EP3258021A1 - Module de construction et système de construction modulaire comprenant un ou plusieurs desdits modules - Google Patents

Module de construction et système de construction modulaire comprenant un ou plusieurs desdits modules Download PDF

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Publication number
EP3258021A1
EP3258021A1 EP16175031.0A EP16175031A EP3258021A1 EP 3258021 A1 EP3258021 A1 EP 3258021A1 EP 16175031 A EP16175031 A EP 16175031A EP 3258021 A1 EP3258021 A1 EP 3258021A1
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EP
European Patent Office
Prior art keywords
prefab
concrete slab
reinforced concrete
construction module
construction
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Withdrawn
Application number
EP16175031.0A
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German (de)
English (en)
Inventor
Patricia DECEUNINCK
Danny VANDEMOORTELE
Tibo VANDEMOORTELE
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Amenagement Renovation Electricite SA
Original Assignee
Amenagement Renovation Electricite SA
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Amenagement Renovation Electricite SA filed Critical Amenagement Renovation Electricite SA
Priority to EP16175031.0A priority Critical patent/EP3258021A1/fr
Publication of EP3258021A1 publication Critical patent/EP3258021A1/fr
Withdrawn legal-status Critical Current

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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
    • E04B1/3483—Elements not integrated in a skeleton the supporting structure consisting of metal

Definitions

  • the invention relates to a prefab construction module and a modular construction system comprising one or more such prefab construction modules, more specifically a prefab construction module consisting of a metal structural frame and a reinforced concrete slab.
  • the invention also relates to a method of manufacturing such a prefab construction module and modular construction system.
  • the prefab building structures can roughly be divided into two groups, namely (quick) construction kits and container structures.
  • Construction kits consisting of more or less finished construction elements can be built relatively quickly at the location of the site, but require significant preparatory works to take place beforehand (e.g. foundation works). In addition, a significant amount of time may still be lost on the site as a result of actual assembly and construction of the structure. As a result thereof, the final finishing (such as e.g. installing windows and internal woodworking, insulation, interior decoration, such as kitchen and sanitary fittings, carpets and the like) can only be carried out after the kit has been assembled.
  • these construction kits usually consist of lightweight materials (wood, Gyproc/plasterboard on a wooden or metal frame) to render transportation and construction easier. They therefore require a support structure which carries the actual load of the structure in order to be able to withstand extreme weather conditions, such as heavy rain and high winds, or when building upwards, as is the case with a structure consisting of several floors.
  • Container structures are often used as temporary structures and are thus often limited with regard to the comfort, insulation, size and degree of finish.
  • the dimensions of a prefab container are often chosen so as to transport and install them in as short a time as possible.
  • holes are provided in the walls and/or floor of the containers for discharge pipes and utilities, which is a drawback for, inter alia, the insulation of the container.
  • Further finishing or connecting to other container structures is also made more difficult by the fact that the strength of a container depends completely on the walls, due to which the strength of the entire container structure is compromised if a wall in a container is partly or completely removed.
  • the current invention relates to a transportable prefab construction module or a modular construction system comprising such transportable prefab construction modules, in which case this transportable prefab construction module in its most general form comprises a metal structural frame coupled to a foundation slab consisting of a concrete slab made of reinforced concrete.
  • this transportable prefab construction module in its most general form comprises a metal structural frame coupled to a foundation slab consisting of a concrete slab made of reinforced concrete.
  • the invention relates to a transportable prefab construction module (100), comprising
  • a surface area ratio may be defined as described further below, with the SAR varying between 0.9 and 2.0; preferably between 0.95 and 1.5; more preferably between approximately 1 and 1.2; with the SAR most preferably being approximately 1.
  • the foundation component (200) in particular the reinforced concrete slab, comprises one or more recesses or shaped or manufactured passages for utilities or as sanitary ducts.
  • the prefab construction module contemplated herein furthermore comprises one or more of the following elements:
  • the invention relates to a modular construction system (400), comprising at least two transportable construction modules (100) according to a first aspect of the invention, in which a first and a second prefab construction module (100) are fastened to each other by means of a fastening means.
  • a first and a second prefab construction module are fastened to each other by one or more fastening means, in which:
  • the modular construction system (400) contemplated herein furthermore comprises a plurality of piles (450) which, in the fitted position, are positioned in the ground and attached to the construction module (100) of the modular construction system (400), with the piles (450) together being configured to completely support the prefab construction module (100) or the modular construction system (400).
  • the invention relates to a method of manufacturing a prefab construction module contemplated herein or a modular construction system contemplated herein, preferably comprising the following steps: (i) providing or producing a reinforced concrete slab as described herein, provided with at least four coupling elements; (ii) fitting of the structural frame and fastening of the structural frame to the reinforced concrete slab by means of the columns of the frame to the coupling elements; (iii) installing the wall panels and the roof panels so as to form side walls and the roof structure and (iv) in case of producing the modular construction system, installing different prefab construction modules, preferably by means of one or more fastening means as described herein, so as to form the modular construction system. Steps (i) and (ii) may be performed in series or parallel.
