EP4481129A1

EP4481129A1 - Prefabricated building construction kit, the method of making said kit and the method of constructing a building using said construction kit

Info

Publication number: EP4481129A1
Application number: EP23184467.1A
Authority: EP
Inventors: Marijus Seduikis
Original assignee: Individual
Current assignee: Individual
Priority date: 2023-06-23
Filing date: 2023-07-10
Publication date: 2024-12-25
Also published as: LT2023529A; LT7054B

Abstract

Prefabricated building construction kit, the method of making said kit and the method of construction works using this construction kit for residential or commercial prefabricated buildings include factory/workshop-made concrete slabs for walls (11) , foundations/floor, floors and/or roofs (10) reinforced with reinforcing mesh and rebars and fixed heat-insulating layer (7). Using this kit, i.e., connecting the slabs of the construction kit by means of insertion utilising the reinforcements arranged around the perimeter, a homogenous compound of the foundation/floor, floor slabs, roof beams and wall columns is obtained. This solid structure ensures the strength and stability of the structure, quick connection, elimination of cold bridges. This solid structure ensures the strength and stability of the structure, quick connection, elimination of cold bridges.

Description

Field of the Invention

The present invention relates to the technical field of construction industry, in particular, to the field of rapidly assembled concrete structures for multi-purpose buildings, from prefabricated concrete slabs for building foundations/floors, walls, floor slabs, roofs, with a fixed insulation layer, and to the manufacture of these slabs.

