GB2442959A

GB2442959A - Modular building construction

Info

Publication number: GB2442959A
Application number: GB0620882A
Authority: GB
Inventors: Mehdi Robert Teers
Original assignee: Individual
Current assignee: Individual
Priority date: 2006-10-20
Filing date: 2006-10-20
Publication date: 2008-04-23
Also published as: GB0620882D0

Abstract

A precast concrete modular building system comprises a range of elements that are interlocked to form multiple levels by means of a steel coupling device. A method of building and means of coupling two opposing elements together by installing steel spiral shaped steel bars is disclosed. Building elements are interlocked to form a fully integrated monolithic structural building with all such elements having a universal use and being reusable/recycleable. The invention reduces the need of large numbers of conventional building items, thereby reducing costs, and increasing lead times. The modular building structure is self supported from foundation to rooftop level, with low to medium height construction capabilities. The steel coupling device creates a 'dry-form' of joining such construction elements together, that enables complete buildings to be fully dismantled for onward use, to form almost any building shape and use. In the modular building system all elements are 'stock items' for immediate delivery and site assembly.

Description

DESCRIPTION

A BUILDING A1'W/OR BUILDING METHOD THAT INCORPORATES CROSS-WALL' SHAPED COLUMNS WITH

STEEL COUPLING DEVICES TO CREATE FULLY

DEMOUNTABLE ELEMENT MODULAR BUILDINGS

This invention relates to a new method of constructing multi-storey buildings from precast concrete/steel elements with the use of columns of generally cross section in full or multi-storey height that incorporate steel coupling devices into prepared voids to enable opposing wall and or beam elements to be locked together to form a monolithic structure in both horizontal and vertical directions.

Using other known techniques there was a need to produce modular forms of building methods. However, most of which incorporate inherent disadvantages such as, excessive use of elements required: -Highly combustible interiors and wasted rooftop construction High risk of damage in extreme weather conditions Multi-storey structure that become non demountable for onward use.

Non expandable Storey height limitation Environmentally poor standards Excessive cost methods, in manufacture Inability to withstand extreme forces structurally It is an object of the invention to overcome most of these disadvantages and to provide a construction system that would be relatively faster and more economical construction when produced in the method as created in this invention from the range of elements as herewith illustrated incorporating steel coupling devices as also described.

In one broad aspect, the present invention relates to a building structure including cross-wall' shaped columns in one piece with horizontal and vertical coupling bars to secure opposing elements together such as upper column sections, beams, wall and floor panels, plus foundation elements, in the form of steel bars and cross section steel locking plates.

Foundation elements have been specially designed to form a secure base for the building structure into which both columns and ground level wall panels are inserted into and that become integrally locked together.

In drawings which illustrate embodiments of the invention: -Figure 1 illustrates a perspective view of a typical multi-storey structure in process of assembly from the range of precast concrete modular edge units as so described in the proceeding pages 2 to 10.

Figure 2 Illustrates reinforcing and steel coupling assembly in stage form, that is capable of coupling adjacent modules in both vertical and horizontal directions, with each connection providing a torsional strength in excess of tons per coupling if carried out and assembled in the method as so described in my claims. Steel tubes are welded to both steel mesh reinforcing sheets to house steel connecting bars as described Figure 3 illustrates the method of producing multi sub wall columns individually, with exposed reinforcing steel bars projecting at end to enable each column to be as so required (two-way, three-way or four-way) by setting them into foundation base, securing all vertical wall panels together with locking bracket to reinforcing bars, then filling central void with a suitable grout mix, to form a solid multi directional construction column that can be created at factory or on-site level.

It also illustrates the unique mean of the steel coupling devices that comprise of a spiralled threaded bar, two plates and two nuts.

The method of coupling two opposing elements together, for which I claim the invention for, is by passing the steel coupling bar into the housing tube onto which two sets of steel plates and nuts are threaded onto when the bar enters the locking void. When adjacent elements is erected in it's assembled position, one set of plate and nut are removed, bar is the passed through prepared holes in both elements into opposing coupling void, plate and nut replaced on opposite end then tightened together. Vertical edge neoprene or similar compression material' strips are secured to both edges to accommodate thermal expansion movement. The length of steel bar housed in the column edge is the same length that secures both elements together in the assembly stage. The unique action pennits a wall to be assembled in either a sideways or vertical direction, in a dry method of securing two such opposing modules together.

Figure 4 illustrates a column assembly section (A) with assembled wall (C) in position, plus a steel beam assembly (G) (K, L, M and 0) illustrates a type (A) foundation node.

