Classifications

• • 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.
• 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.
• a building pod comprising:
• structural floor, walls, and ceiling have sufficient load-bearing strength to support at least one other pod.
• the structural walls each comprise a structural metal frame.
• the structural frame comprises box-section steel structural members.
• the structural walls comprise vertical load-bearing studs.
• the structural floor comprises concrete cast in a structural frame.
• the floor structural frame comprises edge structural members having top horizontal flanges.
• the structural walls are secured to the top flanges.
• the structural walls are secured by bolting to the top flanges.
• the edge structural members have a C-shape in cross section, comprising the top flange, a vertical web providing an edge surface of the floor, and a bottom horizontal flange.
• the structural floor comprises reinforcing bar and meshes within the concrete.
• the structural ceiling comprises a plurality of vertical trusses interconnecting and spanning opposed structural walls.
• 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 interior is finished to finished room specifications with all required plumbing and electrical services and fitted furniture and sanitaryware.
• the building pod further comprises internal partition walls defining a plurality of rooms within the pod.
• 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.
• FIG. 1 is a flow diagram indicating the major steps of a method of the invention for constructing a multi-storey building
• Fig. 2 is a vertical cross-sectional view through part of a floor, a full wall, and part of a ceiling of a pod;
• Fig. 3 is a perspective view from above of the structural frameworks of pods where they are placed one above the other and side-by-side, details such as cladding and insulation being omitted for clarity;
• Fig. 4 is a diagram showing how a floor of a pod is manufactured
• Figs. 5 (a) and 5(b) are diagrams showing how lifting rods are inserted for lifting of a pod
• Fig. 6 is a vertical section at floor level of two adjoining pods, showing how they are placed on pods underneath;
• Fig. 7 is a cross-sectional plan view showing interconnection of pods at a corner
• Fig. 8 is a vertical section showing how a pod fits atop another pod at an external wall
• Fig. 9 is a plan section showing construction of a window in a pod wall
• Figs 10 and 11 are a perspective view and a cross-sectional elevation respectively of a balcony of a pod
• Fig. 12 is a cross-sectional elevation of a parapet of a pod.
• Fig. 13 is a cross-sectional elevation showing connection of a pod floor to a stair core. Description of the Embodiments
• 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.
• Wall panels are separately manufactured by fabricating structural steel frames according to the building specification, inserting services and insulation, and securing board to the internal and external surfaces.
• Lifting rods are screwed into sockets in the structural frame at the edges of the floor so that they extend vertically at spaced-apart locations around the periphery of the frame.
• the lifting rods extend through the wall panels, passing through apertures in the wall panel frame.
• Structural steel vertical trusses for the ceiling are placed on a jig and board is secured in the upper plane using self-drilling and tapping screws.
• the interconnected trusses are rotated by crane and placed over the wall panels, with bearing plates of the ceiling trusses resting on the wall panels, and then welded in place.
• the ceiling truss bearing plates are directly over wall panel vertical structural studs.
• the interior of the pod is finished in the manner of a conventional pod, with all services, fitted furniture, sanitary ware, tiling, windows, doors, and painting.
• the pod is then sealed and no further interior work will be required until final inspection of the building. Because all of the interior work is done in the factory there is excellent quality control and little waste. This completes the factory work.
• the pod After covering with rain-proof GRP sheeting over the ceiling the pod is lifted into position on a lorry with a crane lifting tackle engaging the lifting rods, and so the pod is lifted from the floor.
• a podium structure or basement is poured to provide a base for the building, and underground building services are incorporated according to the plans. Also a stair core and/or an elevator core is erected by casting re-enforced concrete.
• the pods are lifted into position with some side-by-side with opes in alignment, and the pods are placed one atop the other so that vertical load is applied down through the wall panels and floor frames of the pods.
• Pods adjoining the stair or elevator core are butt-jointed to the core.
• the pods are lifted from the bottom, as described in more detail below, thus avoiding distortion of the pods during lifting.
• the utility services protruding from the sealed pods are hooked up to the main building services, or alternatively this is left until final commissioning of building services in step 23. There is no need for construction of support structures above ground level, the pods themselves being self-supporting.
• 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.As all of this work is done in the factory, 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 allows 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 bathrooms, 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)

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• 2006
  • 2006-12-13 WO PCT/IE2006/000139 patent/WO2007080561A1/fr active Application Filing
  • 2006-12-13 EP EP06821548A patent/EP1971727B1/fr active Active
  • 2006-12-13 AT AT06821548T patent/ATE532914T1/de active
  • 2006-12-13 IE IE20060907A patent/IES20060907A2/en not_active IP Right Cessation

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