Background of the Invention

When constructing buildings from reinforced concrete structures, a reinforcement frame with or without an insulating layer is usually formed, followed by placing the mould and pouring concrete. If the frame is without an insulating layer, the building will need to be insulated later.
Due to the decreasing natural resources, all industries are at a constant lookout for innovative and efficient solutions facilitating a more efficient use of these resources. In the construction industry, great efforts are directed into the search for innovative structural solutions in order to ensure greater safety, reliability, and durability of the structures as well as the speed of construction.
Three-layer reinforced concrete walls with insulating material are characterised by superior tightness and heat accumulation properties, which results in lower energy consumption to heat the building. External three-layer wall slabs protect against noise, internal partitions reduce airborne and structure-borne (impact-generated) noise, furthermore, the following qualities are guaranteed: fire resistance, mechanical resistance protects against accidental damage, restricts disruptive effects on the structure from the inside caused by absorption of precipitation moisture, does not require plastering; the wall and ceiling structures are smooth enough to be processed only by applying putty before painting, there is no need to install a suspended ceiling; ready installation; there is minimal to none cutting and filling of electrical and plumbing ducts after installing the systems required.
The invention patent US 11053675, published on 6 July 2021 , presents building structural panels and building structural panel assemblies. The slab is composed of a foam insulation core with first and second oppositely positioned nonlinear longitudinal surfaces, each of the first and second nonlinear longitudinal surfaces include a plurality of pockets defined by a plurality of peaks and a plurality of troughs. A reinforcement mesh panel is positioned along at least a portion of each of the first and second longitudinal surfaces of the foam core. Reinforcing bars are positioned at least partially within the pockets of the surfaces of the foam core, and concrete is layered on top of the surfaces of the foam core and the mesh reinforcement panels to secure the reinforcing bars therein. In some embodiments, the reinforcing bars are positioned between the surface of the foam core and the mesh reinforcing panel. In this case, the concrete is poured at the construction site and a set of rebars is attached to the foundation of the building when pouring concrete. In this way, the resulting structure is of sufficient strength, however, forming the structure and pouring concrete at the construction site requires a lot of time, and the quality of the concrete cannot be guaranteed. Poor composition of concrete or technological shortcomings can cause damage to the finishing layers of the structure. In addition, it is unclear how other floor slab or roof structures are connected to maintain a uniform and robust structure without cold bridges.
Changes in the technologies of manufacturing prefabricated concrete elements, as well as in the product quality, versatility and speed of installation have led to the rapid development and recognition of prefabricated concrete structures. However, the global construction industry accounts for around 40% of emissions and around 60% of waste. Concrete production accounts for about 7 percent of total CO₂ emissions. A large amount of CO₂ is also emitted during the production and transportation of steel used for concrete reinforcement. In order to reduce the amount of CO₂ emitted into the atmosphere, it is necessary to reduce the volumes of concrete used and the weight of construction structures without compromising on the strength characteristics of the structure.
When prefabricated in the factory, three-layer reinforced concrete slabs allow better control of the quality of concrete and achieve better strength properties while forming a thinner layer of concrete. The construction duration is up to two times shorter compared to that of building structures from other materials, it is easier to ensure the quality of prefabricated reinforced concrete structures compared to monolithic reinforced concrete structures.
In the patent US2020240144, published on 30 July 2020 , a prefabricated lightweight composite heat-insulating external wall slab with a fixed heat-insulating core, a reinforcing mesh on both sides of the heat-insulating layer, and a concrete layer poured over the reinforcing mesh is described. There is more than one curve along the entire length of the heat-insulating core. Between the adjacent curves of the heat-insulating core, stable connection elements connecting with the reinforcing mesh are inserted, and pre-stressed tension rods are installed along the adjacent curves of the heat-insulating core and between adjacent layers of concrete. This pre-formed composite slab is of sufficient stability, but it is only intended for wall structures and has no integration with other elements of a building such as foundations or floors. In order to use it in construction, it is necessary to form a separate supporting frame, which prolongs the installation process and results in additional costs. In addition, a cold bridge forms at the connection point.
The scope of application of precast reinforced concrete structures includes buildings and structures of any purpose. Such building structure is suitable for public facilities, such as large and small shopping and entertainment centres, shops, schools, kindergartens, hospitals, office buildings, and industrial objects, such as warehouses, factories and their administrative quarters, terminals, etc. The elements of precast reinforced concrete structures take their rightful place in the construction of multi-storey buildings. This is due to rapid construction and good quality.
Speed of construction is one of the features of prefabricated reinforced concrete structures. Usually, the frame of a prefabricated reinforced concrete is made of separate reinforced concrete elements - columns, beams, panels. All these elements form an integral unity. When designing the frame of a prefabricated building, a considerable role is played by the interconnections of the prefabricated elements, or the so-called nodes. Also, nodes of prefabricated elements are very important when assembling products on the construction site. Usually, in the construction of buildings from reinforced concrete elements, initially, the columns are attached to the base by means of the extended reinforcing bars or anchor bolts. Columns are fastened to each other with bolts or by means of continuous reinforcement at the connection node, after which beams are usually supported on the console. This is where the connection nod for the beam resting on the column appears, as well as the connection nod for the beam and the floor slab. They get fixed in place by using the bolt protruding from the console. A neoprene spacer is usually provided between the beam and the console to evenly distribute the load transmitted by the beam. The above is followed by building walls, assembling blocks, which are usually connected to each other with epoxy glue, in addition, for the connection of the walls (vertical seams), connecting rods are used. In individual cases, three-layer walls can be fixed by providing other connection methods (for example, by welding and using specially designed inserts).
For the durability and longevity of the structure (building), proper installation of precast reinforced concrete construction joints, their protection from various possible environmental effects (moisture, chemicals) are very important.
Connection nods are subject to a continuous improvement in order to achieve the highest possible speed of installation using the simplest solutions for connecting prefabricated elements.
Improper assembly of structures can cause damage that will affect the load-bearing capacity of the structures and the building, as well as their aesthetic properties.
There are many types of buildings known to utilise different methods for connecting various elements. Although the known methods of constructing a building have various advantages, they also have a number of disadvantages, one of which is the time it takes to construct a building. For example, the construction of a small multi-storey building would normally take several weeks, depending on the building and the construction method used.
Some individual building elements are known, such as columns, wall or floor slabs which are connected by joining. Also with holes or openings into which another building element can be inserted by using extended reinforcement rods, thus ensuring a tight and strong connection of the elements.
For example, the Chinese patent document no. 106638987, published on May 10, 2017 , a method of connecting a concrete column is described, in which vertical holes and a vertical groove are formed in the upper plane of the lower part of the precast concrete column, which correspond to the arrangement of the reinforcement rods extended from the lower part of the formed upper column. The parts of the column are connected dry by utilising glue at the connection point. This connection method is convenient and fast. However, it is not connected to other elements of the building.
Another Chinese patent document no. 110644663, published on January 3, 2020 , describes a structural reinforced floor slab with connecting elements protruding on the sides, for connecting another floor slab with cavities, also with connecting elements protruding upwards at the edge in the upper part of the slab for connecting a wall. This concrete floor slab does not have a heat-insulating layer, which causes cold bridges to form. Quite a lot of rebar is used to manufacture the slab.
The proposed invention eliminates the mentioned disadvantages: a light, yet durable structure is created, the elements of which use significantly less concrete and rebar than in conventional concrete structures. This design is characterised by such features as quick connection, elimination of cold bridges and production of products that are fully ready for installation (no additional plastering, painting or other works are required). Due to the light weight of the structure, large cranes are not required, installation manipulators are sufficient (for lifting light structures of several tons). By reducing the amount of concrete (a 5-fold reduction in CO₂ emissions), rapid installation and dismantling can be achieved, and the products can be reused in other places. The products are fully prepared in the factory and interconnected by special fasteners; they can be installed rapidly and easily on the construction site, thus saving time and avoiding construction waste. In addition, the lightweight products that can be transported stacked horizontally on top of each other, which reduces transportation costs and environmental pollution.
These concrete structures adhere to all safety and quality parameters, and they are superior to conventional concrete structures due to the following features:

