EP1971727B1 - Construction de batiments - Google Patents

Construction de batiments Download PDF

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Publication number
EP1971727B1
EP1971727B1 EP06821548A EP06821548A EP1971727B1 EP 1971727 B1 EP1971727 B1 EP 1971727B1 EP 06821548 A EP06821548 A EP 06821548A EP 06821548 A EP06821548 A EP 06821548A EP 1971727 B1 EP1971727 B1 EP 1971727B1
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EP
European Patent Office
Prior art keywords
structural
pod
floor
walls
pods
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EP06821548A
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German (de)
English (en)
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EP1971727A1 (fr
Inventor
John Joseph Fleming
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Biomedy Ltd
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Biomedy Ltd
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    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • E04B1/348—Structures composed of units comprising at least considerable parts of two sides of a room, e.g. box-like or cell-like units closed or in skeleton form
    • E04B1/34815—Elements not integrated in a skeleton
    • E04B1/3483—Elements not integrated in a skeleton the supporting structure consisting of metal

Definitions

  • the invention relates to construction of buildings.
  • US4,107,886 describes a construction method in which building modules are formed into a building by placing a layer of modules with one side wall of each module adjacent but spaced apart from one side wall of a different module. Concrete is poured into the space between the side walls to form a supporting column which is reinforced by bar girders extending out from the side walls. For multi-storey construction, a shoulder or saddle is formed on top of the supporting column for supporting modules to be placed directly above. While this method appears to speed up building construction, there is still considerable on-site work required.
  • US4,050,215 describes a modular construction method for a multi-storey building.
  • U-shaped reinforced concrete modules are placed one atop the other to build up the building height, and at the top level there is a layer of modules having both floors and ceilings. These modules are used to provide the building frame and the remaining construction work is then performed.
  • EP0544609 describes a modular construction method, but gives very little detail about how this is achieved. It appears that a concrete mould is made and the module is then unmoulded.
  • US4833841 describes a prefabricated transportable building module.
  • the invention is directed towards providing for greater efficiency in construction of multi-storey buildings, both in terms of labour required and/or materials required. Another object is to provide a more consistent achievement of building quality. A still further object is to achieve better control of a project, with better predictability of dates for completion of activities. Another object is to reduce the extent of time and materials handling on site. A further object is to reduce construction materials waste.
  • the structural walls are secured by bolting to the top flanges of the floor edge structural members.
  • the trusses each comprise at least two horizontal structural members interconnected by vertical studs.
  • the structural members and studs of the vertical trusses are of box-section steel.
  • each ceiling truss comprises a horizontal bearing plate overlying a wall plate of a structural wall.
  • the bearing plate overlies a vertical stud of the structural wall.
  • the walls comprise non-combustible board cladding on both sides, with insulation such as mineral wool between the claddings.
  • the building pod further comprises a balcony secured to the structural floor.
  • the method comprises the steps of moving the platform from one work position to the next with successive steps being performed to erect the walls and the ceiling.
  • the platform is moved on rollers.
  • the pod is lifted for transport by lifting it from lifting points on the floor.
  • lifting rods are secured to the floor frame and extend to a height greater than the walls, and the pod is lifted by engagement of lifting tackle with the lifting rods.
  • the rods extend upwardly from edge members of the structural floor frame and through the structural walls.
  • the rods engage in sockets between flanges of floor edge structural members.
  • the platform is coated with oil to allow easy separation of the floor concrete from the platform.
  • the structural ceiling is manufactured by placing a number of vertical trusses horizontally across a jig, securing internal cladding to the trusses, and lifting and flipping over the ceiling so that it spans the structural walls.
  • the pods are placed with structural walls aligned so that vertical load is transferred down through the pod structural walls.
