GB2491144A

GB2491144A - Precast modular building unit

Info

Publication number: GB2491144A
Application number: GB1108737.6A
Authority: GB
Inventors: Dainius Simkus
Original assignee: Individual
Current assignee: Individual
Priority date: 2011-05-25
Filing date: 2011-05-25
Publication date: 2012-11-28
Also published as: GB201108737D0

Abstract

The unit 1, which in use provides a factory made modular structure, comprises a floor 11, walls 12, 13, ceiling 16 and is characterised by being formed as a single molded structure from a settable material. Alternatively the unit may be formed from precast elements such as the floor, walls, etc and connected in position by the pouring of settable material. The unit may further comprise features such as partitions 17, stairs or specially adapted elements 18, 73 for supporting the unit on the ground or a base or on further units. Each modular unit may include all the necessary openings, voids and other structural details that may be used to install doors, windows, fixtures, furniture etc. Such modules can be in-factory completed with these elements and insulation materials, electrical, mechanical and other building systems. Modular units may be connected together onsite with slide in type connections.

Description

Precast modular building

THE FIELD OF INVENTION

This invention relates to a precast modular building. h more specific aspect, this invention relates to a single or plurality of volumetric precast modules that can be manufactured in a factory, transported to its designated location and assembled together according to the most varied requirements to form a building of any purpose.

BACKGROUND ART

Precast structures offer economy and reliability and today are commonplace. For example precast applications include walls, floor and ceiling slabs and other architectural elements. The advantage with precast structures is that the building elements are produced in plant under close quality supervision that ensures durability and strength. The precast items then are transported to site and installed. Such construction method requires less on site labour and time.

There are a number of inventions showing houses made of precast items ready for site assembly. Some inventions have taken it the step forward making precast volumetric modules comprising of floor and walls with ceiling elements added later on site.

Other invention show volumetric modules that are completed in factory with the necessary architectural finishes, insulating materials, electrical and mechanical, sanitary and other systems and furniture and once assembled are ready for occupation. Such modules are made of steel frame and other light weight materials to form floor, walls and ceiling. Concrete is not used as a main building material of such structures mainly due to its heavy weight.

This invention has, therefore, as its purpose to provide a volumetric precast module that has the advantage of being factory precast as an integral structure comprising floor, walls, ceiling, partitions and other elements formed in a suitable mold for settable material pour. Such material can be but not limited to concrete.

Such module can be in-factory completed with the necessary architectural finishes, thermal, acoustic and moisture insulating materials, electrical and mechanical, sanitary and other systems and furniture. Delivered to its destination such module will form a building that is ready for occupation. Plurality of such modules assembled together will form a larger building for residential, commercial or other purposes.

Buildings that are formed using the above described individually fabricated modules can be easily extended or modified if necessary at the later time adding more modules and also transported to a new location.

Using such building method, most of work related to individual modules can be completed in a factory therefore it will significantly reduce on-site construction time. This therefore offers further advantages like substantially reduced site pollution with construction materials, better waste control, reduced site traffic, noise etc. Moreover, by constructing the modules with the specialized technologies, means and skills available in the factory of origin, it is possible to achieve qualitative standards of construction that are decidedly superior to those that can be obtained with the traditional techniques available on site.

It is another object of the invention to provide joints for assembly of multiple modules to form a building.

It is yet another object of the invention to provide a module with all necessary opening, cavities, voids and other means that are necessary for installation of doors, windows, thermal, acoustic and moisture insulation materials, electrical, mechanical, plumbing and other systems and also embedded support elements that can be used to install and fix the above mentioned materials, systems, fixtures and furniture.

It is yet another object of the invention to provide a module with a sloping roof and either slopping or horizontal ceiling.

It is yet another object of the invention to provide a module in-factory completed with necessary architectural finishes, thermal, acoustic and moisture insulating materials, electrical, mechanical, plumbing, sanitary and other systems, fixtures and furniture.

It is yet another object of the invention to provide a method of forming a precast module It is yet another object of the invention to provide a method of lifting of a precast module.