1. Strength - they bear the pressure of over 1000 kg per 1 m².
2. Lightweight - about 70 kg per 1 m². Due to the light weight, transportation costs are saved, construction elements for a 80 m² structure fits into 2 trucks;
3. Longevity;
4. Resistance to higher tensile stress (resistance in case of earthquakes);
5. Resistance to crushing, impact, fire, water absorption and other environmental factors; 6. Simple installation of multiple structures, avoiding cold bridges;
7. Complete absence of adhesion in the structure between concrete and heat-insulating material;
8. No risk of corrosion.

Summary of the Invention

In order to eliminate the above-mentioned disadvantages, a construction kit for residential or commercial prefabricated buildings has been developed, which includes factory/workshop-made concrete slabs for walls, foundations/floors and/or roofs reinforced with reinforcing mesh and rebars and a fixed heat-insulating layer. Using this kit, that is, connecting the slabs of the construction kit by means of insertion using the rebars arranged around the perimeter, a solid assembly of the foundation/floor, floor slabs, roof beams and wall columns is obtained. This solid structure ensures the strength and stability of the structure, quick connection, elimination of cold bridges.
The proposed prefabricated construction kit includes: fully factory-prepared lightweight concrete composite slabs with fixed heat-insulating layer with internal, outer, top, bottom and side surfaces for foundations/floors, floor slabs, roof, walls consisting of internal concrete layer reinforced with rebar and reinforcing mesh; outer concrete layer reinforced with rebar and reinforcing mesh; a heat-insulating layer material between said concrete layers;
connecting rebar present at all layers, to which the rebar and reinforcing mesh in the internal concrete layer and the rebar and reinforcing mesh in the outer concrete layer are attached. Due to the strengthening of the points of insertion of the rebar in the concrete layer, the reinforcement elements of the wall slab are embedded in the openings in the heat-insulating material layer, at the edges of the longitudinal part, which are formed in such a way that said reinforcements are arranged along the slab and surrounded by concrete; in addition, the said reinforcement elements extend beyond the edges of the upper and lower surfaces of the wall slab. In the inner concrete layer of the wall corner slab, at the point of connecting an adjacent wall slab, a strip of heat-insulating layer is additionally formed over the entire height, corresponding to the width of the heat-insulating layer that is present on the side surface of the wall slab. Meanwhile, in the foundation/floor, floor slabs, roof slabs, at least a pair of reinforcing bars are disposed parallel to each other at a distance, so as to strengthen the place where the reinforcement is anchored in the concrete layer, inserted into the openings of the heat-insulating material at the edges of the longitudinal and the transverse parts so that they get surrounded by concrete; in addition, in the part of the inner concrete layer of said foundation/floor, roof slab, where the wall slab is installed, a strip of heat-insulating material corresponding to the width of the heat-insulating layer on the lower surface of the wall slab is formed, and in the place where the wall slab is installed, holes corresponding to the arrangement of extended reinforcement dowels are formed, and in the parts of the inner and outer concrete layers of the floor slab, where the wall slab is installed, strips of the heat-insulating material layer are formed corresponding to the width of the heat-insulating layer on the lower and upper surfaces of the wall slab, and in the place where the wall slab is installed, holes are formed corresponding to the arrangement of the extended reinforcement rods present in the wall slab. The roof slab can be additionally pre-formed with a slope.
Due to the strength, lightness, and thermal insulation properties of the structure, the rebars and the reinforcing mesh are made of fibreglass or other materials with similar properties.
The said concrete slabs are lightweight because the thickness of the concrete layer is from 1 to 5 cm; the optimal thickness is 2 cm, and the wider part of the concrete layer is only in those places where the reinforcement is installed, and the thickness of the heat-insulating material layer is from 10 to 25 cm; the optimal thickness is 20 cm; the heat-insulating material layer consists of polyurethane or other material with similar properties.
So as not to require additional finishing of the constructed building, the outer side surfaces of the edge foundation/floor, floor slab, roof and wall corner slabs can be poured with concrete during the production/forming of the slabs.
The elements of the prefabricated building construction kits are manufactured in the production facilities, and can be manufactured according to the provided design.
In the production of composite slabs, a heat-insulating layer can be additionally formed, and the heating and cooling elements can be installed on the inner surface side by bringing the tubes or wires of the heating and cooling elements to the outside of the panel/slab, so that they could be connected to the heating and cooling system; also, integration of other utilities can be done during the production of the panel/slab.
The method of making a prefabricated building construction kit comprise the following steps:

