EP2175088B1

EP2175088B1 - Method of installation on site of a prefabricated semi-resistant module for construction

Info

Publication number: EP2175088B1
Application number: EP20090380161
Authority: EP
Inventors: Angel Moreno Cano; Julio César Moreno Cano
Original assignee: Moreno Cano Angel
Current assignee: Moreno Cano Angel
Priority date: 2008-10-10
Filing date: 2009-10-08
Publication date: 2014-09-03
Anticipated expiration: 2029-10-08
Also published as: ES2333636B1; EP2175088A2; ES2333636A1; EP2175088A3

Description

OBJECT OF THE INVENTION

The present invention comes within the sector of industrialized construction and relates to a prefabricated semi-resistant module for construction and a method for its installation on site in such a way that a modular construction system is defined.
The prefabricated semi-resistant module can be for residential use, equipment, industrial use, etc., and the installation method on site is carried out on gantries with a prefabricated structure. So, the system defined by the semi-resistant module and its installation method has the advantage of a rapid execution of the work (both the manufacture of the module in an assembly chain and the execution/installation process on site), a considerable reduction in construction costs and the fact that all the materials used are easily reusable and recyclable,
The invention comes within the technical field of construction, specifically within modular construction techniques.

BACKGROUND OF THE INVENTION

To date, modular or prefabricated construction systems can be categorized into three groups characterized in that:

A) they are fully executed in the factory by means of light materials, both for the enclosures and for the structure which merely permit their application in houses for single families or constructions of one or two stories, and it is very difficult to apply them to apartment blocks or buildings comprising several stories.
B) they concern prefabricated systems for tall buildings which are focused on the structure and the enclosures, or in that
C) they concern fully finished modular systems characterized by being self-resistant modules of considerable weight which makes them difficult to transport and install on site, generally made of a gantried reinforced concrete structure or of load-bearing walls with a "stackable" construction concept. Although these systems shorten the execution time in a very considerable way, they cause the difference in budget for the executed work in comparison with traditional construction systems to be small or even negative.

The construction systems of group A) comprise light meshed structures of galvanized folded sheet and "slabs" of water-repellent board made of wood agglomerate of the kind that exists in many systems among those that are currently on the market.
The construction systems of group B) are composed of structures-enclosures produced in situ, characterized by projecting gunned concrete onto insulating panels with steel reinforcement, the actual structural enclosure being both vertical (wall) and horizontal (floor slab), with the rest of the work being carried out in situ by traditional methods (facilities, coverings, etc.).
The construction systems of group C) comprise structural boxes made of reinforced concrete and fully finished, calculated in order to resist several boxes resting one on top of another, with several stories being stacked up, for which there exist various patents depending on the system for securing one module to another and the passage and connection systems for the facilities, such as for example Patents ES 2 094 179 T3 , ES 2 098 090 T3 , ES 2 090 175 T3 .
So, it was desirable to have a prefabricated semi-resistant module suitable for attachment to steel gantries (thereby completing the structural system) and later to other similar or equal modules arranged both laterally and on top, for the construction of buildings, and a method of installation on site for that module which would have a rapid execution for the work, both in the manufacture of the module in an assembly chain and the execution/installation process on site, at the same time as achieving considerable savings in construction costs and the fact that all the materials used are easily reusable and/or recyclable.
Document WO 00/36238 A1 discloses a method for installation on site of prefabricated semi-resistant modules, comprising the steps of:

creating a foundation where the module is to be positioned;
positioning a first storey of prefabricated modules on said foundation;
positioning a first storey of supporting pillars connected to said foundation and to the upper corners of said prefabricated modules;
positioning another storey of prefabricated modules on the supporting pillars of the previous storey;
positioning another storey of supporting pillars connected to the supporting pillars of the previous storey and to the upper corners of the prefabricated modules of the current storey;
repeating successively the last two steps as many times as there are stories to the building to construct.

