KR20230155459A - Modules used in the preparation of prefabricated structures, module manufacturing methods, and transfer frames - Google Patents

Abstract

The present invention is a reinforced concrete module used to prepare a prefabricated structure, comprising a horizontal slab, four corner columns, extending downward from each longitudinal and transverse edge of the horizontal slab, extending between adjacent columns and connected to adjacent columns. perimeter beam; Provided is a reinforced concrete module comprising at least two transverse ribs located on the underside of a horizontal slab and extending between two opposing perimeter beams, the module being manufactured as a single piece. Additionally, a method of manufacturing a module and a transport frame configured to support the module on a transport vehicle are provided.

Description

Modules used to prepare prefabricated structures, methods of manufacturing them and transport frames

The present invention relates to the field of prefabricated buildings, and more particularly to reinforced concrete modular structures.

WO 2018/174825A1 is a method of constructing prefabricated prefinished bulk construction (PPVC) modules for buildings, comprising (i) pouring concrete to form the body of the PPVC module, wherein the body of the PPVC module supports one or more loads; pouring concrete, comprising six walls including columns and beams, and a roof covering the top of the PPVC modules; and (ii) substantially finishing the interior of the PPVC module before the PPVC module is transported to a site for assembly into a building.

US3568380 discloses a prefabricated building unit consisting of a prefabricated rectangular floor panel structure with prefabricated vertical load bearing columns for attachment at each corner and in the middle region of the length of each side.

EP3498929A1 is an architectural module having a cuboid housing formed of stackable monolithic tubular bodies composed of concrete material, the four tubular walls of which form the floor, ceiling and side walls, and doors and windows are provided in the end walls. Start the module.

Therefore, there is a need for modular systems that are easily customizable and transportable, while still providing great design flexibility for habitable structures formed from one or more modules.

This background information is provided to identify information that the applicant believes may be relevant to the present invention. There is no intention and should not be construed as an admission that any of the foregoing information constitutes prior art to the present invention.

The object of the present invention is to provide a module used to manufacture a prefabricated structure and a method for manufacturing the same. According to one aspect of the invention, a reinforced concrete module used to manufacture a prefabricated structure, the module comprising: a horizontal slab forming two opposing longitudinal edges, two opposing transverse edges and four corners; four corner pillars, each of the corner pillars being located at a respective corner; and two longitudinal perimeter beams, each longitudinal perimeter beam extending downward from a respective longitudinal edge of the horizontal slab and extending between and connected to adjacent columns; two transverse perimeter beams, each transverse perimeter beam extending downward from a transverse edge of a horizontal slab and extending between and connected to adjacent columns; at least two transverse ribs located on the underside of the horizontal slab and extending between opposing longitudinal perimeter beams; and an attachment element located at the base of each of the corner posts and configured to attach to a support surface; The module is configured to rest on a support surface; Adjacent columns and each lower edge of the perimeter beam define an opening configured to receive a wall fill assembly; A reinforced concrete module is provided, wherein the horizontal slabs, corner columns, perimeter beams and transverse ribs are each manufactured from steel reinforced concrete and the module is manufactured as a single piece.

According to another aspect of the invention, a method of manufacturing a reinforced concrete module, comprising providing an array of reinforcement cages comprising a horizontal slab cage, four corner column cages, four perimeter beam cages and at least two transverse rib cages. step; assembling the array into a reinforcing bar framework for the desired modular configuration within the form, wherein the reinforcing bar framework and formwork are in an inverted configuration; pouring concrete slurry into formwork in a single injection; and curing the concrete slurry within the formwork for a period of time sufficient to form the reinforced concrete module.

According to another aspect of the invention, a transport frame configured to support one or more modules of the invention on a transport vehicle, the transport frame comprising first and second pairs of support legs, each support leg being vertical. first and second pairs of support legs, each pair of support legs having a telescopic leg insert oriented and configured to extend upwardly from each support leg; a first lateral bracing beam extending between each leg of the first pair of support legs; a second lateral brace beam extending between each leg of the second pair of support legs; first and second longitudinal brace beams extending between the first and second pairs of support legs; a first horizontal support beam extending between telescopic leg inserts of the first pair of support legs and attached to upper ends of the leg inserts; and a second horizontal support beam extending between the telescopic leg inserts of the second pair of support legs and attached to the upper ends of the leg inserts; A transport frame is provided, wherein each of the first and second horizontal support beams includes a telescopic arm insert configured to extend outwardly from a respective end of the respective support beam.

