EP2456928B1 - A structural module for construction of buildings - Google Patents
A structural module for construction of buildings Download PDFInfo
- Publication number
- EP2456928B1 EP2456928B1 EP10739707.7A EP10739707A EP2456928B1 EP 2456928 B1 EP2456928 B1 EP 2456928B1 EP 10739707 A EP10739707 A EP 10739707A EP 2456928 B1 EP2456928 B1 EP 2456928B1
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- EP
- European Patent Office
- Prior art keywords
- module
- structural
- modules
- wall
- concrete
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- 238000010276 construction Methods 0.000 title description 9
- 239000004567 concrete Substances 0.000 claims description 30
- 239000011381 foam concrete Substances 0.000 claims description 13
- 238000004519 manufacturing process Methods 0.000 claims description 13
- 238000000034 method Methods 0.000 claims description 12
- 239000000203 mixture Substances 0.000 claims description 10
- 229910000831 Steel Inorganic materials 0.000 claims description 8
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- 239000010959 steel Substances 0.000 claims description 8
- 238000005266 casting Methods 0.000 claims description 6
- 238000003466 welding Methods 0.000 claims description 6
- 229910000746 Structural steel Inorganic materials 0.000 claims description 5
- 239000000463 material Substances 0.000 claims description 5
- 239000011150 reinforced concrete Substances 0.000 claims description 5
- 229910001294 Reinforcing steel Inorganic materials 0.000 claims description 2
- 230000001413 cellular effect Effects 0.000 claims description 2
- 239000003795 chemical substances by application Substances 0.000 claims description 2
- 239000000945 filler Substances 0.000 claims description 2
- 238000009413 insulation Methods 0.000 description 5
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- 239000004088 foaming agent Substances 0.000 description 2
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Images
Classifications
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- 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
-
- 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
- E04B1/34823—Elements not integrated in a skeleton the supporting structure consisting of concrete
-
- 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
- E04B1/16—Structures made from masses, e.g. of concrete, cast or similarly formed in situ with or without making use of additional elements, such as permanent forms, substructures to be coated with load-bearing material
- E04B1/161—Structures made from masses, e.g. of concrete, cast or similarly formed in situ with or without making use of additional elements, such as permanent forms, substructures to be coated with load-bearing material with vertical and horizontal slabs, both being partially cast in situ
-
- 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
-
- 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
- E04B1/62—Insulation or other protection; Elements or use of specified material therefor
- E04B1/92—Protection against other undesired influences or dangers
- E04B1/94—Protection against other undesired influences or dangers against fire
- E04B1/941—Building elements specially adapted therefor
- E04B1/942—Building elements specially adapted therefor slab-shaped
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04H—BUILDINGS OR LIKE STRUCTURES FOR PARTICULAR PURPOSES; SWIMMING OR SPLASH BATHS OR POOLS; MASTS; FENCING; TENTS OR CANOPIES, IN GENERAL
- E04H1/00—Buildings or groups of buildings for dwelling or office purposes; General layout, e.g. modular co-ordination or staggered storeys
- E04H1/02—Dwelling houses; Buildings for temporary habitation, e.g. summer houses
- E04H1/04—Apartment houses arranged in two or more levels
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04H—BUILDINGS OR LIKE STRUCTURES FOR PARTICULAR PURPOSES; SWIMMING OR SPLASH BATHS OR POOLS; MASTS; FENCING; TENTS OR CANOPIES, IN GENERAL
- E04H9/00—Buildings, groups of buildings or shelters adapted to withstand or provide protection against abnormal external influences, e.g. war-like action, earthquake or extreme climate
- E04H9/02—Buildings, groups of buildings or shelters adapted to withstand or provide protection against abnormal external influences, e.g. war-like action, earthquake or extreme climate withstanding earthquake or sinking of ground
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04H—BUILDINGS OR LIKE STRUCTURES FOR PARTICULAR PURPOSES; SWIMMING OR SPLASH BATHS OR POOLS; MASTS; FENCING; TENTS OR CANOPIES, IN GENERAL
- E04H9/00—Buildings, groups of buildings or shelters adapted to withstand or provide protection against abnormal external influences, e.g. war-like action, earthquake or extreme climate
- E04H9/02—Buildings, groups of buildings or shelters adapted to withstand or provide protection against abnormal external influences, e.g. war-like action, earthquake or extreme climate withstanding earthquake or sinking of ground
- E04H9/021—Bearing, supporting or connecting constructions specially adapted for such buildings
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04H—BUILDINGS OR LIKE STRUCTURES FOR PARTICULAR PURPOSES; SWIMMING OR SPLASH BATHS OR POOLS; MASTS; FENCING; TENTS OR CANOPIES, IN GENERAL
- E04H9/00—Buildings, groups of buildings or shelters adapted to withstand or provide protection against abnormal external influences, e.g. war-like action, earthquake or extreme climate
- E04H9/14—Buildings, groups of buildings or shelters adapted to withstand or provide protection against abnormal external influences, e.g. war-like action, earthquake or extreme climate against other dangerous influences, e.g. tornadoes, floods
Definitions
- the invention relates to structural modules for construction of buildings.