  • the invention relates to a transportable prefab construction module and a modular construction system comprising one or more prefab construction modules, as well as methods of manufacturing a transportable prefab construction module, in which such modules of modular construction systems may be used for constructing dwellings or holiday homes, apartments, offices, garages, working spaces, studios, garden pavilions, bathhouses, etc.
  • a first construction module according to the invention may furthermore be combined/expanded with a basically unlimited number of further prefab construction modules, which are connected to this first prefab construction module in a lateral, transverse, adjacent or stacked manner.
  • prefab construction module and modular construction system contemplated herein can be finished in its entirety in a workshop (both with regard to the interior decoration and the external finish). This allows the manufacturer, architect, the client or prospective occupant to carry out an extensive check (quality, finish, etc.) of the structure before the building structure is transported to the destination location. Each finished module can then easily be transported by means of standard transport vehicles, such as trucks, and positioned using standard construction vehicles, such as cranes.
  • the invention relates to a transportable prefab construction module comprising a foundation component and a structural frame, in which:
  • the main advantage of the prefab construction module contemplated herein is the stability.
  • the combination of a foundation component comprising a concrete slab made of reinforced concrete, and a structural frame made of metal (steel) which is securely anchored in the reinforced concrete slab gives the current transportable prefab construction module greater stability compared to other prefab construction kits or containers which require an external foundation, which results in additional work, costs and time on the site.
  • the connection between the reinforcement of the foundation component and the structural frame by means of the coupling element improves the stability still further.
  • the great stability of the structure is also an advantage during transportation of the construction module from the production site to the site where the building structure is ultimately positioned and reduces the risk of damage during transport, for example in extreme weather conditions or when the transport vehicle is involved in a collision.
  • the materials used are not flammable and readily and freely available in different sizes.
  • the foundation component contemplated herein, in particular the reinforced concrete slab is made from a combination of metal and concrete, preferably made from steel and concrete, such as reinforced concrete.
  • the reinforced concrete slab is provided with a metal mesh, preferably a steel mesh, which prevents or greatly reduces crack formation and improves the strength and stability.
  • the reinforced concrete slab contemplated herein is configured in such a way that it allows the foundation component to be used as foundation or base slab for the prefab construction module.
  • the advantage thereof is, inter alia, that no separate foundation has to be provided, and therefore no foundation works have to be carried out, at the site where the prefab construction module or the modular construction system is ultimately positioned, which may result in a significant time saving.
  • the reinforced concrete slab comprises concrete of a concrete density of at least 1500 kg/m 3 or 2000 kg/m 3 ; preferably between 2000 kg/m 3 and 3000 kg/m 3 ; most preferably approximately 2400 or 2500 kg/m 3 .
  • An additional advantage of concrete is the waterproofing and the lack of condensation formation. This makes a prefab construction module suitable for use in moist regions with possible waterlogging, such as flood areas.
  • a higher concrete density of the concrete slab increases the degree of waterproofing of the foundation component.
  • the underside of the reinforced concrete slab comprises one or more hollowings, recesses or slots.
  • a recess in the concrete slab may provide space for supply and discharge lines, utility cables and the like.
  • Such a recess may comprise at least 20%, 30%, 40%, 50%, 60%, 70%, preferably approximately 2/3 to 3/4 of the surface of the concrete slab.
  • the coupling element contemplated herein is preferably a coupling element which is compatible with both steel and concrete.
  • the coupling element makes it possible to couple a column of the structural frame to the reinforced concrete slab of the foundation component.
  • at least one coupling element is provided for each column.
  • the frame as described herein preferably comprises at least four columns, preferably there are also at least four coupling elements provided.
  • each coupling element is situated in the reinforced concrete slab and is integrated in, connected or anchored to the reinforcement of the reinforced concrete slab, such as e.g. by welding the coupling element to the reinforcement.
  • the coupling element is near the edge of the reinforced concrete slab, such as preferably at less than 50 cm, 40 cm, 30 cm or 20 cm from an edge of the reinforced concrete slab.
  • At least one coupling element is positioned near one or more corners of the reinforced concrete slab, such as preferably at least than 50 cm, 40 cm, 30 cm or 20 cm from a corner of the reinforced concrete slab.
  • each corner of the reinforced concrete slab is provided with a coupling element.
  • each coupling element depends on the individual embodiment of the invention.
  • Coupling elements or coupling systems by means of which a column can be coupled or anchored to a reinforced concrete slab (via a first end) are known.
  • the coupling element comprises a bolt anchor, a concrete screw, a threaded rod or reinforcing steel (reinforcing iron), in which case the latter protrudes from the reinforced concrete slab and can be attached to a column.
  • the coupling element may also be removable or repeatedly fittable.
  • the coupling element is permanently anchored to the foundation component.
  • the structural frame contemplated herein comprises at least four columns.
  • Each column is made of metal, preferably steel.
