ES2333636B1 - PRE-MANUFACTURED SEMIRRESISTENT MODULE FOR CONSTRUCTION AND PROCEDURE ASSEMBLY ON THE WORK OF THE SAME. - Google Patents

Abstract

Prefabricated semi-resistant module for construction and assembly procedure on site. Y assembly procedure

It consists of a module manufacturing process semi-resistant residential, equipment, industrial, etc., containing part of the structure, stiffness and transport cage enclosures, installations and finishes suitable for processes industrialized, and a work assembly procedure on porches and prefabricated, which are completing the structure and the building progressively completed both on floor and in height to the limit marked by the construction program.

Description

Prefabricated semi-resistant module for construction and assembly procedure on site.

Object of the invention

The present invention, as expressed in the set forth in this specification, refers to a module semi-resistant prefabricated building and procedure for its assembly on site in a way that defines a characteristic system modular construction. It is within the sector of the industrialized construction

The prefabricated semi-resistant module can be for residential use, equipment, industrial, etc. and the assembly procedure on site is performed on porches of prefabricated structure. Thus, the system defined by the module semi-resistant and its assembly procedure has the advantage of Rapid execution of the work (both module manufacturing in assembly line, such as the process of execution / assembly on site), of a significant reduction in construction costs and that all  Materials used are easily reusable and recyclable

The invention is within the field construction technician, specifically within the technique modular construction.

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Background of the invention

Currently building systems Modular or prefabricated can be included in three groups which are characterized, well because:

a.- They are fully factory executed by lightweight materials both in enclosures and in structure that only allow its application in homes single-family or constructions of one or two floors, being very difficult to apply to multi-family homes in height in multi-storey buildings.

b.- These are prefabricated systems for tall buildings that focus on the structure and the enclosures

c.- Either it is modular systems fully finished characterized by being self-resistant modules of a considerable weight that hinder their transport and put in work, generally of structure and reinforced concrete contributed or of load-bearing walls with a "stackable" construction concept. These systems, although they significantly reduce the term of execution, make the difference in the budget of the work executed with respect to traditional construction systems be Small or even superior.

The constructive systems of the group "a" They are composed of lightweight mesh structures of folded sheet galvanized and "forged" waterproof chipboard board wood of those that exist in many systems of which They currently market.

The construction systems of the group "b" are composed of structures-enclosures made in situ characterized by projecting concrete-gunite on insulating panels with steel reinforcement, the structural enclosure itself being both vertical (wall), horizontal (forged), performing the rest of the work in situ by traditional procedures (installations, coating, etc. ...).

The constructive systems of the "c" group they are composed of structural reinforced concrete drawers fully finished, calculated to withstand several drawers leaning on each other stacking several plants of which there are several patents depending on the anchoring systems of some modules with others and the systems of passage and connection of the facilities such as patents with number of Publication ES 2 094 179 T3, ES 2 098 090 T3, ES 2 090 175 T3.

Thus, it was desirable to have a module semi-resistant prefabricated that can be joined by porches of steel (thus completing the structural system) and subsequently to other similar or equal modules arranged both laterally as above, for the construction of buildings and a quick assembly method of said module work execution, both module manufacturing in the chain assembly, such as the process of execution / assembly on site, at the same time that significant reductions in construction costs were achieved and that all the materials used are easily reusable and / or recyclable.

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Description of the invention

The prefabricated semi-resistant module of the This invention is carried out at the factory by means of the system of "assembly line" according to the following process.

About beams-jácenas of rolled steel profiles, preferably rolled steels in hot set in standard UNE EN 10025, especially from S235 to 5450, UNE EN 10210 standard and cold formed UNE EN 10219 according CTE-SE-Steel, which forms "part" of the building structure, a floor is executed lightweight composite sheet metal (any of the products existing on the market), which is welded or screwed to said beams on which a lightweight expanded aggregate concrete is poured, preferably arlite or similar and mesh, preferably of steel.

This type of existing floor slab allows reduce its own weight by about 50%, and in lights that facilitate its subsequent transport around 3 m., edges are about 12 cm.

On this floor a "cage" is executed profiling, preferably rolled steel, which allows, by on one side, bracing the prefabricated partitions and, on the other, serving as crane hardware for subsequent transport and commissioning.

