MXPA06002866A

MXPA06002866A - Monolithic module structure to build constructions and method for its manufacture.

Info

Publication number: MXPA06002866A
Application number: MXPA06002866A
Authority: MX
Inventors: Isidro Agustin Rivera Ramos; Eduardo Ochoa Garay; Manuel Marquez Cano; Juan Carlos Ares Cardenas; Armando Garcia Luna; Carolina Prieto Gomez
Original assignee: Gcc Technology And Processes S
Priority date: 2006-03-14
Filing date: 2006-03-14
Publication date: 2007-09-13
Also published as: US20090113814A1; WO2007105105A1

Abstract

A new monolithic module structure for construction and its manufacture method to build monolithic constructions. The monolithic modules can be easily- transported and easily arranged on the conceived site for the construction of the edification. The method comprises the stages of : a) manufacture of the necessary number of harnesses for the fabrication of modules and panels; b) manufacture of modules, where the foundations are fabricated over which the module exterior walls will be manufactured; c) manufacture of panels and flat roofs and of interior panels, if required, simultaneously to the modules; d) integration of interior panels into the modules; e) assembly of the flat roof over the module walls; f) transport and storage of the already assembled module for its commercialization and distribution. The method permits to obtain construction modules at high volumes to be used for diverse constructions.

Description

Method of manufacturing modules to build monolithic constructions.

Field of the invention. The present invention relates to a method for the manufacture of building modules that are integrated from a plurality of harnesses, which in combination with a roof are capable of building a variety of constructions of the monolithic type, allowing to vary the dimensions, capacities and uses of said constructions implementing in each module a plurality of panels. The field of application of the present invention is referred to any building, particularly housing constructions, classrooms and prefabricated sanatoria, among others.

Background of the Invention Traditionally, building systems for buildings of prefabricated type, have agreed to manufacture concrete-covered modules that supported by metal structures or concrete pillars are used to replace traditionally built walls with partition and concrete or any other material of this type to cover the empty spaces between the flanks of structural elements of the building.

The function of the modules known to this day is reduced only to the fact that said modules are used as false walls and not as proposed by the present invention as structural elements from which and in combination with a roof and a plurality of panels used for the convenience of space and functionality, they define by themselves monolithic building structures, which can be easily transported, arranged in the place designed for the construction of a building and that above all result in an economical option, fast in its process and versatile , in such a way that they adapt to the construction needs of different communities where it is implemented.

Currently, various construction system solutions are known from prefabricated elements and methods to obtain them, examples of which are those disclosed in the following documents: Correrta Artacho1 describes a building construction system, which combines traditional or non-structural construction with structural construction, where concrete is used in both walls and slabs. According to this system, a concrete slab serves as a foundation medium and reinforced concrete structural pillars are placed on it. By another part, cover plates are used to produce the walls, based on lightweight concrete which is reinforced using electrically welded mesh, additionally drywall or similar are connected to the inner faces of the walls, thus defining the final finish of the interior of the walls. Additionally, other expanded gypsum panels are positioned inside the gypsum panels that are connected to the inner faces of the walls in order to provide thermal and acoustic insulation. Finally it is described that gypsum panels or the like are also provided in the cover plates corresponding to the slabs and in this case, the panels are moisture proof and are used to form the apparent face of the ceilings.

Another system that shows the limitations of inventions in this field is that described by Shen Grace2, in which convertible buildings and methods for their production are disclosed. Particularly this system refers to a method to build a building that includes the stages of building a floor, building walls on top of the floor and building a roof over them. Where at least one of the walls contains at least one opening to pass through it. Also internal mechanical and electrical connections are fixed along at least the floor, walls, openings and roof in a predetermined route and connected to the corresponding external connections. Another step is to cover the internal mechanical and electrical connections with removable fittings that assume the appearance of aesthetic or functional counterparts found in non-convertible apartments, in such a way that the mechanical and electrical routes are not perceived, but they are always accessible to be transformed without having that demolish the floor, the ceiling or the walls.

Also other documents that are part of the state of the art, describe methods for building constructions from prefabricated elements, however in none of them is described a method to manufacture prefabricated elements such as modules, panels and roofs from which can build monolithic constructions, durable, versatile, flexible and easy to transport, representing structural and economic advantages over those already known today.

The method of manufacturing modules for building monolithic constructions object of the present invention comprises the steps of: a) Making harnesses, where the harnesses necessary for the manufacture of modules and panels must be manufactured, said harnesses being classified according to their use in structural, electrical, hydraulic, sanitary and gas, b) Manufacturing modules, this being the most important stage, since it is where the foundation is manufactured on which the exterior walls of the module will be manufactured, c) Manufacturing panels and roof, both the interior panels, if required, as the roof are manufactured simultaneously to the modules, d) Integration of the interior panels to the module, e) Assembly of the roof on the walls of the module, and f) Transport and storage of the module already assembled for marketing and distribution.