Figure 1 shows a perspective view of a half module according to one embodiment of the invention.
Figure 2 shows a top view of a half module according to one embodiment of the invention.
Figure 3a shows a perspective view of the entire module according to one embodiment of the present invention.
Figure 3b shows a top view of the entire module according to one embodiment of the present invention.
Figure 4a shows a perspective view of the entire module according to another embodiment of the present invention.
Figure 4b shows a top view of the entire module according to another embodiment of the present invention.
Figures 5A-5G show perspective views of different assembly and stacking configurations of modules according to embodiments of the invention.
Figure 6a shows a partial perspective view of the end of a module with a slab opening according to one embodiment of the invention.
Figure 6B is a top view of the module of Figure 6A, according to one embodiment of the invention.
Figure 7 shows a perspective view of an assembly of three modules according to an embodiment of the invention with an enlarged inset view of the upper peripheral joints between adjacent modules.
Figure 8 shows a partial perspective view of the reinforcement bar framework of a corner column according to one embodiment of the invention;
Figure 9a shows a partial perspective view of the reinforcement bar framework of a central column according to one embodiment of the present invention.
Figure 9b shows a partial perspective view of the reinforcing bar frame at the connection point between the center beam and the perimeter beam according to one embodiment of the invention.
Figure 10 shows a cross-sectional view of a corner pillar according to one embodiment of the present invention.
Figure 11 shows a cross-sectional view of a central pillar according to one embodiment of the present invention.
Figure 12 shows a cross-sectional view of a T-shaped beam according to one embodiment of the present invention.
Figure 13 shows a cross-sectional view of a perimeter beam according to one embodiment of the invention.
Figure 14 shows a cross-sectional view of a central beam according to one embodiment of the present invention.
Figure 15 shows a side view of a corner post connector assembly according to one embodiment of the present invention.
Figure 16 shows a perspective view of a corner post connector assembly according to one embodiment of the present invention.
Figure 17 shows a side view of a center pillar connector assembly according to one embodiment of the present invention.
Figure 18 shows a perspective view of a center pillar connector assembly according to one embodiment of the present invention.
Figure 19 shows a perspective view of the end of a headed bar according to an embodiment of the present invention.
Figure 20 shows an end view of a corner pillar according to one embodiment of the present invention.
Figure 21 shows an end view of a central pillar according to one embodiment of the present invention.
Figure 22 shows a perspective view of a reinforcement bar frame of a corner column according to one embodiment of the present invention.
Figure 23 shows a perspective view of a central column reinforcement bar frame according to one embodiment of the present invention.
Figure 24a shows a side view of the reinforcement bar framework on the longitudinal side of the entire module according to one embodiment of the present invention.
Figure 24b shows a side view of a reinforcement bar framework on the longitudinal side of the entire module according to another embodiment of the invention.
Figure 25 shows a side view of a reinforcement bar framework on the transverse side of a module according to one embodiment of the invention.
Figure 26 shows a perspective view of a half module with a partial cutaway to show a reinforcing bar framework according to one embodiment of the invention.
Figure 27a shows a perspective view of the entire module with a partial cutaway to show the reinforcing bar framework according to one embodiment of the invention.
Figure 27b shows a perspective view of the entire module with a partial cutaway to show a reinforcing bar framework according to another embodiment of the invention.
Figure 28 shows a perspective view of a precast portion of a concrete footing assembly according to one embodiment of the present invention.
Figure 29 shows a top plan view of a footing assembly according to one embodiment of the present invention.
Figure 30 shows a side view of a footing assembly according to one embodiment of the present invention.
Figure 31 shows a footing top view according to one embodiment of the present invention.
Figure 32 shows a perspective view of a transport frame in a collapsed configuration according to one embodiment of the invention.
Figure 33 shows a perspective view of a transport frame in an extended configuration according to one embodiment of the invention.
Figure 34 shows a perspective view of a transport frame loaded with complete modules according to one embodiment of the invention.
Figure 35 shows a perspective view of a transport frame loaded with two half modules according to one embodiment of the invention.

As used herein, the term "about" means +/-10% variation from the nominal value. Such variations, whether or not specifically stated, should always be understood to be included in the given values provided herein.

Unless otherwise defined, all technical and scientific terms used in this specification have the same meaning as commonly understood by a person skilled in the art to which this invention pertains.

The present invention provides reinforced precast concrete modules suitable for use in constructing habitable structures. The modules are manufactured using precast standard Portland cement construction with steel rebar reinforcement and have a basic structural design of ceiling/roof slab on column supports. In a preferred embodiment, the module is manufactured as a single piece.

In a preferred embodiment, the modules are pre-cast at the factory and then transported by existing flatbed tractor-trailers via existing roads/highways to the site where they are assembled into the final structure.

According to the invention, the modules may be provided as rectangular full modules or square half modules which can be positioned, interconnected and/or vertically stacked in any combination to form many different single or multi-layer configurations.

In a preferred embodiment, the module includes a horizontal concrete slab forming two opposing longitudinal edges, two opposing transverse edges, and four corners, and four corner columns located at each corner of the horizontal slab. The horizontal slabs form a single-story roof while also serving as the floor of the upper storey in a stacked configuration.

In one embodiment, as shown in Figure 1, the module is a square half module comprising a horizontal concrete slab whose longitudinal edges are the same length as the transverse edges.

