EP1356167A1

EP1356167A1 - Integral prefabrication system with frame structure featuring finished lightweight components

Info

Publication number: EP1356167A1
Application number: EP01986410A
Authority: EP
Inventors: Alberto Dal Lago
Original assignee: DLC Srl
Current assignee: DLC Srl
Priority date: 2000-12-20
Filing date: 2001-12-13
Publication date: 2003-10-29
Anticipated expiration: 2021-12-13
Also published as: ITMI20002758A1; CN1483101A; DZ3458A1; RU2288331C2; EP1356167B1; RU2003118154A; IT1319592B1; DE60144028D1; AU2002237233A1; WO2002050382A1; DOP2001000314A; ATE498037T1

Abstract

An integral prefabrication system with frame structure featuring finished lightweight components comprising: internal parting walls (11) spaced to form an apartment module with incorporated portal for supporting the floors, filler panels (12) with top beam for horizontal earthquake-proof joints (17), storey floors (22) and roof floors (25) spanning the parting walls to form a rigid surface, portals (26) and bracing elements (27). According to the invention the horizontal joints of the rigid surface, the continuity of the vertical reinforcement and the seismic resistance of the bracing elements are obtained by the injection of shrink-resistant material in the recesses provided (32) and by means of connection devices (31).

Description

INTEGRAL PREFABRICATION SYSTEM WITH FRAME STRUCTURE FEATURING FINISHED LIGHTWEIGHT COMPONENTS

The present invention concerns an integral prefabrication system with frame structure featuring finished lightweight components.

As is known, various systems exist for the construction of prefabricated buildings, for residential use, which can be classified in two categories: frame systems and supporting panel systems.

The frame systems create, by means of beams, pillars and floors, the structural skeleton of the building which must then be completed on site with the filler panels, partitions and floor consolidation castings. The frame systems are therefore not "global" as the prefabrication has to be integrated with completion work on site.

In supporting panel structures, the outer and inner walls have the job of sustaining the floor and creating a box-shaped structure forming . the room module, the disadvantages being that it is not possible to alter the distribution from floor to floor, consequently it is not possible to design the ground floor as required, on piloty and underground garage. Furthermore, although it is possible to obtain integral prefabrication, the concrete supporting elements make the structure heavy and therefore anti-economic especially in countries where the cost of materials affects the final cost to a far greater extent than labour costs.

The aim of the present invention is to produce an integral prefabrication system with frame structure featuring finished lightweight components that overcome the above-mentioned disadvantages.

This and other aims are achieved by an integral prefabrication system with frame structure featuring finished lightweight components, according to claim 1, which is here referred to for the sake of brevity. Further characteristics of the present invention are defined in the subsequent claims.

Briefly, it should firstly be observed that the system of the invention uses walls that create an apartment module and not a room module; the walls are finished and incorporate a frame structure and a lightweight internal area to reduce the weight as far as possible with channels which can also be used. In addition to the floors being extremely lightweight, ducts for wiring and other installations can be made inside them and connected to the vertical wall channels. All the components are finished and no on-site casting is required during assembly, only mortar injections. The system is defined integral in the sense that the building is constructed 100% with finished lightweight prefabricated components, maintaining the static advantages of the frame structures and the finishes of the supporting panel structures, but eliminating the negative aspects of the two structures; the system is therefore lightweight, economic and versatile and is competitive both for single-family terraced buildings and for buildings with over 20 floors.

Further aims and advantages of this invention will become clear from the following description and the attached drawings, provided purely as a non-restrictive example, in which: figure 1 shows an axonometric view, partially in section, of the integral prefabrication system with finished lightweight components, according to the present invention; figure 2 shows a wall supporting the floor, called parting wall, belonging to the prefabrication system of the invention; figure 3 shows a filler panel belonging to the prefabrication system of the invention; figure 4 shows a floor belonging to the prefabrication system of the invention; figure 5 shows a roofing floor belonging to the prefabrication system of the invention; figures 6-6A-7-7A show a variation of the roofing floor by means of a flat frontal panel that conceals the pitch of the roof, belonging to the prefabrication system of the invention; - figures 8-9 show beam and pillar elements forming a portal frame, belonging to the prefabrication system of the invention; - figure 10 shows a bracing element belonging to the prefabrication system of the invention; - figure 11 shows a bathroom shell belonging to the prefabrication system of the invention;