DESCRIPTION OF THE INVENTION

The prefabricated semi-resistant module of the present invention is produced in the factory by means of an "assembly chain" system in accordance with the following method: some load-bearing beams made of rolled steel sections, preferably hot rolled steel as per standard UNE EN 10025, especially S235 to S 450, standard UNE EN 10210 and shaped cold as per UNE EN 10219 according to CTE-SE-Steel, which forms "part" of the structure of the building, are taken and on them is executed a lightweight slab composed of decking sheet (any of the products existing on the market) which is welded or screwed to said beams on which a lightweight concrete of expanded aggregate is poured, preferably arlite or similar, and mesh, preferably of steel.
This type of slab, already existing, permits the actual weight thereof to be reduced by around 50%, and to be produced in spans of around 3 m, which facilitate its later transportation. The edges are approximately 12 cm.
Executed on this slab is a "cage" made of shaped sections, preferably in rolled steel, which on the one hand permits securing of the prefabricated partitions and on the other hand it serves as a crane attachment for its later transportation and placement on site.
On this "cage" and lightweight slab the partitioning is then executed by means of shaped sections, preferably of galvanized steel, and panel, preferably of cardboard, plaster or any of the systems existing on the market, with the difference that instead of being secured to the lower interior slab or floor and the upper interior slab or ceiling, it is secured to the lower interior slab and to the "cage" of metallic sections of rolled steel by means of additional galvanized steel sections which will later on serve for the fixing of the lightweight plates that are going to form the ceiling of the module.
Once the partitioning has been carried out for the interior divisions, party walls and façade backings, the sanitary facilities, made of PVC or similar, are installed under the slab, along with branch pipes to runoffs and sections of main down-pipes for the story, and at that moment the entire area underneath the slab and the beams is then sprayed with fire-resistant foam. After that the hot and cold water facilities are fitted in polybutylene or similar which permits an industrialized or kit preparation, and also the electricity and telecommunications, by means of chases, ducts, pipes and cabling in the ceiling, which, depending on the use, will have the greatest possible degree of prefabrication or industrialization.
Following the facilities, the floor coverings and paneling in damp areas will then be carried out using adhesives with elastomeric properties.
The next step in the installation process relates to the prefabricated façade panels with complete exterior carpentry and the rest of the panel starting from the insulating chamber being finished with any kind of covering, with lightweight prefabricated modular types being recommended. The façade panel is secured to the "cage" made of metallic shaped sections and to the mesh of the galvanized shaped sections for the partitions.
Finally, after sealing the joints, laying of the ceiling plates and painting, the sanitary ware, taps and fittings and electrical mechanisms are installed, and the module is then fully finished for being loaded onto a truck or means of transportation by crane which will be secured to the "cage" made of metallic sections, with the hanging points and securings for the crane coinciding with the support points which it will have in the final structure. The finished module Is transported to the site, and the appropriate size for it will therefore be less than 3 m x 12 m with an approximate total weight of 10 mt. It is understood that these figures have to be considered overall as being merely by way of example and that they refer to a preferred form of embodiment.
Moreover, the finished module preferably has the shape of a rectangular parallelepiped. The method of installation of the module or modules is executed entirely on the site, starting with the foundation which will need to be calculated depending on the characteristics of the ground and in which in most cases will be a traditional foundation using isolated footing pieces secured with reinforced concrete, since the system is characterized by its lightness with a load transmission to the foundation of around 50% of the figure that would correspond to a traditional construction. The rest of the structural system is executed on the foundation story by story, alternating the installation of the gantries for each story with the positioning of the finished modules of the building, joining them together after positioning them In the story