In another embodiment, as shown in Figure 3, the module is a rectangular overall module, with the longitudinal edges being twice the length of the transverse edges. The rectangular module further includes two center columns in addition to the four corner columns located at each corner of the horizontal slab, with the center column located at the midpoint of each longitudinal edge.

According to the present invention, two basic modular configurations (full module and half module) can be combined to provide access to an array of structural design configurations. The 2:1 length-to-width ratio allows multiple modules to be arranged in a variety of adjacent and stacking relationships, providing architectural design flexibility.

Accordingly, in a preferred embodiment, multiple precast modules can be assembled together to form a larger structure comprising multiple stacked units. 5A-5G illustrate example configurations that can be achieved using combinations of half and full modules of the present invention, including parallel, vertical, stacked, and any combinations thereof. Although the drawings illustrate stacked arrangements of up to three units in height, the modules of the present invention present load intensity values that make them suitable for use in constructing stacked construction structures of up to seven units.

In one embodiment, the modules (half modules and full modules) are designed to be transported to a site where they are assembled into the final structure without negatively affecting structural integrity and functionality. In a preferred embodiment, the length, width and height dimensions of the modules are compatible with standard highway grade tractor trailer dimensions, allowing passage under standard bridges for unimpeded highway transportation.

In a preferred embodiment, the half modules have a length equal to the width. In one embodiment, the length and width of the half modules are from about 2.5 m to about 7.0 m. In one embodiment, the half module has a length of about 4.5 meters and a width of about 4.5 meters.

In a preferred embodiment, the entire module has a length that is twice the width. In one embodiment, the overall module has a length from about 5.0 m to about 14 m and a width from about 2.5 m to about 7 m. In one embodiment, the entire module has a length of about 9.0 m and a width of about 4.5 m.

In one embodiment, the height of the full module and half module is from about 3.15 m to about 3.45 m.

In one embodiment, the module of the present invention provides a reinforced concrete structure designed to weigh less than about 1 MT per square meter of living space. In one embodiment, the module of the present invention provides a reinforced concrete structure designed to weigh from about 0.6 MT to about 0.85 MT per square meter of living space. In one embodiment, the module of the present invention provides a reinforced concrete structure designed to weigh approximately 0.77 MT per square meter of living space.

In one embodiment, the module of the present invention provides a reinforced concrete structure designed to weigh less than about 3 MT per cubic meter of usable living space. In one embodiment, the module of the present invention provides a reinforced concrete structure designed to weigh from 0.18 MT to about 2.6 MT per cubic meter of usable living space. In one embodiment, the module of the present invention provides a reinforced concrete structure designed to weigh approximately 0.22 MT per cubic meter of usable living space.

According to the present invention, to provide additional structural strength and torsional stability, the module further includes a perimeter beam extending downward from each edge of the horizontal slab and extending between and connected to adjacent columns.

For a half module, the perimeter beams include two longitudinal perimeter beams extending downward from each longitudinal edge between adjacent columns and connected to adjacent columns, and two longitudinal perimeter beams extending downward from each transverse edge between adjacent columns and connected to adjacent columns. It is provided by two transverse perimeter beams that are connected.

For an entire module, a perimeter beam extends downward from each longitudinal edge and extends between adjacent corner columns and a central column and connects to the adjacent corner column and central column, and each transverse beam between adjacent corner columns. It is provided with two transverse perimeter beams extending downward from the directional edges and connected to adjacent corner posts.

According to the invention, the module adds at least two transverse ribs (or "T-beams") located on the underside of a horizontal slab and extending between and connected to opposing longitudinal perimeter beams. Included as.

The combination of the transverse ribs on the underside of the horizontal slab and the "skirt" formed by the perimeter beams located around the outer edge of the horizontal slab provides bending tolerance combined with strength and stiffness. Therefore, the presence of T-beams and perimeter beams does not require the amount of reinforced concrete normally used to manufacture rigid, homogeneous slabs with strengths similar to those known in the art and with high tolerances to torsional forces. Provides reinforced concrete modules.

1 shows a horizontal slab 15, four corner columns 12, lifting anchors 75 located at each corner of the horizontal slab, and a connector assembly located at the foot of each corner column. 40 shows a perspective view of a half module 10 according to one embodiment showing the relative relationships between them.

Figure 2 shows a top view of a half module 10 according to one embodiment showing the relative relationship between the four corner posts 12, the perimeter beam 17 and the two transverse ribs 29.

Figure 3a shows a horizontal slab 25, four corner columns 22, a center column 23, a lifting anchor 75 located at each corner of the horizontal slab, and a connector assembly 40 located at the foot of each corner column. ) and a central connector assembly 45 located at the foot of each central pillar is shown in a perspective view of the entire module 20 according to one embodiment.

3B shows one embodiment showing the relative relationships between four corner posts 22, two center posts 23, perimeter beams 27, 28, center beam 26 and four transverse ribs 29. Shows a top view of the entire module 20 according to .