Objectives of the invention. An objective of the present invention is to provide a method of manufacturing modules for monolithic constructions, from which modules whose functional characteristics and structural resistance are obtained, allow to build long-lasting constructions that meet the established quality and safety standards. for said constructions.

Another objective of the present invention is to provide a method of manufacturing modules for monolithic constructions, which allows a high volume manufacture of said modules at competitive costs.

Another objective of the present invention is to provide a method of manufacturing modules for monolithic constructions, wherein the modules obtained can be stored, transported and placed quickly and easily in the places originally conceived for each stage.

Still another objective of the present invention is to provide a method of manufacturing modules for monolithic constructions, so that through modules obtained constructions of creative and sustainable solutions can be built to the needs of a growing and demanding society such as ours.

These and other objects, as well as the advantages of the module manufacturing method for monolithic constructions of the present invention, will be more clear and evident from the detailed description presented below.

Brief description of the figures. Figure i. A flow diagram is shown where the workstations are represented, as well as the steps and sub-steps of the module manufacturing method for building monolithic constructions, in accordance with the present invention.

Detailed description of the invention. The method of manufacturing modules for building monolithic constructions of the present invention, consists of the following steps: I. Manufacture of harnesses, II. Module manufacturing, III. Panel and roof manufacturing, IV. Integration of the interior panels to the module, V. Assembly of the roof over the walls of the module, and VI. Transport and storage of the module already assembled for marketing and distribution. 1. Manufacture of harnesses In this step, the different types of harnesses that are integrated into each of the parts that form a module obtained according to the present invention, that is to say, are manufactured, preferably in a harness manufacturing unit (see figure i)). This stage is made harnesses for roof, interior panel, foundation and exterior walls, more particularly as detailed below: Rooftop. The manufacture of four harnesses, a structural mesh harness, an electrical harness, a reinforcing structural harness and a harness of union plates are contemplated.

The structural mesh harness for the roof is manufactured from the following steps: i. Using a mesh and wire rod manufacturing machine as a raw material, the electro-welded structural mesh is performed. 2. The mesh is placed in a work station to cut excesses, holes and overlaps according to the specifications. of the harness; 3. The reinforcement rods are fastened, 4. The structural harness identified in the armed harness station (which has already been prefabricated) is installed. In this station the electric harness is integrated to the structural mesh; 5. Flexible pipelines are already connected to electrical boxes and plastic ties are placed on the ends of the cables; 6. It is carried out the sealing of electrical boxes, the identification and verification of quality of the complete harness; Y 7. The integrated harness is transported to the harness store.

The electric harness for the roof is manufactured from the following steps: i. The assembly of electrical boxes consists of the perforation of the boxes and the mooring of the fixing rods, which have already been previously cut to the specified dimension, 2. Using a universal cutting machine, the cutting of the pipeline is carried out to the specified dimensions, 3. Using a cable cutting machine, the cable cutting of various cables and colors is made according to the specified dimensions, 4. The pipeline wiring is carried out in accordance with the specifications given, and The electrical harness is inspected and transported to Step 4 of the roof mesh structural harness.

The structural reinforcement harness for the roof is manufactured from the following steps: 1. Using a universal cutting machine, the rods and the necessary wire rod are cut to the specified dimensions. 2. The reinforcement is tied using annealed wire, and 3. Reinforcements are inspected and transported to the harness warehouse.

The harness of union plates for the roof, is manufactured from the following steps: 1. The cut is made to the specified dimensions of the connecting plates and rods for the anchoring of the plates, 2. They are folded rods through a universal bending machine, 3. Finally the bent rods for anchoring are welded to the jointing plates, and 4. The assembly is inspected and sent to the harness store.

Interior Panel For the Interior Panel, a structural mesh harness, an electric harness and a tie plate harness will be manufactured.

The mesh structural harness for the inner panel is manufactured from the following steps: 1. Using a mesh and wire rod manufacturing machine as a raw material, the electro-welded mesh is made, 2. The mesh is placed in a work station to make the cut of surpluses and overlaps according to the specifications of the module, 3. The tie-in of reinforcing rods is made, 4. The identified structural harness is installed in the assembly station of the electrical harness (which has already been prefabricated). In this station the electric harness is integrated to the structural mesh, 5. Connected flexible pipelines are already wired to electrical boxes and plastic ties are placed on the tips of the cables. 6. The sealing of electrical boxes is carried out, the identification and quality verification of the complete harness, and 7. The integrated harness to the harness warehouse.