by means of screwed or welded connections, with the complete structure at that moment being created by the following method: Positioned on the footing pieces are some gantries prefabricated in hot rolled steel as per standard UNE EN 10025, especially S235 to S 450, standard UNE EN 10210 and shaped cold as per UNE EN 10219 according to CTE-SE-Steel, as with the steel for the columns and main beams. Positioned on those gantries are the modules, resting on the main beams of rolled steel, and they are joined to the gantry and the main beam with the structure thereby being completed. Next, the rolled steel "cages" of the different modules making up the same story of the building are joined together by means of screws or welding and the "cages" are in turn joined together with the columns of the gantry. After that, the facilities for the different modules are connected together.
Once one story has been positioned, the upper and contiguous story is then proceeded to be created in the same way, screwing or welding the adjacent upper gantries to the already executed structure forming part of the finishing building.
The system is repeated, both on the same story and upwards, as might be required by the works program, respecting the expansion joints, until the façade party wall has been reached, which is created as the façade of the prefabricated module, in other words, a prefabricated façade party wall with complete exterior carpentry and the rest of the party wall, starting from the insulating chamber, being finished with any kind of covering, with lightweight prefabricated modular types being recommended. The façade party wall panel is secured to the "cage" made of metallic shaped sections and to the mesh of the galvanized shaped sections of, or until reaching, the roof of the building, which is created as the lightweight prefabricated slab of the module, in other words, slab composed of decking sheet which is welded or screwed to beams, especially to the beams of the final gantry, on which a lightweight concrete of expanded aggregate is poured, preferably arlite or similar, and mesh, preferably of steel or any other system of prefabricated slab existing on the market. It is then waterproofed with special care being taken in the overlaps and reinforcements in the joints of slabs and is then thermally insulated. Said final gantry is positioned as for the others, and has the function of, on the one hand, completing the structural system of the semi-resistant module that it has below and, on the other, of supporting the slab for the roof.
Finally, it merely remains to seal on site the exterior connections of facades between modules, and modules with structure, by means of a fire-resistant spray on columns and beams, and the positioning of special flashings made of a lightweight material with screwed connections, or connections that click into place, or using adhesive with silicones or similar, the building then being finished.
The communal zone for vertical communication, such as stairways and lifts, are carried out "a posteriori" by means of existing self-supporting prefabricated systems or kits which are attached to the building permitting access to the different stories, with an accessible zone being created at the attachment point through which in the vertical direction will run the general community facilities for the building in shunts (vertical down-pipes) and prefabricated ducts hanging from the structure of the building from prefabricated enclosures or cupboards for each facility or service on the ground floor.
The said general community facilities are included in the module and run along the ceiling of the communal zone containing the access doors to the apartments and which form part of the module. The said vertical down-pipes will have their inspection holes and prefabricated connection cupboards inside the space for those down-pipes.
So, taking the semi-resistant modules as the basis, it can be highlighted that it is possible to manufacture a building without any major limitations in its dimensions of length and width, such limitation therefore not existing since they are not stackable. It is a meccane in which part of the structure, which is always the same (with the same loads), contained in the module is assembled with the rest of the structure: gantries of columns and main beams, which is indeed variable depending on the height, above all the columns on account of the number of stories they support (in a building with six stories the last three will be equal to a building of three stories), and depending on the wind and seismic factors, the additional X-shaped securings which the building as a whole might require according to its location and the seismic zone will also be varied.