4A is an alternative showing the relative relationships between the four corner columns 122, the lifting anchors 75 located at each corner of the horizontal slab, and the connector assemblies 40 located at the feet of each corner column, without a center column. A perspective view of the entire module 120 according to a typical embodiment is shown.

Figure 4b shows the relative relationship between the horizontal slab 125 and the four corner columns 122, the perimeter beams 127, 128, the center beam 126 and the four transverse ribs 129 in one embodiment. A top view of the entire module 120 is shown.

In one embodiment, perimeter beams are provided to transfer loads from the columns to the perimeter beams, transverse beams (ribs) and roof slabs. In one embodiment, the perimeter beams are manufactured to a depth of 30 inches (760 mm) to achieve the required loading tolerances for modules with dimensions of 4.5 m x 9 m, a very efficient size that is transportable and can give 'optimal' living space. .

In one embodiment, each perimeter beam is provided with an opening (or service access) therethrough to allow utilities or infrastructure to be provided to the interior of the structure. In a preferred embodiment, service access is provided at regularly spaced locations along the length of the beam. The regularly spaced openings ensure that the openings of adjacent modules are co-located to facilitate sharing of utilities or infrastructure between multiple adjacent modules, regardless of their relative configuration. In a preferred embodiment, service access is incorporated at the time of manufacture of the module, eliminating the need to introduce access openings after the module has been manufactured, which could negatively affect the structural integrity of the concrete, reducing the lifespan of the module. By providing service access openings during manufacturing, post-manufacturing modifications can be avoided.

In one embodiment, for a half module, each transverse and longitudinal perimeter beam includes a standard length, i.e. two service accesses located across the sides of the half structure. Figure 25 shows a reinforcement bar framework that can be used to form the longitudinal side of the entire module, including the service access openings 84, according to one embodiment of the invention.

In one embodiment, for a full module, the longitudinal sides of the full module carry four service accesses and the transverse peripheral beams include two service accesses. FIG. 24A shows a reinforcement bar framework that may be used to form the longitudinal side of a half module containing service access openings 84 according to one embodiment of the invention. A longitudinal side view of an alternative embodiment of the entire module without a central pillar is shown in FIG. 24B , which also shows the service access opening 184 .

The number of service accesses may be modified as determined by the functional requirements of the final structure within engineering requirements to maintain the overall structural strength of the module.

Modules of the present invention may also be provided with openings in the horizontal slabs to accommodate structural features such as interfloor stairs, skylights, elevators, mechanical services, etc. According to the invention the slab openings are located in the space between the beams of the modules. In one embodiment, the opening is located between the perimeter beam and adjacent transverse ribs (T-shaped beams), for example as shown in FIGS. 6A and 6B. In one embodiment, the opening is located between the central beam and adjacent transverse ribs. In one embodiment, the opening is located between adjacent transverse ribs. 6A and 6B show the end of a module according to one embodiment with an opening 34 for receiving a step 35.

Figure 7 shows an example assembly of three modules including the module of Figure 6A. In the embodiment shown in Figures 6a and 7, the modules are provided with vertical indentations 38 extending along a vertical plane around the upper outer perimeter of each module. This indentation is provided to ensure that a gap, i.e. an empty space 37, is formed between the upper perimeters of adjacent modules. According to one embodiment, the upper surface of the modules is also provided with a horizontal indentation 39 extending along a horizontal plane around the upper outer perimeter of each module. The void 37, shown in the enlarged inset of Figure 7 together with the horizontal indentation 39, provides an annular space through which a sealing material can be applied between the joints of adjacent modules to seal the elements for external joints. It can provide an external seal or, in the case of a laminate configuration, a seal between floor levels. In one embodiment, the sealing material is a liquid sealant applied to fill the joint, a foam-type material filled into the joint, or a combination of the two.

The modules of the present invention provide structures with a high ratio of habitable open space to the volume occupied by structural columns without sacrificing the strength of the overall structure. The modules of the present invention can also be combined into a variety of other configurations formed by any combination of half and full modules with or without slab openings and with a wide range of custom additional features.

Reducing the volume of the module's structural elements (e.g., slabs, columns, and beams) relative to the available living space also reduces the amount of cementitious material required, significantly reducing energy demand and life cycle carbon footprint for manufacturing and transporting the module. can do.

The horizontal slabs, corner and center columns, perimeter beams, center beams and transverse ribs are each formed of reinforced concrete. Illustrative cross-sectional views of these components are shown in FIGS. 10-10 , including corner posts (FIG. 10), center posts (FIG. 11), transverse ribs (FIG. 12), perimeter beams (FIG. 13), and center beams (FIG. 14). Provided at 14. As shown in Figures 8 and 9, the corner pillars and the central pillar are each provided with a connecting element 60 cast into the foot of the pillar, which connects to a respective connector assembly 40 for connection to the support surface. 45) is used to connect.