figure 12 shows a staircase belonging to the prefabrication system of the invention; figures 13-15 show a device used to produce bracing elements by connecting several parting walls and to produce the earthquake-proof joints, belonging to the prefabrication system of the invention; figure 16 shows a section view of the staircase belonging to the prefabrication system of the invention; and figure 17 shows an exploded axonometric view of a structure created with the prefabrication system of the invention. With particular reference to the figures mentioned, the integral prefabrication system with frame structure featuring finished lightweight components of the invention comprises firstly a component 11 called parting wall. The internal parting wall 11 fitted at intervals on the apartment module to sustain the floor, is cast in vertical formworks to obtain the two finished outer surfaces and consists of a flat frame, made of two end pillars 12 and an upper beam 13, and a lightweight wall with vertical holes 14, obtained by means of special tubular formworks that contract elastically for extraction.

The flat columns or pillars 12 have dimensions that can be adjusted to static requirements, and contain a sheath (a sheet metal tube) 15 which is injected.

The injection ensures distribution of the loads from floor to floor and vertical continuity of the reinforcing bars inserted one on top of the other. The tubes that form the lightening holes 14 can be positioned as required and have fixed and modular dimensions. They can also be used to obtain continuous vertical channels for wiring, ventilation and fume expulsion, and to provide vertical structural continuity with continuation of the reinforcement.

The parting walls permit the creation of walls with different total thickness for the variable loads due to the different number of floors (in general, purely as an example, 15, 20, 25 cm for holes of 10 cm * 55 cm) . Another component of the system of the invention is the filler panel 16 shown in figure 3.

It is made with continuous thermal insulation by means of one fixed and one moving support and with stainless steel connectors that disengage the outer wall supported by the inner supporting wall and with internal hollow ventilation tubes which during the winter prevent internal condensation of humidity and in the summer prevent internal temperature increases due to radiation. The panel is characterised by a top beam 17 which rests at the level of the parting wall 11 on its end pillar 12.

The top beam 17 has the following functions: - earthquake-proof joint beam; - beam supporting the external facing, which can be blind, windowed or absent; assembly template for the parting wall above;

- parting wall bracing right from the assembly stage; - stiffening of the filler panel which can cover spans up to 10 m, minimising concrete thickness.

The parting wall - filler panel node is provided by the insertion of a vertical bar 18 that enters the sheath

15 of the parting wall 11 and crosses a stainless steel loop 19, so that it is not necessary to make holes in the formworks, with ropes coming out of the top beam 17. Further injection:

- provides an earthquake-proof connection that transmits the action of the joint to the bracing element;

- at the same time ensures vertical continuity of the reinforcement; ensures distribution of the vertical loads, providing a seal that allows the injected mortar to embed the resting surface. Another component of the system of the invention is the floor component 20 of figure 4. It is a floor covering a large span (up to 10 m) produced by pre-stressing, with adjustable width and length. It is completed on site by panels 21 which rest between two elements 22 thus providing a series of channels 23 which can be used for wiring and other installations also because the statics of the floor are independent of the panels 21 which can therefore be positioned once the structure is complete and also removed subsequently. The horizontal hole of the floor can be made not only by means of polystyrene blocks but also, like the wall holes, via special tubular formworks which contract elastically for extraction based on exactly the same concept as those of the parting walls. The horizontal holes of the floors are connected to the vertical holes of the parting walls thus permitting distribution of the wiring and other installations both horizontally and vertically.

The floors are fixed to the parting wall not by means of the usual on-site casting but by means of a mechanical connection 40 (fig. 1), while on the joining line of two elements one, two or three welded connections 24 can be performed so that the intrados of the floors creates a rigid horizontal surface. In the floor, the panel 21, which is independent of the floor statics, can be positioned at the end of assembly and can be subsequently raised like a trapdoor to access the wiring and other installations or can be entirely eliminated to obtain, for example, an earth container flush with the floor.

The floor and the panels can have a finished surface which, once laid, constitutes the finished floor of the house, or the floor can be used as a base for laying a self-levelling material on which an impact noise insulation layer and then tiles, carpet, linoleum etc. are glued to provide dry flooring.

Figure 5 shows a roofing floor 25, belonging to the prefabrication system of the invention.