- This invention is directed towards achieving improved technical features to such modules such as superior robustness, greater fire resistance, improved acoustical performance, and improved sustainability, particularly in terms of materials used. Another objective is to achieve a more efficient manufacturing process. A further objective is to achieve improved resistance to hurricane forces and seismic activity. Another structural module for the construction of multi-story buildings is described in GB 1021664 .
- a structural module comprising a structural floor, load bearing walls, and a structural ceiling, arranged to support a plurality of other structural modules in a multi-storey building, wherein at least one load bearing wall comprises a structural frame and lightweight concrete having a density in the range of 400kg/m 3 to 600kg/m 3 between frame members of said structural frame, the concrete being cellular, including air entrainment, the concrete being moulded between the frame members, completely filling voids between the frame members along the plane of the wall.
- the wall is configured so that when two modules are juxtaposed there is a combined wall comprising a cavity between the modules.
- the wall is lined on at least one side by boards, the lightweight concrete and the boards providing at least two hours fire resistance.
- the wall boards include MgO.
- the concrete is cast against the steel frame and boards.
- At least part of the ceiling includes lightweight cellular concrete between structural members in trusses.
- the floor includes a perimeter structural steel frame and includes lightweight concrete with reinforcing steel.
- the module includes at a corner a vertical dowel pin for engagement in a socket in a corner of another module, and wherein the module comprises a substantially vertical socket at a corner for engagement with a substantially vertical dowel pin of an upper or lower adjoining module, and wherein the module comprises a tie plate configured to be secured to a plurality of other modules at a corner, and wherein the plate comprises a through hole for receiving a dowel pin of an adjoining module
- the module comprises an internal wall connected to a structural wall by a releasable joint, and wherein the releasable joint comprises a joint of a flexible filler extending in a vertical direction.
- the invention provides an assembly of a plurality of modules as defined above in any embodiment mounted one atop another.
- At least some of the modules adjoin a reinforced concrete core and abut it in a vertical plane, and wherein at least one module has a tie with a head engaging behind a vertical slot in the core, and wherein the vertical slot is in an embedded insert within the core.
- the insert comprises flanges parallel to the plane of an outer surface of the core facing the module, and side walls connecting the flanges to a front wall incorporating the slot, and wherein a plurality of the modules are tied together at adjoining corners by a tie plate and at least one dowel pin extending through the tie plate and into a socket of an upper or lower module.
- the invention provides a method of manufacturing a structural module as defined above in any embodiment, the method comprising manufacturing the structural floor, structural walls, and structural ceiling and interconnecting them together, the method including the steps of choosing a concrete composition and/or density for each structural wall according to intended location and function of the structural wall in a building to be constructed using the module, and casting in the chosen lightweight concrete into said wall.
- the concrete is prepared with choice of proportion of the materials and a foam agent in a concrete mix before casting the concrete within the wall structural frame.
- the invention provides a method of constructing a building comprising the steps of manufacturing a structural module in a method as defined above in any embodiment, transporting the modules to a site with an erected core, placing at least some of the modules in position butting the core, and tying at least some of said modules to the core.
- said modules are tied by engagement of a tie within a vertical slot in the core and securing the tie to the module by welding or fasteners, and wherein a plurality of said modules are tied at adjoining corners by engagement of a substantially vertical dowel pin on a module with a substantially vertical socket in an upper or lower module.
- a structural module 1 comprises a floor 2 having a perimeter structural steel frame and reinforced concrete.
- Structural walls 3 are supported on the floor 2 and they comprise box-section structural steel studs 4.
- a ceiling 5 comprises structural steel trusses 6 spanning the walls 3.
- the walls 3 have sufficient structural strength to support many modules in a multi-storey building such as a hotel or apartment block, as shown in Fig. 2 .
- the wall studs 4 are 60 x 60 x 3 SHS steel at 600mm centres, supported on a flanged edge frame member 7 of the structural floor 2.
- the trusses 6 have bearing plates 8 on the walls 3, directly overlying the studs 4.
- the arrangements of the structural walls, floor, and ceiling are as described in WO2007080561 in terms of their structural frameworks.
- braces 9 extending from a central location of an end wall 10 and longitudinal walls 3.
- Fig. 2 shows how there may be a break in a module 1, in this example 2.25 times the height of the module 1.
- a break in a structural wall 3 may occur due to any of a range of accidental events such as a vehicle crash or a gas explosion.
- the floor 2, the structural walls 3 and 10, and the structural ceiling 5 provide sufficient strength to prevent collapse in the event of an accidental event effectively removing a section of a structural wall up to 2.25 times the module height.
- the structural walls 3 comprise the steel studs 4 which are square hollow sections or rectangular sections typically 60 x 60 x 3 SHS at varying design centres. Where two modules are installed adjacent to each other there are two module walls 3 and 16, with two aligned studs 4 separated by a cavity 15.
- Each of the walls 3 and 16 has moulded-in lightweight cellular concrete 20, produced using foam to provide air entrainment, resulting in a very low density.