The electrical harness for the interior panel is manufactured from the following steps: 1. The assembly of electrical boxes consisting of the perforation of the boxes and the lashing of the fixing rods, which have been previously cut to the specified dimension, 2. Using a universal cutting machine, the cutting of the pipeline is carried out to the specified dimensions, 3. Using a cable cutting machine, the cutting of the cable of various calibers and colors according to the specified dimensions is carried out. performs the pipeline wiring according to the given specifications, and 5. The electrical harness is transported to Step 4 of the mesh structural harness for the inner panel.

The joint plate harness for the inner panel is manufactured from the following steps: 1. The cut is made to the specified dimensions of the connecting plates and rods for the anchoring of the plates, 2. They are doubled the rods by means of a universal bending machine, 3. Finally the bent rods for anchoring are welded to the jointing plates, and 4. The assembly is inspected and sent to the harness store.

Foundation For the Foundation, seven different types of harnesses are manufactured, a structural mesh lower harness, a structural mesh upper harness, an electric harness, a structural harness of beams, a sanitary harness, a harness of union plates and a hydraulic harness .

The bottom mesh structural harness for the foundation is obtained as follows: i. Using a mesh and wire rod manufacturing machine as a raw material, the electro-welded structural mesh is performed. 2. The mesh is placed in a work station to cut excesses, holes and overlaps according to the specifications. of the module, 3. The structural mesh goes to the next station where the bending of the corners and of the lifting channel passages is made, 4. The structural mesh lower harness is inspected and transported to the harness store.

The upper mesh structural harness for the foundation is obtained from the following steps: 1. Using a mesh and wire rod manufacturing machine as raw material, the electro-welded structural mesh is made, 2. The mesh is placed in a work station to make the cut of surpluses, holes and overlaps according to the specifications of the module, 3. The identified structural harness is installed in the electrical harness assembly station (which has already been prefabricated). In this station the electric harness is integrated to the upper structural mesh and quality verification of the whole harness is performed, and 4. The upper mesh structural harness with the integrated electric harness is inspected and transferred to the harness store.

The electrical harness for the foundation is obtained as follows: 1. The assembly of electrical boxes consisting of the drilling of the boxes and the lashing of the fixing rods, which have been previously cut to the specified dimension, are carried out. Using a universal cutting machine, the cutting of the pipeline is done to the specified dimensions, 3. Using a cable cutting machine, the cutting of the cable of various calibers and colors according to the specified dimensions is carried out. perform the pipeline wiring according to the given specifications, and 5. The electrical harness is inspected and transported to Step 3 of the structural upper mesh harness of the foundation.

The structural harness of beams for the foundation is obtained from the following steps: 1. The cutting of rod and wire rod is made using a universal cutting machine and according to the specifications given. 2. The rods and the wire rod are bent by a universal bending machine, 3. Finally the bent rods are tied with stirrups of wire rod and annealed wire to form the beams, and 4. The beams are inspected and transported to the harness store.

The sanitary harness for the foundation is obtained as follows: 1. Using a universal cutting machine, the PVC pipe is cut according to the specified dimensions. 2. The PVC pipe is glued according to the given specifications. , and 3. The sanitary harness is inspected and transported to the harness warehouse.

The harness for joining plates for the foundation is obtained from the following steps: 1. The cut is made to the specified dimensions of the connecting plates and rods for anchoring the plates, 2. The rods are bent by means of a universal bending machine, 3. Finally, the bent rods for the anchoring are welded to the joining plates, and 4. The harness of union plates is inspected and sent to the harness store.

The hydraulic harness for the foundation is obtained as follows: 1. Using a tube cutting machine, the pipe is cut according to the specified dimensions, 2. The union of the pipe is made, which can be by welding, thermofusion or other depending on the type of material of the pipe, and 3. A tightness test is carried out according to the specified, the hydraulic harness is inspected and transported to the harness warehouse.

External walls. For the exterior walls, seven different types of harnesses, a structural mesh harness, an electric harness, a sanitary harness, a hydraulic harness, a gas harness, a union plate harness are also manufactured for the foundation. a door harness.

The structural mesh harness for the exterior walls is obtained as follows: 1. Using a mesh and wire rod manufacturing ine as raw material, the electro-welded structural mesh is made, 2. The mesh is placed in a work station to make the cut of surpluses, holes and overlaps according to the specifications of the module, 3. The tie-in of reinforcing rods is made in doors, windows, discharges, openings, electrical boxes and mooring of reinforcement brackets in corners, 4. The structural harness identified in the electrical harness assembly station (which has already been prefabricated) is installed. In this station the electrical harness is integrated to the structural mesh and quality verification of the whole harness is performed, and 5. The mesh structural harness is transported with the integrated electrical harness to the harness storage.