The element has a flat intrados constituting the ceiling of the last floor, while the extrados consists of a covering slab with transverse and longitudinal pitch of 15%, in order to create: an air space between the intrados slab and the roofing slab providing thermal inertia; - a well-insulated roof, with an insulating layer factory-laid on the ceiling panel and turned up over the tile ribbing in order to eliminate heat bridges; a sloping roof made of highly waterproof concrete that does not require any further waterproofing layer;

- a roof with the possibility of a false ceiling at the intrados between tiles which can be lifted up for access to and inspection of the air space; - a roof resistant to tornadoes and whirlwinds as it has no lightweight elements;

- a ventilated roof, like the walls, obtained by exploiting the pitch of 15%.

Ventilation is obtained by means of 2 air inlet grilles at the level of the flashing and 2 air outlet grilles at the ridge. lastly, a roof that is finished and can be assembled immediately, thus permitting maximum construction speed. An end element 41 can also be provided featuring a flat front panel that conceals the pitched ventilated roof behind, as shown in figure 7.

Figures 8-9 show particular views of a portal frame structure 26, belonging to the prefabrication system of the invention.

It consists of collar pillars 51 supporting an upturned T connection beam 50, which form a portal where the beam supports the floor and the pillars directly support the loads transmitted by the flat pillars in -li¬

the parting walls of the upper floors.

The pillar with collar has one fixed and one variable dimension with the possibility, therefore, of also obtaining ^Λblade" pillars ranging, for example, from the minimum section of 25 cm x 40 cm to a section of 40 cm x 60 cm or 25 x 200. '

This is very useful when a ground floor on pillars is required or there is a garage below the building, or the ground floor has a height that would make the parting walls and filler panels impossible to transport.

Figure 10 shows a bracing element 27 consisting of parting walls that form the stairwell or lift shaft. Some of the parting wall holes can be through holes in order to contain the vertical reinforcement cage 28 which continues from floor to floor.

The parting walls are interconnected by the insertion of bars 18 in the protruding steel wire rope loops 19 and by further injection as for the top beam of the panels.

Figure 11 shows a bathroom shell 29, belonging to the prefabrication system of the invention.

The bathroom shell 29 contains a fully accessoried bathroom, equipped and finished to provide integral prefabrication by components. The shell is made of a concrete element completely closed on the six sides, self-supporting, but able to perform also a bracing function for single-floor constructions during assembly. Its reduced height means that a storage compartment can be obtained in the upper part between the shell and the ceiling.

Figure 12 shows a staircase 30, to make the prefabrication system integral. The staircase 30 consists of three overlapping finished elements consisting of a tubular structure fitted with the overhanging steps which constitutes the stair supporting element inside which it is also possible to install a lift by removing the floor slab. The three inter-floor elements are positioned one on top of the other and consolidated by injection of sheath reinforcement, as for the parting walls. In this way, a stair unit 30 is produced, complete with landings, which can be fitted either inside or outside the building and is totally independent from the static point of view.

The steps can be made with finished risers and treads so that, once the component is fitted, there is no need for any further work. In the earthquake-proof frame structure of the invention, the horizontal joints of the rigid floor, the continuity of the vertical reinforcement and the bracing elements are obtained without additional castings on site, but simply by injections at set points and with connection devices 31 consisting of stainless steel loops.

Said connection devices are made by inserting in the formwork retrievable magnetic elements which pull out of the wall, at the required intervals, a loop 19 made of stainless steel wire rope which does not require holes in the side and which, due to its flexibility, permits easy positioning of two adjacent walls during assembly. During production the magnetic element that holds the loop is positioned in a semi-circular recess which permits, after on-site insertion of a reinforcing bar 18, overhead injection of shrink-resistant mortar into a recess 32. While the vertical reinforcement, continued, provides vertical continuity, the protruding loops provide both the insulated connection of the walls that constitute the earthquake-proof structure and the joints in the top beam of the filler panels. To ensure quick assembly regardless of the climatic conditions, the frame with the earthquake-proof joints is produced by simple injections of mortar and therefore basically without on-site castings of cement mix, ensuring complete finishing of the building.

Finally, figure 17 shows an exploded axonometric view of a structure, indicated overall by reference number 100, made with the prefabrication system of the invention. From the description provided, the characteristics of the integral prefabrication system featuring finished lightweight components, subject of the present invention, are clear as are the resulting advantages . Finally, it is clear that numerous variations can be made to the integral prefabrication system with° frame structure featuring finished lightweight components while remaining within the principles of novelty inherent in the inventive idea. In practical implementation of the invention, the materials, forms and dimensions of the details illustrated can be of any type according to requirements and the same may be replaced with other technical equivalents. The scope of the invention is defined in the claims attached to the present application.