- An example is that marketed by NeoporTM and referred to as cellular lightweight concrete.
- the density in this embodiment is about 500 kg/m 3 .
- the structural strength of the module walls 3 and 16 is provided by the steel studs 4 assisted by the cast-in concrete 20.
- the cellular concrete 20 fills up the voids between the studs 4 and MgO facing board 21 on the internal surfaces. There are strips 23 of MgO board between the studs 4 and the MgO panels 21.
- the wall construction contributes very significantly to the required properties of a structural module both in terms of its manufacture, its use in constructing a building, and its ongoing use for residential or business purposes.
- the wall properties can be varied in the factory according to the intended nature of use of the module 1. This is achieved by adjustment of the cellular concrete density 20 during off-site (factory) manufacture of the module 1.
- the cellular concrete preparation is as follows in one embodiment:
- a joint at corners if formed by a tie plate 30 with four corner holes 31, a socket 32, and a dowel pin 33.
- the tie plate 30 is welded at a joint 37 to a corner member 32 of the module 1 below.
- Chamfered top edges 34 of the tie plate 30 facilitate the required amount of weld for securing the plate 30 directly to the bearing plates 8 of ceiling trusses 6 of the adjoining modules 1. This secures the plate to the four underneath modules 1, and these edges are accessible from above.
- These welds are indicated as numeral 36 in the drawings.
- the next module 1 above is welded to the tie plate 30 at a weld 37 around the corner angle of the upper module floor 2.
- the tie plate 30 has four holes 31, one at each corner.
- the next two upper modules 1 are then placed and secured in a similar manner.
- the final upper module is secured in place by insertion of the dowel pin 33 through a hole 31 in the plate 30. It extends into the socket 32 which is directly below and has been filled with non-shrink and high-strength grout.
- the depth of the pocket and the length of the dowel are determined by the forces it needs to cater for. In some circumstances this grout may also need to be of the type which hardens quickly, in order to achieve the desired strength in the connection as soon as possible.
- the grout is Sikadur-42 HE high performance epoxy grout, for example.
- This dowel connection has the same capabilities as the welds between the upper module and the tie plate to cater for all relevant forces.
- This arrangement allows a fourth module 1 to be tied in even though access to weld to the plate 30 is not possible after three upper modules have been put in place. Also, it allows at each corner a combination of both welding and dowel pin engagement. By providing four holes 31 in the plate it is possible to choose on site which upper module to lower into position last.
- This arrangement is designed to take the static and dynamic forces of a seismic event. Compressive loading is taken primarily by the vertical studs 4. Vertical tension loads are resisted by the corner ties 40 which are specifically designed for such loading. The horizontal forces are transferred via diaphragm action, utilizing the floor slabs and the corner connections, to the reinforced concrete building cores. These corner module connections use welding and/or grouted pins to achieve the structural design requirements.
- a non load-bearing internal wall 50 of the module 1 is connected to the structural floor 2 and the ceiling 5 by fastening the structural members.
- Connection of the internal wall 50 to a structural wall 3 is achieved by a rail 52 of channel configuration in cross-section fastened by screws 53 to the wall 3.
- Strips 54 of plasterboard are secured to the rail 52.
- the internal wall 50 is then moved into position butting against the plasterboard 54 at the side edges.
- the plasterboard 54 fixed to the channel bears onto the first stud of the internal wall panel but is not mechanically fixed to it.
- a joint 55 of flexible material is then made between the plasterboard strips 54 and the plasterboard panels 56 of the internal wall 50.
- the internal wall 50 will not be forced to move with it due to the joint characteristics.
- the joint may open or become damaged, but all damage will be cosmetic and easily repaired.
- the main advantage is that the internal wall 50 will maintain its own stability and integrity and will not incur forces which could cause further damage to property or more significantly cause injury to inhabitants.
- Figs. 7 to 10 are views showing connection of a module 1 to a reinforced concrete core 61 which had previously been erected on site.
- the core 61 typically includes a lift shaft and stairwell of the building.
- a slotted insert 60 is embedded in the core 61 at an exactly vertical orientation and in predetermined locations to coincide with module floor and ceiling levels. The number of inserts is determined by the magnitude of the forces calculated.
- the slotted insert 60 comprises lateral flanges 62, angled side walls 67 converging to a front wall 63 with a vertical slot 64.
- a tie 65 comprises a flat plate with one end notched to provide a head 66 configured to suit the core slotted insert 60.
- the tie 65 is engaged to the slotted insert 60 in a vertical orientation and is then rotated through about 90° until the tie 65 is in a horizontal orientation.
- the tie 65 is then slid vertically until it engages either the floor 2 of a module ( Figs. 9(a) to 9(c) ) or the top of the module 1 ( Figs. 10(a) to 10(c) ).
- the tie 65 is then welded to the module and is free to slide within the core wall slotted insert 60 in a vertical direction only. This enables it to resist both shear and tension forces but cater for any differential settlement between the modules and the core, particularly in multi-storey buildings.
- welding of the tie 65 may involve initially welding a buffer plate ( Figs 10(a) to 10(c) ) so that the top surface of the tie 65 is brought up to the level of the top surface of the bearing plates 8.