  • each column is coupled at right angles to the foundation component, in particular the reinforced concrete slab, preferably in/on the corners of the reinforced concrete slab, by means of a coupling element, as a result of which consequently the structural frame is also anchored to the foundation component by means of the columns, preferably to the reinforcement mesh of the reinforced concrete slab.
  • additional columns may be provided, such as near the edges of the reinforced concrete slab, which increases the stability and the strength.
  • optional columns may be removable: in some embodiments, such optional columns may be installed during manufacturing and finishing of a modular construction system consisting of the prefab construction modules contemplated herein in order to improve the stability, assembly, finish and transportation, in which case, not all columns may still be required or desired after transportation to the site where the modular building structure is ultimately positioned, because they may possibly limit the available living space.
  • one or more columns may be removed, in particular the columns which are situated in the centre of the modular building structure, without limiting the stability of the modular construction system.
  • a column is preferably positioned near a corner and/or near the edge of the reinforced concrete slab. As the columns are anchored to the reinforced concrete slab by means of a coupling element, the installation of a coupling element and the advantages thereof described above also apply to the installation of the columns.
  • the structural frame contemplated herein furthermore comprises a top supporting element.
  • the top supporting element is made from metal; preferably steel.
  • the top supporting element is composed of one or more long bar-shaped elements, such as metal rods, beams or bars, such as e.g. having an I-shaped profile, which are supported by the columns and are bonded to a second end of the columns, parallel to the foundation component.
  • the metal rod has a U-shaped profile facing the foundation component for the installation of further finishing or sealing elements, such as wall panels.
  • the top supporting element connects at least two neighbouring columns.
  • the top supporting element is rectangular in shape, with all columns of the structural frame being connected.
  • the transportable prefab construction module contemplated herein furthermore comprises at least one roof element which forms part of the roof component.
  • a roof element is a supporting element, such as a rod or beam, positioned between and attached to the metal rods of the top supporting element, bridging the space between the rods of the top supporting element.
  • the roof element is made from metal; most preferably steel.
  • the structural frame contemplated herein may furthermore comprise a bottom supporting element .
  • the bottom supporting element is made from metal, preferably steel.
  • the bottom supporting element is composed of one or more long linear elements, such as metal rods, beams or bars, which adjoin the reinforced concrete slab and are positioned between at least two neighbouring columns, and attached to the reinforced concrete slab and/or one or more columns.
  • the metal rod has a groove or an L-shaped or U-shaped profile facing away from the foundation component for installation of further finishing or sealing elements, such as wall panels or sliding doors.
  • prefab finishing elements such as cassettes, wall panels, windows and/or (glass) sliding doors, can easily be fitted between the top and the bottom supporting element by means of a bottom supporting element.
  • the choice of the embodiment of the bottom supporting element contemplated herein depends on the embodiment of the prefab construction module, in particular the embodiment of the modular construction system comprising several construction modules.
  • the rods which form the bottom supporting element are only positioned on the outer edges of the modular construction system composed of the construction modules.
  • the structural frame has a bar-shaped structure, in which the basic area, such as determined by a rectangle with the four columns as corners, is approximately equal to the top surface, such as determined by the top supporting element of the roof component. Ways and means to fasten the various steel elements which form the (optional) bottom and top supporting element to the columns of the roof elements are known.
  • the metal components may be connected to each other, for example by means of welding, bolting or a combination thereof, in such a way that a stable structure is produced which makes it possible to support the prefab construction module and which, in addition, is also able to resist external stress factors, such as wind load or earthquakes.
  • the structural frame furthermore comprises one or more cross or X-shaped bracing systems between adjacent columns.
  • Such bracing systems may be permanent or temporary and improve the stability of a prefab construction module, in particular during transport or when combining different construction modules to form a modular construction system.
  • the metal components, in particular steel components, of the structural frame and/or roof or wall panels preferably those portions of the structural frame of the roof or wall panels which are situated on the outside of the module after manufacture, have undergone one or more surface treatments, in particular to make them more resistant to ambient influences and/or for aesthetic reasons, such as e.g. a surface treatment according to C3 (ISO12944) which makes it possible to protect the steel structure against corrosion, coating with a primer and painting, etc.
  • a surface treatment according to C3 ISO12944
  • the metal parts which are directed inwards do preferably not require treatment due to the presence of insulation and/or further coating.
  • both the structural frame and the reinforced concrete slab are a bar-shaped structure, characterized by a basic area, having a length and a width, and by a height.
  • the term "length" and “width” of a prefab construction module or concrete slab as used herein corresponds to the longest dimension and shortest dimension, respectively, of the basic surface, defined by the concrete slab and/or the structural frame.
  • the length and width of the structural frame corresponds to the longest and shortest distance, respectively, between two neighbouring columns or the longest and shortest dimension, respectively, of the surface defined by the top supporting element, optionally including the width or diameter of the columns themselves.
  • the term "height" of a prefab construction module corresponds with the height or thickness of the concrete slab augmented by the length of a column, optionally augmented by the thickness of the roof component and/or top supporting element.