SUMMERY OF THE INVENTION

In accordance with the present invention there is provided a precast module which is formed from a pour of a settable material such as but not limited to concrete. The module comprises a substantially horizontal floor adaptable for placement on a ground or base or another module below, substantially vertical walls (i.e. two opposed end walls and two opposed side walls) extending upright from the perimeter of the floor, substantially horizontal ceiling, other architectural or structural elements (i.e. partitioning walls, staircases, structural joints, etc.) and formed or precast integrally therewith, that is, as an integral module from poured settable material.

The above described module can be formed to any manageable size and shape. If required modules can be assembled on two or more floors by placing modules on top of each other and connecting them to one another. Each module is characterized so it is designed and built according to the specific position that it will assume when assembled with other modules to form a building. Each module will have its designated purpose of use and therefore relevant layout and features, for example, room modules may have walls and partitions as per designed layout, staircase module will have built-in staircase, corridor module may exclude walls relevant to the adjacent module, building top module may have sloping roof etc. In the prefened embodiment of this invention a precast module can be formed in a suitable mold by pouring settable material into the mold and allowing the settable material to cure and harden either in a single pour or in stages. An alternative method will be to precast some elements like floor, walls and ceiling separately, place them into a specially designed form in the required positions and join the precast elements by pouring settable material and therefore form an integral structure.

In another modification of this invention each module is precast with all necessary opening, cavities, voids that are necessary for installation of doors, windows, thermal, acoustic and moisture insulation materials, electrical, mechanical, plumbing and other systems. In addition, a precast module can include support elements that can be used to fix, support and help in any other way to install the above mentioned materials and systems, architectural finishes, fixtures, furniture etc. In yet another modification of this invention a module has sloping ceiling and roof. It is also foreseeable that such module can have sloping roof, however its interior ceiling or part of it can be horizontal. The sloping roof of such module is preferred to have a sufficient overhang to provide adequate run-off and drainage.

In yet another modification on this invention each module is completed in factory with all necessary architectural details (for example doors, windows, stairs, partitions etc.), thermal, acoustic, moisture and other insulation materials, architectural finishes, interior and exterior decor, furniture, fixtures and other elements.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention and its advantages will be more readily understood by reference to the following detailed description when read in conjunction with the following drawing, wherein: FIG. 1 is a perspective view of an example precast module formed in accordance with the invention.

FIG. 2 is a section perspective view of a module illustrating an example module.

FIG. 3 is a perspective view of some examples of buildings formed of a plurality of the modules.

FIG. 4 is a perspective view of an example mold that can be used to form the module.

FIG. 5 is a perspective view on an example mold with inserted shape to form an opening in the structure of the module.

FIG. 6 is a perspective view of the module with embedded arrangement for installation of pipes FIG. 7 is a perspective view of an example structural joint for assembly of modules.

FIG. 8 and 9 illustrates different views of the structural joints shown separately from the module.

FIG. 10, 11 illustrates an example arrangement for lifting the modules.

FIG. 12 illustrates an example provision made within the module to facilitate lifting.

FIG. 13, 14, 15, 16, 17 illustrates different modification of modules with sloping roof.

DETAILED DESCRIPTION OF THE INVENTION

In referring to the drawings, wherein like reference numerals refer to similar parts throughout the various views, there is illustrated in FIG 1 a volumetric precast module indicated by numeral 1 formed as an integral structure from settable material pour.

It should be understood that the shape and details of a precast module may vary depending on requirements. The modules in the drawings are shown for better understanding of the invention and represent one of the possible options how invention can be implemented. The invention is applicable in general to a precast module completed with floor, walls, ceiling and other necessary elements of its structure.

FIG 2 illustrates a perspective view of the precast module with section for illustrative purposes. The module comprises a floor 11, opposed side walls 12 and 13 and opposed end walls 14 and 15 (not visible) extending upright from the perimeter of the floor, substantially horizontal ceiling 16, other necessary architectural and structural element for example: partition 17, stairs, specially adopted base 18 for placing the module on a ground or base or on another module below, specially adopted base 73 for placing another module on top, specially adopted joint 61 for connecting the module with another module on aside etc. It will be observed that the floor, walls, ceiling and other structural and architectural elements are shaped in a suitable mold as an integral form from poured settable material such as but not limited to concrete.

