DE9111674U1 - Prefabricated module for the production of structures and buildings - Google Patents

Description

DIPL-ING. PETER OTTE PATENT ATTORNEY ■ .··,. D-7250Leonberg.

Representative at the European Patent Office / European Patent Attorney ; **'- Tiroler Straße-15 :

2472G/ot/wo
13.09.1991

Mr Eberhard Schrade,
Kelterweg 43, 7036 Schönaich

Prefabricated module for the manufacture of structures and buildings

State of the art

The invention is based on a dimensionally accurate prefabricated module for the production of structures and buildings according to the preamble of claim 1.

The application of modular construction technology is known in many ways, with prefabricated, box-like solid concrete modules being used primarily in garage construction or as flat panels in wall, floor and ceiling constructions of buildings.

In this context, it is already known to manufacture individual modules, which consist, for example, of a concrete floor slab and a concrete ceiling slab, which are connected to one another via side walls or even just vertical supports, using a steel frame as a basis, whereby the steel frame forms the

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measurements and the walls, which may also be missing, can then be filled either with concrete parts, but also using wooden parts or with lightweight construction elements specifically for such buildings that are not subject to fire safety conditions.

In such modules, the steel construction is used as an external and also visible frame because of its perfect dimensional accuracy, which means that, for example, each module has eight support points on which they can then be placed on top of one another. The individual modules arranged on top of one another or next to one another are then usually connected using so-called "twist and lock connections". However, a multi-storey construction based on such modules with a steel corset is not permitted in Germany for fire safety reasons, for example, mainly because the steel reinforcement protrudes from the outside. On the other hand, the dimensional accuracy of the modules usually used and the buildings later made from them is based precisely on the steel frame, which has so far been considered indispensable.

Another problem with the previous modular construction is that it is not possible to provide different construction heights for several floors, as one is rigidly bound to the construction height of the individual module specified by the steel construction, so there is no flexibility in the basic concept. It is also impossible to create gaps between the individual modules or to use them in a suitable way, apart from the fact that the

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The steel pipes used in the steel frame, which are usually hollow, can often come into contact with liquids, as it is difficult to create a completely tight seal and over long periods of time rainwater can penetrate into pipes that are exposed to the outside and then corrode them.

The invention is based on the object of enabling the construction of buildings or structures, in particular simple residential buildings, where for any reason, for example due to natural disasters such as floods or earthquakes or due to the effects of war, a large number of residential units must be constructed quickly, which also meet higher comfort requirements while having perfect statics.

The invention solves this problem with the features of claim 1 and has the advantage that the precisely manufactured modules and the basic concept provided by the invention enable a rapid production of a large number of residential units, whereby the corresponding houses can also be built by less experienced personnel, since the prefabrication of the modules, which usually consist of reinforced concrete, can be carried out centrally with the help of modern production facilities or directly at a then sensibly larger construction site.

Another advantage of the present invention is that a highly precise vertical and horizontal alignment is possible, even when a large number of prefabricated modules are placed one above the other or next to one another

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or room cells, as these are connected and aligned horizontally using a type of plug-in technology, so that stacking the modules on top of each other is possible by plugging them together, while in the vertical direction the exact alignment is based on a prefabricated foundation that was previously not thought possible.

If the basic principle of the invention is that the modules are connected to one another horizontally by plugging, then refinements and improvements of the invention, which are then the subject of the dependent claims, are based on the fact that, for example, a prefabricated foundation frame makes it possible to align it horizontally with high precision and to insert it into prefabricated trenches, which may already be partially filled with lean concrete, whereby this prefabricated foundation frame in turn also accommodates the first level of the row of modules, which in this respect forms the ground floor, by plugging.

For this purpose, in one embodiment of the invention, modules and the foundation frame, preferably in the corner areas, have complementary plug-in sockets, for example in the form of peg-like projections that engage in corresponding recesses. These pegs and recesses are formed by head and foot plates, which are inserted into the corner areas of the modules at the top and bottom or of the foundation frame only at the top and are anchored in a suitable manner, for example by an anchor loop that extends into the reinforced concrete.

A further advantage is that when modules are arranged next to each other, the ceiling area

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has a central depression or depression so that, for example as is usual with flat roofs, a border or peripheral edge is formed, which, however, ensures continuity when modules are placed next to one another through inserted sleeves that form openings that are aligned with one another, which is beneficial for rainwater drainage, for example, but which can also be used to make fixed cross connections between the modules in the ceiling area, so that any other force effects, such as shear forces, etc., can be absorbed.

Further embodiments of the invention and improvements are then the subject of the subclaims and are set out therein.

drawing

Embodiments of the invention are shown in the drawing and are explained in more detail in the following description. They show:

Fig. 1 shows a schematic side view of the basic concept of the building construction process with several modules placed next to and on top of each other and each lower module has its own foundation frame;

Fig. 2 a possible arrangement of foundation frames in plan view and

Fig. 3 the positioning of a foundation frame within a frame-shaped trench excavation with the lower module indicated placed on the foundation frame;

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Fig. 4 the simultaneous use of sleeve-shaped transverse openings in the surrounding roof edge of each module for its transport and

Fig. 5 a possible embodiment of a head plate with positioning pin and anchor loop.

