EP0568165B1 - Method of integrating construction and building block for its implementation - Google Patents

Abstract

The integration construction method is used for the production of buildings, characterised in that building is carried out from the inside outwards, by first of all the individual, self-supporting building blocks being connected only in a positively locking manner and then the inner functionality of these building blocks being established such that the latter takes the form of an inner-shell compact unit, which is essentially ready for covering, before the statically determinate frictionally locking connection of the building blocks with respect to one another is carried out by the production of the exterior masonry structure, the anchoring of the exterior masonry structure and building block, the insulation and, if appropriate, the provision of engineering bricks. This ensures extremely short construction times on the building site. The integration construction method is carried out with integration building blocks (13, 14) which comprise a lower frame (3), a monolithic floor (5) and an upper frame (8) with monolithic ceiling (7), which are arranged between at least four supports (6) such that the result is preferably a cuboidal frame structure, floor plane and ceiling plane into which the longitudinal partition wall (10), the transverse partition wall (11), the inner surfaces of the exterior wall with window reveal (12) and windows, doors and built-in objects with installation lines are integrated such that they can be mounted as a complete mounting unit. <IMAGE>

Description

The invention relates to an integration process for the production of buildings, in particular residential buildings, terraced houses, single-family houses, hotel, office, commercial and industrial buildings, in which self-supporting building blocks made of conventional building materials are prefabricated and assembled individually in size and shape on site Building.

The invention further relates to an integration module for carrying out the method, consisting of a self-supporting, closed frame construction, for example cuboid and made of section steel, which can be assembled together and one above the other in variable size and shape to form a statically effective complex, the modules being one below the other can be non-positively connected by means of an outer wall panel.

In the course of its development, the conventional design has produced the most varied forms of prefabrication of building parts.

The high weight of conventionally manufactured parts of the building has so far limited the size or the voluminous size of the assembly units. This applies to the block construction as well as the plate or cell construction.

This well-known series production also led to a uniformization of the prefabrication, which in turn caused a uniform design and a lack of flexibility in solving the constructive tasks in the building industry.
In the known methods, such as the skeleton construction or the ceiling lifting method, which achieve sufficient variability, however, the degree of prefabrication is significantly lower than in the previously mentioned methods.
However, the improvement in prefabrication makes a decisive contribution to increasing efficiency in the construction industry. In addition, the construction work cannot be carried out sufficiently enough regardless of the weather according to the known methods, and its degree of expansion is not sufficient for the extensive automation of the prefabrication.

Other known processes for the production of buildings, such as prefabricated house construction, container construction or lightweight construction, have a relatively high degree of prefabrication.

From DE-C-823 652 a method for building houses is known, in which shear-resistant, transportable room elements are made in a lightweight construction without external cladding and after they have been completed Installation at their final location can be provided with an outer cladding, in particular a cladding of the outer walls, which due to its weight and / or the material used for its construction is not suitable for being transported together with the room elements.
The lightweight construction elements are non-positively fastened to one another by screw connections and must be stiffened appropriately before the non-positive connection takes place in order to be able to absorb the forces and loads from floors above. This means that the individual room elements are mounted one above the other or next to each other with a high degree of accuracy, so that the vertical and horizontal lines for gas, water and sanitary installation, electrical installation and heating can be connected without any problems.
If it is necessary to correct the position of individual room elements, this can only be done by loosening the screw connections.

From DE-U-71 23 623 a transportable living or work space cell with a frame made of profile bars is also known, in which the side walls abut from the inside. The framework of each cell forms the edges of at least one cuboid with a square base.
Two side-by-side wall elements with the same area dimensions are provided on each outer cuboid side surface. The side wall elements have fillets on their vertical edges for inserting seals and are dimensioned such that they abut under horizontal pressure. The vertical profile bars have a box profile. The scaffold is there from vertical corner bars, vertical center bars, horizontal lower bars and horizontal upper bars. They are firmly welded together, but can also be detachable.