On said "cage" and light forged it executes the partitioning by profiling, preferably steel  galvanized, and panel, preferably cardboard, plaster or any of the existing systems in the market, with the difference that instead of being braced to lower interior floor or floor and upper or roof, is braced to a lower light floor and to a "cage" of rolled steel metal profiles by additional galvanized steel profiles that later It will serve to hold the light plates that will form the module roof.

Once the partition of both interior divisions, medians and facade transdos, se they install the sanitation facilities in PVC or similar under the forged, drainage referrals and downspouts sections main, so that at this moment the whole bass is projected of the slab and the beams with fire retardant foam, later it mount the hot and cold water in Polybutylene or similar that allows an industrialized elaboration or "kit", electricity and telecommunications, through gutters, ducts, pipes and wiring per ceiling, which depending on the use will obtain the highest possible degree of prefabrication or industrialization.

After the installations, the floor coverings and cladding of wet areas by adhesives of elastomeric properties.

The next step in the assembly procedure refers to prefabricated facade cloths with carpentry complete exterior and rest of the cloth from the insulating chamber finished with any type of coating, recommending Prefabricated and lightweight modular, the facade cloth braces to the "cage" of metal profiles and mesh profiles galvanized partitions.

Finally, after the joint sealing phase, placement of the ceiling and painted plates, the sanitary appliances, taps and electrical mechanisms, leaving the fully finished module for loading onto a truck or medium of transport by crane that will anchor in the "cage" of metal profiles, coinciding with the crane hanging points and anchors with the support points that the structure will have definitive The finished module is transported to the site, from here that the ideal size of it is less than 3 m. x 12 m. with a total weight of approximately 10 tons. It is understood that this data they should be considered together, just as an example and that refer to a preferred embodiment.

In addition, the finished module is shaped preferably rectangular parallelepiped. The procedure of Module assembly or modules runs entirely on the site, starting with the foundation that will require calculation based on the characteristics of the land and that in most cases it will be a traditional foundation by insulated shoe braced from reinforced concrete, since the system is characterized by its lightness with a transmission of foundation loads of the order of 50% of those that would correspond to a traditional construction.

On the foundation the rest of the structural system by plants, alternating the assembly of porches per floor with the placement of the finished modules of the building joining them after plant placement through bolted or welded joints, remaining at this time the complete structure by the following procedure.

Porches will be placed on the shoes prefabricated hot rolled steels established in standard UNE EN 10025, especially from S 235 to S 450, standard UNE EN 10210 and cold formed UNE EN 10219 according CTE-SE-Steel just like steel of the pillars and jácenas or main beams. About said porches they are placed supported on the main beams of rolled steel, the modules and join the gantry and the main beam of the module, leaving the structure completed. Then they join each other, by means of screws or welding, the "cages" of steel laminate of the different modules that make up the building in the same plant and, in turn, join the "cages" with pillars of the portico. Subsequently, the facilities are connected between the different modules

Once placed a plant comes from it mode on the top and next floor, screwing or welding the upper frames adjacent to the structure and executed that is part of the finished building.

The system is repeated, both on the same floor, as in height, as the program of the work requires, respecting expansion joints, until reaching the mediator of facade, which is resolved as the facade of the prefabricated module, is that is to say, prefabricated facade with carpentry complete exterior and the rest of the party, from the chamber insulating, finished with any type of coating, recommending the prefabricated and lightweight modular, the medianera facade braces the "cage" of metal profiles and to galvanized grid mesh, or until you reach, cover of the building, which is solved as the lightweight precast floor of the module, that is to say, forged composed of collaborating sheet that welds or bolts to beams, in particular to the beams of the last gantry on which a light aggregate concrete is poured expanded, preferably arlite or similar and mesh, preferably of steel or any other forging system or prefabricated existing in the market, which is waterproofed with special care of overlaps and reinforcements in floor joints and  It is thermally insulated. Said last porch is placed as the other, and has the function, on the one hand to complete the system structural of the semi-resistant module that has underneath and on the other side will support the roof slab.

Finally, it only remains to seal on site the exterior joints of facades between modules, and modules with structure, by projected fire retardant on pillars and beams, and placement of special lightweight flashing parts with screw connection, in "click", or adhesive with silicones or similar, leaving the building finished.

