said reinforcement rods which extend in parallel are combined to form a connecting unit and are connected at ends to a same one of said connecting elements.

6. The wall module according to claim 1,

further comprising support elements having at least one holding plate;

further comprising a U-shaped saddle element with a base plate and two leg plates, each said holding plate being engaged around by said U-shaped saddle element with said base plate and said two leg plates, said two leg plates fixedly connected in turn to an associated one of said connecting elements being a horizontal connecting element; and

wherein said reinforcement rods which extend horizontally in an assembled state are fixedly connected, at ends to one of said support elements having said at least one holding plate.

7. The wall module according to claim 6, wherein each of said support elements having one single square said holding plate being fixedly connected to a total of two of said reinforcement rods.

8. The wall module according to claim 7, further comprising square cross plates, said support elements each having two square holding plates connected together by means of two of said square cross plates, wherein each of said support elements is fixedly connected, to four associated ones of said reinforcement rods, and each of said two holding plates is engaged around by said saddle element which is connected to a horizontal one of said connecting elements.

9. The wall module according to claim 6, wherein said connecting elements include female connecting elements each having a bushing with an internal thread and complementary male connecting elements each having a threaded bolt with an external thread and an associated locknut, wherein said male connecting elements and said female connecting elements, when connected together, interact in a manner of a turnbuckle.

10. The wall module according to claim 9, wherein said connecting element having an end facing said support element, on said end facing said support element, said bushing is screw-connected onto said threaded bolt for fastening on said saddle element.

11. The wall module according to claim 10, wherein said leg plates of said saddle element are aligned parallel to horizontally extending ones of said reinforcement rods and have receiving slots formed therein which extend parallel thereto and are defined by slot edges, wherein said thread bolt of said connecting element is pressed along said receiving slot between said leg plates and is fixedly connected, to said leg plates in a region of said slot edges.

12. The wall module according to claims 1,

wherein said connecting elements each having a threaded bolt;

further comprising support elements each having a recess formed therein for a passage of said threaded bolt, anchor nuts and anchor plates;

wherein said reinforcement rods which extend vertically in a mounted state are fixedly connected, at their ends to one of said support elements; and

wherein said threaded bolt has an external thread and is active in interaction with two screwed-on said anchor nuts and said anchor plates, which are penetrated by said threaded bolt.

13. The wall module according to claim 12, wherein said support elements each have four square frame plates which are connected together in a manner of a rectangular frame, wherein two of said frame plates which are located opposite one another are fixedly connected in each case to one of said reinforcement rods.

14. The wall module according to claim 1,

further comprising reinforcement elements; and

wherein said wall body, is in a manner of a sandwich structure, and has an outside shell, an inside shell and a core filling lying between said outside and inside shells, said outside shell and said inside shell are connected together in a shear resistant manner by said reinforcement elements.

15. The wall module according to claim 1, wherein said connecting elements are configured to be connected together by means of a screw connection.

16. A structure, comprising:

a plurality of wall modules each having a regular base and a number of edges;

a plurality of reinforcement rods which, as a whole, form a regular reinforcement grid and being sealed into said wall modules, said reinforcement rods passing through said wall modules in each case substantially from edge to edge; and

connecting elements provided on ends of said reinforcement rods, said connecting elements producing a connection to complementary ones of said connecting elements of a directly adjacent one of said wall modules and a respective one of said connecting elements connected to an associated one of said reinforcement rods with clearance such that said respective connecting element is displaceable in a plane which is at right angles to a longitudinal direction of said associated reinforcement rod on all sides by at least 2 millimeters in relation to a provided central position, said connecting elements connecting said wall modules to each other.

17. The structure according to claim 16, further comprising a filling compound, joints present between said wall modules and, recesses which are present in a region of said connecting elements are sealed in a respective one of said wall modules by way of said filling compound.

18. The structure according to claim 17, wherein said filling compound is concrete.

19. A connector system for a prefabricated part structure, comprising:

a plurality of wall modules each containing: a wall body having a regular base and a number of edges; a plurality of reinforcement rods which, as a whole, form a regular reinforcement grid and being sealed into said wall body, said reinforcement rods passing through said wall body in each case substantially from edge to edge; connecting elements provided on ends of said reinforcement rods, said connecting elements producing a connection to complementary ones of said connecting elements of a directly adjacent one of said wall modules and a respective one of said connecting elements connected to an associated one of said reinforcement rods with clearance such that said respective connecting element is displaceable in a plane which is at right angles to a longitudinal direction of said associated reinforcement rod on all sides by at least 2 millimeters in relation to a provided central position; and

at least one component selected from the group consisting of: a first U-beam disposed in a gap between two of said wall modules and by way of which said reinforcement rods are screw-connected; a first box disposed in said gap between two of said wall modules and by way of which said reinforcement rods are screw-connected; a second U-beam disposed in said gap between two of said wall modules and in which said reinforcement rods engage in a form-locking manner by screwed-on metal claws; a second a box disposed in said gap between two of said wall modules and in which said reinforcement rods engage in a form-locking manner by said screwed-on metal claws; two closure plates connected together by screw bolts, each of said closure plates being screw-connected to one of said reinforcement rods; two third boxes connected together by screw bolts, each of said third boxes screw-connected to one of said reinforcement rods; and a double-headed anchor.