The electrical harness for exterior walls is obtained from the following steps: 1. The assembly of electrical boxes consisting of the drilling of the boxes and the lashing of the fixing rods, which have been previously cut to the specified dimension, 2. Using a universal cutting ine, the pipeline cut is made to the specified dimensions, 3. Using a cable cutting ine, the cable cut of various calibers and colors is made according to the specified dimensions, The pipeline wiring is carried out in accordance with the given specifications, and 5. The electrical harness is inspected and transported to Step 4 of the external wall mesh structural harness. \ The sanitary harness for exterior walls is obtained as follows: 1. Using a universal cutting ine, the PVC pipe is cut according to the specified dimensions. 2. The PVC pipe is glued according to the given specifications. , and 3. The sanitary harness is inspected and transported to the harness warehouse.

The hydraulic harness is manufactured as follows: 1. Using a tube cutting ine, the pipe is cut according to the specified dimensions, 2. The connection of the pipe is made by means of thermofusion, welding or other suitable means to the material of the pipe used, according to the given specifications, and 3. The hermeticity test is carried out according to the specified, the harness is inspected and transported to the harness store.

MO The gas harness of the exterior walls is obtained as follows: i. Using a universal cutting ine the pipe is cut according to the specified dimensions, 2. The pipe is joined by means of welding or threading and nut, according to the specifications given according to the type of material used in the pipe, and 3. The hermeticity test is carried out according to the specified, the harness is inspected and transported to the harness store.

The harness of outer wall jointing plates is as follows: 1. The cut is made to the specified dimensions of the jointing plates and rods for the anchoring of the plates, 2. The rods are bent by means of a universal bending ine , 3. Finally the bent rods for anchoring are welded to the jointing plates, and 4. The assembly is inspected and sent to the harness store.

The door harness is manufactured from the following steps: 1. Using a universal cutting ine the metal profile is cut according to the specified dimensions, 2. Anchors are manufactured, consisting of the cut of the rebar and the bent of it, 3. The rod for inferior reinforcement is cut using a universal cutting ine, 4. Door frames are manufactured according to the following operations: i. weld anchors in profile sections for door, ii. weld profile sections to form a door frame, iii. solder reinforcing rod on lower part, iv. polish frame welding, and v. seal frame joints; and 5. The harness is inspected and transported to the harness store.

II. Module manufacturing The module manufacturing process consists of five work stations, called A, B, C, D and E, where specific operations are carried out, identified as sub-steps of the manufacturing method, remaining as follows (see figure 1): Subway Station A i. In Station A of the process, an interior wall mold is subjected to a cleaning process, basic maintenance and application of release oil on the surfaces that have contact with the concrete, and Sub-step 2. They are assembled on the interior wall mold. steel, electrical, sanitary, hydraulic and gas mesh harnesses. Likewise, the molds of windows and openings, the door frames and the connection plates to the interior panel and to the roof are placed on the interior wall mold. All this process is carried out according to the specifications given.

Station B Sub-step 3. The platform and the foundation mold are subjected to a cleaning process, basic maintenance and application of release oil on the surfaces that have contact with the concrete, and Sub-step 4. The foundation mold is placed on the platform . This metallic mold is formed by several sections depending on the size of the foundation to be manufactured and according to the specifications given, Sub-step 5. The steel rod ties are assembled on the metal mold, which have been prefabricated in the harness unit. . Next, the steel mesh structural harness that has also been prefabricated in the harness unit is assembled. This structural harness has the corresponding electric harness integrated. Hydraulic and sanitary harnesses are then integrated into the structural harness. v Wall plates and rods are finally installed. These operations are carried out according to the manufacturing drawings. Sub-step 6. Concrete is prepared in the Concrete Plant, preferably hydraulic concrete according to the NMX-C155 Standard and with the required design characteristics, which is perfectly compatible with cellular concrete, which is distributed with a hopper up to the station for effecting the casting of the concrete on the foundation mold, Sub-step 7. When the emptying is completed, the mixing of the concrete is carried out to ensure the consistency and proper distribution of the concrete. Subsequently, it is given a surface finish and polish according to the given specifications, and Sub-step 8. Once the foundation has been finished, the preliminary steam curing is carried out under specifications of temperature, humidity and time to ensure the suitable setting of concrete.