DE-A-27 19 953 discloses a building which has a frame covered by a roof, which is divided into different levels, with access means to the different levels, with installation and with a large number of prefabricated, mobile living elements for interchangeable adaptation the frame is fitted. The frame mainly consists of vertical components, vertical access means such as stairways and elevators, installations in the form of risers for waste pipes and water, electricity and gas lines.
The living elements are industrially prefabricated with installations and are partially furnished. They can be fitted into the frame by simply placing them on the frame elements and / or a fixed connection.

This known building accordingly consists of a fixed or firmly anchored, i.e. immobile parts and mobile parts, the living elements, so-called block cells.
These block cells have the character of caravans or motorized houses. They contain finished floors and walls with linings, door and window frames, window panes and blinds, lighting and running water. For their manufacture, light materials are used that are mounted on a metal frame and suitably insulated.

The individual block cells are self-supporting, but for their static assembly they need a frame that is able to absorb the building loads and forces as a whole. This means that correspondingly complex frame constructions with foundations have to be created on site.

DE-A-28 47 251 describes a living element consisting of a container-like hollow body. A metal skeleton structure is provided with side walls that have windows and doors. In the base frame of the side walls, in addition to vertical corner profiles, four recesses are formed symmetrically to one another in the spars, in each of which a winch is arranged. The side walls are detachably attached to the skeleton structure.
One skeleton structure is connected to the other skeleton structure on the front and / or long side. The skeleton consists of a cage made of profile parts made of steel or light metal, the side walls made of galvanized sheet steel or light metal.
Further skeleton constructions are known from GB-A 2 192 916 and EP-A 0 128 777.

The large number of individual parts required, the problems in the production of large-volume rooms, the difficulties in the production of multi-storey buildings therefore only allow the limited use of these known methods for residential and commercial building construction and are therefore not very suitable for long-term use.

Knowing this state of the art, the invention has for its object to develop an integration method of the type mentioned so that a largely high degree of prefabrication while maintaining high flexibility and variability in building design is achieved while largely maintaining the conventional design.
The object is also to provide a self-contained static system of the type mentioned at the outset for carrying out the method according to the invention, which consists primarily of conventional building materials and can be used variably in shape and size for single and multi-storey buildings.

This is achieved by the integration construction method of the type mentioned at the beginning with self-supporting building blocks made of conventional building materials, which are prefabricated for assembly and individually assembled in size and shape to form a building on the building site in such a way that one builds from the inside out by first carrying out the individual self-supporting ones Blocks are only connected positively and then the internal functionality of these blocks is manufactured in such a way that they receive a substantially ready-to-use inner shell compact unit from gas, water and sanitary installation that can already be used, electrical installation, heating, surface treatment, furniture element installation, before the statically effective adhesion by the Manufacture of the outer masonry, the anchoring of the outer masonry and building block is made.

Advantageously, the degree of expansion of the integration modules in the prefabrication is chosen so high that after the assembly of the integration modules lined up in a form-fitting manner, only the connection surfaces have to be made and the interior of the building can be used.
The installation lines are pre-assembled and are connected horizontally and vertically to the connecting masonry during the assembly of the integration modules.

The configuration according to which the outer wall facade surfaces can be designed individually from conventional building materials or lightweight materials after completion of the assembly is particularly advantageous.

With the choice of the length of the integration modules, it is possible to determine the depth of the building and by lining up the integration modules along the length, the length of the building and thus also the interior length can be varied.

The integration building method according to the invention is carried out with integration building blocks consisting of a self-supporting, closed frame construction, for example cuboid and made of section steel, which can be assembled together and one above the other in variable sizes and shapes to form a statically effective complex, the building blocks being non-positively connected to one another by means of an outer wall panel can be connected.

