MX2014002063A - Housing construction system based on prefabricated elements and high performance nanoconcrete. - Google Patents

Abstract

A housing constructive system based on prefabricated elements and UHPC nanoconcrete, which comprises: traces, squaring and levels in the foundation, rod anchoring, wall construction, casting of vertical bars, roofing and casting of beams, where the walls and roofs of the housing are built using prefabricated panels having dimensions and configurations according to the characteristics of the previously designed housing, said panels being produced in plant using vibro-compressed alveolar blocks, equidistant therebetween and attached together by a mixture of UHPC nanoconcrete, where the periphery of said panels has a width higher than the separation between the blocks, including steel at each third and center portion that protrudes from the periphery of said panels, some panels having spans that will form the windows and doors of the housing, having a size that will depend on the design of the same.

Description

SYSTEM OF CONSTRUCTION OF HOUSES BASED ON ELEMENTS PREFABRICATED AND NANOCONCRET OF HIGH PERFORMANCE O.

The present patent application is related to a system for the construction of houses based on structural elements prefabricated in the plant, with the purpose of providing greater quality, precision and reduction of construction times, as well as lowering the cost of housing. The prefabricated elements have a flexible modulation that allows their adaptation to any architectural design that, when integrated, allows the complete prefabrication of the house in plan, in a modulated manner, and ready for its rapid assembly "in situ". This system allows a substantial saving in building time; eliminates all waste of materials on site; ensures the dimensions of the elements, of door and window openings; guarantees the quality and stability of the structure and achieves a construction that fulfills to satisfaction all the requirements of the Construction Regulations and national and international regulations for the construction in seismic zones.

It is of general knowledge of the professionals of the construction of houses the exigencies that are stipulated and that must be fulfilled in the design and structuring or edificación of the housings, not only applicable for seismic zones but that of general way for all type of zones, obviously being of greater relevance for those areas where, due to their location, they are classified as high risk, in such a way that the possibility of their collapse is minimized in a telluric event, that by its intensity and duration could result in the loss of lives of those who occupy them as well as the patrimony of their holders.

The construction of houses according to the construction methods observed so far appear to satisfy the required regulations. However, it has been found that in many cases, before seismic events suffer damage to the detriment of their owners. In some cases these damages can be repaired, but often obliges the occupants to evict them, to the detriment of those who have acquired them and in most cases it is impossible to hold the constructor responsible. It is clear that in an effort to lower the cost of construction is not always used materials that comply with standards or specialized labor. In addition, the supervision of part of the personnel in charge of the work is neglected, which results in a construction outside of required quality and safety specifications.

In recent times materials have been used for the construction of houses such as prefabricated panels composed of various materials. Some with the purpose of lightening structural loads, others that, according to their conformation, suggest to be insulating to noise and / or heat. However, until now a modular construction has not been proposed through the use of prefabricated panels composed of traditionally used materials, such as partition, solid or hollow block, multi-perforated ceramic, polystyrene cassette, F etc., particularly due to the resistance problems and in some cases, due to its excess weight, which causes fractures in the panels since these are transported as well as the use of robust assembly equipment. On the other hand and in addition to the aforementioned problems, there is skepticism on the part of the clients to not accept as suitable a building erected on the basis of prefabricated panels, which has resulted in a restricted use of such elements, since it would appear to be of the general taste to verify the progress of the work erected in the traditional way, that is to say from its foundations, the lifting of walls, beams, castles and their finishes. This type of traditional construction entails a substantial time for its construction, under structural behavior, deficient quality and waste of materials, etc. all of which results in an increase in the cost of the building and even, in extreme cases, without guaranteeing the quality of the home.

Another problem inherent in the construction of "social interest" housing is that related to the precise control of the use of materials used, that comply with the regulations, generally speaking of all the structural elements used in the lifting of walls and slabs, chains of reinforcement, quality of concrete, etc., whose quality in many cases leaves much to be desired, since in the industrialization of construction what at first sight matters is to lower its cost of building and consequently increase profits.