Station C Substack 9. At the end of the curing process, the platform moves to Station C, Sub-step 10. The foundation is demolded and the mold is returned to Station B, Sub-Stage 11. The interior wall mold (originating from from Station A) on the foundation. This mold is metallic and is manufactured in one piece. Previously in Station A, the required harnesses have been assembled on the inner wall mold. Likewise, the molds of windows and bays, the door frames and the junction plates have been placed on the interior wall mold, Sub-step 12. The exterior wall mold is subjected to a cleaning process, basic maintenance and application of Release oil on the surfaces that have contact with the concrete, Sub-step 13. The molding of the walls is completed using an external wall mold that is closed on the interior wall mold. This exterior wall mold is made of metal and is made of two pieces that slide simultaneously with such precision that it allows the tight sealing of the wall mold. The dimensions of the walls are in accordance with the given specifications, Sub-step 14. In the Concrete Plant the cellular concrete is prepared and distributed in a hopper to the station to effect the emptying of the concrete on the wall mold, Sub-step 15. When the emptying is completed, the surface is leveled to ensure the specified slope for the walls, Sub-step 16. The walls are curing until they have set sufficiently, Sub-Stage 17. After the concrete has set for a certain time, the inner wall is demolded and the mold is returned to Station A, Sub-Stage 18. The outer wall mold opens and remains in Station C waiting for the next cycle of molding and casting walls.

Station D Sub-step 19. The platform is moved to Station D, Sub-step 20. Once the walls have been demolded, the final steam curing of the module is carried out under specifications of temperature, humidity and time.

Station E Subtape 21. The platform is moved to Station E, Sub-step 22. Once the foundation-wall combination has its nominal resistance, the module integration process is carried out beginning with the preparation of the surface and the assembly of the interior panel. The interior panel-wall connection is carried out by means of a welding process of the connection plates previously placed both on the foundation and on the outer walls and on the interior panel, Sub-step 23. The preparation of the surface and the assembly of the roof. The roof-wall junction is carried out by means of a welding process of the union plates previously placed both on the walls and on the roof, Subetapa 24. The last phase of the integration process of the module consisting of resane is carried out , detailed and sealed of the module already integrated, Sub-step 25. Once the process of integration of the module has been carried out, the platform moves towards the outside of the plant, Sub-step 26. The module on the platform dries in the middle environment for a certain time, Sub-step 27. The module is removed from the platform and transported to the module warehouse using a gantry crane, Sub-step 28. The platform is returned to Station B to restart the cycle III. Manufacture of panels and roof. Simultaneously to the manufacture of modules, the panel manufacturing unit produces the interior panel and the roof for the integration of the module. The panel manufacturing unit consists of three work stations, identified as F, G, and H, where specific operations are performed, identified as sub-steps of the manufacturing method, in the panel manufacturing unit, the interrelation between these stages as detailed below (see figure 1): Station F Sub-step 29. The platform and the roof mold are subjected to a basic maintenance process and application of release oil on the surfaces that have contact with the concrete, Sub-step 30. The mold of the roof is placed on the platform. This metallic mold is formed by several sections depending on the size of the roof to be manufactured and in accordance with the specifications given, Substack 31. The polystyrene vault is placed on the platform of the mold. The reinforcing reinforcements and the steel mesh structural harness that has been prefabricated in the unit are positioned on the vault. of harnesses This structural harness has the corresponding electric harness integrated. Finally, the wall junction plates Sub-step 32 are installed. In the Concrete Plant, the normal concrete is prepared and distributed in a hopper to the station to effect the emptying of the concrete on the roof mold, Sub-step 33. When Once the emptying has been completed, the vibration of the mixture is carried out to ensure the consistency and proper distribution of the concrete. Subsequently, it is given a surface finish that includes the configuration of the roof parapet according to the given specifications, Sub-step 34. Once the roof has been finished, the preliminary steam curing is performed under temperature specifications, humidity and time to ensure the setting required for the roof.

Station G v Sub-step 35. At the end of the curing process, the platform is moved to Station G, Sub-step 36. After the concrete has set, the roof is demolded and the mold is returned to Station F, Sub-Stage 37. The platform and The mold of the interior panel is subjected to a process of cleaning, basic maintenance and application of release oil on the surfaces that have contact with concrete, Subetapa 38. The inner panel mold is placed on the platform. This metallic mold is formed by several sections depending on the size of the inner panel to be manufactured and according to the given specifications, Substack 39. The steel mesh structural harness that has been prefabricated in the harness unit is assembled. This structural harness has the corresponding electric harness integrated. Finally, the connection plates to exterior walls, Subetapa 40, are installed. In the Concrete Plant, the cellular concrete is prepared and distributed in a hopper to the station to effect the emptying of the concrete on the mold of the interior panel, Substack 41. When the emptying is completed, the surface is leveled and a surface finish is given according to the specifications given, Substage 42. Once the interior panel has been finished, the preliminary steam curing is carried out under specifications of temperature, humidity and time to ensure the proper setting of the concrete, Substack 43. After the concrete has set, it is brought to out the demolding of the interior panel. The mold remains in Station G waiting for the next cycle of molding and emptying the inner panel.