formwork preparation, wherein
each separate heat-insulating layer is formed according to the dimensions of the foundation/floor, wall, wall corner, floor, roof slabs with openings for reinforcement and holes for inserting connecting fittings; the connecting reinforcement is guided through the holes; the reinforcement mesh is applied from the outer side of the heat-insulating layer corresponding to the outer area of the heat-insulating material, and from the inner side to the area corresponding to the installation place of the wall formed in the heat-insulating layer; reinforcement is disposed in the openings formed in the heat-insulating layer and is guided through the holes formed in the heat-insulating layer, where necessary; the said reinforcement meshes and reinforcing bars are connected to each other by joints for stability;
the formation of concrete composite foundation/floor, wall, corner, floor, roof slabs with an insulating layer in individual forms, wherein
the shaped formwork is placed in the appropriate mould of the foundation/floor, wall, corner, slab, roof and poured with concrete mix;
removal of the formed slab;
storage/preparation for transportation.

In addition, the making of said construction kit is available with using separate moulds in which the foundation/floor, wall, floor, corner, roof slabs with concrete-covered external side surfaces are formed by pouring concrete.
With the purpose of making more slabs simultaneously, several connected perpendicular moulds can be used, thus forming several composite slabs, when several moulds with formwork placed in them are poured over with concrete at the same time.
In order to additionally strengthen the connection points of the foundation/floor, wall, floor and/or roof slabs, additional connecting elements, such as plates, can be used to strengthen the connection points of the slabs.
Prefabricated buildings are constructed by using the aforementioned kit elements, when the foundation/floor slabs are laid on the foundation or compacted soil surface in the intended spot of a building, with the inner surface facing up, and are connected to each other on the side surfaces; due to the formation of a continuous heat-insulating layer throughout the building structure, in the place of the heat-insulating layer, the joining is made with thermal insulation glue (such as thermal insulation foam), and with concrete glue in the places where concrete is used. After laying the foundation, said wall slabs are placed with the bottom surface down, the inner surface inwards, in those places where the wall is intended, they are fixed to the foundation/floor, when glue is added to the holes in the foundation/floor slabs, the extended reinforcement dowels of the wall slabs are inserted in said holes, the bottom of the wall slabs is secured using thermal insulating foam in the places where the heat-insulating layer is, and concrete glue in the places where concrete is; another wall next to it is installed and connected by connecting adjacent wall slabs to each other, using thermal insulation foam in the place where the heat-insulating layer is, and concrete glue in the places where concrete is, and when connecting the corner, the side of the wall slab is connected at the edge of the inner surface of the wall corner slab with a strip of heat-insulating layer formed lengthwise over the entire height of the slab and concrete glue in the places where concrete is, and thermal insulation foam where the heat-insulating layer is. On the walls installed in accordance with the project, the floor slabs are installed side by side, with the inner surface facing up; they are connected by pouring glue into the holes and by securing on the reinforcement dowels extended from the top of the installed walls, and they are secured with concrete glue in the place where concrete is, and with thermal insulation foam where the heat-insulating layer is; for the connection of floor slabs on the sides of the slabs concrete glue is used in the places where concrete is, and thermal insulating foam where the heat-insulating layer is. For the next floor, walls are installed and connected in the same way as on the foundation/floor slabs. Roof slabs are used for the roof; these roof slabs are laid and connected in the same way as laying of the floor slabs, only with the inner surface facing downwards.
When the foundation/floor, wall, floor and/or roof slabs are connected to each other according to the present invention, a solid structure is formed with lintels evenly distributed throughout the building, which ensures the strength, stability and uniformity of the structure, and a heat-insulating layer distributed continuously throughout the building structure ensures the elimination of cold bridges.
These concrete structures adhere to all safety and quality parameters, and they are superior to conventional concrete structures due to the following features:

Brief Description of the Drawings

Fig. 1 - A composite concrete slab with fixed heat-insulating layer is presented.
Fig. 2 - The layout of the disassembled components of the composite concrete edge slabs with heat-insulating layer of the foundation/floor, roof is presented.
Fig. 3 - The layout of the disassembled components of the composite concrete edge slabs with heat-insulating layer of the foundation/floor, roof, including the heating, cooling system element is presented.
Fig. 4 - The arrangement of components of a composite concrete wall slab with a heat-insulating layer is presented.
Fig. 5 - A cross-sectional view of the foundation/floor, roof slab at the connecting reinforcement is presented.
Fig. 6 - A fragment of the connection of the foundation/floor, wall, wall corner and roof slabs of the prefabricated building construction kit is presented.