Where the above described module is a part of a larger building, some walls, ceiling and other structural and architectural elements can be omitted from the precast module allowing to form larger spaces extending through the joint modules.

It is also foreseeable that where the above described module is a part of a building, some walls and other structural and architectural elements can be omitted where the structural and architectural elements of other adjacent modules compensate the omitted parts of the said module. This way duplication of walls, columns, ceiling and other elements between the modules can be avoided.

It is however can be observed that duplication of walls and ceiling will form voids and cavities between modules that can be used for installation of thermal, acoustic and moisture insulating materials, electrical, mechanical, plumbing and other systems. Omitting parts of the structure would call for the said systems being installed within the voids and cavities of the other walls of the modules or by providing other means necessary for installation of the said systems.

The above described modules can be formed in a variety or shapes and sizes. Each module can have its designated purpose of use and therefore relevant layout and features, for example, room modules may have walls and partitions as per its designed layout, staircase modules may have a built-in staircase, conidor modules may exclude walls relevant to the adjacent modules, building top modules may have sloping roof etc. It will be observed that by reason of this invention that a plurality of such modules can be assembled in many different ways, connected to one another and therefore form various buildings of residential, commercial or any other purpose. Each module forming a building will be characterized so that it is designed and built according to the specific position that it will assume when assembled with other modules. Some examples of such buildings are demonstrated in the FIG. 3, therein: 21 and 22 are examples of residential houses, 23 and 24 are examples of larger buildings of any purpose, 25 is a garage formed in accordance to the invention.

The form of a precast module described above can be shaped in a suitable mold in which settable material can be poured. When cured and hardened the form is removed from the mold as an integral module shown in the FIG. 1.

The mold can be made of steel or other suitable material. It may consist of a plurality of separate parts that can be assembled and adjusted to varied requirement. The settable material may be regular concrete used for precasts. Formulation of concrete may vary depending upon building requirements. Some parts of the module, especially those not load bearing can be precast from light weight material, such as light-weigh concrete or other in order to reduce the weight on the module. Where necessary or desired the elements of the module can be provided with a plurality of rods embedded in the settable material. To ensure completeness of the form, settable material can be poured and compacted into the mold in stages. After molding the form is allowed to cure and then removed from the mold.

An alternative method of forming the precast module is to form some of its elements like floor, walls and ceiling separately by pouring settable material in suitable molds. FIG.4 illustrates floor 11, walls 12, 13, 14, 15 and ceiling 16 that are formed separately. When cured and hardened, these elements are placed in to the designated positions in the suitable mold 30 and jointed into a single continuous form by settable material pour. When cured and hardened the form is removed from the mold as an integral structure shown in the FIG.1 In another modification of this invention each module is precast with all necessary opening, cavities, voids that are necessary for installation of doors, windows, thermal, acoustic and moisture insulation materials, electrical, mechanical, plumbing and other systems. It is one of the possible embodiments of the invention the specially designed shapes are made and inserted into the frame of the mold so that these shapes prevent the poured settable material filling in the areas where such openings are to be formed. FIG 5 illustrates an example of such shape 32 inserted into the mold 31 to form a door opening.

In addition, a precast module can include support elements that can be used to fix, support and help in any other way to install the above mentioned materials and systems, architectural finishes, interior elements, fumiture, fixtures etc. An example of embodiment of such invention is illustrated in FIG 6, therein, module 5 is precast with a service opening for water drainage pipes 91. The support element 92 is embedded into the structure of the module 5. It can be achieved by inserting it in the freshly poured settable material. After settable material is cured and hardened, support element 92 becomes permanently fixed in place.

It will be observed that by reason of this invention each module forming a building has a set of structural joints precast as an integral part of the module for the purpose of connecting them with other modules with the necessary precision of alignment. FIG. 7 illustrates a set of modules each comprising a set of structural joints that allow to achieve accurate alignment between modules at the time of assembling them to form a larger buildings.

In the prefened but not exclusive embodiment on this invention, the sequence of assembly of the example modules 1, 2, 3 and 4 is described below. As suggested in this method of assembly, module 1 is placed in the designated location on site first, then module 2 will be jointed with the module 1, then module 3 will be placed on the top the module 1 and then module 4 will be placed on the top of the module 2.