Station H Sub-step 44. The platform is moved to Station H, Sub-stage 45. In Station H, the final steam curing of both the roof and the interior panel is performed under temperature, humidity and time specifications.

IV. Integration of interior panels to the module. This stage of the manufacturing method, consists only of two sub-steps, carried out in a work station identified as I, which in the detail are explained as follows (see figure 1): Station I Sub-step 46. The platform is moved to Station I, Sub-step 47. Using a crane system, the inner panel is transported to Station E where it is assembled in the module.

V. Assembly of the roof over the walls of the module. This stage, also identified as the final stage or operative conclusion of the module manufacturing method for building monolithic constructions, is carried out as the following sub-step (see figure 1): v Sub-step 48. Using the crane system, the roof is transported to Station E where it is assembled on the walls of the module. Once the module is integrated, it is detailed and detailed.

SAW. Transport and storage of the assembled module for commercialization and distribution (see figure 1). Substage 49. Once the roof and the interior panel have been integrated into the module, the platform moves towards the outside of the plant, Substage 50. The platform is returned to Station F to restart the panel manufacturing process.

The cellular concrete that is referred to in the different stages of this manufacturing method, is a concrete of the base type of anhydrous calcium sulphate or anhydrite and Portland cement, which do not have the undesirable effects associated with construction materials that use sulphate of calcium and that at the same time develop high resistance to compression, conserving low volumetric weights that allow them to occupy them as convenient cellular materials in the construction industry. Due to the high compressive strength developed by this type of cellular concrete, these can be used as lightweight structural materials and at the same time provide constructive projects with all the advantages that cellular materials provide, because they also possess the common properties characterize Although for the purposes of the present invention any cellular concrete that provides high compression strengths can be used in such a way that it can be used as a structural material in construction, it is preferable to use the compositions of improved cellular material described by Prieto Gómezs that develop high values of resistance. compression (= no Kg / cm2) and convenient volumetric weights (>1200 Kg / m.3) and whose cellular composition is basically a mixture of the following elements: 1. A cementitious material consisting of: a) Portland cement or Portland cement clinker and b) Anhydrous calcium sulphate, 2. Silica sand, 3. Polyester fiber, 4. Foaming additive, and 5. Water reducing agent.

The method of the present invention has several advantages that are reflected mainly in the significant reduction of the execution time of the work to build various constructions, in the labor used and in the costs, both of the work and of the building finally built , without demerit the quality of the constructions obtained that meet the standards of quality and safety established for them. ? Likewise, the method described here allows obtaining, in high volumes, modules for monolithic constructions that can later be used for any type of construction, whether complete construction, expansion or remodeling. For example, by working at the same time the different work stations that are part of the process of the present invention, a significant amount of building modules can be generated practically in series that can supply the current demand for new housing. On the other hand, the production of high volumes of modules for construction allows them to be offered to the construction industry at very competitive costs.

In this sense, the manufacturing process of modules of the present invention allows a production capacity of up to one module per hour, which under a work structure of three shifts allows to obtain up to 24 modules per day leaving the last stage of manufacture .

This led to a continuous process of field placement, allows to place 8 houses per day of 2 modules each. Each of these houses requires about 1 week for connections and external details to be able to be inhabited, this depends on the speed of preparation of the land where the houses will be placed and the speed of the builder to finish the exterior details and connections of the building.

Due to the above, the process of the present invention allows to significantly reduce the manufacturing time of any building by at least 50% compared to the time invested by traditional manufacturing processes to generate the same buildings. For example, in the case of the generation of two-room houses by the process of the invention, it is possible to obtain them in an average time of 4 weeks, while to generate the same building by means of a traditional method of construction it results in a average time of 8 weeks.

References. 1. Log Artacho Juan Antonio, et. to the. 2005. Building construction system. International patent application PCT / ES2003 / 00Ó431. 2. Shen Grace, Wai-Yee. 2004. Convertible buildings and method of production thereof. International patent application PCT / GB2003 / 005482. 3. Prieto Gómez, Carolina, et. to the. 2005. Improved compositions of cellular materials containing anhydrite and methods for their preparation. Patent application MX PA / a / 2005/001125.