Designations of the elements of the invention:

1', 1", 1'" - inner concrete layer;
2 - heating/cooling system;
3, 3', 3", 3‴ - reinforcing mesh;
4, 4', 4" - reinforcement;
5 - connecting reinforcement;
6', 6", 6‴, 6ʺʺ - heat-insulating layer;
7, 7' 7" - a formed strip of the heat-insulating layer on the surface of the slab;
8 - roof slabs;
9', 9", 9‴ - outer concrete layer;
10, 10' - foundation/floor slabs;
11, 11' - wall slab;
12 - inner surface;
13 - outer surface;
14 - upper surface;
15 - lower surface;
16 - side surface.

An Example of the Implementation of the Invention

According to the construction project and to the demand of construction structural elements - foundation/floor, wall, floor, and/or roof slabs, rectangular heat-insulating layers (polyurethane/polystyrene) are formed in special moulds:

the heat-insulating layer 6ʺʺ intended for the foundation/floor slab 10 (Fig. 5):
on the sides of the inner and outer surfaces of the heat-insulating layer (12, 13) (Fig. 1), lengthwise and crosswise, on the edges and at a distance (preferably, across the width of the heat-insulating layer of the lower surface of the wall slab), openings are formed for placing the reinforcement elements 4', 4", and in these openings fixation elements can be formed from the heat-insulating layer to secure the reinforcement elements; in the place of wall installation, a heat-insulating layer strip 7" is formed which coincides with the parameters of the heat-insulating layer 6‴ of the lower surface 15 of the slab 11 and during the construction process rests on the heat-insulating layer 6‴ of the lower surface 15 of the wall slab 11, and the outer edges are formed narrower by the thickness of the concrete layer;
the heat-insulating layer 6' intended for the foundation/floor edge slab 10' (Fig. 2):
on the sides of the inner and outer surfaces of the heat-insulating layer (12, 13), lengthwise and crosswise, on the edges and at a distance (preferably, across the width of the heat-insulating layer of the lower surface of the wall slab), openings are formed for placing the reinforcement elements 4', 4", and in these openings fixation elements can be formed from the heat-insulating layer to secure the reinforcement elements; in the place of wall installation, a heat-insulating layer strip 7' is formed which coincides with the parameters of the heat-insulating layer 6‴ of the lower surface 15 of the slab 11 and during the construction process rests on the heat-insulating layer 6‴ of the lower surface 15 of the wall slab 11, and the outer edges are formed narrower by the thickness of the concrete layer;
the heat-insulating layer intended for the floor slab:
the same as the heat-insulating layer 6"" intended for the foundation/floor slab 10 (Fig. 5), only on both surfaces 12, 13, the inner and outer, a connection of the formed wall is present, the heat-insulating layer strip 7';
the heat-insulating layer intended for the edge floor slab:
the same as the heat-insulating layer 6' intended for the foundation/floor edge slab 10' (Fig. 2), only on both surfaces 12, 13, the inner and outer, a connection of the formed wall is present, the heat-insulating layer strip 7';
the heat-insulating layer intended for the roof slab:
the same as the heat-insulating layer 6"" intended for the foundation/floor slab 10 (Fig. 5), only longitudinally formed with a slope, one edge is higher and lowers down to the other longitudinal edge;
the heat-insulating layer 6 intended for the roof edge slab 8, (Fig. 6):
the same as the heat-insulating layer 6' intended for the foundation/floor edge slab, only longitudinally formed with a slope, one edge is higher and lowers down to the other longitudinal edge;
the heat-insulating layer 6‴ intended for the wall slab 11 (Fig. 4, 6):
on the sides of the inner and outer surfaces (12, 13) of the heat-insulating layer, along the edges, opening for placing reinforcement elements 4 are formed, and in these openings fixation elements can be formed from the heat-insulating layer to secure the reinforcement elements;
the heat-insulating layer 6" intended for the wall corner slab 11' (Fig. 6):
on the sides of the inner and outer surfaces of the heat-insulating layer (12, 13) lengthwise, on the edges openings are formed for placing the reinforcement elements 4, and in these openings fixation elements can be formed from the heat-insulating layer to secure the reinforcement elements; on the side of the inner surface 12, a heat-insulating layer strip 7 is formed at the edge which coincides with the parameters of the heat-insulating layer 6‴ of the side surface 16 of the slab 11 and during the construction process rests on the heat-insulating layer 6‴ of the side surface 16 of the wall slab 11, and the outer edge is formed narrower by the thickness of the concrete layer;