Figures 26, 27a and 27b show perspective views of embodiments of half modules (Figures 26) and full modules (Figures 27a and 27b) with partial cutaways to show the basic reinforcing bar framework.

While the reinforcing bar (rebar) frames for slabs, perimeter beams, center beams, and transverse ribs are manufactured using standard rebar assembly methods, columns require minimal use of concrete to meet these structural requirements, i.e. Headed bar configurations are provided to meet the necessary structural requirements, e.g. strength, while minimizing the column cross-section.

The headed bar 70 is formed by welding a square plate washer 71 to the end of the reinforcing bar 72 located at the top of each column, as shown in FIG. 19. The use of multiple headed bars 70 to form the circumference of a rebar frame for each column, as shown in Figures 20 and 21, can provide the necessary vertical strength to each column. By avoiding the need to bend the upper part of the rebar into an 'L' shape to provide the required strength in the vertical direction, as is commonly done in prior art reinforced concrete construction, the intrusion of the bent rebar into the central space of the column can be avoided. there is. Therefore, using a bar with a head can also create an open space at the center of each column to accommodate the placement of poured attachment elements 60 as shown in FIGS. 8 and 9A.

As also shown in Figures 8 and 9a, each pillar is also provided with a connecting element 60 cast on top of each pillar. A lifting anchor 75 (not shown) may be removably attached to each poured attachment element 60 at the upper surface of each corner and, if present, at the upper surface of the center column. Lifting anchors are provided to facilitate the operation of lifting the module by crane or the like for loading or unloading from the vehicle and placing it on the habitable structure site.

Figure 9b shows the poured connection element 60 provided in a fully modular embodiment without a central pillar.

Cast-in attachment elements 60 may also be used to attach the connector assembly to the module. According to one embodiment, the connector assembly includes an upper bracket attached to an upper base plate, a lower bracket attached to a lower base plate, and a pin connecting the upper bracket and the lower bracket. A cast-in attachment element located at the foot of each post is attached to the connector assembly via bolted connections through the upper base plate of the connector assembly. The other of the base plates of the connector assembly (i.e., the bottom base plate) is bolted to the corresponding surface to which the module is to be attached. Accordingly, a connector assembly located at the bottom of a module column may be used to physically connect a module to the upper surface of a submodule if provided in a stacked configuration, or to a support surface if provided in a single or low layer configuration. there is. 15 and 16 show a corner pillar including an upper connector base plate 41b, a lower connector base plate 41a, an upper bracket 43b, a lower bracket 43a, pins 42, and bolt holes 44. A connector assembly suitable for use is shown. 17 and 18 show a central pillar including an upper connector base plate 46b, a lower connector base plate 46a, an upper bracket 48b, a lower bracket 48a, pins 42, and bolt holes 44. A connector assembly suitable for use is shown. The center post connector assembly is longer than the corner post connector assembly and is provided with two bolt holes for attaching two corresponding bolts on the support surface as described below.

The pin connections of the connector assemblies shown in Figures 15-18 are particularly suitable for use with the modular system of the present invention. The connector assembly is designed to provide flexibility in module orientation when stacked vertically or adjacently, while limiting moment transfer from one module to another or from a module to a support surface on which the module rests.

According to one embodiment, the connector assembly can be fastened in any orientation via bolted connections to the bottom of the column and each support surface. This modular connection allows for a solution that can be adapted to different vertical and horizontal configurations of the attached units. In one embodiment, each connector assembly is rotated 90 degrees relative to the connector assembly mounted on an adjacent pole.

Pin connections allow modules to be easily removed for relocation without destructive steps that could compromise the structural integrity of individual modules.

According to the present invention, the connector assembly attached to the foot of the column may be mounted on any suitable support surface, such as a concrete foundation slab or footing or the upper surface of a sub-module for a stacked construction.

In one embodiment, the support surface on which the module is placed is provided as a basic footing assembly as shown in FIGS. 28-30. In this embodiment, the connector assembly located at the foot of the module post is attached to a footing post ( 53) is used to connect to the support surface 56 on the top.

In a preferred embodiment, the footing assembly is provided as a precast hybrid foundation footing, manufactured at a manufacturing facility and then transported to site. The footing assembly includes a precast reinforced concrete base 52 as shown in Figure 28. Base 52 is formed as a square concrete body or frame with a central opening. The reinforcing bars extend inward and upward from the base to form the framework of the footing post. In a preferred embodiment, a formwork that serves as a mold for pouring the footing posts is also provided at the manufacturing facility. This assembly is transported to the installation site, where it is installed on the ground to provide a support surface for one or more modules. Additional concrete is poured in situ within the mold form to provide footing posts of the desired height.

By performing the final pouring steps on-site, it becomes easier to achieve the same final height for each foundation footing and allows for final placement of each module horizontally, regardless of the variety of ground-accommodating foundation footing assemblies. In one embodiment, the bottom surface of the footing assembly base 52 has a central concave portion to facilitate horizontal placement on uneven ground.