The prefabricated modular construction has been used under different modalities and materials, whether in reinforced concrete or lightweight panels. Without i however, the first ones are very heavy for their transportation and assembly; and the seconds do not have the structural characteristics resistant. On the other hand, traditional masonry systems do not have the guarantee of quality neither in process nor materials, they are slow in their construction and generate great waste.

The construction system proposed in this patent application combines the best virtues of the systems described above as it integrates structural safety, lightness, speed in the building and, all this, with traditional materials: hollow block, high performance concrete (UHPC) with nanoparticles, eliminating waste, guaranteeing dimensional quality and structural safety, at low cost.

As a result of a technically supported research, the construction of a house building based on prefabricated structural elements has been proposed, based on a construction system whose implementation minimizes each and every one of the problems mentioned above, guaranteeing quality structural construction. This proposal is supported in principle in the formulation of a new concrete high performance (UHPC), which by its physical characteristics allows the manufacture of panels that will be used for the lifting of walls and slabs. For castles and bars, thin plates are used that are used as lost formwork in the wet connections, forming the confined or structural castles to stiffen and form the monolithic structure of the system. The result of this innovative construction system allows to guarantee the quality of housing, reduce costs, reduce construction times, eliminate waste of the inputs, and offer the market a highly competitive and with sustainable characteristics.

OBJECTIVES OF THE INVENTION Therefore, it is a main objective of the invention to design high quality prefabricated products for the construction of dwellings based on modules that, due to their structural quality, fully comply with the regulatory requirements and existing regulations that are required for this purpose. , at a competitive cost.

Another objective of the invention is a housing construction system, based on panels manufactured between 70 to 80% in plan, with commonly used materials that are assembled "in situ" in a time quantified in hours.

Another objective of the invention of the housing construction system with prefabricated structural elements that will make up the walls, is the integration of bays with high dimensional accuracy and controlled quality that allow the placement of doors and windows with standardized dimensions.

Yet another object of the invention is the "in situ" assembly of the prefabricated elements using high performance concrete (UHPC) in a time i reduced and at a competitive price applicable to all types of buildings.

It is a further object of the invention a construction system based of prefabricated modules with a significant reduction in the time of construction of houses, reduction of flows of building materials, elimination of waste of inputs, efficient control and quality of construction and reduction of administrative and financial operations.

It is another objective of the invention to provide a construction system which, due to its structural characteristics, can be applied to horizontal residential construction and buildings of three to five levels and without affecting its quality, safety and design.

A further objective of the invention is to provide a modular system composed of prefabricated elements that include hydraulic and electric ducts plant according to the isometrics designed for the building.

The proposed construction system will be more clearly interpreted based on the drawings that illustrate it and that accompany the present application.

IN THE DRAWINGS Figure 1 is a schematic representation of the manufacture in plan of a panel for the construction of a house, according to the teachings of the invention; Figure 2 illustrates an isometric view of alveolar and multi-perforated vibro-compressed blocks used in the production of the prefabricated panels for the construction of pre-engineered housing, object of the present application; Figure 3 illustrates the erection of a wall formed by a section of a prefabricated panel, placed on a foundation slab; Figure 4 represents a sectional view of the "in situ" connection of two panels for the integration of a wall of the house through the use of extra-thin plates of nanoconcrete, in the form of lost forms and integral elements of the wet gasket; Figure 5 is an isometric view of the raising of a castle at the angular confluence of two panels; Figure 6 is an isometric view of the placement of the slab on the walls for the conformation of the roof with panels of blocks confined with nanoconcrete of a house built according to the teachings of the invention; Figure 7 illustrates in isometric the mechanical connection with screws, plates steel and grout of two slabs for the roof of the house; Figure 8 depicts, in a sommetrical manner, the wet joints of two prefabricated slabs in the erection of the walls joined by ribbons and the emptying of the UHPC nanoconcrete of a dwelling; Figure 9 illustrates, in isometric, the assembly of two plates joined with ribbons, chamfering and emptying of nanoconcrete UHPC for the formation of openings for access and intercommunication doors of the various areas of the house, and; Figure 10 illustrates, in isometric, a variation of types of elements for walls and slabs formed by plates, high performance concrete ribs (UHPC) and polystyrene. This solution is applicable to walls and slabs with high solar incidence.