The common areas of vertical communication, such as stairs and elevators, are carried out " a posteriori " by means of prefabricated systems or existing self-supporting "kits" that join the building allowing access to the different floors, creating in the union an accessible area through which the general community facilities of the building will run vertically in shunts (vertical downspouts) and prefabricated pipes hung from the building structure from the prefabricated premises or cabinets of each installation or service on the ground floor.

The general community facilities of building are included in the module itself and run through the roof  of the common area where the access doors to the homes and that are part of the module. It should also be noted that the mentioned vertical downpipes will have their records and cabinets of prefabricated connection within it.

Thus, based on the modules semi-resistant it is remarkable that it is possible to manufacture a building without major limitations in its length dimensions and width, therefore there is no limitation since they are not stackable, being rather a meccano in which part of the structure contained in the module that is always the same (with the same loads) with the rest of the structure: pillars and jácenas, which is variable depending on the height, especially pillars for the number of plants they support (in a building of six floors the last three will be the same as a three building plants) and depending on the wind and the earthquake will also vary Additional San Andres cross bracings that require the whole building depending on its situation and area seismic

Next to facilitate a better understanding of this descriptive report and being part of the same are accompanied by figures in which with an illustrative character  and not limiting the object of the invention has been represented.

Brief description of the drawings

Figure 1.- Shows a plan view of the arrangement of beams-jácenas (1), and forged lightweight (2) and a cage (3) in the process for manufacturing the semi-resistant prefabricated module.

Figures 2a and 2b.- They show respective views in  plant of two semi-resistant modules that incorporate a prefabricated partition walls (4), sanitary ware and facades.

Figure 3.- Shows a perspective view of the layout of the beams-jácenas (1), the floor slab lightweight (2) and the cage (3).

Figure 4.- Shows a sectional view of the lightweight forging (2) of Figure 3 with the inclusion of a flame retardant foam application 21.

Figures 5a and 5b. - Show views in perspective of two modules finished with coverings and ceilings ready to be attached and a detail of the different layers that make up the facades.

Figure 6.- Shows the transport of a module by a truck 8.

Figure 7.- Shows a perspective view of two modules corresponding to Figures 5a and 5b, already attached and with their corresponding railings 7a that will be placed afterwards in the previous transport work. It also includes a detail of a finished railing for placement in the modules.

Figure 8.- Shows a schematic view of the foundation of a first prefabricated gantry plant 10 that is carried out " in situ ".

Figure 9.- Shows a scheme of how it fits a module on the foundation of the first gantry floor 10 prefabricated

Figure 10.- Shows a scheme of how it fits a second module on the foundation and the first floor of prefabricated frames 10 with the module of figure 9.

Figure 11.- Shows a diagram of the coupling of a  second floor of porches 10 as a continuation of the assembly of the shown in the previous figure 10.

Figure 12.- Shows a diagram of how it fits a third module on the second floor of porches 10 of the figure 11.

Figure 13.- Shows a scheme of how it fits a fourth module on the structure of figure 12.

Figure 14.- Shows a scheme of how it fits a third floor of prefabricated porches to the structure of the figure 13.

Figure 15.- Shows a scheme of how it fits a fifth module to the structure of figure 14.

Figure 16.- Shows a diagram of how it fits a sixth module to the structure of figure 15.

Figure 17.- Shows a diagram of how it fits a fourth floor of prefabricated porches to the structure of the figure 16.

Figure 18.- Shows an outline of the core of housing of figure 17 with cover.

Figure 19.- Shows an outline of the core of houses of figure 18 with medians.

Figure 20.- Shows a diagram of a block of "H" shaped homes composed of four cores of similar homes to those in figure 18 and with common areas, stairs, elevators and general community facilities.

Description of the preferred embodiment

Considering the numbering adopted in the figures, as a preferred embodiment the modular construction system to the construction of a building 14 multi-family housing VPO (Official Protection Housing) of two three-story high bedrooms with typological solution of block "H" of twelve houses.

As the first phase two factory are carried out modules other than 3 x 12 m which, once mounted on site and together, they will form a two bedroom house.

The material execution process is carried out in factory through assembly line on part of the structure definitively, specifically beams-jácenas 1, beams transversal 13 and light forging 2, being able to do without cross beams 13.