Claims

8 Claims i. A method of manufacturing modules for building monolithic constructions, of the type that are integrated from a plurality of harnesses and a roof, where each module is able to implement a plurality of internal panels, from the which can vary the dimensions, capacities and uses of each construction, the method is characterized because it comprises the steps of: a) manufacture harnesses, in this stage the different types of harnesses are made that are integrated to each of the parts that form the module, that is, in this stage harnesses are made for roof, interior panel, foundations and exterior walls; b) manufacture modules, where sub-stages are carried out along five work stations, called A, B, C, D and E; c) manufacture panels and roof, simultaneously to the manufacture of modules the panel production unit produces the interior panel and the roof for the integration of the module, the panel manufacturing unit consists of three work stations, identified as F, G, and H, where specific operations are performed; d) integration of the interior panels to the module, this stage of the manufacturing method, consists only of two sub-steps, carried out in a work station identified as I; e) assembly of the roof over the walls of the module, this stage also identified as the final stage or operative conclusion of the method of manufacturing modules to build monolithic constructions; and f) transportation and storage of the module already assembled for marketing and distribution. 2. The method according to claim 1, characterized in that in the stage of manufacturing harnesses, four types of harnesses are manufactured for the roof, a structural mesh harness, an electric harness, a reinforcing structural harness and a harness of connecting plates . 3. The method according to claim 1, characterized in that in the stage of making harnesses, a structural mesh harness, an electric harness and a harness of connecting plates are manufactured for the inner panel. 4. The method according to claim 1, characterized in that in the stage of making harnesses, for the foundation, seven different types of harnesses are made, a structural mesh lower harness, a structural mesh upper harness, an electric harness, a harness structural of trabes, a sanitary harness, a harness of union plates and a hydraulic harness. The method according to claim 1, characterized in that in the stage of making harnesses, for the exterior walls, a structural mesh harness, an electric harness, a harness are manufactured sanitary, a hydraulic harness, a gas harness, a harness of union plates and a door harness. The method according to claim 1, characterized in that in the stage of manufacturing modules, in the work station A, the following sub-steps are carried out: Sub-step i) an inner wall mold is subjected to a cleaning process, basic maintenance and application of release oil on the surfaces that have contact with the concrete; and Sub-step
2) the steel, electric, sanitary, hydraulic and gas mesh structural harnesses are assembled on the inner wall mold. The method according to claim 6, further characterized in that in the work station A, the molds of windows and bays, the door frames and the plates of connection to the interior panel and the roof are placed on the interior wall mold. The method according to claim 1, characterized in that in the stage of manufacturing modules, in work station B, the following sub-steps are carried out:
3) the platform and the foundation mold are subjected to a cleaning process, basic maintenance and application of release oil on the surfaces that have contact with the concrete; Sub-step
4) the foundation mold is placed on the platform; Sub-step
5) the steel rod ties are assembled on the metal mold, which have been prefabricated in the harness unit; Sub-step
6) in the concrete plant, the normal concrete is prepared and distributed in a hopper to the station to effect the emptying of the concrete on the foundation mold; Sub-step
7) when the emptying is completed, the vibration of the mixture is carried out to ensure the consistency and proper distribution of the concrete and then it is given a surface finish and polish according to the specifications given; and Sub-step
8) once the foundation has been finished, the preliminary steam curing is carried out under specifications of temperature, humidity and time to ensure adequate setting of the concrete. The method according to claim 8, further characterized in that in the workstation B, between the sub-steps 5) and 6) the steel mesh structural harness which has also been prefabricated in the harness unit is assembled, this structural harness it has the corresponding electric harness integrated, then the hydraulic and sanitary harnesses are integrated to the structural harness, to finally install the plates and rods for joining to walls. The method according to claim 1, characterized in that in the stage of manufacturing modules, in the work station C, the following sub-steps are performed: Sub-step
9) at the end of the curing process, the platform moves to station C; Sub-step
10) the foundation is demolded and the mold is returned to station B; Sub-step
11) the inner wall mold (coming from station A) is placed on the foundation; Sub-step
12) the wall mold The exterior is subjected to a cleaning process, basic maintenance and application of release oil on the surfaces that have contact with the concrete; Sub-step
13) the molding of walls is completed using an external wall mold that closes on the interior wall mold; Sub-step
14) in the concrete plant is prepared cellular concrete that is distributed in a hopper to the station to effect the emptying of the concrete on the wall mold; Sub-step
15) when the emptying is completed, the surface is leveled to ensure the specified slope for the walls; Sub-step
16) the preliminary curing of the walls is carried out, remaining there until the concrete has set sufficiently; Sub-step
17) after the concrete has been set for a certain time, the inner wall is demolded and the mold is returned to station A; and Sub-step