  • the method comprises the further step of erecting a stair or elevator core on site over the podium structure, and some pods are placed to butt against the core.
  • the method comprises the further step of embedding a metal plate in a wall of the core, and the floor of a pod butts against said embedded plate.
  • an interface structural member is mounted between the floor and the embedded core plate.
  • the interface structural member has a vertical flange welded to the core plate and a horizontal flange welded to the pod floor.
  • a building is constructed in a method 1 by constructing in a factory a number of modules (or "pods"), transporting them to the site, placing them one atop the other and side-by-side to provide the rooms, and then erecting external cladding and a roof.
  • the pods are complete, with no need for internal work to be performed. Moreover, they provide the building structure, and so there is no need for any structural work to be done on site other than providing a ground-level floor. The extent of work done on site is considerably reduced in comparison with conventional construction methods.
  • FIG. 2 and 3 an individual pod 30 is shown.
  • the main components are a structural floor 31, structural walls 32, and a structural ceiling 33.
  • the floor 31 comprises C-section edge frame structural members 35, poured concrete 36 with enmeshed re-bars 37 moulded in situ within the frame, and bolt fasteners 40 securing wall panels 32 to the floor 31.
  • the wall panels 32 each comprise a structural steel frame cladded on the outside by non-combustible board 45 and on the inside by board 46 and plasterboard 47.
  • the frame comprises a wall plate 60 of angle-section steel, a bottom angle-section 62, and vertical box-section studs 61 at typically 600mm spacings.
  • the structural ceiling 33 comprises multiple vertical trusses 33(a), each having upper and lower horizontal box-section members 50 and vertical box-section steel studs 51 at 300 mm spacings, a bearing plate 52 resting on top of the wall panel 32, and a vertical plate 53 to which the horizontal members 50 and the bearing plate 52 are welded.
  • Fig. 3 The structural aspects of the pod are shown most clearly in Fig. 3 , the non-structural items being omitted for clarity.
  • the ceiling vertical trusses 33(a) terminate at both ends with the vertical plate 53 to which the bearing plates 52 are welded, and this diagram shows how the bearing plates 52 are carefully positioned on the wall panel angle-section wall plate 60 at locations directly over the box-section vertical studs 61.
  • the vertical loading is transferred primarily down through successive bearing plates and wall panel vertical studs 61.
  • This diagram also shows the bottom angle-section members 62 of the wall panels to which the vertical studs 61 are welded. All structural steel is surface treated for corrosion resistance.
  • Fig. 3 also shows a corner vertical stud 70 welded to adjoining vertical studs 61. It also shows an interface plate 71 interconnecting four pods at their corners.
  • the walls illustrated are the external walls of the pod, and these are structural.
  • the pod may contain a number of rooms defined by internal non-structural walls. Indeed, a pod may be a complete apartment or a combined hotel room or suite with integrated bathroom.
  • a platform 80 is movable along a production line on rollers 81. It has a flat planar upper surface and the rollers 81 are carefully positioned so that the top surface of the platform is perfectly horizontal. A film of oil is deposited on the platform top surface.
  • the fabricated floor frame with the edge members 35 is placed by crane onto the platform (or alternatively the floor frame may be fabricated in situ on the platform 80). Re-bar and steel meshes (shown generally as 37) are placed into the frame between the members 35, spacers (not shown) being used to provide a gap between them and the platform surface.
  • a low viscosity Concrete with a low viscosity is poured into the mould formed by the edge frame members 35 until it is flush with the top surfaces of them.
  • sockets 85 are welded into the edge frame members 35 at a mutual spacing chosen according to the estimated final weight of the pod.
  • Lifting rods 87 are subsequently screwed into the sockets 85 at threaded rod ends 86.
  • the lifting rods 87 also have threaded upper ends 88 for subsequent engagement with lifting tackle of a crane.
  • the lifting rods are threaded through the wall panel (there are apertures in the wall plate member 60 and the bottom member 62 to accommodate the rods) to engage into the sockets 85 within the floor frame.
  • Connection of the wall panels to the floor and of the ceiling trusses 33 to the wall panels is shown most clearly in Fig. 3 .
  • overhead gantry cranes are used for lifting and placing the wall panels and ceiling assemblies. This lends itself to a large degree of automation and allow accurate placement of the various assemblies.