- the method may involve removing a plate section to create space for the tie ( Figs. 9(a) to 9(c) ). The latter connection is made between a lateral extension of the floor provided by the inverted U-shaped channel as shown.
- the cellular concrete in the module walls 3 adds significantly to its overall stiffness. This in turn improves the capacity of the wall 3 to resist racking forces. This is particularly advantageous in hurricane and seismic zones where braced frames and/or shear walls may otherwise be required to resist such forces.
- the modules cater for the avoidance of disproportionate collapse which could occur during an accidental event.
- the wall construction technique of casting in lightweight cellular concrete may also be used for ceilings, roofs and floors.
- there is a cavity between walls of two adjoining modules it is envisaged that a wall such as an internal wall of a single module may incorporate a cavity. If so, there may be a structural frame on both sides of the cavity.
- the tie arrangement for tying a module to a core may be reversed, with the core having ties which engage slots in the modules.
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Description
- The invention relates to structural modules for construction of buildings.
- Our published specification no.
WO2007080561 describes a structural module, its manufacture, and construction of a multi-storey building by placing one module atop the other. - This invention is directed towards achieving improved technical features to such modules such as superior robustness, greater fire resistance, improved acoustical performance, and improved sustainability, particularly in terms of materials used. Another objective is to achieve a more efficient manufacturing process. A further objective is to achieve improved resistance to hurricane forces and seismic activity. Another structural module for the construction of multi-story buildings is described in
GB 1021664 - According to the invention, there is provided a structural module comprising a structural floor, load bearing walls, and a structural ceiling, arranged to support a plurality of other structural modules in a multi-storey building, wherein at least one load bearing wall comprises a structural frame and lightweight concrete having a density in the range of 400kg/m3 to 600kg/m3 between frame members of said structural frame, the concrete being cellular, including air entrainment, the concrete being moulded between the frame members, completely filling voids between the frame members along the plane of the wall.
- In one embodiment, the wall is configured so that when two modules are juxtaposed there is a combined wall comprising a cavity between the modules.
- In one embodiment, the wall is lined on at least one side by boards, the lightweight concrete and the boards providing at least two hours fire resistance.
- In one embodiment, the wall boards include MgO.
- In one embodiment, the concrete is cast against the steel frame and boards.
- In one embodiment, at least part of the ceiling includes lightweight cellular concrete between structural members in trusses.
- In one embodiment, the floor includes a perimeter structural steel frame and includes lightweight concrete with reinforcing steel.
- In one embodiment, the module includes at a corner a vertical dowel pin for engagement in a socket in a corner of another module, and wherein
the module comprises a substantially vertical socket at a corner for engagement with a substantially vertical dowel pin of an upper or lower adjoining module, and
wherein the module comprises a tie plate configured to be secured to a plurality of other modules at a corner, and wherein
the plate comprises a through hole for receiving a dowel pin of an adjoining module
In one embodiment, the module comprises an internal wall connected to a structural wall by a releasable joint, and wherein
the releasable joint comprises a joint of a flexible filler extending in a vertical direction. - In another aspect, the invention provides an assembly of a plurality of modules as defined above in any embodiment mounted one atop another.
- In one embodiment, at least some of the modules adjoin a reinforced concrete core and abut it in a vertical plane, and wherein
at least one module has a tie with a head engaging behind a vertical slot in the core, and wherein
the vertical slot is in an embedded insert within the core. - In one embodiment, the insert comprises flanges parallel to the plane of an outer surface of the core facing the module, and side walls connecting the flanges to a front wall incorporating the slot, and wherein
a plurality of the modules are tied together at adjoining corners by a tie plate and at least one dowel pin extending through the tie plate and into a socket of an upper or lower module. - In another aspect, the invention provides a method of manufacturing a structural module as defined above in any embodiment, the method comprising manufacturing the structural floor, structural walls, and structural ceiling and interconnecting them together, the method including the steps of choosing a concrete composition and/or density for each structural wall according to intended location and function of the structural wall in a building to be constructed using the module, and casting in the chosen lightweight concrete into said wall.
- In one embodiment, the concrete is prepared with choice of proportion of the materials and a foam agent in a concrete mix before casting the concrete within the wall structural frame.
- In another aspect, the invention provides a method of constructing a building comprising the steps of manufacturing a structural module in a method as defined above in any embodiment, transporting the modules to a site with an erected core, placing at least some of the modules in position butting the core, and tying at least some of said modules to the core.
