Innovation for double wall elements
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Fig. 1 Isometric view of the Kap-Steel-Wave.
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Fig. 2 Mounting scheme into a double-wall element.
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Fig. 3a and b Concrete coverage for a lattice...
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The double-wall convinces customers and manufacturers more than ever and is enjoying a growing popularity. Similar to the floor slabs in the past, the use of the double wall is sharply increasing, because it substitutes cast-in-place concrete walls. Kappema® released an innovation that allows for new saving potentials at the double-wall production.
The Kappema technology further enhances the status of the double wall. The wall system, manufactured with the new innovative Kap-Wave elements, optimizes the handling during the production at site, simplifies the everyday work on the building site and for the first time at all allows for variants in the installation of the double wall. The disadvantages of conventional lattice girders are overcome through the use of the Kap-Steel-Wave.
Kap-Steel-Wave replaces lattice girder
The Kappema steel mold wave is made of steel. In connection with form rods made out of high-quality steel, the wave is able to withstand high extraction forces, to override shear forces as well as to secure the join compounds. A high amount of casting pressure can thus be absorbed. The Steel-Wave is available for a wall thickness of 18 cm, 20 cm, 25 cm, 30 cm, 35 cm and 40 cm. Upon request individual sizes can also be delivered.
With the conventional DWE-System the lattice girders remain in the reinforcement layers also serving as a spacer and consequently influencing the wall thickness. Therefore quite a number of different lattice girders would have to be hold on stock for producing different types of wall elements. Avoiding this with the new system means savings in terms of costs and capacity. Regardless of which structurally accounted concrete ceilings are necessary, in each case only one Steel-Wave can be used.
It is imperative with conventional types of lattice girders according to the authorization that the wicket and girt are overlapping by at least 17 mm per shell due to the chunking resistance owing to the concreting pressure. The result: thick and heavy concrete shells.
With the new product the high quality steel form sticks seize completely through the concrete shell. Thus the concrete coverage of 2 x 17 mm can be left out and a weight reduction of up until 25 % (75–100 kg /m²) can be reached. In this case a pull out strength of 16 KN per stick is achieved (48 KN per Wave).
Processing inside the factory
The Kap-Steel-Wave is characterized by its simplicity in handling. Compact in size, the delivery takes place on a europalett (Weight approx. 300 kg for 700 m² DWE) which can be placed in the factory next to the concreting station. Here the employee takes the wave (low weight, very small volume) and simply puts it on the production pallet at intervals of 80 cm. Instead of using lattice girders logistics can dramatically be facilitated and time and cost consuming working steps can be omitted.
Apart from the enormous saving of time (in total approx. 2 minutes installation time per palette) mounting parts such as tubes, junction boxes and socket outlets are not destroyed or crushed. Because of the wave intervals of 80 cm a lateral refinishing between the shells of the wall is possible. Installations can be included laterally or at a subsequent point. Equally the grinding of the second shell surface is not a problem. Among other products “Quicky” a fixing for tilt-up brace can also be obtained from BVT. Usually made of plastics, the fixing for sizes M 12 and M 16 is made of steel.
Practice and certification
Notable institutes and universities e.g. the University of Kaiserslautern / Germany as well as the Technological Institute of the University of Graz / Austria have cooperated in research work for the new system. At present the Kap-Steel-Wave may be used according to DIN 1045. The admission to the Technological Institute in Berlin has been applied for. For the major part of the remaining European countries no building supervisory authority is necessary. Related certification for durability, chunking resistance and shearing stress are existent.