  • Fig. 6 shows details of how two pairs of pods are placed alongside each other and atop each other.
  • the wall panels 32 have mineral wool insulation 105. It is clear from this drawing how vertical loads are transferred, directly down via the wall panels 32, the edge floor members 35 and the reinforced concrete of the floor adjacent the members 35.
  • FIG. 7 A plan section is show in Fig. 7 , in which insulation 111 is visible between pods for preventing fire spread and flanking sound transmission.
  • insulation 110 directly on the outside of the external pod wall panels 32. This is applied on site or in the factory.
  • An external stone cladding 112 is tied to the external pod walls.
  • This diagram also shows the vertical angle-section structural member 70 interconnecting adjoining wall panels, vertical strips 116 of non-combustible board within the wall panels, a breathable membrane 115 on the outer surface of the insulation 110, and vertical timber battens 114 between polyisocyanurate/ polyurethane insulation 110 and the fire insulation 111.
  • Fig. 8 also shows how one pod is placed above another at an external wall.
  • This diagram also shows mineral wool cavity barriers 136 and 137 separated by a stone support bracket 139.
  • FIG. 9 An example of pod construction at a window is shown in Fig. 9 .
  • the pod external wall has a layer 150 of insulation applied in the factory, and cladding 155 is tied in place over this on site.
  • the window comprises a conventional window 140 secured in place offset from the wall panel by treated timber battens 157.
  • This drawing also shows a high-density insulation packer piece 156, and an end vertical strip of board 158 forming an internal window reveal.
  • a pod may be provided with a balcony, again manufactured off-site as an integral part of manufacturing a pod.
  • a balcony assembly 200 is secured to an edge floor member 35 via an interface 201 having vertical connector plates 202.
  • the balcony assembly 200 comprises a vertical connector plate 210, horizontal I-beams 211, horizontal angle beams 212, and a peripheral C-shaped member 215 with the flanges extending outwardly. This illustrates versatility of the construction method, and the avoidance of on-site work.
  • a parapet 250 comprises a reinforced concrete slab 260 supporting a vertical parapet having a steel frame 255, inner slab panels 256, external stone cladding 257, and a hand-rail 252.
  • a corridor floor 265 is simply an integral extension of a pod structural floor. It is supported by a pod 30 underneath, and it supports a wall 32.
  • the floor 265 abuts a stair core 270, which was previously cast on site.
  • the stair core comprises cast concrete 271 with embedded re-bars 272, and a side butting plate 278 cast into the side of the concrete 271.
  • An angle-section member 275 is welded to the edge frame member 35 of the floor 265, and is in turn welded to the embedded plate 278. Concrete 276 is cast into the gap between the members 35 and 275.
  • the cast concrete floors provide not only considerable structural strength but also fire and sound insulation.
  • the concrete floor is covered by a soft covering matting, which reduces sound from impacts on the floor.
  • the floors 3 provide an excellent foundation for the wall panels.
  • the structural continuity through the wall panels (particularly the vertical studs), the bearing plates 52, and the floor C-section frame members 35 provide sufficient load-bearing strength to allow up to at least 10 pods to be placed one atop the other for a ten storey building. Because of the structural aspects, the work on site is dramatically reduced as compared to traditional construction methods.
  • Figs. 7 to 9 for example illustrate how simple it is to finish an external cladding of the building, with excellent insulation being provided for the external pods.
  • Figs. 11 and 12 further demonstrate the versatility, as a parapet or balcony can be manufactured off-site, with the option of connecting the balcony to the relevant pod off site or on site if desired.
  • the invention therefore achieves the benefit of factory-production of individual rooms or groups of rooms with completely finished interiors, on a much greater scale than heretofore.
  • the pods are structural and so there is no need for supporting structures to be built on site other than the ground-level floor and a stair and/or elevator core.
  • time for construction on site which is particularly advantageous where access to the site is restricted and there is disruption to adjacent premises, roads, or footpaths.
  • the invention overcomes the perception that one can not provide simultaneously both structural frames and room finishing work.
  • the approach had been to attempt modularity in terms of "drop-in" pods such as bathroom, or pre-cast structural steel or formwork pods - not both together.