DETAILED DESCRIPTION OF THE INVENTION As proposed, the housing construction system of the invention is carried out with national and accessible materials commonly used in the erection of buildings, particularly as regards the use of vibro-compressed concrete blocks, structural steel, joint mortars and for plasters and finishes. It also proposes the construction of houses using prefabricated panels with vibrocompressed hollow blocks confined with high performance concrete that adapt to any architectural design in order to accelerate their assembly, avoid the waste of the inputs, and guarantee, from a structural point of view, the safety of the same with reduction of time and costs with high precision and quality.

In the accompanying figures, particularly in Figure 1, the fabrication of one of the panels by means of the use of a steel platform 12 of such dimensions that are feasible for the placement and support of steel borders has been exemplified in sufficient detail. 14, obviously, the dimensions of said steel border 14 are variable and are a function of the modulation of the panels, thereby having a great flexibility in production. Once the steel borders 14 are placed on the base or steel platform 12, the placement and distribution of the blocks 16 on the base or steel platform 12 is ensured, ensuring a uniform separation 20 between them by means of the separators 18. The perimeter blocks of the panel will have a greater separation with respect to the borders 14, which allows to shape the structural perimeter frame of the panels. The steel rods 22 are placed in the thirds of the panel and by their diameter they allow to be embedded in the space 20 between contiguous block lines. These rods 22 are subsequently anchored with the vertical rods 32 to thus form a structural diaphragm, of course and depending on the dimensions of said panels it may be necessary to place structural rods between intermediate block lines either in a longitudinal and / or transverse direction of the panel, with the purpose of providing said panel with the necessary resistance for its handling and to support the loads foreseen for said element. Once the above is done, we proceed with the casting of the high performance nanoconcrete (UHPC), either manually or with pump between the blocks 16 and its periphery, the structure or panel remaining on the platform12 for the time necessary for the setting of the nanoconcrete UHPC, time that in the present case and due to the special characteristics of the nanoconcrete used it is substantially reduced from 6 to 12 hours.

Finally, it proceeds to the removal of borders 14, releasing the magnets that keep the steel borders 14 fixed to the platform 12, which allows an easy and quick process of the configuration of the panel, proceeding later to the removal of the fabricated panel from the aforementioned way, action that is facilitated due to the characteristics presented by the upper face 13 of said platform 12, on which said panel has been formed. Of course, in this stage of manufacture of the panels, the layout of the electrical and hydraulic installations is anticipated, as well as the clearings that will form the openings for the placement of windows, all in accordance with the specific design of the proposed housing. build. In an embodiment of the invention it is also proposed that both hydraulic and intercommunication as well as electrical installations complement each other "in situ" with quick connections once the structural part of the dwelling is properly built.

Figure 2 shows, by way of example, various types of blocks 16, which due to their variation in dimensions facilitate the i construction of the various panels according to the design of the proposed home.

In figure 3 of the accompanying drawings, for the purpose of illustration, the placement of two of the prefabricated panels 24 on the seat mortar 25 and the foundation 26, the latter having been formed in advance with the corresponding dimensions, has been shown. to the surface of the proposed home and with the vertical rod anchoring 32 by means of drilling the slab and the addition of high strength resin, for this purpose and prior to the manual discharge or pumping of high performance nanoconcrete UHPC and the placing the panels on the foundation slab 26, plastic shims 30 are placed which will conveniently delimit the thickness of the seating mortar between the surface of the foundation slab 26 and the lower edge of the panels 24. Once the prefabricated panels are arranged 24 on the foundation slab 26 are leveled and maintained in position by their shoring in order to ensure their verticality. Once the panels 24 are leveled, the horizontal rods 22 of the panels 24 are connected with the vertical structural rods 32 located in the space between the vertical edge of two adjacent panels, all with the purpose of obtaining an integration monolithic of the work in question through a wet board.