Description of the embodiments

The basic idea of the invention is to stack precisely manufactured individual modules on top of each other using a plug-in construction, so that the dimensional accuracy is also maintained in the finished building, whereby designs and improvements of the invention are also

the plug-in construction is also implemented in the transition area between a prefabricated foundation frame and the lower module placed on top of it. and finally the possibility is offered of creating a cross connection between modules arranged next to one another by inserting and connecting pipes or similar in the ceiling edge area of adjacent modules.

Fig. 1 shows the basic concept of a building 10, which is only partially shown, consisting of a lower row of modules 11a, 11b placed next to one another and upper, only partially shown modules 12a, 12b placed on top of this row of modules, with the lower row of modules itself resting on prefabricated foundation frames 13a, 13b.

The connection of the individual components, including the foundation frames 13a, 13b assigned to each module, is carried out in the vertical direction in the manner of a plug-in construction, with pin-like projections 14 protruding from corresponding recesses.

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ments 15.

Preferably, the pin/recess plug connections are located at the respective corner points of modules, at the top and bottom, while the foundation frames 13a, 13b only have pins 14 protruding upwards.

The type and structure of the pins and the corresponding recesses can be as described in the German patent application P 41 15 643.9 corresponding to DE-OS 41 15 643, the priority of which is claimed.

Each recess and each tenon is formed by a corresponding head or base plate 16 (see Fig. 5), which either forms the tenon 14 projecting upwards in the preferred construction in its outer contour or has the recess 15 indicated by dashed lines and which is firmly connected to the modules and foundation frames to be placed on top of one another, i.e. specifically the corner areas, at the corresponding points, namely by at least partially inserting and connecting it to the foundation frame and the reinforced concrete forming the modules.

For this purpose, each head or foot plate 16 can have an anchor loop 16a to achieve a firm anchoring in the surrounding material of the module corner area or foundation frame corner area, which can also be connected to further reinforcements in the module and foundation frame area.

Since during the prefabrication of the respective modules or

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Foundation frame, the head and foot plates can be positioned with high precision, this plug-in construction method also ensures the dimensional accuracy of the building constructed in this way as a whole.

The invention also takes a new approach to the manufacture of foundations, a process that is usually complex and labor-intensive and which, at least if work is subsequently carried out using a modular construction method, also requires very precise horizontal leveling of the foundation.

Here, an embodiment of the invention results in advantages in that, as shown in Fig. 3, it is only necessary to dig a circumferential trench 17 in the respective soil, which is at least partially filled, and then especially in the corner areas of the trench, with a lean concrete fill of a predetermined height.

A prefabricated foundation frame is then lowered into the rectangular trench, until the foundation frame rests on the lean concrete layer that has been introduced. The foundation frame itself can be of a simple construction, but one that is dimensionally accurate due to factory prefabrication, and forms, as shown in particular in Figs. 2 and 3, a closed, all-round frame shape without a floor or ceiling, which can be rectangular, but also of any shape, depending on the type of module, and has the upwardly protruding fitting or centering pins 14 on the four upward-pointing corner areas, as shown in more detail in Fig. 2.

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When setting up and inserting the foundation frame into the excavated trench, its horizontal leveling can be ensured by placing appropriate fitting pieces underneath until an exact horizontal alignment is achieved.

Then you can, for example, fill the remaining excavated trench completely so that the horizontal position is secured. However, it is also possible to provide the trench with a suitably horizontally aligned concrete layer placed in the ground right from the start.

Usually, several of the concrete frames provided are installed next to each other to create a building, as shown in the figure in plan view.

It has proven to be advantageous that the foundation frames 13 can have openings at points aligned with one another, which are shown in dashed lines in Fig. 2 and designated 18. These openings can not only be used to run cables through, but they can also be used to firmly anchor and fix the individual foundation frames 13 to one another by filling the aligned openings with concrete using an external formwork that can be removed later. It is also possible to make the openings uneven in their inner diameter for secure anchoring. The filling or pouring of concrete takes place after the necessary installations have been carried out, i.e. attaching the appropriate water and sewage pipes, electrical installations, etc.

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The foundation frame also offers advantages in that when the earth material within the respective foundation frame(s) sinks down to about level 19 as shown in Fig. 3 below the first module placed on the foundation frame, a cavity is created that can also be designed as a type of crawl space or as another accessible space. However, this is not necessary.

In a further embodiment of the invention, the respective prefabricated modules can also be effectively connected to one another or make it possible to run pipes or drain rainwater; for this purpose, the ceiling of each module is designed as shown in Fig. 1; a central trough-shaped depression 20 is thus formed, which, if it is the last uppermost module, can also take on the functions of a flat roof. The lowered trough results in a peripheral edge structure 21 for each module, which can, for example, merge into the bottom area of the trough 20 via an inclined surface 21a.