BRIEF DESCRIPTION OF THE FIGURES

The present invention will be fully understood on the basis of the brief description appearing below and the accompanying drawings that are presented, solely by way of example and, in this way, they are non-restricting within the present invention, and where:

Figure 1.- Plan view of the arrangement of load-bearing beams (1), the lightweight slab (2) and the cage (3) in the method for manufacture of the prefabricated semi-resistant module.
Figures 2a and 2b.- Plan views of two different modules which incorporate the prefabricated partition (4), sanitary ware and façades.
Figure 3.- Perspective view of the arrangement of load-bearing beams (1), the lightweight slab (2) and the cage (3).
Figure 4.- View in cross-section of the lightweight slab (2) of figure 3 and indication of the application of the fire-resistant foam (21).
Figures 5a and 5b.- Perspective views of two finished modules with coverings and ceilings, ready for being backed on to each other, and detail of the different layers making up the façades.
Figure 6.- Shows the transportation of a module by means of a truck (8).
Figure 7.- Perspective view of the two modules of figures 5a and 5b now backed on to each other and with their corresponding handrails which are subsequently positioned on site following transportation; it also includes a detail of a handrail finished and ready for positioning in the modules later on and also facilities (20) for electricity, telecommunications and plumbing.
Figure 8.- Shows a diagram of the foundation and the first story of prefabricated gantries (10) that are created in situ.
Figure 9.- Shows a diagram of how a module is coupled on the foundation and the first story of prefabricated gantries (10).
Figure 10.- Shows a diagram of how a second module is coupled on the foundation and the first story of prefabricated gantries (10) with the module of figure 9.
Figure 11.- Shows a diagram of the coupling of a second story of gantries as the continuation of the installation of that shown in figure 10.
Figure 12.- Shows a diagram of how a third module is coupled on the second story of prefabricated gantries (10) of figure 11.
Figure 13.- Shows a diagram of how a fourth module is coupled on the structure of figure 12.
Figure 14.- Shows a diagram of how a third story of prefabricated gantries is coupled to the structure of figure 13.
Figure 15.- Shows a diagram of how a fifth module is coupled to the structure of figure 14.
Figure 16.- Shows a diagram of how a sixth module is coupled to the structure of figure 15.
Figure 17.- Shows a diagram of how a fourth story of prefabricated gantries is coupled to the structure of figure 16.
Figure 18.- Shows a diagram of the set of apartments (14) of figure 17 with roof.
Figure 19.- Shows a diagram of the set of apartments of figure 18 with party walls.
Figure 20.- Shows a diagram of a block of apartments in the form of an H consisting of four sets of apartments similar to those of figure 18 and with communal zones, stairways, elevators and general communal facilities.

List of references shown in the figures:

1: Structural beams
2: Lightweight slab
3: Cage
4: Prefabricated partitioning
5: Façades consisting of:
- 5a: exterior façade material
- 5b: insulating chamber
- 5c: interior prefabricated partition
6: Sanitary and ventilation facilities
7: Coverings and ceilings
7a: Handrail fully finished for later placement
8: Transport
9: Foundation
10: Gantries
11: Structural connections
12: Connection of facilities
13: Transverse beams
14; Set of finished apartments, with roof and party walls
14 a: finish for roof
14 b: finish for party wall façade
15: Communal zones, stairways, elevators and general communal facilities
16: Apartment block in the form of an H with finished apartments
17: Decking sheet
18: Lightweight concrete
19: Mesh
20: Installations of prefabricated kits for electricity, telecommunications and plumbing via the module ceiling
21: Fire-resistant foam, applied both to the lower face of the lightweight slab of the module and to the gantries of the structure.