Figures 4 and 5 and schematically represent one more of the characteristics of the invention and in particular the formation of castles 42 between two adjoining panels by extra-thin plates 34 prefabricated nanoconcrete UHPC used as formwork elements, with which will have to conform the respective walls of length corresponding to the proposed work, creating a structural diaphragm, this being a neutral element, as well as the angular disposition of these with what will be defined the diverse areas of the house to be built. For this purpose and subsequently to the placement of two panels 24 conveniently separated and propped up to give place to the walls of the house, we proceed to the removal of the damp joints or castles 42 type diaphragm of the building, for this purpose two plates are placed 34 between the two adjacent panels 24, suitably separated by a resilient polyurethane seal and joined together by bows for formwork and, prior to the discharge of the nanoconcrete UHPC, the clamping of the tips of the structural steel 22 protruding from the edges of the panels 24 and the vertical rods 28 are carried out, the lower points of which have previously been embedded in the concrete of the foundation slab, with what is built in this way the walls of the house. Note that the extra-thin plates 34 used for the lifting of the castles are forming a permanent part of these and at the level of the respective wall.

In the case of the angular confluence of slabs 24 for the lifting of the walls of the house, the shoring of the castle is also carried out by plates 34 of high performance nanoconcrete UHPC, these are positioned in the traditional way by the assembly of wooden bars. or metal formwork in order to limit the dimensions of the corresponding castle.

With reference to figures 6 and 7 of the drawings that illustrate the novel housing construction procedure object of the application in question, they have represented the way in which the roofing stage is carried out. of housing. In accordance with the construction proposal, the prefabricated slab 46 is placed on the edge 44 of the walls 48 previously erected, leaving the corresponding space for the assembly and casting of a reinforced electrically welded reinforcement 50 perimeter of the construction. In the case that it is required to join several slabs 46 to form the roof 52 of the house, the resilient neoprene sealants 56 and 56 'are provided in the union 54 of said slabs 46. In figure 7 the union of two slabs 46 for the integration of the roof 52 is schematically represented, note that in order to guarantee non-structural union between the slabs that make up the roof 52, steel plates 58 have been used. mechanically connected to the slabs 46 by screws 60 and neoprene for their seal 56.

Figure 8 shows, as an example, one of the extra-thin nanoconcrete plates 34 used in the lifting of wet joints or castles arranged between two panels 24, note that they provide holes 36 for the placement of bows of shoring, with the purpose of defining the volume of the castles. In figure 9 of the accompanying drawings, the integration of two prefabricated plates 38 made of nanoconcrete UHPC has been represented, used to define the opening where an intercommunication door will be placed between the different areas of the house or for define the access space to this. In the illustrated embodiment, the plates 38 are formed by a horizontal section 64 and a vertical section 66 whose space between them is delimited by a steel or aluminum membrane 68 and the edge of a slab of the corresponding wall, which will be filled with nanoconcrete, of course, said plates 38 may be formed by two vertical sections 66 to define the corresponding portico. In this representation, the means for holding two plates 38 together have been illustrated with references 40 and 46.

One aspect of particular importance in the construction of houses, according to the proposed construction procedure, is the use of UHPC nanoconcrete, which is made up of cement, nanoparticles of silicon dioxide, sand of a suitable granulometry and, of course, water, all of them mixed, resulting in a fluid mixture that can be poured and self-compacted without the use of a compaction equipment, with physical-mechanical properties of a high performance concrete, allowing the use of concrete in confinement with a reduction up to 80% and steel also with a reduction of up to 80%, without detriment to the quality and structural characteristics of the construction, this of course results in the cost of housing, which combined with the substantially reduced time employed in the integration of it, makes the construction project of the invention an advantageous option for both the company with structora as for the buyer of this.