At points aligned with one another, sleeves 22 are inserted in the (circumferential) edge structure 21 in the ceiling plate of each module, directed from the inside, i.e. starting from the trough 20, outwards and with the lower edge preferably at the level of the trough bottom, which thus enable passages or openings of any cross-sectional shape in the ceiling area between individual modules standing next to one another.

This results in further advantages, which include the fact that rainwater can be drained through the cross connections

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between individual module ceilings; however, it is also possible to lay appropriate cables here, so that the troughs 20 in conjunction with the transverse passages 23 formed by the sleeves 22 form a type of installation level for each floor.

The transverse passages 2 3 can then finally serve another purpose, namely the relative fixation of the individual modules in the ceiling area to one another by pushing pipes through the sleeves 22, which are designed as metal pipes, and in this case from one module to the next, and then welding or otherwise connecting the outwardly protruding pipe ends to the corresponding sleeve end areas. In this way, an effective fixation against generally acting shear forces or other forces of the individual modules to one another is achieved, whereby the pipes used nevertheless keep the installation transition between the individual troughs 20 of the modules free, since they themselves are hollow.

Finally, as shown in Fig. 4, the passages 23 formed by the sleeves 22 can serve another purpose, namely the problem-free transport of individual prefabricated modules by inserting support forms 24 provided with a crane hook 25 on the side into these roof openings. The hooks 25 then serve as hangers for a transport and/or lifting crane.

In Fig. 5 it is also indicated that it is also possible to position the respective head or foot plate 16 with the positioning pins 14 or the corresponding recesses 15 receiving them only up to a certain height, the

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Level in Fig. 5 is marked 26, into the surrounding concrete material 2 7 of the module or foundation frame, so that a distance A results which, for example, can be 1 cm, to give numerical values which do not restrict the invention. This distance A ensures that the modules can be placed on top of one another and positioned correctly even if there are particles of material, stones or the like on the surface and also serves the purpose of filling this distance with mortar or the like, if necessary, even in advance, i.e. ideally immediately before the next module is placed, so that the modules form the common building as if they were bricked up one on top of the other.

In this context, it is also understood that the pins 14 preferably have a conical shape that tapers towards the top, so that even if the upper module is not placed exactly, it is automatically straightened and finally positioned when it is lowered further.

Claims (7)

DIPL-ING. PETER OTTE PATENT ATTORNEY Representative at the European Patent Office / European Patent Attorney 2472G/ot/wo 13.09.1991 Mr. Eberhard Schrade, Kelterweg 43, 7036 Schönaich Protection claims 1. Precisely dimensioned prefabricated module for the manufacture of structures and buildings, in particular two- to three-storey residential buildings, hospitals, hotels, commercial or office buildings, retirement homes and the like, whereby prefabricated room cells are arranged next to and above one another and connected to one another using modular construction technology (made of reinforced concrete), characterized in that each module (11a, 11b, 12a, 12b) has centering means directed upwards and downwards, serving for horizontal alignment and fixation, in the form of pin-like projections (fixing pins 14) and recesses (15) receiving these, and that a likewise prefabricated, encircling foundation frame (13) is provided, onto which, after its horizontal alignment, the respective lowest module (11a, 11b) is placed and centered directly using the same plug-in connection technology within an excavated trench. /2 2472G/ot/wo 13.09.1991 - 2 - 2. Precisely dimensioned prefabricated module and foundation frame according to claim 1, characterized in that the centering pins (14) on the respective corner areas of prefabricated foundation frames (13) and modules (11a, 11b, 12a, 12b) are directed vertically upwards and the recesses (15) receiving them are located on the lower corner area surfaces of the modules. 3. Precisely prefabricated module and foundation frame according to claim 1 or 2, characterized in that the ceiling plate of each module (11a, 11b, 12a, 12b) has a central recess (20) which is formed by a peripheral edge (21) in which transverse passages (23) are arranged in alignment with the openings in the other modules, the openings being formed by inserted sleeves (22). 4. Precisely prefabricated module and foundation frame according to claim 3, characterized in that continuous pipes are inserted into aligned sleeves (22) of adjacent modules and are connected (welded) to the sleeves to fix the modules relative to one another. 5. Precisely prefabricated module and foundation frame according to one of claims 1 to 4, characterized in that the foot or head plates (16) carrying the projections (14) or the recesses (15) are projecting by a predetermined distance (A) above the level /3 2472G/ot/wo 13.09.1991 - 3 - of the surrounding material to accommodate the mortar layers that connect the individual modules together. 6. Precisely prefabricated module and foundation frame according to one of claims 1 to 5, characterized in that support structures (24) with crane hooks (25) are inserted into the transverse passages (23) for transporting the modules. 7. Precisely prefabricated module and foundation frame according to claim 6, characterized in that the foundation frames (13) have aligned openings (18) for carrying out installations and later concrete pouring.