Using a footing assembly that includes a combination of a precast base and cast-in-place posts has the advantage of reducing the time and material costs typically incurred by the field installation of floor slabs. Additionally, the footing assembly may be reduced in size and weight, making it more easily transportable.

In one embodiment, the footing assembly including the concrete base and footing posts may be poured as a single piece.

In one embodiment, the method of manufacturing the module of the present invention includes providing a reinforced framework or cage for each of the horizontal slab, corner column, center column, center beam, perimeter beam, and transverse rib, and prior to the concrete pouring step. assembling each frame into the desired modular configuration within the formwork, wherein the pouring step is performed while the formwork for the modules is in an inverted arrangement with horizontal slabs at the bottom and columns pointing upwards. The upside-down pouring ensures that the top surface of the module is smooth and of good quality. In a preferred embodiment, the modules are poured in a single injection.

In one embodiment, the formwork is provided with one or more bolt inserts for providing poured bolt inserts to the pour module. In one embodiment, poured bolt inserts are provided on one or more outward facing surfaces of corner and/or center columns, upper surfaces of horizontal slabs and/or lower surfaces of horizontal slabs. In one embodiment, poured bolt inserts are provided on all sides of the corner and center columns. In one embodiment, poured bolt inserts are provided on all sides of the perimeter and center beams. In one embodiment, poured bolt inserts are provided on all sides of the transverse ribs. In one embodiment, the poured bolt inserts are provided in two rows on each side.

Poured inserts are provided to attach decorative, structural or functional elements to the modules. For example, bolt inserts located on the outward facing surface of a column can be used to attach decorative elements. As another example, bolt inserts located on the interior surface of a horizontal slab may be used to attach ceiling components or support utility or other infrastructure components.

The modules of the present invention are formed with open spaces extending between adjacent pillars. This open design provides a lightweight module suitable for transport to site. Open spaces also offer the possibility of design flexibility through the integration of various wall fill assemblies with different functional properties.

In one embodiment, adjacent posts and each lower edge of the perimeter beam define an opening configured to receive a wall fill assembly. In one embodiment, the wall fill assembly is configured to receive one or more decorative, structural, or functional elements. Bolt inserts located on the column surfaces facing the open space between adjacent columns facilitate attaching the wall fill assembly.

For example, wall infill assemblies can be used to integrate functional elements such as window units, door units, wall panels and insulation.

In one embodiment, the wall fill assembly is a prefabricated wall unit that can be integrated into openings between columns at a factory or in the field after manufacturing a basic modular structure to provide options for access, lighting, and heat/energy conservation and control. am.

In one embodiment, one or more wall fill assemblies are attached to a precast module at a manufacturing facility for transport to the site with the structure. In one embodiment, the wall fill assembly is attached to the module in the field.

As mentioned earlier, casting the module upside down ensures that the top surface of the module is smooth and of good quality. The integrity of the roof surface is important to ensure resistance to the elements, including impermeability to water infiltration. In a preferred embodiment, there is no need to coat or pre-treat the concrete surface to render it impermeable to water.

In one embodiment, the roof of the module may be configured to retain and manage rainwater through attaching a frame to form a rooftop catch basin. In one embodiment, the frame may be attached using poured attachment points located around the perimeter of the roof slab. In one embodiment, means for controlling the outflow/discharge of collected water may be incorporated to allow the rooftop sump to function as a water management system for use in irrigation or recycled water applications, for example. By controlling the discharge of water from rooftop catch basins, the negative environmental impacts of runoff discharged directly into natural waters can be mitigated.

The impermeable nature of the roof allows the roof surface to be used as a garden or growing space.

As previously mentioned, each module may be provided with removable lifting anchors attached to pour-in attachment elements on the upper surface of the horizontal slab adjacent to each column. Lifting anchors are provided to facilitate lifting the module with a crane, etc., placing it on or off a vehicle, and placing it on site in a habitable structure. In one embodiment, the removable lifting anchor is threadedly coupled to a cast-in attachment element. In one embodiment, a half module uses 4 lift points and a full module uses 8 lift points.

In one embodiment, the module is lifted by a bolted lifting device at the location of the cast-in attachment elements. In one embodiment, the bolted lifting device is a bolted lifting plate.

Through the design of modules and specific components, and the selection of materials for modules and their components, the resulting structures are recyclable, relocatable/portable, reusable, have high durability and longevity over their lifetime, and have the lowest Ensures life cycle costs and has a net positive environmental impact.

The modules of the present invention meet the performance characteristics required to meet or exceed building codes for snow loads, wind loads and seismic forces required by the Province of Ontario while maintaining structural integrity during transport. Additionally, habitable structures constructed using one or more modules of the present invention also comply with these building codes.

In one embodiment of the invention, a transport frame is provided configured to support a module on a transport vehicle.