18) the outer wall mold opens and remains in station C waiting for the next wall molding and emptying cycle. The method according to claim 1, characterized in that in the step of manufacturing modules, in the workstation D, the following sub-steps are performed: Sub-step
19) the platform is moved to station D; and Sub-step
20) once the walls have been demolded, the final steam curing of the module is carried out under specifications of temperature, humidity and time. The method according to claim 1, characterized in that in the step of manufacturing modules, in the work station E, the following sub-steps are performed: Sub-step
21) the platform is moved to station E; Sub-step
22) once the foundation-walls combination has its nominal strength, the module integration process is carried out beginning with the preparation of the surface and the assembly of the interior panel; Sub-stage
23) the preparation of the surface and the assembly of the roof is carried out .; Sub-step
24) the last phase of the integration process of the module consisting of resane, detailed and sealed of the already integrated module is carried out; Sub-step
25) once the module integration process has been carried out, the platform moves towards the outside of the plant; Substage
26) the module on the platform dries to the environment for a certain time; Sub-step
27) the module is removed from the platform and transported to the module warehouse using a gantry-type crane; and Sub-step
28) the platform is returned to station B to restart the cycle. The method according to claim 12, further characterized in that in the stage of manufacturing modules, in the work station E, the interior panel-walls junction is carried out by a welding process of the union plates previously placed in both the foundation as in the exterior walls and in the interior panel. 14. The method according to claim 12, further characterized in that in the step of manufacturing modules, in the work station E, the roof-wall junction is carried out by means of a welding process of the union plates previously placed both on the walls and on the roof. The method according to claim 1, characterized in that in the stage of manufacturing panels and roof, in the work station F, the following sub-steps are carried out: Sub-step
29) the platform and the roof mold are subjected to a maintenance process basic and application of release oil on the surfaces that have contact with the concrete; Sub-step
30) the mold of the roof is placed on the platform; Sub-step
31) the polystyrene vault is placed on the platform of the mold; Sub-step
32) in the concrete plant, the normal concrete is prepared, which is distributed in a hopper to the station to effect the emptying of the concrete on the mold of the roof; Sub-step
33) when the emptying is completed, the vibration of the mixture is carried out to ensure the consistency and proper distribution of the concrete, then a surface finish is given that includes the configuration of the roof parapet according to the specifications given; and Sub-step
34) once the roof has been finished, preliminary preliminary steam curing is performed under temperature, humidity and time specifications to ensure the required setting for the roof. The method according to claim 1, characterized in that in the stage of manufacturing panels and roof, in the work station G, the following sub-steps are made: Sub-step
35) at the end of the curing process, the platform moves to station G; Sub-step
36) after the concrete has set, the roof is demolded and the mold is returned to station F; Substate
37) the platform and the mold of the interior panel are subjected to a process of cleaning, basic maintenance and application of release oil on the surfaces that have contact with the concrete; Sub-step
38) the inner panel mold is placed on the platform; Sub-step
39) the structural steel mesh harness that has been prefabricated in the harness unit is assembled; Sub-step
40) in the concrete plant is prepared cellular concrete that is distributed in a hopper to the station to effect the emptying of the concrete on the mold of the interior panel; Sub-step
41) when the emptying is completed, the surface is leveled and a surface finish is given according to the specifications given; Substage
42) once the interior panel has been finished, the preliminary steam curing is carried out under temperature, humidity and time specifications to ensure adequate setting of the concrete; and Substage
43) after the setting of the concrete, the demolding of the interior panel is carried out, the mold remains in station G waiting for the next molding and emptying cycle of the interior panel. The method according to claim 1, characterized in that in the stage of manufacturing panels and roof, in the workstation H, the following sub-steps are performed: Sub-step
44) move the platform to station H; and Sub-step
45) the final steam curing of both the roof and the interior panel is performed under temperature, humidity and time specifications. 18. The method according to claim 1, characterized in that in the step of integrating the panels inside the module, in the work station I, the following sub-steps are performed: Sub-step
46) the platform is moved to station I; and Sub-step
47) using a crane system, the inner panel is transported to station E where it is assembled in the module. 19. The method according to claim 1, characterized in that in the stage of assembling the roof over the walls of the module, the following sub-step is performed: Sub-step
48) using a crane system, the roof is transported to station E where it is assembles on the walls of the module and once the module is integrated, it is detailed and detailed. 20. The method according to claim 1, characterized in that in the stage of transport and storage of the module already assembled for marketing and distribution, the following sub-steps are performed: Sub-step
49) once the roof and the interior panel have been integrated module, the platform moves towards the outside of the plant; and Sub-step
50) the platform is returned to station F to restart the panel manufacturing process.