  • the height of the structural frame is typically the length of a column, optionally augmented by the height or thickness of the top supporting element or the roof component.
  • the structural frame comprises a bar-shaped structure having a length of at least 4 m, preferably having a length between 4 and 16 m; more preferably between 6 m and 12 m or between 7 and 10 m; and most preferably is approximately 8 m.
  • the structural frame comprises a bar-shaped structure having a width of at least 2 m of 3 m, preferably having a width between 2 m and 10 m; more preferably between 2.5 m and 8 m or between 3 to 6 m; most preferably between approximately 4 and 5 m or is approximately 4 or 5 m.
  • the structural frame comprises a bar-shaped structure having a height of at least 2 m, preferably between 2 m and 10 m; more preferably between 2 m to 8 m or between 2 m and 5 m; most preferably between 2.5 m and 3 m or between 2.5 m and 3.5 m or 4 m.
  • the reinforced concrete slab is a bar-shaped structure having dimensions similar to those of the structural frame as described above and having a maximum height or thickness of at least 20 or 25 cm, preferably has a height between 25 cm and 60 cm; more preferably between 30 cm and 50 cm or between 30 cm or 40 cm, and most preferably is approximately 35 cm.
  • the thickness of the concrete slab in the recess is at least 10 cm, preferably between 10 cm and 30 cm or between 10 cm and 25 cm, more preferably between 10 cm and 20 cm or between 10 cm and 15 cm.
  • the prefab construction module furthermore comprises one or more transport elements or lifting elements to make lifting and/or displacing the assembled construction module possible, such as one or more hooks, rings, lifting eyes or anchors, which are attached, for example, to the top supporting element or the roof component, or wheels, which are attached to the underside of the foundation component, such as in one or more of the recesses contemplated herein of the reinforced concrete slab, or a combination thereof.
  • transport elements or lifting elements to make lifting and/or displacing the assembled construction module possible, such as one or more hooks, rings, lifting eyes or anchors, which are attached, for example, to the top supporting element or the roof component, or wheels, which are attached to the underside of the foundation component, such as in one or more of the recesses contemplated herein of the reinforced concrete slab, or a combination thereof.
  • the prefab construction module furthermore has a surface area ratio (SAR) defined as the ratio between a surface area defined by the top surface of the foundation component, in particular the surface of the reinforced concrete slab, to a surface area defined by the (rectangular) base of the structural frame.
  • SAR surface area ratio
  • the SAR varies between at least 0.8 to at most 2.0.
  • the SAR varies between at least 0.85 and at most 1.5.
  • the SAR varies between at least 0.9 and at most 1.1.
  • the SAR is approximately 1.0, or in other words, the surface of the reinforced concrete slab is approximately equal to the basic area of the structural frame.
  • the reinforced concrete slab furthermore comprises one or more recesses or preformed or produced passages for one or more utility cables, for the supply and discharge of the water and sanitary fittings, for gas supply and/or for the heating installation (comprising one or more heating elements).
  • utilities is typically understood to mean electricity, telephone, television, internet and the like.
  • the duct contemplated herein may be formed in various ways.
  • the central part of the reinforced concrete slab is partly hollow or locally reduced in thickness, as a result of which a recess is formed on the underside of the concrete slab, the hollow space of the recess making it possible to secure one or more ducts.
  • the ducts are positioned or formed at the same time as manufacturing of the reinforced concrete slab is effected, thus improving the speed of production and finishing.
  • the reinforcement is configured in such a way that the presence of such recesses or ducts is possible.
  • the prefab construction module furthermore comprises at least one and preferably a plurality of wall panels positioned between the foundation component/the reinforced concrete slab and the top supporting element and between at least two columns, in order to completely or partly close off one or more sides of the prefab construction module contemplated herein.
  • wall panels may be made of metal, glass, plastic, concrete, wood, sandwich panels, or any other suitable material metal or combinations thereof, optionally combined with insulating material.
  • the wall panels consist of metal or glass.
  • Metal wall panels have the advantage that they further improve the stability.
  • windows and doors may also be incorporated in the wall panels. Such an embodiment has the advantage that it allows free positioning of the windows in a self-supporting façade structure.
  • such wall panels may also subdivide the interior space into rooms or spaces.
  • a wall panel is a prefab cassette, as is known by the person skilled in the art and is used, for example, in wood skeleton construction.
  • An advantage of prefab cassettes is the fact that they do not have to be made to measure, but are supplied in a standard format. When installing the prefab construction module, the prefab cassettes are adjusted in such a way that they can easily be fitted between the (optional) bottom and top supporting element. This has advantages with regard to manufacturing costs and installation time.
  • the roof component in addition to at least one roof element, also comprises one or more roof panels which form a closed roof structure and which are supported by the roof elements and/or the top supporting element.
  • a flat roof structure is formed.
  • the roof component, in particular the roof panels may consist of several materials, as is known to the person skilled in the art, including plastic, metal, wood, glass, roofing, fibre cement panels, bituminous materials or combinations thereof.