COMPOSITION OF THE NANOCONCRETE UHPC The various steps that make up the construction process of the invention can be summarized as follows: stroke, squaring and levels in foundation, anchor rods, seat joint, transport and assembly of walls and plates, transport and assembly of slabs and plates , shoring walls, joining walls, transport and assembly of roofing slabs and slab joints, all complemented by the assembly of chains and castles as well as casting them. Of course, the work will have to be complemented with the integration of the hydraulic, gas, intercommunication and electrical installations as well as the finishing or flattening of the walls.

As an embodiment of the invention, the use of extra-thin nanoconcrete plates in the design of furniture for bathrooms and kitchens is proposed, which will only have to be complemented, if necessary, by a carpentry work.

In the table that is provided below, the advantages of the construction method of the present invention in relation to two of the traditional procedures are demonstrated in a comparative manner: From the above described and illustrated it is evident that the proposed objectives have been met and it is obvious that modifications to the proposed invention can be devised, it is intended that such changes form part of it, provided that said changes occur within the scope of the claims that make up this chapter.

Claims (10)

1. - A construction system of homes based on prefabricated elements and high performance nanoconcrete (UHPC), which includes: trace, square and foundation levels, anchor rods, lifting walls, casting castles, roofing and casting trabes, in where the walls and roof of the house are built with prefabricated panels of dimensions and configuration in accordance with the characteristics of the previously designed housing, said panels highly flexible in their modulation are produced in plant based on alveolar vibro-compressed blocks, multiperforated and solid, equidistant from each other and joined with a nanoconcrete mixture (UHPC), the periphery of these panels has a width greater than the separation between the blocks, the steel assemblies are located in the thirds and centers of the concrete joints of the panels, whose ends protrude to achieve the mooring of the same to the vertical ribs, some of said panels are They are provided with openings that will make up the windows and doors of the house, of such size that it will depend on the design of the same.

2. - The construction system according to claim 1, wherein the panels that make up the walls of the house are joined by cast castings "in situ", using for this purpose extra-thin plates of nanoconcrete (UHPC) that make the times of formwork and that remain as part of the casillos, with which a monolithic character is conferred to the construction.

3. - The construction system of claim 1, wherein the union of the panels that make up the roof of the house are joined together by steel plates prior to the placement of deformable neoprene ribbons, in order to guarantee the sealing between adjacent slabs and avoid separation between them.

4. - The construction system of claim 1, wherein after the placement of the panels of the roof of the house strands a peripheral chain that will delimit and reinforce the structure of said housing and generates the monolithic structure that allows absorbing structural stresses of the earthquakes.

5. - The construction system of claim 1, wherein the frame or access bay to the home is delimited by a frame composed of two nanoconcrete plates, separated from each other with bows and casting "in situ", said plates are configured by one or two vertical sections and one horizontal depending on the location of said access door.

6. - The construction system of any of the preceding claims, wherein the prefabricated panels include concealed installations for electrification and / or hydraulic installations and intercommunication in accordance with the preconceived design of the dwelling, which are complemented once the part has been lifted structural of it.

7 -. 7 - The construction system according to claims 1 and 6, wherein the casting of the castles and beams of the house is carried out with UHPC nanoconcrete.

8 -. 8 - The construction system of claim 7, wherein the nanoconcrete UHPC is a mixture of gravel cement, gravel and sand of a granulometry according to its use, either for the confinement of the blocks or for the casting of the castles and trabes, silicon dioxide, superplasticizer and water, forming a sufficiently fluid mixture that can be compacted by itself, and which guarantees the total filling of the entire volume in which the mixture is poured.

9. - A house built using prefabricated panels in the plant, where said prefabricated panels are made up of vibro-compressed honeycomb blocks joined together with a nanoconcrete mixture (UHPC), said panels being of a size and design that will depend on the preconceived design of the housing and where the wet joints of the various panels are cast "in situ" with UHPC nanoconcrete in order to form a monolithic structure that guarantees the removal of the structure against earthquakes of considerable magnitude.

10. - A prefabricated and structured panel with vibro-compressed and nanoconcrete alveolar blocks (UHPC) for the construction of pre-engineered homes.