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  • Engineering & Computer Science (AREA)
  • Architecture (AREA)
  • Physics & Mathematics (AREA)
  • Electromagnetism (AREA)
  • Civil Engineering (AREA)
  • Structural Engineering (AREA)
  • Building Environments (AREA)
  • Conveying And Assembling Of Building Elements In Situ (AREA)

Claims (21)

  1. Module de construction comportant :
    un plancher de structure (31),
    des murs de structure (32) assujettis au niveau du plancher de structure, et
    un plafond de structure (33) chevauchant les murs de structure,
    dans lequel le plancher, les murs, et le plafond de structure ont une résistance à la charge suffisante pour supporter au moins un autre module, et
    dans lequel les murs de structure (32) comportent chacun une ossature de structure métallique comportant des poteaux porteurs verticaux (61) espacés l'un de l'autre sur toute la longueur du mur ;
    les ossatures de structure du mur comportent des éléments de structure en acier en caisson ;
    caractérisé en ce que,
    le plancher de structure (31) comporte du béton (36) coulé dans une ossature de structure (35) et des barres d'armature (37) et se met en prise à l'intérieur du béton,
    l'ossature de structure du plancher comportant des éléments de structure de bord (35) ayant des brides horizontales supérieures et ayant une forme de C en coupe,
    comportant les brides supérieures, une âme verticale procurant une surface de bord du plancher, et des brides horizontales inférieures, et les murs de structure (32) sont assujettis au niveau des brides supérieures ;
    le plafond de structure (33) comporte une pluralité de fermes verticales (33(a)) reliant et chevauchant des murs de structure opposés, et
    dans lequel l'intérieur est fini selon une spécification de l'espace fini avec la plomberie et les installations électriques, les meubles incorporés et les sanitaires, et
    comportant par ailleurs des murs de cloisonnement intérieur permettant de définir une pluralité de pièces à l'intérieur du module.
  2. Module de construction selon la revendication 1, dans lequel les murs de structure (32) sont assujettis par boulonnage (40) au niveau des brides supérieures des éléments de structure de bord de plancher.
  3. Module de construction selon l'une quelconque des revendications précédentes, dans lequel les fermes (33(a)) comportent chacune au moins deux éléments de structure horizontaux (50) reliés par des poteaux verticaux (51).
  4. Module de construction selon la revendication 3, dans lequel les éléments de structure (50) et les poteaux (51) des fermes verticales sont réalisés en caisson d'acier.
  5. Module de construction selon la revendication 3 ou la revendication 4, dans lequel chaque ferme (33(a)) de plafond comporte une plaque d'appui horizontale (52) recouvrant une poutre sablière (60) d'un mur de structure.
  6. Module de construction selon la revendication 5, dans lequel la plaque d'appui (52) recouvre un poteau porteur vertical (61) du mur de structure.
  7. Module de construction selon l'une quelconque des revendications précédentes, dans lequel les murs comportent un parement de planches incombustibles (45, 46, 47) des deux côtés, avec de l'isolation telle de la laine minérale (105) entre les parements.
  8. Module de construction selon l'une quelconque des revendications précédentes, comportant par ailleurs un balcon (200) assujetti au plancher de structure.
  9. Procédé (1) de fabrication d'un module selon l'une quelconque des revendications précédentes, le procédé comportant les étapes consistant à
    placer (10) une ossature de plancher sur une plateforme et couler (11) du béton dans l'ossature pour la mise en oeuvre du plancher de structure (31), et
    assujettir (13) les murs de structure (32) ou les ossatures de structure des murs au niveau du plancher de structure (31),
    assujettir une ossature de plafond de structure (33(a)) au niveau des murs de structure (32) pour chevaucher et relier les ossatures de murs de structure,
    construire (18) l'intérieur du module pour sensiblement terminer les murs de structure et le plafond de structure pour réaliser une pièce ou des pièces à l'intérieur du module, et
    sceller le module à des fins de transport jusqu'à un site et de manipulation sur le site.
  10. Procédé selon la revendication 9, comportant les étapes consistant à déplacer la plateforme d'une position de travail à la suivante, des étapes successives étant réalisées pour ériger les murs et le plafond.
  11. Procédé selon la revendication 10, dans lequel la plateforme est déplacée sur des roulettes.
  12. Procédé selon l'une quelconque des revendications 9 à 11, dans lequel le module est soulevé (19) à des fins de transport en le soulevant à partir de points de levage sur le plancher.
  13. Procédé selon la revendication 12, dans lequel des barres de levage (87) sont assujetties à l'ossature de plancher (35) et s'étendent jusqu'à une hauteur supérieure aux murs, et le module est soulevé par mise en prise du mouflage de levage avec les barres de levage.
  14. Procédé selon la revendication 13, dans lequel les barres (87) s'étendent vers le haut depuis des éléments de bord de l'ossature de plancher de structure (35) et au travers des murs de structure, et se mettent en prise dans des douilles entre des brides des éléments de structure de bord de plancher.
  15. Procédé selon l'une quelconque des revendications 9 à 14, dans lequel la plateforme est enduite d'huile pour permettre une séparation facile entre le béton du plancher et la plateforme.
  16. Procédé selon l'une quelconque des revendications 9 à 15, dans lequel le plafond de structure est fabriqué (15) en plaçant un certain nombre de fermes verticales à l'horizontale en travers d'un gabarit, en assujettissant un parement intérieur au niveau des fermes, et en soulevant et retournant le plafond de sorte qu'il chevauche les murs de structure.
  17. Procédé de construction d'un bâtiment comportant les étapes consistant à :
    fabriquer une pluralité de modules d'après un procédé selon l'une quelconque des revendications 9 à 16,
    transporter (19) les modules jusque sur un site où une structure de type socle ou soubassement a été coulée (20), et soulever et placer (21) les modules pour la mise en oeuvre d'un arrangement autoporteur multi-étagé des modules, au moins certains modules étant sur des modules inférieurs et étant supportés par lesdits modules inférieurs,
    ériger (22) un panneau de mur extérieur attaché aux murs exposés des modules,
    ériger (22) un toit de construction sur les modules, et
    mettre en service (23) les branchements sur les modules.
  18. Procédé selon la revendication 17, dans lequel les modules sont placés avec des murs de structures alignés de sorte que la charge verticale est transférée vers le bas au travers des murs de structure du module, et comportant l'étape supplémentaire consistant à ériger un escalier ou un noyau renfermant les ascenseurs sur le site au-dessus de la structure de type socle, et certains modules sont placés pour venir se mettre en butée contre le noyau.
  19. Procédé selon la revendication 18, comportant l'étape supplémentaire consistant à noyer une plaque métallique dans un mur du noyau, et le plancher d'un module allant se mettre en butée contre ladite plaque noyée.
  20. Procédé selon la revendication 19, dans lequel un élément de structure d'interface est monté entre le plancher et la plaque de noyau noyée.
  21. Procédé selon la revendication 20, dans lequel l'élément de structure d'interface a une bride verticale soudée au niveau de la plaque de noyau et une bride horizontale soudée au plancher du module.
EP06821548A 2006-01-12 2006-12-13 Construction de batiments Active EP1971727B1 (fr)