  • attic windows or skylights may be incorporated in a roof panel.
  • the prefab construction module contemplated herein is sufficiently strong to support specific roof structures, such as a green roof, the installation of solar panels, or as a fitness room.
  • the prefab construction module furthermore comprises an insulating material adjoining one or more wall panels, one or more roof panels and/or the reinforced concrete slab, to insulate the prefab construction module against external temperatures (heat/cold) or prevent thermal bridges.
  • the insulating material is positioned between two layers of wall panels; for example a wall panel adjacent to the outer side and a wall panel adjacent to the inner side of the prefab construction module.
  • the insulating material is positioned between two layers of roof panels; for example a roof panel adjacent to the outer side and a wall panel roof panel on the inner side of the prefab construction module.
  • the insulating material is selected from synthetic material, such as polyurethane (PUR) - polyisocyanurate (PIR), phenolic foam (PF), expanded polystyrene (EPS), extruded polystyrene (XPS), and the like.
  • the insulating material is selected from mineral materials, such as mineral wool (MW) glass wool, rock wool, cellular glass (CG), expanded perlite (EPB), and the like.
  • the insulating material is selected from vegetable materials, such as flax, wood fibre, cellulose (paper, wood fibre), sheep's wool, hemp, straw and reed, cork and the like.
  • vegetable materials such as flax, wood fibre, cellulose (paper, wood fibre), sheep's wool, hemp, straw and reed, cork and the like.
  • synthetic materials are used, because these can be supplied in the form of a prefab cassette or be sprayed directly onto a prefab cassette panel. This has advantages with regard to the installation time and simplicity of a prefab construction module. In addition, these materials often have a good fire behaviour which improves the fire resistance of a prefab construction module; which is important for prefab construction modules which are intended for areas with an increased fire risk, for example near wooded areas or in dry regions.
  • the insulating material is a polyurethane foam (PU foam or PUR foam) which is sprayed onto the inner side of a wall panel or into the space between two wall panels.
  • the current invention relates to a modular construction system consisting of at least two prefab construction modules according to the present invention, in which the at least two construction modules are attached to one another.
  • the at least two construction modules may be positioned laterally next to each other or on top of each other. In the case of relatively large numbers of construction modules, these may be both positioned laterally and stacked.
  • the modular construction system comprises at least two construction modules according to the present invention, and at least one fastening means, configured to attach two or several of the construction modules contemplated herein; in which the at least two construction modules are fastened to each other by the fastening means.
  • the at least two construction modules according to the current invention are positioned laterally adjacent to each other.
  • the at least two construction modules as described herein are stacked on top of one another, in which, alternately, a structural frame is separated by a foundation component.
  • the fastening means is to provide additional stability and strength to a modular construction system which comprises at least two prefab construction modules.
  • the fastening means may be any structure which is capable of connecting construction modules and attaching them to each other; such as an anchor, hook, plate, bar, rod, and the like.
  • the fastening means is a structure which connects and/or partly of completely overlaps the adjacent edges or lateral surfaces of at least a first and a second construction module.
  • the fastening means may be made of metal; preferably steel.
  • both the foundation component and the structural frame and the roof element or top supporting element of two adjacent prefab construction modules according to the current invention are attached to each other, as is schematically illustrated in Fig. 5A .
  • the reinforced concrete slabs of at least one first and one second construction module are configured to be laterally attached to each other, as is schematically illustrated in Fig 5B .
  • Fig. 5A a preferred embodiment, as illustrated in Fig. 5A
  • each concrete slab is provided with one or more hollowings or recesses on its underside and the adjacent lateral surfaces of the at least one first and one second concrete slab are provided with holes which are aligned with each other and thus make it possible for a lateral fastening means as described herein, e.g. a metal rod, to be placed in the holes of the first and second concrete slab.
  • a lateral fastening means as described herein, e.g. a metal rod
  • the preferably threaded metal rod connects the hollowing of the concrete slab of the first module to the hollowing of the concrete slab of the second module by means of the aligned holes and the rod can be detachably secured by means of a nut in order to attach the first and second concrete slab/construction module.
  • the reinforced concrete slab of at least one prefab construction module comprises at least one rod which protrudes laterally from this reinforced concrete slab and the reinforced concrete slab of at least one second prefab construction module comprises a hole for each protruding rod, with the diameter of each hole approximately corresponding to the diameter of the protruding rod which is aligned with the hole during installation of the modular construction system, in which case this protruding rod is positioned in this corresponding hole and acts as lateral fastening means.
  • the modular construction system furthermore comprises at least one lateral fastening means for the lateral attachment of the structural frame.
  • a lateral fastening means for the structural frame of a first and a second construction module according to the current invention comprises at least one beam (also referred to as side beam herein) which is configured to absorb stress or pressure and which is positioned between and attached to the structural frame of the at least two adjacent prefab construction modules according to the current invention.
  • a beam is a U-shaped beam which is configured to absorb stress or pressure.