Such a building block has a lower frame, a floor designed as a monolithic ceiling and an upper frame with a reinforced concrete ceiling, which are arranged between at least four supports in such a way that a statically determined, inherently stable rectangular frame, preferably made of steel, with a floor level and ceiling level is created.

The integration module according to the invention provides that when arranging one above the other the upper frame of the lower module can engage behind the lower frame of the upper module in a positive and sealing manner.
The lower frame can be designed as a vertically positioned, circumferential U-profile with its webs outwards, in which a self-contained, self-contained reinforced concrete ceiling is arranged as a floor, and the upper frame consists of a circumferential T-profile consists of a web pointing vertically upwards, which engages behind the vertical central web of the U-profile and on the one flange half of which the reinforced concrete ceiling is arranged on the inside.

The lower frame can, however, just as well be designed as a vertically positioned, circumferential U-profile with its webs facing inwards, which inevitably accommodates a known, self-contained monolithic disc as the floor, and the upper frame from an angular profile with vertical there is a web pointing upwards, and the monolithic disc is arranged in the region of the frame to be supported by supports.

For this purpose, the web of the profile of the lower frame is provided with a seal, preferably a rubber seal.

Without restricting the invention, however, it is also possible that the lower frame is formed only by a circumferential frame with a monolithic pane and likewise the upper frame is formed only by a circumferential frame with a reinforced concrete ceiling. The static loads from the ceiling and floor of the building block are diverted separately to the vertical support structure. The partition construction is advantageously produced in a lightweight construction in the prefabrication site. Doors, windows and other built-in parts are assembled in the module.

Preassembled supply lines in the ceiling and in the partition walls enable quick and secure connection from block to block.

The finished longitudinal partition walls, transverse walls and the inner surfaces of the outer walls with window reveal, windows and / or doors are already installed in the building blocks as a complete inner shell compact unit.
The entire interior, including the ceiling and floor construction, is then completed with the prefabrication of the integration modules according to the invention, the internal functionality of the usage units being given with the longitudinal assembly of the modules and only the abutting surfaces of the integration modules having to be adjusted.

Further advantages, details and features result from the following description of a preferred exemplary embodiment with reference to the attached drawings.

Fig. 1

einen Querschnitt des erfindungsgemäßen Integrationsbausteines und

Fig. 2

eine räumliche Darstellung eines nach dem erfindungsgemäßen Verfahrens montierten Gebäudes.

The individual shows:

Fig. 1

a cross section of the integration module according to the invention and

Fig. 2

a spatial representation of a building assembled according to the inventive method.

The integration modules 13 and 14 consist of a basic structure formed from steel profiles, the lower frame 3 of which are connected by supports 6 to an upper frame 8 to form a static cuboid. In the horizontally arranged lower frame 3, a reinforced concrete rib ceiling 5 reinforced with steel mats is introduced monolithically with a 20 mm overhang from the upper edge of the steel profile. These reinforcement meshes each end on the longitudinal and transverse sides on the flange widening 4, on which the ends of the meshes are welded. The concrete ends at the inner edges of the U-profile of the frame 3. The reinforced concrete ribbed disc installed in the lower frame 3 is a self-contained ceiling disc that only has to absorb the loads that occur from the floor.
The upper frame 8 is a T-profile with webs pointing upwards. It is chosen in its dimensions so that the outer flange half can accommodate a lower frame 3 to be placed over it.

The inner flange half of the T-profile of the upper frame 8 serves to receive the reinforcement mats of the reinforced concrete ceiling 7. The length of the supports 6 determine the floor height to a decisive extent.

The floor-to-ceiling lightweight partition elements of the longitudinal partition 10, the transverse wall 11 and the inner surface of the outer wall with window reveal 12 are manufactured in separate operations. They are installed one after the other between the upper edge of the reinforced concrete rib ceiling 5 and the lower edge of the reinforced concrete ceiling 7 in the integration modules 13 and 14 in the prefabrication site. Of course, the light partition elements can also be manufactured conventionally from a sheet steel stand construction that is to be clad with commercially available panel material. The supply lines to be laid vertically are integrated in the light partition wall elements. All interior wall surfaces are provided with doors and windows as far as is necessary for the intended functional use of this section of the building.