Refening to FIG.7, joint 61, which is a part of module 1 structure, is a female type slide in joint designed to accommodate male type joint 62, which is a part of module 2 structure. It will be observed that joints 61 and 62 has sloping parts 66, 67, 68 and 69 with the purpose of precise alignment of the modules 1 and 2 in relation to each other. During assembly, after module 1 is installed, module 2 will be jointed with the module 1 by accurately bringing it towards the module 1 so that joints 61 and 62 are above each other and then lowered down so that the male type joint 62 slides into the female type joint 61.

Perspective view of the joints 6i and 62 is illustrated in FIG 8A. FIG 8B illustrates these joints in place after modules 1 and 2 are assembled. FIG 8C illustrates detailed view of the connected joints 61 and 62 at one of their ends. The gap indicated by numeral 65 is formed specifically to allow for some clearance in order to protect the corners of the joints from damage during assembly. FIG 8D illustrates perspective section view of the connected joints and the other gaps for the above said purpose indicated by numerals 63 and 64.

Refening to FIG 7, numerals 73 and 74 indicate joints of the modules I and 2 at the upper end of the modules. The joints 73 and 74 are best illustrated in FIG 9A. After assembly of the modules 1 and 2 as described above, joint 74 will rest on the joint 73 as best illustrated in FIG 9B.

Refening to FIG 7, numerals 71, 72 and 75 indicate slide-in type joints for the purpose of placing the module 3 on top of the module I. The joints 71 and 72 are best illustrated in FIG 9C. FIG 9D illustrates the position of the said joints after modules 1 and 3 are assembled. The joints 75 before assembly is best illustrated in FIG 9E. FIG 9F illustrates the position of the said joint after modules 1 and 3 are assembled.

Lastly, then module 4 is added, joint 76 will rest on the joint 74 as best illustrated in FIG 9G.

The set of joints indicated in FIG 7 and assembly method described above represent one of the examples how modules can be assembled together. It should be understood the suggested joints represents one of the possible options and other methods and solutions are possible and obvious to those skilled in art.

It will be observed that by the reason of this invention the precast modules can be transported from the factory to its designated location. Due to a potentially heavy weight of the precast module it is preferred, but not exclusive that the below described method is used for the purposed of lifting the module while loading, unloading and otherwise lifting the modules.

For the purpose of lifting a precast module it is preferred to use a suitable lifting arrangement which is designed so that the precast module is placed on the said arrangement. Therefore during lifting the module will be supported from below. The example of which is illustrated in FIG. 10. Therein the lifting arrangement can be made of a number of steel rods 80 that are arranged in accordance to the size of a module to be lifted. Rods 81 are connecting rods attached to rods 80 with the purpose of keeping the frame rigid. It is preferred that the rods 81 are detachable from the rods 80 in order to allow the frame to be removed from under the module once it is placed into the required position.

The specification and design of the frame must ensure its ability to handle the precast module during lifting and assembly. The corners of the said frame can be attached to crane cables 82.

FIG 11 illustrates the precast module 1 placed on the above described lifting arrangement so that corners of the module laid on the lifting arrangement rods 80. Crane cables are proposed to be offset from the module in order not to damage the architectural finishes of the module.

When placing the module in its designated position, provision must be prepared for the rods to be removed. Where module is placed on the ground or other base, such provision may become a simple channel made in the ground or base in the form of groove or recess. Having such groove, once module is placed on the ground, frame will seize to support the module and can be disassembled and removed from under the module.

Where a module is placed on a top of another module, the provision may consist of a recess formed in one of the modules. Example of such provision is shown in FIG. 12 indicated by numeral 83.

Alternative means of lifting arrangements may include coils, recesses and other means of arrangements that can be attached or embedded in the precast structure to facilitate secure lifting of the module. Design of lifting arrangements will depend on the shape, weight and other characteristics of the modules therefore should be designed accordingly by those skilled in art.

In another modification of this invention herein is provided a precast integral roof module as best illustrated in FIG. 13 and FIG. 14. Such module comprise a substantially horizontal floor 40, top panel 41 that is sloped relative to the horizontal plane of the floor, substantially vertical end walls 42 and 43 sloped or inclined so that the front end is higher than the back end, substantially vertical side walls 44 and 45, necessary joint arrangement 46 to join the module with a module below.