- In one embodiment, said modules are tied by engagement of a tie within a vertical slot in the core and securing the tie to the module by welding or fasteners, and wherein
a plurality of said modules are tied at adjoining corners by engagement of a substantially vertical dowel pin on a module with a substantially vertical socket in an upper or lower module. - The invention will be more clearly understood from the following description of some embodiments thereof, given by way of example only with reference to the accompanying drawings in which:-
-
Fig. 1 is a perspective view of structural members of a structural module of the invention, andFig. 2 is a perspective view showing a number of such modules arranged to form a building, again only showing the structural frameworks of the modules; -
Fig. 3 is a cross-sectional plan view through adjoining structural walls when two modules are placed side by side; -
Figs. 4 and5 are perspective views at corners of modules, showing how they are tied together for enhanced seismic resistance; -
Fig. 6 is a plan view showing connection of a non-load bearing internal wall to a load-bearing external wall of a module; and -
Figs. 7 and8 are perspective views of tie parts for tying a module to a building core,Figs. 9(a) to (c) are side views showing use of the tie parts for tying a module at the floor level, andFigs. 10(a) to 10(c) are side views showing their use for tying at ceiling level. - Referring to
Fig. 1 astructural module 1 comprises afloor 2 having a perimeter structural steel frame and reinforced concrete.Structural walls 3 are supported on thefloor 2 and they comprise box-sectionstructural steel studs 4. Aceiling 5 comprisesstructural steel trusses 6 spanning thewalls 3. Thewalls 3 have sufficient structural strength to support many modules in a multi-storey building such as a hotel or apartment block, as shown inFig. 2 . Thewall studs 4 are 60 x 60 x 3 SHS steel at 600mm centres, supported on a flanged edge frame member 7 of thestructural floor 2. Thetrusses 6 havebearing plates 8 on thewalls 3, directly overlying thestuds 4. The arrangements of the structural walls, floor, and ceiling are as described inWO2007080561 in terms of their structural frameworks. - There are
braces 9 extending from a central location of anend wall 10 andlongitudinal walls 3. -
Fig. 2 shows how there may be a break in amodule 1, in this example 2.25 times the height of themodule 1. Such a break in astructural wall 3 may occur due to any of a range of accidental events such as a vehicle crash or a gas explosion. Thefloor 2, thestructural walls structural ceiling 5 provide sufficient strength to prevent collapse in the event of an accidental event effectively removing a section of a structural wall up to 2.25 times the module height. - Referring to
Fig. 3 thestructural walls 3 comprise thesteel studs 4 which are square hollow sections or rectangular sections typically 60 x 60 x 3 SHS at varying design centres. Where two modules are installed adjacent to each other there are twomodule walls studs 4 separated by acavity 15. Each of thewalls cellular concrete 20, produced using foam to provide air entrainment, resulting in a very low density. An example is that marketed by Neopor™ and referred to as cellular lightweight concrete. The density in this embodiment is about 500 kg/m3. - The structural strength of the
module walls steel studs 4 assisted by the cast-inconcrete 20. Thecellular concrete 20 fills up the voids between thestuds 4 andMgO facing board 21 on the internal surfaces. There arestrips 23 of MgO board between thestuds 4 and theMgO panels 21. - This combination of materials and their physical arrangement provides the following properties:
- Fire resistance. The
MgO board 21 has excellent fire resistance properties. Thecellular concrete 20 reduces transfer of heat to the steel, and it has a thermal conductivity significantly lower than conventional concrete, which is a contributing factor to its improved fire performance. The delay in temperature rise of the steel to the critical level of about 500°C is very advantageous for fire safety of a multi-storey building. With EN1365-1 loaded fire testing, over 120 mins Fire Resistance has been achieved, despite the fact that the wall is relatively thin, in this example 82mm. - High strength to weight ratio. With the low density cellular concrete a similar dead weight of structure can be achieved compared to the module of
WO2007080561 , which can be about 15% lighter than traditional build. - Excellent acoustic performance. The acoustic performance of the module is significantly improved due to the wall composition as the wall is designed to deal with a wider range of sound frequencies. A compartment wall formed by two module walls has been tested in a laboratory and has achieved 62dB Rw and Rw + Ctr of 57dB. This is approximately 9dB better than the current Building Regulations in Ireland and 12 dB better than the current UK Building Regulations.
- Robustness.
- Improved thermal insulation in comparison to conventional concrete. The cellular lightweight concrete (CLC) at about 500 kg/m3 has on average 14 times better thermal insulation than that of conventional concrete. This reduces the requirement for insulation for external walls.
- Sustainability. There are no man-made or manufactured aggregates needed. The foaming agent used in the mix is made from natural ingredients and is biodegradable and non-polluting to water courses. Eco-cement can also be used with the product It reduces the need for additional manufactured insulation.
- It will be appreciated that the wall construction contributes very significantly to the required properties of a structural module both in terms of its manufacture, its use in constructing a building, and its ongoing use for residential or business purposes.
- The wall properties can be varied in the factory according to the intended nature of use of the
module 1. This is achieved by adjustment of the cellularconcrete density 20 during off-site (factory) manufacture of themodule 1. The cellular concrete preparation is as follows in one embodiment: - In a mechanical rotating drum mixer river run sand of the correct grading is firstly mixed with cement in the required proportions. Optionally, polypropylene fibres can be mixed in to reduce shrinkage. Then water is added to the required volume and mix consistency. Once this is reached the required volume of foam is added to produce the desired wet density of the mix.
- The foam is produced in a machine that takes water, compressed air, and a biological foaming agent that produces lightweight foam which encapsulates small air bubbles. This enables the foam to be mixed into a sand-cement-water mortar without the bubbles collapsing, thus keeping the mix at a stable density. Once the foam is fully integrated in the mixture, it is transferred into a hopper before being cast into the wall panels on a horizontal bed and screeded off level.