The integration modules 13 and 14 are as long as the building is wide. The depth of the building accordingly determines the length of the integration modules.

All interior surfaces are already treated painterly in the prefabrication site and all installation objects are also assembled there.

The integration modules 13 and 14 thus prepared in the prefabrication site are transported to the construction site using special vehicles. On the construction site, the longitudinal foundation base 1 with rubber support and the anchoring bolt 2 and the basement must be prepared beforehand.

Starting at a gable, the first integration module 13 on the ground floor is removed from the transport vehicle by a mobile crane, placed with its lower frame 3 on the longitudinal foundation base 1 and anchored. The integration modules 13 of the ground floor are then strung together from side to side from one gable to the other.
The supply lines to the basement are connected to the connecting lines during the assembly of the integration module 13. The connection points created when the integration modules 13 on the ground floor are lined up can then be closed.
With the completed assembly of the integration modules 13 to the ground floor, the functionality of the ground floor is completely established. After completion of the residual material work in the area of the connections and the flooring work, the internal functional use is possible without further ado.
After the ground floor has been installed, the assembly of the 1st floor with integration modules 14 on a gable is started.
However, before the assembly of the 1st floor begins, the exposed webs of the T-profile must be used of the upper frame 8, a rubber seal 9 can be put over. The assembly is then carried out in the same way as the assembly of the integration modules 13 on the ground floor. The integration modules 13 and 14 are then arranged one above the other without being non-positively connected. In this phase of assembly, your bond is achieved through a purely positive fit.

After completion of the assembly on the 1st floor, only the lower frame 3 with reinforced concrete rib ceiling 5 is placed over the upper frame 8. On the narrow sides of the lower frame 3, abutments and anchoring options for fastening the roof truss are additionally provided. The stacked frames are firmly connected. Then the roof structure with the entire roof structure including roof skin 15 is put on and fastened.

With the completion of this work, the functional use of all interiors that already have partial furniture is possible. The adhesion of the integration modules 13 and 14 is then produced in a conventional manner with the creation of the outer wall panel 16.

The integration construction method according to the invention permits the individual planning and construction of commercial buildings, apartment buildings, production halls, single-family houses, hospitals, hotels and other buildings with individual adaptability and diversity.

Components such as balconies, bay windows, loggias and the like can also be easily integrated.

The integration module according to the invention enables construction with conventional building materials and is suitable for achieving a very high degree of prefabrication. It is easily possible to set up a flow production, which means that construction times can be reduced considerably and construction costs can be significantly reduced.
If buildings with great depths, for example over 12 m, are required, two or more integration modules can also be arranged one behind the other in a segment area on the respective floor.

List of the reference symbols used

Longitudinal foundation base / basement wall

1

Rubber support with anchoring bolts

2nd

Lower frame

3rd

Flange widening

4th

Monolithic floor / ceiling

5

Support

6

Reinforced concrete floor

7

Upper frame

8th

Rubber seal

9

Longitudinal partition

10th

Cross partition

11

Inner surface of the outer wall with window reveal

12th

Integration module ground floor

13

Integration module upstairs

14

Roof construction with roof skin

15

Outer wall panel

16

Claims (17)