  • such a beam in particular such a U-shaped beam, is fitted between at least two adjacent columns of at least two mutually attached construction modules, in which one side of the beam, in particular a U-shaped beam, is fitted to a first column of a first prefab construction module and the other side of the beam, in particular a U-shaped beam, is fitted to a second column of a second prefab construction module, as is illustrated in Fig. 5F .
  • Such beams, in particular U-shaped beams make it possible to absorb the external stress or pressure factors.
  • the side beam is configured in such a way that it prevents the foundation components of two adjacent construction modules from touching each other and forms a joint or gap between the two adjacent construction modules.
  • the modular construction system furthermore comprises at least one lateral fastening means for the lateral attachment of the roof component.
  • the roof components or top supporting elements of at least one first and one second construction module are configured to be laterally attached to each other, as is schematically illustrated in Fig 5C .
  • the roof component of top supporting element comprises a protruding edge and the mutually adjacent lateral surfaces of the at least one first and one second roof component/top supporting element are provided with holes which are aligned with each other and thus make it possible for a lateral fastening means as described herein, e.g.
  • a metal rod to be positioned in the holes of the first and second roof element/supporting element.
  • the metal rod is threaded and can be releasably secured by means of a nut in order to attach the first and second construction module.
  • the advantage of this embodiment is that the modular construction system which is finished in a workshop can easily be disassembled into its individual prefab construction modules and be transported, in order to be reassembled and reattached to each other at the site where it is ultimately positioned.
  • a sealing means is preferably provided between adjacent roof components of different prefab construction modules.
  • Such sealing means are known to the person skilled in the art and comprise, for example, a layer of covering rubber (such as EPDM rubber), which may be additionally protected by a metal cover.
  • the modular construction system furthermore comprises at least one central fastening means for the central attachment of at least three or four prefab construction modules according to the current invention.
  • the central fastening means may be made of metal; preferably steel.
  • the central fastening means may, in principle, be any structure which is capable of connecting and fastening three or four construction modules to each other; such as an anchor, plate, bar, rod, and the like.
  • the central fastening means is a cross or X-shaped structure which connects and/or partly of completely overlaps the adjacent columns of four construction modules.
  • at least two or three cross-shaped structures are positioned between the adjacent columns of four construction modules at different height.
  • the main advantage of a central fastening means is the additional stability which is achieved compared to the modular construction system by connecting the columns which are positioned centrally in the modular construction system.
  • the central fastening means makes it possible for the foundation components of the at least three or four construction modules to not contact each other as a result of internal or external pressure while forming a joint or gap between adjacent reinforced concrete slabs. Contact between reinforced concrete slabs could cause structural damage to a reinforced concrete slab.
  • the central fastening means ensures that each of the at least three or four construction modules can be positioned or pushed to the desired position in a correct and simple manner. In this case, the central fastening means fulfils an additional role as adjustment aid which ensures that the modular construction system can be installed in the same way at the site where it is ultimately positioned after it was disassembled for transportation.
  • the present prefab construction module and the modular construction system comprising several such prefab construction modules may furthermore contain additional devices and/or components:
  • the invention relates to a method for manufacturing a prefab construction module contemplated herein or a modular construction system contemplated herein.
  • the method according to present invention comprises the following steps:
  • the prefab construction module and modular construction system contemplated herein are very flexible with regard to the finish and design of the interior, and also with regard to the finish of the façades and roofs.
  • the present prefab construction module may comprise one and preferably a plurality of floor panels, which cover the reinforced concrete slab at least partly.
  • Floor panels are known to the person skilled in the art and may be made of, inter alia, plastic, ceramic, wood, glass, textile or combinations thereof. Examples thereof are laminate, parquet, tiles, carpet, etc.
  • Example 1 Prefab construction module (100)
  • a prefab construction module (100) as illustrated in Figs 1, 2 , 3 and 4 has a bar-shaped structure.
  • the prefab construction module (100) comprises a bar-shaped foundation component (200) having a length of 8.0 m, a width of 4.0 m and a height of 35 cm.
  • the surface area defined by the top surface of the foundation component (200) is 32 m 2 .
  • the foundation comprises a reinforced concrete slab (210) made of reinforced concrete with a density of approximately 2500 kg/m 3 and reinforced with a steel structure.
  • the foundation furthermore comprises four coupling elements (250), each coupling element (250) of which is positioned on one of the four corners of the rectangular top surface of the bar-shaped foundation (200); as is illustrated in Fig. 2 .
  • the prefab construction module (100) furthermore comprises a bar-shaped structural frame (300) having a length of 8.0 m, a width of 4.0 m and a height of 3.0 m.
  • the surface area defined by the basic surface of the structural frame (300) is 32 m 2 , which leads to a surface area ratio (SAR) of about 1.
  • the structural frame (300) is made up of four steel columns (325), each of which is coupled to a coupling element (250), in a corner of the reinforced concrete slab, such as e.g. by means of four bolt anchors in the reinforced concrete slab (210), at right angles with respect to the foundation component (200).
  • the structural frame (300) may contain one or more steel rods or elements which form a bottom supporting element (310).