DESCRIPTION OF A PREFERRED FORM OF EMBODIMENT

As a preferred mode of embodiment, the modular construction system will be applied to the construction of an apartment block of the VPO type (those built with government subsidies) consisting of 2 bedroom apartments with 3 stories in height in which the block takes on the form of an H with 12 apartments.
As a first phase, two different modules of 3 x 12 m are manufactured in a factory which, once installed on site and joined together, will form a 2 bedroom apartment.
The process of material execution is carried out in a factory by means of an assembly chain on part of the final structure, specifically load-bearing beams (1), transverse beams (13) and lightweight slab (2), in which the transverse beams (13) can be dispensed with.
So, figure 1 shows the arrangement of the load-bearing beams (1), transverse beams (13) and lightweight slab (2), thereby defining the base surface of one of the two modules, the load-bearing beams (1) and transverse beams (13) preferably being made of rolled steel shaped sections and the lightweight slab (2) being composed of a decking sheet (17) welded or screwed to the load-bearing beams (1), on which decking sheet (17) some lightweight concrete (18) is poured, preferably of the expanded aggregate type with mesh (19), as illustrated by the transverse cut of figure 4.
In figure 3 it can be seen how a cage (3) of metallic shaped sections is created on the lightweight slab (2). The idea of the "cage" is to stiffen each module, permitting the complete carrying out of partitioning (4), façades (5), interiors and facilities (6) and an easy transportation and installation on site.
As can be seen in figures 2a and 2b, the prefabricated partitioning is carried out on the cage (3) and the lightweight slab (2) by means of shaped sections and panel secured to the lightweight slab (2) and to the cage (3) by means of additional shaped sections.
It is also possible to have load-bearing beams and carry out the cage of these and then create the lightweight slab.
Figures 5a, 5b and 7 show the sanitary facilities (6) which are installed once the prefabricated partitioning (4) has been secured, and installed below the lightweight slab (2) are branch pipes, runoffs and sections of main down-pipes for the story.
The lower part of the lightweight slab (2) and the load-bearing beams (1) are then sprayed with fire-resistant foam (21) and the installation is then proceeded with of an industrialized or kit preparation of hot and cold water, electricity and telecommunications by means of chases, ducts, pipes and cabling in the ceiling.
Finally, the coverings (7) for floor, ceiling and walls are carried out, along with paneling in damp areas by means of adhesives with elastomeric properties.
Moreover, the prefabricated façade panels (5) will be installed which comprise the complete exterior carpentry (5a) and, starting from an insulating chamber (5b), an interior finish (5c) with covering in such a way that the façade panels (5) are secured to the cage (3) and to a mesh (5d) of the prefabricated partitioning shaped sections (4).
Finally, the joints are sealed, the ceiling plates are laid and it is painted. The sanitary ware, taps and fittings and electrical mechanisms are also fitted.
Moreover, some handrails (7a) are prepared which can be seen in figure 7 and which are delivered separately for being positioned later on, in situ, on the site.
Once all or some of the modules that are going to make up the building have been carried out, they are transported to the site where the building is to be erected. There, the method is defined for the installation on site of each prefabricated semi-resistant module that is going to form part of the building it is wished to construct.
Figures 8-20 illustrate this method where, as shown in figure 8, the first thing that is done is the foundation (9) of the plot of land and positioning of the first story of gantries (10), columns and main beams. In a preferred embodiment, the first story of gantries (10) is made of rolled steel of free span 6 m, height 3 m and distance between gantries of 5 m.
Starting from figure 9 and up to number 20, each step in the construction of the building of the preferred embodiment is shown, in other words, in figure 9 a first module Is coupled on the foundation (9) and the first story of prefabricated gantries (10) of the previous figure 8.
In figure 10 a second module is coupled to the structure of the previous figure 9 and it also shows the positioning of the handrails (7a).
In figure 11 a second story of gantries (10) is attached to the structure of the previous figure 10.
Figure 12 shows how a third module is coupled on structure of the previous figure 11.
Figure 13 shows a diagram of how a fourth module is coupled on the structure of the previous figure 12, and in which the handrails (7a) have also been positioned.
In figure 14 a third story of prefabricated gantries is attached to the structure of the previous figure 13.
Figure 15 indicates the positioning of a fifth module in the structure of the previous figure 14.
Figure 16 shows the attachment of a sixth module to the structure of the previous figure 15, with the corresponding positioning of the handrails (7a).
Figure 17 shows the positioning of a fourth story of prefabricated gantries on the structure of the previous figure 16.
Figure 18 shows the positioning of the roof (14a) on the structure of the previous figure 17 and figure 19 adds the positioning of the party walls (14b).
A set of apartments is thus defined.
Figure 20 illustrates four sets of apartments comprising a block of apartments in the form of an H (16) where communal zones (15), such as stairways, elevators and general communal facilities, have also been illustrated in diagrammatic form.
Figure 9, for example, shows more structural connections (11) in order to connect each module on the gantries (10).
Figure 13 in turn shows a connection (12) for sanitary and ventilation facilities (6).