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
IE20060016 2006-01-12
IE20060126 2006-02-21
PCT/IE2006/000139 WO2007080561A1 (fr) 2006-01-12 2006-12-13 Construction de batiments

Publications (2)

Publication Number Publication Date
EP1971727A1 EP1971727A1 (fr) 2008-09-24
EP1971727B1 true EP1971727B1 (fr) 2011-11-09

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Family Applications (1)

Application Number Title Priority Date Filing Date
EP06821548A Active EP1971727B1 (fr) 2006-01-12 2006-12-13 Construction de batiments

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Country Link
EP (1) EP1971727B1 (fr)
AT (1) ATE532914T1 (fr)
IE (1) IES20060907A2 (fr)
WO (1) WO2007080561A1 (fr)

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US11225789B2 (en) 2018-05-17 2022-01-18 Spanminx Limited Structural module with vertical ties

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RU2543396C2 (ru) * 2009-07-23 2015-02-27 Байомеди Лимитед Строительный модуль для строительства зданий
ES2458917B1 (es) * 2012-07-26 2015-02-10 Cubria Home, S.L. Vivienda unifamiliar de estructura modular
JP6174430B2 (ja) * 2013-09-06 2017-08-02 ミサワホーム株式会社 付帯構造物の支持構造
WO2016032537A1 (fr) 2014-08-30 2016-03-03 Innovative Building Technologies, Llc Panneau de paroi préfabriqué pour installation de services publics
WO2016032538A1 (fr) 2014-08-30 2016-03-03 Innovative Building Technologies, Llc Couplage d'un diaphragme à un support latéral dans une structure
EP3805477B1 (fr) 2014-08-30 2023-06-28 Innovative Building Technologies, LLC Panneau de plancher et de plafond destiné à être utilisé dans des bâtiments
SG11201807193UA (en) 2016-03-07 2018-09-27 Innovative Building Technologies Llc Floor and ceiling panel for slab-free floor system of a building
SG11201807196RA (en) 2016-03-07 2018-09-27 Innovative Building Technologies Llc Prefabricated demising wall with external conduit engagement features
US10961710B2 (en) 2016-03-07 2021-03-30 Innovative Building Technologies, Llc Pre-assembled wall panel for utility installation
CN109072607B (zh) * 2016-03-07 2021-01-12 创新建筑技术有限责任公司 防水组件和包括防水组件的预制墙面板
US11098475B2 (en) 2017-05-12 2021-08-24 Innovative Building Technologies, Llc Building system with a diaphragm provided by pre-fabricated floor panels
US10724228B2 (en) 2017-05-12 2020-07-28 Innovative Building Technologies, Llc Building assemblies and methods for constructing a building using pre-assembled floor-ceiling panels and walls
US10487493B2 (en) 2017-05-12 2019-11-26 Innovative Building Technologies, Llc Building design and construction using prefabricated components
US11085181B2 (en) 2017-06-09 2021-08-10 Spanminx Limited Structural module tie
US11898341B2 (en) 2021-08-16 2024-02-13 Greencore Structures Ltd. Building core and kit for assembly

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US3717964A (en) * 1970-07-09 1973-02-27 Behring Corp Module frames
US3925679A (en) * 1973-09-21 1975-12-09 Westinghouse Electric Corp Modular operating centers and methods of building same for use in electric power generating plants and other industrial and commercial plants, processes and systems

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US11225789B2 (en) 2018-05-17 2022-01-18 Spanminx Limited Structural module with vertical ties

Also Published As

Publication number Publication date
ATE532914T1 (de) 2011-11-15
EP1971727A1 (fr) 2008-09-24
IE20060906A1 (en) 2007-09-05
WO2007080561A1 (fr) 2007-07-19
IES20060907A2 (en) 2007-09-05

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