By using the same method of joining and securing two corresponding elements together as so described in drawings 1 to 10, can be equally applied to joining wall to column, or, wall to wall coupling in the same manner, with the same column configuration element being used as a connecting beam element, i.e. one element capable of creating and forming a complete building multi-storey super structure framework, in precast concrete material.

Figure 5 illustrates (A, C and D) column coupling method in the vertical direction (with E) illustrating a column to beam means of connection using the same principle. Sketch (F) illustrates a foundation node with a four-way column placed in the assembled position, in plan.

Figure 6 illustrates an alternative beam assembly in steel enabling two opposing steel beams (or one) to become interlocked by means of passing steel bars through both end plate holes that enable both bars to pass on either side of sub column walls then tightened together to secure both opposing steel beams together.

Figure 7 illustrates a range of wall panels to be assembled to two, three or four-way wall colunms in the manner as so described in figure (3). Such wall panels can be produced as a single leaf or, a double leaf sandwich fonn.

Beams (G and H) illustrates precast concrete beams and spandrel elements.

Figure 8 illustrates a foundation assembly into which all main structural elements are inserted to form a secure and accurate means of constructing and assembling a multi-storey structure.

Figure 9 illustrates design flexibility of this new form of modular precast concrete building systems that enables total building structure to become assembled in dry form', up to medium height level as open' or closed floor plan layout, with all such elements being interchangeable and totally demountable for a 100% recyclable use.

Claims

* CLAIMS A building structure comprising vertical support elements in

the form of a cross wall' column, foundation, wall, beam, floor and ceiling elements, preferably in precast concrete, each element being adapted to be attached securely to at least one other element by means of the steel coupling devices as so described in attached figures (ito 10).
2. A building structure that is created from precast concrete or steel beam elements according to Claim 1 that pennit two such opposing elements to become securely attached when the steel coupling bar is extracted from its chamber in sub column panel or wall, with thick steel plates and specified nuts threaded onto bar on opposing wall edge, then tightened together to form a solid locking action.

Locking voids are then infilled with a rapid hardening cement mix that enhances the steel bar locking action plus creating a safety lock. Being removable if dismantling is required.
3. A structure according to Claim 1 the cross wall shaped column is a fi.illy directional supporting element for entire structural buildings that enables wall panel elements to be independently supported within each grid frame, by means of the projecting steel bars and beam.
4. A structure according to Claim I incorporates columns that incorporate two, three or four sub wall sections, each having a square or oblong shaped voids to facilitate the steel bar coupling assembly, with one void at base to enable connection between lower and upper column section, two into vertical wall edge to secure column to adjoining wall, with a recess void at upper level into which cross beam is inserted onto ledge. Each beam having end webs with prepared holes through which steel coupling bars are inserted that also pass through each respective column sub wall and into opposing beam web end, when opposing steel plate and nut are threaded onto bar, then tightened to create a solid locking action between opposing beams and column.
5. A structure according to Claim 1, a solid foundation is created for all modular buildings in this form of construction by installing the precast concrete foundation nodes and connecting beams that enables both cross wall columns and wall panels to be horizontally supported, plus creating a structurally supported mainframe between all vertical and lateral elements, in addition to acting, as a water bather to the building.

I claim that by securing neoprene strips to contour of wall edges enables concrete elements to expand without cause of damage to opposing elements when thermal force is applied.
6. I further claim that a multiple building structure that becomes assembled by the coupling device as so described in pages 1 to 10 can be created and assembled by using any one of the wall panel designs, i.e. (A) two single wall panels (B) a corner shaped column (C) a three way shaped column, or (D) a four way shaped colunm.

All as illustrated on Dg 3.
7. I further claim that the same method of constructing buildings can equally apply to erect barriers, such as defence, flood or road barriers.
8. A building as claimed in Claim (4) herein the spirally coiled bars of steel extend through the cut-out void to the full length of the bar for lateral and horizontal method of coupling.
9. A building as claimed in any preceding claim, wherein the coupling bar as claimed in claim (8 and 9) creates a positive locking action between two opposing elements when steel plates and heavy duty nuts ar threaded on to the spiralled steel bar when tightened together, as described on Dgs 2 and 3.
10. A building as claimed in any preceding claim when assembled together as so described in 7-8-9 and 10 claims provides a dry' form of assembly, that creates the capability to future proof a building to withstand extreme climate changes over the next 100 years, created by global warming, due to its robust form of construction in high yield precast concrete materials with individual element replacement capabilities.
11. A building as claimed in any preceding claims that incorporates access voids in both opposing elements with steel bars locked and made secure, plus mfllling voids with a specified cement mix, provides and creates a higher degree of torsional load resistance