- There are many advantages to the wall construction both in terms of the building constructed from the module and the method of manufacturing the module. One of the most important advantages is that the module solves a particular acoustic problem which is generally associated with modular construction.
- It will also be appreciated that the process of manufacture is more efficient because of avoidance of manual infill of insulation, the lightweight concrete being cast by machine. In the factory the casting machine pours, levels, and screeds the infill concrete automatically.
- Referring to
Figs. 4 and5 a joint at corners if formed by atie plate 30 with fourcorner holes 31, asocket 32, and adowel pin 33. These interconnect eightmodules 1 at a corner, four below and four above. Thetie plate 30 is welded at a joint 37 to acorner member 32 of themodule 1 below. Chamferedtop edges 34 of thetie plate 30 facilitate the required amount of weld for securing theplate 30 directly to thebearing plates 8 ofceiling trusses 6 of the adjoiningmodules 1. This secures the plate to the four underneathmodules 1, and these edges are accessible from above. These welds are indicated as numeral 36 in the drawings. - The
next module 1 above is welded to thetie plate 30 at aweld 37 around the corner angle of theupper module floor 2. Thetie plate 30 has fourholes 31, one at each corner. The next twoupper modules 1 are then placed and secured in a similar manner. The final upper module is secured in place by insertion of thedowel pin 33 through ahole 31 in theplate 30. It extends into thesocket 32 which is directly below and has been filled with non-shrink and high-strength grout. The depth of the pocket and the length of the dowel are determined by the forces it needs to cater for. In some circumstances this grout may also need to be of the type which hardens quickly, in order to achieve the desired strength in the connection as soon as possible. This is particularly true for high-rise buildings, where the structure needs to take wind and other final loads prior to building completion. In one embodiment, the grout is Sikadur-42 HE high performance epoxy grout, for example. This dowel connection has the same capabilities as the welds between the upper module and the tie plate to cater for all relevant forces. - This arrangement allows a
fourth module 1 to be tied in even though access to weld to theplate 30 is not possible after three upper modules have been put in place. Also, it allows at each corner a combination of both welding and dowel pin engagement. By providing fourholes 31 in the plate it is possible to choose on site which upper module to lower into position last. - This arrangement is designed to take the static and dynamic forces of a seismic event. Compressive loading is taken primarily by the
vertical studs 4. Vertical tension loads are resisted by the corner ties 40 which are specifically designed for such loading. The horizontal forces are transferred via diaphragm action, utilizing the floor slabs and the corner connections, to the reinforced concrete building cores. These corner module connections use welding and/or grouted pins to achieve the structural design requirements. - Referring to
Fig. 6 a non load-bearinginternal wall 50 of themodule 1 is connected to thestructural floor 2 and theceiling 5 by fastening the structural members. Connection of theinternal wall 50 to astructural wall 3 is achieved by arail 52 of channel configuration in cross-section fastened byscrews 53 to thewall 3.Strips 54 of plasterboard are secured to therail 52. Theinternal wall 50 is then moved into position butting against theplasterboard 54 at the side edges. Theplasterboard 54 fixed to the channel bears onto the first stud of the internal wall panel but is not mechanically fixed to it. A joint 55 of flexible material is then made between the plasterboard strips 54 and theplasterboard panels 56 of theinternal wall 50. - In the event of significant seismic activity causing movement of a
structural wall 3, theinternal wall 50 will not be forced to move with it due to the joint characteristics. The joint may open or become damaged, but all damage will be cosmetic and easily repaired. The main advantage is that theinternal wall 50 will maintain its own stability and integrity and will not incur forces which could cause further damage to property or more significantly cause injury to inhabitants. -
Figs. 7 to 10 are views showing connection of amodule 1 to a reinforcedconcrete core 61 which had previously been erected on site. The core 61 typically includes a lift shaft and stairwell of the building. A slottedinsert 60 is embedded in the core 61 at an exactly vertical orientation and in predetermined locations to coincide with module floor and ceiling levels. The number of inserts is determined by the magnitude of the forces calculated. The slottedinsert 60 compriseslateral flanges 62, angledside walls 67 converging to afront wall 63 with avertical slot 64. - A
tie 65 comprises a flat plate with one end notched to provide ahead 66 configured to suit the core slottedinsert 60. Thetie 65 is engaged to the slottedinsert 60 in a vertical orientation and is then rotated through about 90° until thetie 65 is in a horizontal orientation. Thetie 65 is then slid vertically until it engages either thefloor 2 of a module (Figs. 9(a) to 9(c) ) or the top of the module 1 (Figs. 10(a) to 10(c) ). Thetie 65 is then welded to the module and is free to slide within the core wall slottedinsert 60 in a vertical direction only. This enables it to resist both shear and tension forces but cater for any differential settlement between the modules and the core, particularly in multi-storey buildings. It also allows the transfer of horizontal forces from themodules 1 into thecore structure 61. This detail is also significant in catering for static and dynamic forces during a seismic event. The extent of differential settlement in a 25-storey building can be in the region of 8mm to 15mm, due to the concrete of the building core shrinking whereas there is no appreciable shrinkage of themodules 1 because of the steel bearing the load. - As shown in