After forming the heat-insulating layers 6, 6', 6", 6‴, 6"" of the slabs, the formwork is made, where the connecting reinforcement 5 is placed in the openings formed in the heat-insulating layers perpendicular to the heat-insulating layer; in the openings formed on the sides of the inner and outer surfaces, the reinforcement elements 4', 4" for foundation/floor, floor, roof are installed, where necessary, reinforcement elements 4 for wall slabs, then reinforcement meshes 3, 3', 3", 3‴ on both inner and outer sides of the slabs are applied according to the formed heat-insulating layer, and the reinforcement meshes and reinforcement bars laid on both sides of the slab are connected to the connecting reinforcement 5, tubes intended for inserting the reinforcement elements 4 of the wall slabs 11, 11' are fixed in the heat-insulating layer of the foundation/floor, floor and roof slabs.
The shaped formwork is placed into moulds to increase the production speed; moulds are connected to each other and filled with high-quality concrete.
Once the concrete hardens, the slabs are taken out of the mould and ready for the construction of the structure.
After forming the elements of the kit required for the prefabricated building according to the project, they are transported to the construction site. Unloading.
Prefabricated building is constructed by using the aforementioned kit elements, when the foundation/floor slabs 10, 10' are laid on the foundation or compacted surface in the intended spot of a building, with the inner surface 12 facing up, and are connected to each other on the side surfaces 16; due to the formation of a continuous heat-insulating layer 6, 6', 6ʺʺ throughout the building structure in the place of the heat-insulating layer 6, 6', 6"", the joining is made with thermal insulation glue (for example, thermal insulation foam), and with concrete glue in the places where concrete is used. The (Fig. 2) foundation/floor edge slabs 10' are installed at the edges. After installing the foundation/floor, the wall slabs 11, 11' are placed with the lower surface (15) down, the inner surface (12) inwards, in those places where the wall is intended, they are fixed to the foundation/floor, when glue is added to the holes (tubes) in the foundation/floor slabs 10, 10' (concrete glue or other types of glue suitable for securing reinforcement elements can be used), the extended reinforcement dowels 4 of the wall slabs 11, 11' are installed in the said holes, the bottom of the wall slabs is secured using thermal insulating foam in the places where the heat-insulating layer 6", 6‴ is, and concrete glue in the places where concrete is; another wall next to it is installed and connected by connecting adjacent wall slabs to each other, using thermal insulation foam in the place where the heat-insulating layer 6", 6‴ is, and concrete glue in the places where concrete is, and when connecting the corner, the side of the wall slab 11 is connected at the edge of the inner surface 12 of the wall corner slab 11' with a strip of heat-insulating layer 7 formed lengthwise over the entire height of the slab and concrete glue in the places where concrete is, and thermal insulation foam where the heat-insulating layer is. On the walls installed in accordance with the project, the floor slabs are installed side by side, with the inner surface 12 facing up; they are connected by pouring glue into the holes and by securing on the reinforcement dowels 4 extended from the top of the installed walls, and they are secured with concrete glue in the place where concrete is, and with thermal insulation foam where the heat-insulating layer is; for the connection of floor slabs on the sides of the slabs concrete glue is used in the places where concrete is, and thermal insulating foam where the heat-insulating layer is. For the next floor, the walls are installed and connected in the same way as on the foundation/floor slabs 10, 10'. Roof slabs are used for the roof; these roof slabs 8 are laid and connected in the same way as laying of the floor slabs, only with the inner surface 12 facing downwards.
In order to additionally strengthen the connection points of the foundation/floor, wall, floor and/or roof slabs 10, 10', 11, 11' 8, additional connecting elements, such as plates, can be used to strengthen the connection points of the slabs.
When the foundation/floor, wall, floor and/or roof slabs 10, 10', 11, 11' 8 are connected to each other according to the described invention, a solid structure is formed with lintels (rigid edges) evenly distributed throughout the building, which ensures the strength, stability and uniformity of the structure, and a heat-insulating layer distributed continuously throughout the building structure ensures the elimination of cold bridges.
These concrete structures adhere to all safety and quality parameters, and they are superior to conventional concrete structures due to the following features:

In order to illustrate and describe the present invention, the description of implementation is provided above. This is a partial representation of the building construction system, which can be used to build single or multi-storey buildings of various architectural styles and purposes. Building more than two floors requires additional supporting structure solutions. This is not an exhaustive or limiting description. Other materials of appropriate strength and insulating properties may be used.