In yet another modification of the said roof module the floor 40 is omitted as it may not be necessary for the roof module with no living or otherwise regularly usable space. In this case ceiling of a module below will serve as a floor for the roof module.

In yet another modification of the said roof module, the roof module side wall 45 is omitted as best illustrated in FIG.15 In yet another modification of the said roof module example of which is illustrated in FIG. 16, roof module has substantially horizontal ceiling 47 below the sloping roof panel 41. Such ceiling can extend throughout the module or part of the module depending on its architecture.

The said roof module may have the size that is designed to cover multiple modules below.

Where architectural finishes like roof tiles and slates are preferred, sloped roof panel can include arrangements necessary or helping to fix such architectural finishes. Example of such arrangements is illustrated in the FIG. 17 indicated by numeral 48.

It is beneficial to minimize or eliminate any contact of water run-off with the joints between the modules. I accomplish this by providing a roof module with an overhang.

Other means of drainage may include already known and widely used arrangements like gutters, roof tiles and slates.

To eliminate water ingress within the joints between the modules, known and available in the market water resistant substances or sealing devices such as rubber seal can be used or applied.

In yet another modification on this invention each module is completed in factory with all necessary architectural details (for example doors, windows etc.), thermal, acoustic, moisture and other insulation materials, architectural finishes, interior and exterior decor, fumiture, fixtures and other elements and after it is delivered to its designated location, where necessary joined and connected with other modules, forms a building that is ready for occupation or use. Services and systems of each module will terminate at each module in the means of connectors that are ready to be connected to the systems of the adjacent modules in a quick way and once connected will form and functional continuity of said systems between modules. Such connectors and joints are available in the market and are used for connecting the said systems when building houses in a conventional way.

It will be observed that by the reason of my invention, the construction using precast modules provide several advantages including in-factory precast structure that is formed as an integral structure comprising a floor, walls and ceiling and therefore is durable and resistant to environmental conditions. In addition, due to present of all structural and architectural elements (i.e. floor, walls, ceiling, partitions, stairs etc.) the modules can be in-factory fitted with all the necessary architectural and structural details, finishes, systems and furniture and delivered to the destination as a product ready to be marketed or occupied. Such in-factory completion offer further advantages like substantially reduced time of works on site, reduction of site pollution that is observed during conventional construction and superior waste control.

It should be understood that the foregoing detailed description has been given for clearness of understanding only and no unnecessary limitations should be understood therefrom as modifications will be obvious to those skilled in the art.

Claims

CLAIMS1. A precast building module comprising a floor, walls, ceiling and other structural and architectural elements characterized by the module being formed as a single molded form in a suitable mold for settable material pour.
2. A precast building module according to claim 1 wherein module is formed from the separately precast elements like floor, walls, ceiling etc. that are cured and hardened in a suitable molds, then placed in the required positions in suitable shape and connected into integral form by settable material pour.
3. A precast building module according to claim 1 wherein the module has sloping roof.
4. A precast building module according to claim 2 wherein top module has horizontal ceiling extending through the whole or part of the module.
5. A precast building module according to claims 1, 2 and 3 wherein module is precast with cavities, voids, openings, grooves and other architectural and structural elements that can be used for installation of various building materials, systems, fixture, furniture and other interior and exterior details.
6. A precast building module according to claims 1, 2, 3 and 4 wherein modules are in-factory completed with necessary building materials, systems, fixtures and furniture to make the modules ready for occupation or use to the stage that is necessary and feasible.
7. A precast building module according to claims 1, wherein structural joints facilitating connection between multiple modules are slide-in type on one or more axis to ensure precise connection of the modules.
8. A precast building module according to claims 5, wherein electrical, mechanical and other building systems terminate at the designed locations of each module that are relevant to the same systems termination locations of the adjacent modules and therefore facilitate an easy access and quick connection to form a functional continuity of the said systems between modules.
9. A precast building module according to claims 1 wherein provisions are made in the module to facilitate its lifting using lifting arrangement placed under the module.