1. Unit-integrating construction method for the production of buildings, particularly apartment blocks, semidetached houses, single-family homes, hotels, office blocks, business and industrial buildings, wherein self-supporting modular units are prefabricated ready for assembly and are then assembled on the site to a building in such way that construction work is executed from inside towards outside by first making only a form-fit connection of the individual, self-supporting modular units (13, 14) and then creating the interior functionality of these units so that they form a compact inner shell unit which is basically ready for occupation containing already the usable gas, water and sanitary services, heating, electrical installation, surface finish, unit furniture, before the statically effective forces are made to flow between the modular units (13, 14) through erection of the external masonry (16) and anchorage of external masonry (16) and modular unit (13, 14).
2. Unit-integrating construction method as set forth in Claim 1, wherein the length of the integral modular units (13, 14) determines the depth of the building.
3. Unit-integrating construction method as set forth in Claims 1 and 2, wherein at first the integral modular units (13) of the ground floor are erected and anchored on pedestals (1), followed by the erection and anchorage of the integral modular units (14) of one or more upper floors on the ground floor, and finally the placing and anchorage of the complete roof structure on the integral modular units (14) of the floor installed last, in abutments provided for that purpose.
4. Unit-integrating construction method as set forth in Claims 1 through 3, wherein the functional unity on one floor level is produced by longitudinal lining-up of the integral modular units (13) on the pedestals prepared (1), with just the contact faces of the integral modular units (13) being left to be touched-up.
5. Unit-integrating construction method as set forth in Claims 1 through 4, wherein the integral modular units (13, 14) are assembled in tandem and longitudinally.
6. Unit-integrating construction method as set forth in Claims 1 through 5, wherein the entire interior finishing work of the building - except the connection of services - is completed with the assembly of the integral modular units (13, 14).
7. Unit-integrating construction method as set forth in Claims 1 through 6, wherein additional components such as stairs, balconies, loggias, and oriels are integrated and fitted along with the respective integral modular unit (13, 14) or later on.
8. Unit-integrating construction method as set forth in Claims 1 through 7, wherein the integral modular units (13, 14) are manufactured in prefabricating plants, preferrably of the permanent type, and are then transported to the site.
9. Integral modular units (13, 14) for the implementation of the method as set forth in Claim 1, consisting of a self-supporting, enclosed frame structure, for instance in parallelepidal form and of sectional steel, where modular units (13, 14) lined-up or superimposed variable in size and form can be composed to a statically effective complex, and where the modular units (13, 14) can be coupled non-positive with each other through an external shear wall, wherein in case of superimposition the top frame (8) of the bottom unit (13) can grip the bottom frame (3) of the top unit (14) for the purpose of a form-fit and tight connection.
10. Integral modular unit as set forth in Claim 9, wherein the bottom frame (3) is designed as vertical surrounding channel section with its webs showing outwards and an actually known and self-contained monolithic plate being arranged rigidly as floor (5), the top frame (8) consisting of an enclosing tee with vertically upward web engaging in the vertical centre web of the channel section of frame (3), the reinforced concrete ceiling (7) being supported inside on one flange half.
11. Integral modular unit as set forth in Claim 9, wherein the bottom frame (3) is designed as a vertically arranged surrounding channel section with its webs showing inwards, carrying an actually known enclosed monolithic plate as floor (5) in a rigid connection, and were the top frame (8) consists of an angle section with the web showing vertically upwards, the monolithic plate in the range of the frame (3) resting on supports for shoring-up.
12. Integral modular unit as set forth in Claims 9 through 11, wherein the web of the section of the bottom frame (3) is provided with a packing, preferably of rubber.
13. Integral modular unit as set forth in Claims 9 through 12, wherein finished longitudinal partitions (10), cross walls (11) and interior faces of external walls are provided with window reveal (12), window and/or doors in the modular units (13, 14).
14. Integral modular unit as set forth in Claims 9 through 13, wherein the utility lines are installed in such way that they can be connected with the lines of other units when these are superimposed.
15. Integral modular unit as set forth in Claim 9, where abutments and fixings for anchorage are provided in the surrounding frame (3) with floor (5) to absorb the forces of the roof structure.
16. Integral modular unit as set forth in Claims 9 through 11, wherein the frames (3, 8) are coupled with each other non-positive alongside.
17. Integral modular unit as set forth in Claims 9 through 11, wherein additional components such as stairs, balconies, loggias, and oriels are integrated.

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