Thus, Figure 1 shows the arrangement of the beam-beams 1, cross beams 13 and of lightweight forging 2 defining the base surface of one of the two modules, being beams-jácenas 1 and beams cross sections 13 preferably of rolled steel profiles and the light slab 2 composed of a welded plate 17 welded or bolted to jácenas 1 and on said collaborating plate 17 is pour a light concrete 18, preferably expanded aggregate and mesh 19, as illustrated by the cross section of the figure Four.

Figure 3 shows how on the floor lightweight 2 a cage 3 of metal profiles is made. Through the  "cage" concept stiffens each module, allowing the complete realization of partitions 4, facades 5 interiors and 6 installations and easy transport and assembly on site.

As seen in Figures 2a and 2b, on the cage 3 and the light slab 2 the prefabricated partition is made  4, by means of profiles and panels braced to the light slab 2 and to cage 3 by additional profiling.

It is also possible to have first the beams-jácenas, on these make the cage and then perform the light slab.

In figures 5a, 5b and 7 show the sanitation facilities 6 that are mounted once the bracing  prefabricated partition 4 and under light slab 2 are mounted shunts, drains and sections of downspouts main.

Then proceed to project the bottom of the light slab 2 and the beams-jácenas 1 with a fire retardant foam 21 and the assembly of an elaboration is carried out industrialized or "kit" of hot and cold water, electricity and telecommunications, through gutters, pipes, tubes and ceiling wiring fixed to it.

Finally the coverings 7 of floor, ceiling and walls and cladding of wet areas through adhesives of elastomeric properties.

In addition, facade cloths 5 are mounted prefabricated comprising the complete exterior carpentry 5a and, from an insulating chamber 5b, an interior finish 5c with cladding so that the facade cloths 5 are bracing to cage 3 and a 5d mesh of the partition wall profiles prefabricated 4.

Finally, the joints are sealed, the  ceiling plates and paints. In addition, the toilets are placed, faucets and electrical mechanisms.

In addition, railings 7a are prepared which are seen in Figure 7 and delivered separately for subsequent placement , in situ , on site.

Once all or some of the modules that will make up the building, are transported to the site where the building will be erected. There, the procedure of assembly on site of each prefabricated semi-resistant module that It will be part of the building you want to build.

Figures 8 to 20 illustrate this procedure where, as Figure 8 illustrates, the first thing that is done is the foundation 9 of the site and placement of a first floor of 10 porches of pillars and jácenas or main beams. In a preferably, the first floor of porches 10 is of 6 m free rolled steel, 3 m high and distance between 5 m porches.

From figure 9 and until 20 they leave showing each step of the building construction of the preferred embodiment, that is, in Figure 9 a coupling is coupled first module on foundation 9 and first floor of porches 10 prefabricated from figure 8 above.

In figure 10 a second module is attached to the  structure of figure 9 above and also shows the placement of railings 7a.

In figure 11 a second floor of 10 prefabricated frames to the structure of the previous figure 10.

Figure 12 shows how a coupling is coupled third module on the structure of the previous figure 11.

Figure 13 shows how a coupling is coupled.  fourth module on the structure of figure 12 above, standing out also that the railings 7a have already been placed.

In figure 14 a third floor of prefabricated frames 10 to the structure of figure 13 previous.

Figure 15 shows the placement of a fifth module in the structure of figure 14 above.

Figure 16 shows the placement of a sixth module to the structure of figure 15 above, with the corresponding placement of railings 7a.

Figure 17 shows the placement of a fourth  prefabricated gantry plant on the structure of the figure previous 16.

Figure 18 shows the placement of the cover 14a on the structure of Figure 17 above and the Figure 19 adds the placement of medians 14b.

This is how a housing nucleus is defined.

Figure 20 illustrates four housing cores  forming an "H" shaped housing block 16 where common areas have also been schematically illustrated 15, such as elevators, stairs and community facilities in general.

It should be noted that Figure 6 shows a Truck 8 to transport the different modules.

In Figure 9 for example, some are shown structural joints 11 to join each module on the porches 10.

In turn, a connection is shown in Figure 13 12 of 6 sanitation and ventilation facilities.