Claims

1. Integral prefabrication system with frame structure featuring finished lightweight components comprising: internal parting walls (11) spaced to form an apartment module with incorporated portal for supporting the floors, filler panels (12) with top beam for horizontal earthquake-proof joints (17), storey floors (22) and roof floors (25) spanning the parting walls to form a rigid surface, portals (26) and bracing elements (27) characterised in that the horizontal joints of the rigid surface, the continuity of the vertical reinforcement and the seismic resistance of the bracing elements are obtained by the injection of shrink-resistant material in the recesses provided (32) and by means of connection devices (31) .

2. Prefabrication system as in claim 1, characterised in that the above internal parting wall (11) consists of a flat frame, made of two end pillars (12) and an upper beam (13), and a wall with vertical lightening holes (14) obtained by means of tubular formworks that contract elastically for extraction.

3. Prefabrication system as in claim 2, characterised in that the above pillars (12) and the walls corresponding to the lightening holes (13) have dimensions that can be adjusted to static requirements. The pillars contain a sheath (15) which, when injected, ensures distribution of the loads and vertical continuity of the reinforcement.

4. Prefabrication system as in claim 1, characterised in that the filler wall (12), which features hollow tubular vertical ventilation elements and continuous insulation, incorporates a top beam (17) which rests at the level of the above-mentioned parting wall (11) on its end pillar (12) .

5. Prefabrication system as in claim 4, characterised in that the top beam performs a number of functions as follows:

- earthquake-proof joint beam

- panel stiffening beam

- panel supporting beam for both the vertical loads and horizontal thrust - assembly template for the parting wall above

- bracing of the parting wall also during assembly

6. Prefabrication system as in claim 1, characterised in that the node between parting wall and filler panels is provided by the insertion of a vertical bar (18) which enters the sheath (15) of the above- mentioned parting wall (11) and connects the loops (19) protruding from the top beam (17) .

7. Prefabrication system as in claim 1, characterised in that the floor (20) is made of a pre-stressed element, of adjustable width, with intrados providing a rigid surface and extrados providing the walk surface with prefabricated panels (21) that rest between two elements (22) providing a series of channels (23) which can be used for wiring and other installations .

8. Prefabrication system as in claim 7, characterised in that the floors (20) are fixed to the parting wall without additional casting but by means of mechanical connections (40) and, on the joining line of two elements (22) , by means of welded connections (24) .

9. Prefabrication system as in claim 1, characterised in that it comprises a roof (25) made of pre- waterproofed and pre-insulated elements with intrados providing a rigid surface constituting the top floor ceiling and extrados made of waterproof concrete with sloping longitudinal section in order to create an air space, with grille apertures for inlet of air at ambient temperature and outlet of the heated air on the ridge, thus providing roof ventilation.

Since no further finishes are required, the roof made of adjacent single-block elements or alternating with roofing panels, is able to withstand tornadoes and whirlwinds .

10. Prefabrication system as in claim 1, characterised in that the above-mentioned portal (26) consists of varying dimension pillars, also constituting "blade" pillars, which directly receive the load of the upper floors and which, with an upper collar (51) , support an upturned T connection beam (50) bearing the floor (20) .

11. Prefabrication system as in claim 1, characterised in that the above bracing element (27) consists of parting walls that form stairwells or lift shafts in which at least some of the parting wall holes are through holes in order to contain the vertical reinforcement cage (28) which continues from floor to floor and the parting walls are interconnected by the insertion of a bar (18) in the loops (19) .

12. Prefabrication system as in claim 1, characterised in that it comprises a bathroom shell (29) containing a fully accessoried bathroom, equipped and finished and made of a concrete element completely closed on the six sides and self- supporting, with a storage compartment between the staircase extrados and ceiling intrados.

13. Prefabrication system as in claim 1, characterised in that it comprises a staircase (30) statically independent of the structure of the building, consisting of a tubular structure fitted with the overhanging steps inside which it is possible to install a lift, also at a later stage. The three inter-floor elements are positioned one on top of the other and consolidated by injection of sheath reinforcement .

14. Prefabrication system as in claim 1, characterised in that the above-mentioned horizontal joints provided in the panel folds and the continuity of the vertical reinforcement are obtained by injection into the recesses provided (32) and by special connection devices (31) which are obtained without making holes in the formwork but by placing, in any position, retrievable magnetic elements that retain the loop folded inside them and, when retrieved, pull the above-mentioned loops (19) out of the wall.