Figs 9 and10 welding of thetie 65 may involve initially welding a buffer plate (Figs 10(a) to 10(c) ) so that the top surface of thetie 65 is brought up to the level of the top surface of thebearing plates 8. Alternatively, the method may involve removing a plate section to create space for the tie (Figs. 9(a) to 9(c) ). The latter connection is made between a lateral extension of the floor provided by the inverted U-shaped channel as shown. - It will also be appreciated that the cellular concrete in the
module walls 3 adds significantly to its overall stiffness. This in turn improves the capacity of thewall 3 to resist racking forces. This is particularly advantageous in hurricane and seismic zones where braced frames and/or shear walls may otherwise be required to resist such forces. - It will also be appreciated that the modules cater for the avoidance of disproportionate collapse which could occur during an accidental event. The modules have the capacity to deal with the removal of up to 2.25h in metres in length on the long wall of the module at one level without the modules above collapsing (h = height of module). Similarly whole short walls of modules can be removed at one level without the danger of collapse of those modules above. This will be appreciated from
Fig. 2 - The invention is not limited to the embodiments described but may be varied in construction and detail. For example, the wall construction technique of casting in lightweight cellular concrete may also be used for ceilings, roofs and floors. Also, in the embodiments described, there is a cavity between walls of two adjoining modules, however, it is envisaged that a wall such as an internal wall of a single module may incorporate a cavity. If so, there may be a structural frame on both sides of the cavity. Also, the tie arrangement for tying a module to a core may be reversed, with the core having ties which engage slots in the modules.
Claims (16)
- A structural module (1) comprising a structural floor (2), load bearing walls (3), and a structural ceiling (5), arranged to support a plurality of other structural modules (1) in a multi-storey building, wherein at least one load bearing wall (3) comprises a structural frame (4) and lightweight concrete (20) between frame members of said structural frame, the concrete (20) being cellular, including air entrainment, characterized in that,
the concrete density is in the range of 400 to 600 kg/m3, and
the concrete (20) is moulded between the frame members, completely filling voids between the frame members along the plane of the wall. - A structural module as claimed in claim 1, wherein the wall (3) is configured so that when two modules (1) are juxtaposed there is a combined wall comprising a cavity (15) between the modules.
- A structural module as claimed in any preceding claim, wherein the wall (3) is lined on at least one side by boards, the lightweight concrete and the boards providing at least two hours fire resistance.
- A structural module as claimed in claim 3, wherein the wall boards include MgO.
- A structural module as claimed in either of claims 3 or 4, wherein the concrete (20) is cast against the steel frame and boards.
- A structural module as claimed in any preceding claim, wherein at least part of the ceiling (5) includes lightweight cellular concrete (20) between structural members in trusses.
- A structural module as claimed in any preceding claim, wherein the floor (2) includes a perimeter structural steel frame and includes lightweight concrete (20) with reinforcing steel.
- A structural module as claimed in any preceding claim, wherein the module (1) includes at a corner a vertical dowel pin (33) for engagement in a socket (32) in a corner of another module, and wherein the module (1) comprises a vertical socket (32) at a corner for engagement with a dowel pin of an upper or lower adjoining module, and wherein the module comprises a tie plate (30) configured to be secured to a plurality of other modules at a corner, and wherein the plate (30) comprises a through hole (31) for receiving a dowel pin (32) of an adjoining module.
- A structural module as claimed in any preceding claim, wherein the module (1) comprises an internal wall (50) connected to a structural wall (3) by a releasable joint (54, 55), and wherein the releasable joint comprises a joint of a flexible filler (55) extending in a vertical direction.
- An assembly of a plurality of modules of any preceding claim mounted one atop another.
- An assembly of a plurality of modules as claimed in claim 10, wherein at least some of the modules adjoin a reinforced concrete core (61) and abut it in a vertical plane, and wherein at least one module has a tie (65) with a head (66) engaging behind a vertical slot (64) in the core, and wherein the vertical slot is in an embedded insert (60) within the core.
- An assembly of a plurality of modules as claimed in claim 11, wherein the insert (60) comprises flanges (62) parallel to the plane of an outer surface of the core facing the module, and side walls (67) connecting the flanges to a front wall (63) incorporating the slot (64), and wherein a plurality of the modules (1) are tied together at adjoining corners by a tie plate (30) and at least one dowel pin (33) extending through the tie plate (30) and into a socket (32) of an upper or lower module.
- A method of manufacturing a structural module as claimed in any of claims 1 to 9, the method comprising manufacturing the structural floor, structural walls, and structural ceiling and interconnecting them together, the method including the steps of choosing a concrete composition and/or density for each structural wall according to intended location and function of the structural wall in a building to be constructed using the module, and casting in the chosen lightweight concrete into said wall.