  • the structural frame (300) furthermore comprises a top supporting element (360), comprising several steel rods, with dimensions similar to those of the concrete slab (210), attached to the top side of the columns (325) and parallel to the foundation component (200); in which a rectangular top surface of the structural frame (300) is formed with a surface area of approximately 32 m 2 .
  • the structural frame (300) furthermore also comprises a steel roof element (370), positioned between and attached to the top supporting element (360), bridging the space between the rods of the top supporting element (360).
  • the prefab construction module (100) furthermore comprises a plurality of panels and insulating materials; as is illustrated in Figs 4 , 9 & 10 .
  • the walls of the prefab construction module (100) are formed by wall panels (315), substantially consisting of steel, positioned between and attached to the bottom supporting element (310) of the reinforced concrete slab (210) and the top supporting element (360) between two neighbouring columns (325).
  • a layer of PU foam is provided as insulating material on the inner side of the wall panels.
  • the roof component (350) of the prefab construction module (100) is formed by a roof element (370) with a plurality of roof panels (375) thereon. In this case as well, an insulating material is provided on the inner side of the roof panels, e.g. a layer of mineral rock wool.
  • Figs 9 and 10 show a prefab construction module in different stages of construction, with several wall panels and roof panels having been positioned to form side walls and the roof.
  • the floor of the prefab construction module (100) is formed by a plurality of floor panels (215) positioned on the foundation component (200).
  • the majority of the floor panels (215) is made from wood for warmth, comfort and aesthetics. Underfloor heating may be installed and/or insulating material may be fitted between the reinforced concrete slab (200) and the floor panels (215).
  • the foundation component (200) has a manufactured duct (220) to which water supply or discharge and sanitary fittings may be connected, or in which the utility cables may be fitted; as is illustrated in Fig. 3 .
  • Example 2 modular construction system comprising several modular construction modules
  • a modular construction system (400) may also consist of several prefab construction modules and may therefore consist of different materials, sizes and embodiments.
  • Figs. 5A, 5B and 5C show a modular construction system (400) consisting of two prefab construction modules (100) which are positioned so as to adjoin each other laterally by their longitudinal direction.
  • the reinforced concrete slab (210) of each construction module comprises two large rectangular recesses (260) which constitute approximately 75% of the surface of the concrete slab.
  • the foundation component and the roof component of the adjacent construction modules (100) are attached to each other by means of a steel lateral fastening means (420).
  • Fig. 5D shows a preferred fastening means for the roof component in which a threaded steel rod is positioned between two projections in the roof component of the two different construction modules through aligned holes provided in each projection and fixed using nuts.
  • Fig. 5E shows a preferred fastening means in which a threaded steel rod is positioned between two recesses (260) in the reinforced concrete slab of the two different construction modules through aligned holes provided in each reinforced concrete slab (210) and fixed with nuts. Two such lateral fastening means may be provided every 4m. Furthermore, two U-shaped steel supporting beams (410) are fitted between the two adjacent columns (325) of the two adjacent construction modules (100), on both sides, as is illustrated in Fig 5F . Based upon the dimensions of the preferred embodiment of the prefab construction module (100) from Example 1, a modular construction system (400) having a total surface area of approximately 64 m 2 is obtained.
  • Figs. 6A and 6B show a modular construction system (400) comprising four prefab construction modules (100).
  • the foundation components of the adjacent construction modules (100) are attached to one another by means of lateral fastening means (420), in which each construction module (100) is laterally connected to two other construction modules (100), as described for Fig. 5 , and a central cross-shaped steel fastening means (430), positioned between the 4 adjacent columns, which centrally connects the four prefab construction modules at different heights.
  • four U-shaped steel beams (410) are fitted between the two adjacent columns (325) of two adjacent construction modules (100), on one side.
  • a modular construction system (400) having a surface area of approximately 128 m 2 is obtained.
  • Figs. 7A and 7B represent an assembled modular construction system (400) comprising four prefab construction modules (100) and show how an assembled modular construction system (400) offers a plurality of living spaces after finishing, including a living room, dining room, kitchen, two bedrooms, two bathrooms, a toilet and an entrance, and shows an example of a façade finish consisting of wooden slats and windows.
  • Fig. 11 shows an external view of a finished modular construction system, in which the façade materials are selected in connection with the concrete slab and the visible steel columns and roof component.
  • Figs. 8A, 8B and Fig 12 show a variant of the modular construction system from Fig. 7 , in which the assembled modular construction system (400) is supported by piles and furthermore comprises a patio module (530).
  • the piles may be driven into the underground up to a depth of approximately 5 to 10 metres, inter alia depending on the slope of the topsoil.
  • the modular construction system (400) is fully assembled, with each prefab construction module (100) resting on six piles.
  • the modular construction system according to Figs 8A and 8B furthermore comprise a fifth prefab construction module (100) for an additional living space, and a staircase (520).
  • Such assembled modular construction systems (400) are highly suitable for use in a flooded area or on sloping ground; as is illustrated in Fig. 8B .