Claims

Prefabricated building construction kit comprising:
fully prepared precast lightweight concrete composite slabs with heat-insulating layer intended for foundations/floor, walls, floors, roofs with inner, outer, upper, bottom and side surfaces (12, 13, 14, 15, 16) comprising:
the inner concrete layer reinforced with rebars and reinforcing mesh;

the outer concrete layer reinforced with rebars and reinforcing mesh;

the heat-insulating material layer between said concrete layers;

connecting rebars present at all three layers, to which the rebars and reinforcing mesh in the internal concrete layer and the rebars and reinforcing mesh in the outer concrete layer are attached,

characterized in that

the reinforcements (4) of the wall slabs (11, 11') are embedded in the heat-insulating material layer (6‴), at the edges of the longitudinal part, by forming openings in a way that said reinforcements (4) are arranged along the slab and are surrounded by concrete and form stiffening edges; in addition, said reinforcements (4) are extended beyond the upper and lower surfaces (14, 15) of the wall slab;

in the inner concrete layer (9") of the wall corner slab (11'), at the point of connecting an adjacent wall slab at a right angle, a strip of heat-insulating layer (7) of the same length as the inner surface (12) is formed over the entire height, corresponding to the width of the heat-insulating layer (6‴) that is present on the side surface of the wall slab (11);

in the foundation/floor (not shown), roof slabs (10, 10', 8), at least a pair of mutually parallel reinforcement bars (4', 4") are inserted into the openings at the edges of the longitudinal part and the transverse part of the heat-insulating layer so that they get surrounded by concrete and form stiffening edges; in addition, in the part of the inner concrete layer of said foundation/floor, roof slabs (10, 10', 8), where the wall slab is installed, there is a formed strip of heat-insulating material layer (7', 7"), even with the inner surface (12) and corresponding to the width of the heat-insulating layer of the wall slab (11, 11') on the lower surface (15); in addition, in the place where the wall slab is installed, holes (not shown) are formed corresponding to the arrangement of the protruding reinforcements (4) on the wall slab (11, 11'), and in the inner and outer concrete layer of the floor slab (not shown), where the wall slab (11) or (11') is installed, there is a formed strip of the heat-insulating material layer corresponding to the width of the heat-insulating layer on the lower and upper surface (14, 15) of the wall slab (11) or (11'); in addition, holes are formed in the place where the wall slab is installed corresponding to the arrangement of the extended reinforcement elements in the wall slab (11) or (11').
Prefabricated building construction kit according to claim 1, characterized in that the roof slabs (8) are additionally formed with a slope.
Prefabricated building construction kit according to claims 1-2, characterized in that, due to the strength, lightness, and thermal insulation properties of the structure, the rebars (4, 4', 4") and the reinforcing mesh (3, 3', 3", 3‴) are made of fibreglass or other material with similar properties.
Prefabricated building construction kit according to claims 1-3, characterized in that the thickness of the inner concrete layer (1', 1", 1‴) and the outer concrete layer (9', 9", 9‴) is 1-5 cm, the optimal thickness is 2 cm, the thickness of heat-insulating layers (6, 6', 6", 6"', 6"") is 10-25 cm, the optimal thickness is 20 cm.
Prefabricated building construction kit according to claims 1-4, characterized in that the heat-insulating layer (6, 6', 6", 6"', 6"") is made of polyurethane or other material with similar properties.
Prefabricated building construction kit according to claims 1-5, characterized in that the outer side surfaces of the foundation/floor, floor, roof, wall corner edge slabs are poured over with concrete.
Prefabricated building construction kit according to claims 1-6, characterized in that the elements of the prefabricated building construction kit are manufactured in a factory according to the intended project.
Prefabricated building construction kit according to claims 1-7, characterized in that it additionally includes heating/cooling system (2) elements that are built-in on the inner side of the specially formed heat-insulating layer of the composite slab so that it can be connected to the heating/cooling system.
The method of making a prefabricated building construction kit comprise the following steps:
preparation of the formwork, when the heat-insulating layer is formed according to the dimensions of the foundation/floor, wall, corner, floor and roof slabs; the rebars and reinforcing mesh are applied from the inner and outer sides of the heat-insulating layer; said meshes and rebars are connected to each other through joints to ensure stability;