- A method of manufacturing a structural module as claimed in claim 13, wherein the concrete is prepared with choice of proportion of the materials and a foam agent in a concrete mix before casting the concrete within the wall structural frame.
- A method of constructing a building comprising the steps of manufacturing a structural module in a method as claimed in any of claims 13 or 14, transporting the modules to a site with an erected core, placing at least some of the modules in position butting the core (61), and tying at least some of said modules to the core.
- A method as claimed in claim 15, wherein said modules are tied by engagement of a tie within a vertical slot (64) in the core and securing the tie to the module by welding or fasteners, and wherein a plurality of said modules are tied at adjoining corners by engagement of a substantially vertical dowel pin on a module with a substantially vertical socket in an upper or lower module.
Priority Applications (1)
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PL10739707T PL2456928T3 (en) | 2009-07-23 | 2010-07-22 | A structural module for construction of buildings |
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IE20090575 | 2009-07-23 | ||
PCT/IE2010/000042 WO2011010300A2 (en) | 2009-07-23 | 2010-07-22 | A structural module for construction of buildings |
Publications (3)
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EP2456928A2 EP2456928A2 (en) | 2012-05-30 |
EP2456928B1 true EP2456928B1 (en) | 2015-09-02 |
EP2456928B8 EP2456928B8 (en) | 2015-10-07 |
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EP10739707.7A Active EP2456928B8 (en) | 2009-07-23 | 2010-07-22 | A structural module for construction of buildings |
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EP (1) | EP2456928B8 (en) |
CN (2) | CN102575465B (en) |
GB (1) | GB2485298B8 (en) |
HK (1) | HK1223664A1 (en) |
IE (1) | IE86614B1 (en) |
PL (1) | PL2456928T3 (en) |
RU (1) | RU2543396C2 (en) |
WO (1) | WO2011010300A2 (en) |
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US10759697B1 (en) | 2019-06-11 | 2020-09-01 | MSB Global, Inc. | Curable formulations for structural and non-structural applications |
US11225789B2 (en) | 2018-05-17 | 2022-01-18 | Spanminx Limited | Structural module with vertical ties |
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CN108301870B (en) * | 2017-12-13 | 2019-06-11 | 中国矿业大学 | A kind of underground coal mine filling bag shaped structure and its application method |
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RU189897U1 (en) * | 2019-04-15 | 2019-06-07 | Федеральное государственное бюджетное образовательное учреждение высшего образования "Санкт-Петербургский государственный архитектурно-строительный университет" | BUILDING MODULE FOR BUILDING BUILDINGS |
RU189896U1 (en) * | 2019-04-15 | 2019-06-07 | Федеральное государственное бюджетное образовательное учреждение высшего образования "Санкт-Петербургский государственный архитектурно-строительный университет" | BUILDING MODULE FOR BUILDING BUILDINGS |
RU2720172C1 (en) * | 2019-07-30 | 2020-04-27 | Федеральное государственное бюджетное образовательное учреждение высшего образования "Санкт-Петербургский государственный архитектурно-строительный университет" | Quick-erect modular building |
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- 2010-07-22 RU RU2012104206/03A patent/RU2543396C2/en active
- 2010-07-22 EP EP10739707.7A patent/EP2456928B8/en active Active
- 2010-07-22 CN CN201080037279.0A patent/CN102575465B/en active Active
- 2010-07-22 WO PCT/IE2010/000042 patent/WO2011010300A2/en active Application Filing
- 2010-07-22 CN CN201610005125.2A patent/CN105625580B/en active Active
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US11225789B2 (en) | 2018-05-17 | 2022-01-18 | Spanminx Limited | Structural module with vertical ties |
US10759697B1 (en) | 2019-06-11 | 2020-09-01 | MSB Global, Inc. | Curable formulations for structural and non-structural applications |
US11008252B2 (en) | 2019-06-11 | 2021-05-18 | MSB Global, Inc. | Curable formulations for structural and non-structural applications |
US11655187B2 (en) | 2019-06-11 | 2023-05-23 | Partanna Global, Inc. | Curable formulations for structural and non-structural applications |
Also Published As
Publication number | Publication date |
---|---|
CN102575465B (en) | 2016-01-13 |
IE86614B1 (en) | 2016-01-13 |
EP2456928A2 (en) | 2012-05-30 |
GB201201028D0 (en) | 2012-03-07 |
RU2012104206A (en) | 2013-08-27 |
HK1223664A1 (en) | 2017-08-04 |
WO2011010300A3 (en) | 2011-03-24 |
GB2485298A (en) | 2012-05-09 |
GB2485298B (en) | 2015-09-02 |
WO2011010300A2 (en) | 2011-01-27 |
EP2456928B8 (en) | 2015-10-07 |
IE20100466A1 (en) | 2011-02-02 |
WO2011010300A8 (en) | 2012-03-08 |
CN105625580B (en) | 2019-09-10 |
RU2543396C2 (en) | 2015-02-27 |
CN105625580A (en) | 2016-06-01 |
PL2456928T3 (en) | 2016-01-29 |
GB2485298B8 (en) | 2015-09-23 |
CN102575465A (en) | 2012-07-11 |
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