In use, the transport frame is fixed to the flat bed of the transport vehicle. A transport vehicle can fit underneath the module (with the transport frame locked in place). Once in place, the transport frame can be telescopically moved to an elevated position to lift the module. The frame is raised and lowered by hydraulic pressure.

Each transport frame has four support legs comprising a rear pair and a front pair, the support legs being connected by a brace beam extending between them. Each support leg has a telescopic leg insert extending vertically upward from the upper end. Hydraulic cylinders are provided inside each support leg to raise and lower the leg insert.

Each transport frame also has two horizontal support beams, one of the horizontal beams attached to the upper end of the leg insert of the rear pair of support legs, and the other of the horizontal beams attached to the upper end of the leg insert of the front pair of support legs. is attached to

The transport frame also has telescopic arm inserts extending horizontally from each end of the horizontal support beam. After the transport vehicle is in place under the module, the leg and arm inserts extend to lift the module off the ground and hold the module(s) in place during transport.

32 and 33 show one embodiment of the transport frame 300 in different stages of deployment. Support legs 310, horizontally oriented support beams 320, longitudinally oriented brace beams 340 and lateral brace beams 330 are shown. Figure 32 shows the transport frame in a retracted configuration and Figure 33 shows the transport frame with telescopic arms 325 and telescopic leg inserts 315 in an extended configuration.

When the module is lowered into place for field installation, the leg and arm inserts retract to provide adequate clearance for transport vehicles to exit underneath the module.

In one embodiment, each transport vehicle has two transport frames secured to a flat bed. In one embodiment, both transport frames can be lifted simultaneously or separately to accommodate a full module (shown in Figure 34), a half module, or two half modules (shown in Figure 35).

The transport frame is designed to reduce or eliminate the requirement for a crane to load and unload modules from the transport vehicle.

It will also be very useful for on-site staging. No crane is required to load the modules onto transport vehicles or to unload them when delivered to the installation site. If a crane is on site, transport vehicles can be used to easily deliver the modules within the site area to a distance that the crane can reach, saving time and costly mobilization and dismantling of crane locations (the crane can be operated in one day). It can cost $8,000 to $10,000 or more). This is highly cost- and time-efficient for module installation. Lifting and lowering can be accomplished in minutes, making it much faster and less effort-intensive than traditional staging. This approach further reduces the need for costly, on-time delivery to site on the day of installation, where most delays in construction occur.

In one embodiment, a support frame may be used to easily install the modules in place to form the first floor of a building.

It is clear that the above-described embodiments of the present invention are merely illustrative of the present invention and that it can be modified in various ways. No such present or future modifications should be construed as a departure from the spirit and scope of the invention, and all modifications apparent to those skilled in the art are intended to be included within the scope of the following claims.

Claims (32)