forming of concrete composite foundation/floor, wall, corner, floor, roof slabs with an insulating layer in separate moulds; placement of a shaped formwork in required moulds of foundation/floor, wall, corner, floor, roof slabs; pouring of concrete mixture; removal of the formed slab; storage/preparation for transportation, characterized in that the method of making prefabricated building construction kit according to any of claims 1-8 comprises:
- formwork preparation, wherein

a separate heat-insulating layer (6, 6', 6", 6‴, 6"") with openings for reinforcement elements (4, 4', 4") and holes for connecting reinforcements (5) for each foundation/floor, wall, floor, and roof slabs is formed; in addition, on the inner surface (12) of the heat-insulating layer (6', 6", 6‴, 6"") of the foundation/floor, wall corner, roof slabs, and on the inner and outer surfaces (12, 13) of the floor plates, in places where the wall slabs (11, 11') will be installed, a heat-insulating material layer strip (7', 7") is formed to match the parameters of the heat-insulating layer of the slabs and/or upper surface (14, 15) of the slab (11, 11'), even with the inner or outer surface of the slab (12, 13); holes are formed in the heat-insulating layer of the foundation/floor, floor, roof slabs, and the connecting reinforcement elements (5) are inserted through the holes; where necessary, the reinforcement elements (4, 4', 4") are guided from the inner and outer sides of the heat-insulating layer into the formed openings

in the places of the foundation/floor, floor, and roof slabs, where the connection of the wall slabs is intended, holes are formed corresponding to the arrangement of the extended reinforcing dowels in the wall slabs (11, 11').
The method of making a prefabricated building construction kit, according to claim 9, characterized in that separate moulds are used for the production of the said construction kit, in which the foundation/floor, wall, floor, corner, roof slabs with concrete-covered outer side surfaces are formed by pouring concrete.
The method of making a prefabricated building construction kit, according to any of the claims 9 or 10, characterized in that it uses several joined perpendicular moulds and forms several composite slabs by simultaneously pouring concrete into several moulds with formwork placed therein.
Method of construction of prefabricated buildings, wherein
fully prefabricated composite concrete foundation/floor slabs (10, 10') are placed on the foundation or compacted surface in the intended spot of a building, with the inner surface (12) facing up, and are connected to each other on the side surfaces (16);

fully prefabricated composite concrete wall slabs (11, 11') are placed on the laid foundation/floor slabs (10, 10') with bottom surface (15) down, inner surface (12) inward, in the places where the wall is intended and installed on the foundation/floor (10, 10'), another wall is installed and secured next to it, adjacent wall slabs (11, 11') are connected to each other on the side surfaces (16);

when building the second floor, the fully prefabricated composite concrete slabs are laid side by side on the upper surface (14) of the installed walls (11, 11'), with the inner surface (12) facing upwards, connected to the upper surface of the installed walls and connected to each other on the sides;

fully prefabricated composite concrete roof slabs (8) are used for roof installations; said rood slabs (8) are laid side by side on the upper surface (14) of the installed walls (11, 11'), with the inner surface (12) facing downwards, connected to the upper surface (14) of the installed walls and connected to each other on the sides (16),

characterized in that a kit is used as in any one of claims 1-8, wherein

concrete glue is used for the connection of foundation/floor slabs (10, 10') at the sides (16) of the slabs in the places where concrete is, and thermal insulation foam where heat-insulating layer is;

glue is injected into the holes present in the foundation/floor slabs (10, 10'), the extended reinforcement elements (4) of the wall slabs (11, 11') are inserted into said holes, the bottom of the wall slabs is secured using concrete glue where concrete is, and thermal insulating foam where the heat-insulating layer is;

on the sides (16) of the wall slabs (11, 11') for mutual connection, concrete glue is used in the places where concrete is, and thermal insulation foam where the heat-insulating layer is, and when connecting the corner, the side of the wall slab (11) is connected to the inner surface (12) of the wall corner slab (11') on the heat-insulating layer strip (7) formed on the longitudinal edge, and concrete glue is used in the places where concrete is, and thermal insulation foam where the heat-insulating layer is; after installing and securing the walls,

the floor or roof slabs (8) are laid, wherein glue is injected into the holes and said slabs are placed on the reinforcement elements (4) extended from the top of the installed walls; for connecting the floor or roof slabs (8) on the sides (16) of the slabs, concrete glue is used in the place where concrete is, and thermal insulation foam where the heat-insulating layer is;

when the foundation/floor, wall, floor, and/or roof slabs are connected to each other, a solid structure is formed with evenly distributed lintels and heat-insulating layer throughout the building.
The method of construction of prefabricated buildings according to claim 12, characterized in that at the connection points of the foundation/floor, wall, floor, and/or roof slabs is used additional connection elements, such as plates, for strengthening the connection points.