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  • Architecture (AREA)
  • Physics & Mathematics (AREA)
  • Electromagnetism (AREA)
  • Civil Engineering (AREA)
  • Structural Engineering (AREA)
  • Joining Of Building Structures In Genera (AREA)
EP16175031.0A 2016-06-17 2016-06-17 Module de construction et système de construction modulaire comprenant un ou plusieurs desdits modules Withdrawn EP3258021A1 (fr)

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Cited By (12)

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Publication number Priority date Publication date Assignee Title
CN109024890A (zh) * 2018-08-29 2018-12-18 上海迅铸建筑科技有限公司 用于钢结构模块化建筑的预紧力连接节点装置
CN109930821A (zh) * 2019-04-26 2019-06-25 岳鹏 柱状框架结构模
RU191530U1 (ru) * 2018-12-31 2019-08-12 Олеся Алексеевна Бакман Модуль мобильного здания
CN111851733A (zh) * 2020-08-20 2020-10-30 北京立建科技有限公司 一种模块化组装式房屋
CN112681851A (zh) * 2020-12-18 2021-04-20 宁波市电力设计院有限公司 大体积地下构筑物的预制单元装配构造
CN112922173A (zh) * 2021-04-01 2021-06-08 中建二局第一建筑工程有限公司 一种装配式钢结构建筑组件及装配方法
CN113250226A (zh) * 2021-04-25 2021-08-13 同济大学建筑设计研究院(集团)有限公司 预制预应力混凝土基础、集装箱模块建筑和模块建筑系统
CN113356364A (zh) * 2021-05-20 2021-09-07 郑州工业应用技术学院 一种快速周转装配式钢结构及其施工方法
CN113775206A (zh) * 2021-09-09 2021-12-10 江苏协和装饰工程有限公司 装配式亭台的构建方法
CN114575509A (zh) * 2022-02-11 2022-06-03 崔现沅 一种装配式建筑梁板连接结构及连接方法
CN115262768A (zh) * 2022-09-01 2022-11-01 陕西隆邦建设有限公司 模块化建筑结构、模块化建筑对接结构及模块化建筑结构的制备方法
CN117306683A (zh) * 2023-11-28 2023-12-29 河北省建筑科学研究院有限公司 一种低能耗装配式建筑

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CA1176865A (fr) * 1980-10-28 1984-10-30 Bevan J. Riekie Dalle en beton
US6101779A (en) * 1998-05-20 2000-08-15 Space Master Building Systems, Llc Construction unit for a modular building
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Cited By (17)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN109024890A (zh) * 2018-08-29 2018-12-18 上海迅铸建筑科技有限公司 用于钢结构模块化建筑的预紧力连接节点装置
RU191530U1 (ru) * 2018-12-31 2019-08-12 Олеся Алексеевна Бакман Модуль мобильного здания
CN109930821A (zh) * 2019-04-26 2019-06-25 岳鹏 柱状框架结构模
CN109930821B (zh) * 2019-04-26 2024-05-07 岳鹏 柱状框架结构模
CN111851733A (zh) * 2020-08-20 2020-10-30 北京立建科技有限公司 一种模块化组装式房屋
CN112681851A (zh) * 2020-12-18 2021-04-20 宁波市电力设计院有限公司 大体积地下构筑物的预制单元装配构造
CN112922173B (zh) * 2021-04-01 2022-07-15 中建二局第一建筑工程有限公司 一种装配式钢结构建筑组件及装配方法
CN112922173A (zh) * 2021-04-01 2021-06-08 中建二局第一建筑工程有限公司 一种装配式钢结构建筑组件及装配方法
CN113250226A (zh) * 2021-04-25 2021-08-13 同济大学建筑设计研究院(集团)有限公司 预制预应力混凝土基础、集装箱模块建筑和模块建筑系统
CN113356364A (zh) * 2021-05-20 2021-09-07 郑州工业应用技术学院 一种快速周转装配式钢结构及其施工方法
CN113775206A (zh) * 2021-09-09 2021-12-10 江苏协和装饰工程有限公司 装配式亭台的构建方法
CN114575509B (zh) * 2022-02-11 2023-09-22 崔现沅 一种装配式建筑梁板连接结构及连接方法
CN114575509A (zh) * 2022-02-11 2022-06-03 崔现沅 一种装配式建筑梁板连接结构及连接方法
CN115262768A (zh) * 2022-09-01 2022-11-01 陕西隆邦建设有限公司 模块化建筑结构、模块化建筑对接结构及模块化建筑结构的制备方法
CN115262768B (zh) * 2022-09-01 2023-08-11 陕西隆邦建设有限公司 模块化建筑结构及模块化建筑结构的制备方法
CN117306683A (zh) * 2023-11-28 2023-12-29 河北省建筑科学研究院有限公司 一种低能耗装配式建筑
CN117306683B (zh) * 2023-11-28 2024-01-30 河北省建筑科学研究院有限公司 一种低能耗装配式建筑

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