A reinforced concrete module used to prepare prefabricated structures, comprising:
a horizontal slab forming two opposing longitudinal edges, two opposing transverse edges and four corners;
four corner pillars, each corner pillar positioned at a respective corner;
two longitudinal perimeter beams, each longitudinal perimeter beam extending downward from a respective longitudinal edge of the horizontal slab, the two longitudinal perimeter beams extending between and connected to adjacent columns;
two transverse perimeter beams, each transverse perimeter beam extending downwardly from a transverse edge of the horizontal slab, the two transverse perimeter beams extending between and connected to adjacent columns;
at least two transverse ribs located on the underside of the horizontal slab and extending between opposing longitudinal perimeter beams; and
An attachment element located at the base of each of the corner posts and configured to attach to a support surface.
Includes;
the module is configured to rest on a support surface;
Adjacent posts and each lower edge of the perimeter beam define an opening configured to receive a wall fill assembly;
The horizontal slab, the corner column, the perimeter beam and the transverse rib are each manufactured from steel reinforced concrete, and the module is manufactured as a single piece. According to paragraph 1,
Reinforced concrete module, characterized in that the longitudinal edge has the same length as the transverse edge. According to paragraph 1,
A reinforced concrete module, wherein the longitudinal edge is twice the length of the transverse edge. According to any one of claims 1 to 3,
Reinforced concrete module, characterized in that it further comprises a lifting anchor located on the upper surface of the horizontal slab adjacent to each corner column. According to paragraph 1,
two central pillars, each central pillar positioned at the midpoint of its respective longitudinal edge, the longitudinal edge being twice the length of the transverse edge; and
a central beam extending between the two central pillars
A reinforced concrete module further comprising: According to clause 5,
A reinforced concrete module further comprising a lifting anchor located on the upper surface of the horizontal slab adjacent to each central column and each corner column. According to any one of claims 1 to 6,
Reinforced concrete module, characterized in that the transverse ribs have a T-shaped cross-sectional profile. According to any one of claims 1 to 7,
Reinforced concrete module, characterized in that the support surface is the upper surface of the horizontal slab of one or more additional modules. According to any one of claims 1 to 7,
Reinforced concrete module, characterized in that the support surface is a base slab. According to any one of claims 1 to 7,
The support surface includes a precast footing configured to support the base of each column, the precast footing comprising:
A precast reinforced concrete base formed by a square concrete body;
a footing post extending upward from the concrete base and having an upper surface; and
Four bolts extending from the upper surface of the footing post
A reinforced concrete module comprising: According to clause 10,
A reinforced concrete module, characterized in that the concrete base and footing posts of the precast footing are cast as one piece. According to any one of claims 1 to 10,
Reinforced concrete module, characterized in that the attachment element is a poured attachment element. According to clause 12,
A reinforced concrete module, wherein the poured attachment elements are configured to attach to corresponding attachment elements on the support surface via a connector assembly. According to clause 13,
The connector assembly includes an upper bracket connected to an upper connector base plate and a lower bracket connected to a lower connector base plate, and the upper bracket and the lower bracket are coupled through a pin connection. According to any one of claims 1 to 14,
further comprising one or more bolt inserts located on one or more outwardly facing surfaces of the corner and/or central column, an upper surface of the horizontal slab and/or a lower surface of the horizontal slab, wherein the bolt inserts are configured to be structural or functional elements. A reinforced concrete module, characterized in that it is configured to accommodate. According to any one of claims 1 to 15,
Reinforced concrete module, wherein the wall fill assembly is configured to receive one or more decorative, structural or functional elements, wherein the one or more structural or functional elements are selected from window units, door units, wall panels and insulation. . According to clause 16,
A reinforced concrete module, further comprising one or more bolt inserts positioned around the interior of the opening, the bolt inserts being configured to receive the wall fill assembly. According to claim 15 or 17,
A reinforced concrete module, wherein the bolt insert is a poured bolt insert. According to any one of claims 1 to 18,
Reinforced concrete modules further comprising external elements selected from decorative or insulating panels, parapets, solar panels, wind turbines, water retention or management features. According to any one of claims 1 to 19,
The reinforced concrete module of claim 1 , wherein the perimeter beam further includes service access openings suitably sized and shaped to provide service access and/or receive utility infrastructure. According to any one of claims 1 to 20,
Each corner column includes a plurality of vertical reinforcing bar elements, each vertical reinforcing bar element including a square plate washer welded to an upper end of each vertical reinforcing bar element for connection to the slab. ) Reinforced concrete module characterized in that. According to any one of claims 1 to 21,
A reinforced concrete module, further comprising a vertical indentation extending around the upper outer perimeter of each module. According to clause 22,
A reinforced concrete module, further comprising a horizontal indentation extending around the upper surface around the outer perimeter of each module. According to any one of claims 1 to 23,
A reinforced concrete module, characterized in that it further comprises sealing means configured to provide a sealing bond between adjacent modules when installed. According to any one of claims 1 to 24,
A reinforced concrete module, characterized in that the module is sized for transportation on a standard-sized tractor trailer. A method of manufacturing a reinforced concrete module, comprising:
providing an array of rebar cages including a horizontal slab cage, four corner column cages, four perimeter beam cages and at least two transverse rib cages;
assembling the array into a reinforcing bar framework for a desired modular configuration within a form, wherein the reinforcing bar framework and formwork are in an inverted configuration;
pouring concrete slurry into the formwork; and
curing the concrete slurry within the formwork for a period of time sufficient to form the reinforced concrete module.
A method of manufacturing a reinforced concrete module comprising a. According to clause 26,
A method of manufacturing a reinforced concrete module, wherein the assembly of the reinforcing bar cages further includes two central column cages and a central beam cage. According to claim 26 or 27,
A method of manufacturing a reinforced concrete module, wherein the formwork further includes one or more bolt inserts on the inner surface of the formwork. According to any one of claims 26 to 28,
A method of manufacturing a reinforced concrete module, characterized in that the pouring step is performed by a single injection. 26. A transport frame configured to support one or more modules as defined in any one of claims 1 to 25 on a transport vehicle, comprising:
a first and second pair of support legs, each support leg being vertically oriented and having a telescopic leg insert configured to extend upwardly from the respective support leg;
a first lateral brace beam extending between each leg of the first pair of support legs;
a second lateral brace beam extending between each leg of the second pair of support legs;
first and second longitudinal brace beams extending between the first and second pairs of support legs;
a first horizontal support beam extending between telescopic leg inserts of the first pair of support legs and attached to upper ends of the leg inserts; and
a second horizontal support beam extending between telescopic leg inserts of the second pair of support legs and attached to upper ends of the leg inserts;
Includes;
and wherein each of the first and second horizontal support beams includes a telescopic arm insert configured to extend outwardly from a respective end of the respective support beam. According to clause 30,
A transport frame, characterized in that a hydraulic cylinder is provided inside each support leg for lifting and lowering the telescopic leg insert. According to claim 30 or 31,
A transport frame, characterized in that a hydraulic cylinder is provided inside each of said support beams for extending and retracting said telescopic arm insert.