Claims

Method for manufacturing and installation on site of a prefabricated semi-resistant module suitable for being joined to other similar or equal modules arranged both laterally and on top, said module comprising :
- at least two load-bearing beams of rolled steel and two securing slab edges which define the perimeter of the base of the module;
said method comprising the steps of:
- executing on the load-bearing beams (1) made of rolled steel shaped sections a lightweight slab (2) by pouring on a decking sheet (17) which is welded or screwed to said beams (1) some lightweight concrete (18) of expanded aggregate and mesh (19) giving as a result the lightweight slab (2);

- creating on the lightweight slab (2), a cage (3) of metallic shaped sections which is used on the one hand for securing a prefabricated partition (4) and on the other hand serves as a crane attachment for its later transportation and location on site;

- once the prefabricated partitioning (4) has been secured, installing the sanitary facilities (6) and, beneath the lightweight slab (2), connecting pipes to runoffs and sections of main down-pipes for the story;

- spraying a fire-resistant foam (21) on the lower part of the lightweight slab (2) and the load-bearing beams (1);

- installing an industrialized or kit preparation of hot and cold water, electricity and telecommunications by means of chases, ducts, pipes and cabling in the ceiling;

- securing prefabricated facade panels (5) comprising complete exterior carpentry (5a), an Insulating chamber (5b), and a covering (5c), to the cage (3) and to a mesh (5d) of the prefabricated partitioning shaped sections (4);
said method further comprising the following steps:
a. creating a foundation (9) for the plot of land where the module is to be positioned;

b. positioning on the foundation (9) a first story of prefabricated gantries (10) made of columns and main beams ;

c. positioning on the gantries (10), resting on their load-bearing beams (1), the prefabricated semi-resistant modules, in such a way that the gantries (10) are joined to the load-bearing beams (1) or the modules;

d. connecting the facilities (6) for the different modules;

e. once one story has been completed, positioning a second story of gantries (13);

f. using screws or welding to join together the cages (3) of the different modules making up a single story of the building and at the same time joining the columns of the gantries (10) to the cages (3);

g. repeating steps c-f above as many times as there are stories of the building to construct;

h. repeating steps a-g or steps b-g depending on the building to construct until arriving at a facade party wall and until arriving at a roof (14a) of the building;

i. sealing the exterior joints of facades (5) between different modules by means of a fire-resistant spray on the columns and main beams and by means of the positioning of special flashing pieces made of lightweight material with a screwed or adhesive union;

j. carrying out the communal zones of the building by means of self-supporting prefabricated systems which are joined to the rest of the structure, creating an accessible zone in the join through which in the vertical direction will run the general community facilities for the building in branch pipes and prefabricated ducts.
Method according to claim 1, characterized in that the facade party wall is manufactured in the same way as the facade (5) of the prefabricated semi-resistant module.
Method according to claim 1, characterized in that the roof of the building is manufactured in the same way as the lightweight slab (2) of the prefabricated semi-resistant module, with the addition of waterproofing and thermal insulation, with reinforcements in overlaps and joints for slabs.
Method according to claim 1, characterized in that the foundation (9) is made with an isolated footing piece secured with reinforced concrete.
Method according to claim 1, characterized in that the structural unions made on site during the installation procedure are carried out by means of any system of groove and tongue, bolts or rivets.
Method according to claim 1, characterized in that the exterior sheet or covering of the façades for the building is done later on at the end of the construction system using any system of enclosure or covering among those existing on the market.
Method according to claim 1, characterized in that the prefabricated gantries (10) are made of metallic shaped sections of any kind.
Method according to claim 1, characterized in that the prefabricated gantries (10) are made of reinforced concrete with the foundation (9), being created in situ.