S

between both elements compared with all other known building systems.
12. 1 further claim that the multi directional steel coupling plate as described in sketches 5B and 31 creates a second locking action to a multiple storey building structure in both horizontal and vertical direction when lowered onto projecting steel bars in heads of connecting wall panels. When the projecting bar enters the prepared round void in the upper wall panel, or, sub column, all connecting elements become fully interlocked in all directions, enabling both methods of locking a composite modular building method together securely, without the use of on-site concrete pour mix, that restricts further use of a building structure, as, a building constructed in precast element form that has been assembled by means of the steel interlocking devices as so described in sketches 1 to 10 enable such complete multiple buildings to dismantled.
13. I further claim that precast concrete column as illustrated in sketch 2, 3 and 4 attached to this application, create sets of column designs in four different ways, i.e. as a single section of the cross wall column (F) where it is presented as a flat panel with the near vertical edge with exposed reinforcing to enable it to be manufactured in the same manner as a concrete plank/narrow panel, as a mass production element, then assembled together to form the required number of sub panels, i.e. 2-3 or 4 by placing them into a vertical prepared cross wall base, locking all reinforcing bar ends together then inserting a concrete pour mix to form a solid cross sectional coupling between such selected sub wall panels, as illustrated in Dgs 2 and 3. Such columns assembled together either on-site or factory level can be dismantled as one section.
14. I claim that this procedure of coupling and moulding, such sub panels together as so illustrated on Dg 3 can be carried out at both factory or site level.
15. I further claim that sub wall panels as so described in 3 can be produced in solid concrete slab or in hollow-core panel form.
16. I further claim that the same column panel configuration can be used to form a structural beam to form a totally formed multiple storey building structure in one fonn of element preferably in precast concrete.
17. I further claim that by elongating the coupling steel tube in the wall panel edges permit direct entry of bolt when assembled to accommodate any panel misalignment, plus supporting wall panel.
18. I further claim that by bolting each beam end together by means of inserting bolts either side of wings and by inserting beam ends into prepared insert wing base of the column provides a solid means of joining such elements together in a dry form', as described in Dg 4 is created.
19. I further claim that by constructing a building in the method as so described in pages 1 to 9 will provide a solid form of building both laterally and longitudinally with each floor level being supported independently, as a prevention against progressive collapse', up, to medium height level, in a closed' or open plan' in a monolithic structural form.
20. I further claim that such a form of construction as so described in sketches 1 to 10 with descriptions can equally be formed to create submersible foundations with columns projecting above water line to support entire building projects in the same manner as dry land' projects, including roads, etc, with entire development projects suspended above water levels, as a permanent way of living on water logged land, with the aid of piles to support the prescribed foundation nodes system and said cross-wall shaped column structure.
21. I further claim that the method of construction as so described in sketches I to 10 also incorporates full environmental services in the form of harvesting of storm water, solar energy and wind power, to enhance environmental standards for inhabitants.
22. A method of building as so* described in hereto previous claims that enables vast reductions of conventional building components to complete a building project, considerably reduces time of build to completion stage, enables large numbers of cellular dwelling units to be built in the same size land area as 4/5 conventionally built dwellings is which is environmentally friendly and 100% recyclable. It also provides a truly affordable building.
23. I further claim that both element design and method of assembly enables all such composite elements to be manufactured as standard stock' items for instant site assembly to create a wide range of multiple height building structure, and in a fraction of the time compared to any form of conventional methods.
24. I further claim that the method of attaching and assembling column to wall panels can be equally applied to securing frames glazed or alternative vertical flat surfaces to column sub wall edges, when assembled and locked together in the manner as so described in drawings 1 to 10.
25. A multi-storey building structure in which elements are produced in precast concrete in the shape and form as so described in sketches 1 to 10 to form complete main structures in both vertical and horizontal directions, i.e. columns and beams.

A modular building system that consists of at least 40% of recycled waste material in the form of sectionalized blocks that form wall surface areas when produced and assembled by means of the dove-tail shaped steel tube inserted into opposing voids, which are then infihled by a suitable pour mix to bind all such wall elements together to form a solid wall panel to this new form of construction which I claim the invention for. A range of wall panel configurations manufactured in a lighter weight premix that comply with required thermal mass standard requirements could also be included for recycling capabilities.