Figure 7 shows installations 20 of prefabricated kits of electricity, teleco and plumbing on the roof of the modules.

Claims (10)

1. Prefabricated semi-resistant module for construction, capable of being joined to other similar or equal modules arranged both laterally and above, which is characterized in that it is manufactured according to the following procedure: - Have at least two beams-jácenas (1) of rolled steel and two edges floor bracing that define the perimeter of the base of the module; - On the beams-jácenas (1) of rolled steel profiles run a light slab (2) composed of a collaborating plate (17), which is welded or screwed to said beams (1) and on said collaborating sheet (17) of pouring a lightweight concrete (18) of expanded aggregate and mesh (19) giving as a result the light slab (2); - On the light slab (2) make a cage (3) of metal profiles that you use, on the one hand to bracing a prefabricated partition wall (4) and, on the other, hardware of crane for later transport and commissioning; - On the cage (3) and the light floor (2) make the prefabricated partition (4) using profiles and panel  braced to the light floor (2) and the cage (3) by additional profiling; - Once the prefabricated partition wall is braced (4) install sanitation facilities (6) and under the slab light (2) shunts and drains of downspouts main; - Subsequently project the bottom of the  Light forged (2) and the beams (1) with flame retardant foam (21). - Proceed with the assembly of an elaboration industrialized or "kit" of hot and cold water, electricity and telecommunications, through gutters, pipes, tubes and ceiling wiring; - Make the floor coverings (7) and damping of wet areas using property adhesives elastomeric; - Assemble prefabricated facade cloths (5) that they include complete exterior carpentry (5a) and, from a insulating chamber (5b) a coating finish (5c), in such a way that the facade cloths (5) are braced to the cage (3) and to a mesh (5d) of the prefabricated partition wall profiles (4); - Seal joints, place ceiling plates and paint, in addition to placing toilets, faucets and mechanisms electric

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2. Prefabricated semi-resistant module for construction, according to claim 1, characterized in that the intervening metal profiles are made of steel. 3. Prefabricated semi-resistant module for construction, according to claim 1, characterized in that its size is variable, being for reasons of transport an ideal measure of less than 3 m by 12 m. 4. Prefabricated semi-resistant module for construction, according to claim 1, characterized in that the panels are plasterboard or cardboard. 5. Work assembly procedure of the semi-resistant module defined in claim 1, characterized in that it comprises: a.- Cement (9) the site where the module. b.- Place a first on the foundation (9)  prefabricated porch plant (10) of pillars and jácenas or beams main (1); c.- Place on the porches (10), supported on its main beams (1), the semi-resistant modules prefabricated defined in claim 1, such that join the porches (10) with the main beams (1) of the modules; d.- Join each other, using screws or welding, the cages (3) of the different modules that configure same floor of the building (14) and in turn join the pillars of the porches (10) with the cages (3); e.- Connect the facilities (6) of the different modules; f.- Once a plant is finished, place a second floor of porticos (10) and continue with the steps previous "c-e"; g.- Repeat steps b-e previous as many times as plants have the building (14) to build; h.- Repeat steps a-e or steps b-e according to the building (14) to be built until you reach a facade (14b) of the facade and even a roof (14a) of the building; i.- Seal the exterior joints of facades (5) between different modules by means of flame retardant projection in pillars and beams and by placing special pieces of flashing of lightweight material with screwed connection or adhesive; j.- Carry out the common areas of the building (14)  by means of prefabricated self-supporting systems that join the rest of the structure, creating in the union an accessible area through which the general community facilities of the branch building and prefabricated pipes.

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6. The method according to claim 5, characterized in that the façade media wall is manufactured in the same manner as the façade (5) of the prefabricated semi-resistant module. Method according to claim 5, characterized in that the roof (14a) of the building (14) is manufactured in the same way as the light slab (2) of the prefabricated semi-resistant module, with the addition of a waterproofing and a term insulation, with reinforcements in overlaps and floor joints. Method according to claim 5, characterized in that the foundation (9) is made of insulated braced reinforced concrete footing. 9. Method according to claim 5, characterized in that the structural joints on site during the assembly procedure are assembled by any bolting or welding system. Method according to claim 5, characterized in that the prefabricated frames (10) are of metal profiles of any type.