US3762122A - Prefabricated buildings - Google Patents

Prefabricated buildings Download PDF

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Publication number
US3762122A
US3762122A US00105835A US3762122DA US3762122A US 3762122 A US3762122 A US 3762122A US 00105835 A US00105835 A US 00105835A US 3762122D A US3762122D A US 3762122DA US 3762122 A US3762122 A US 3762122A
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United States
Prior art keywords
floor panel
end structure
gap
tie members
filler
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Expired - Lifetime
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US00105835A
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English (en)
Inventor
H Grassl
R Mueller
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Elcon AG
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Elcon AG
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    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • E04B1/348—Structures composed of units comprising at least considerable parts of two sides of a room, e.g. box-like or cell-like units closed or in skeleton form
    • E04B1/34815—Elements not integrated in a skeleton
    • E04B1/34823—Elements not integrated in a skeleton the supporting structure consisting of concrete

Definitions

  • ABSTRACT A structural unit for, a transportable prefabricated room element used in the construction of buildings comprises a prefabricated floor panel and rigidly attached to one or each of two opposite ends of the panel, an'upstanding, prefabricated, load-bearing end structure.
  • tie rods which extend within the latter into holes in the end structure and are anchored to the end structure.
  • the tie rods extend through the panel and connect the two end structures together.
  • This invention relates to prefabricated buildings having at least one storey which comprises transportable prefabricated room elements as hereinafter defined, and to the construction of structural units for use in the manufacture of such room elements.
  • transportable prefabricated room element is employed herein to define a transportable prefabricated cell-like structure haveing two opposed sides and two opposed ends constituting four faces of the cell, and comprising a floor panel, and preferably a roof or ceiling, and a vertical load-bearing end structure at each end of the floor panel and rigidly connected thereto for supporting parts of the building (such for example as the roof or ceiling, or the floor panel of a superimposed room room element) extending over and positioned above the floor panel, which room element is adapted to be mounted side-by-side, or end-to-end, or end-to-side, with a further room element in building up a storey of a building from a plurality of such elements.
  • the expression end structure includes a wall, and also includes a vertical column, and a structure comprising spaced vertical columns which may be initially separate from each other.
  • the said spaced columns may support fill-in panelling to'close or partly close an end or side of the room element and the expression fill-in panelling includes a wall panel, a door, or a window, and in the case of the wall panel the latter may be integral with two columns between which it extends or may be attached to them. If one or each end structure comprises two columns, the latter are desirably spaced apart by a distance which is at least sufficient to permit a door or window to be accommodated between them.
  • Such room elements and buildings incorporating them are disclosed in British Pat. Nos. 1,027,241, 1,027,242 and 1,034,101 and US. Pats. Nos. 3,377,755, 3,416,273, 3,473,273, and 3,460,308.
  • An object of the present invention is a rigid structural unit incorporating the floor panel and the end structure or structures which unit is adapted to be incorporated in a transportable prefabricated room element. Another object of the invention is a method of joining each end structure to the floor panel.
  • U'.S. Pats. Nos. 3,377,755 and 3,473,273 disclose various ways of making the joint between a prefabricated floor panel and a prefabricated end structure, some of which involve the use of an adhesive such as an adhesive cement of an epoxy resin. These procedures have a certain drawback.
  • the first is the relatively long period required for the setting of the adhesive cement in the joint: this leads to a bottle-neck in the manufacture of room elements and a corresponding increase in cost and a reduction in output per square foot of floor area in the assembly hall where the room panel and an upstanding, prefabricated, load-bearing end structure rigidly attached to at least one end of the panel with a gap between the structure and the adjacent end of the panel which gap is occupied by a set or hardened filling, wherein the panel is provided with tie members (e.g., tie rods) which extend within it and the ends of which tie members protrude from the panel end into holes (or channels) in the structure and are anchored to the latter, desirably with the tie members under tension.
  • tie members e.g., tie rods
  • the end structure is connected to the end of the panel, at each of two locations spaced apart widthwise of the panel, by two said tie members which are spaced apart heightwise of the structure. This ensures that a force applied to the end structure and tending to alter its angle with the panel, will always be resisted by differential tension in the tie members and differential compression in the filling.
  • Each tie member may extend within the panel for a part only of the length of the panel, with its inner end anchored within the panel.
  • the tie members may extend completely through the panel to connect the end structures.
  • the invention further provides in the manufacture of a structural unit in or for a transportable prefabricated room element as hereinbefore defined, which unit comprises a prefabricated floor panel and an upstanding, prefabricated, load-bearing end structure rigidly attached to at least one end of the panel by tie members extending within the panel and having ends protruding into and secured within holes (or channels) in the end structure, a method of making the joint between the panel and end structure which comprises: (a) effecting such relative movement between the panel and end structure as will enter the tie members into the holes but leaving a gap between the end of the panel and the structure, (b) introducing into the gap a setting filling the thickness of which when set fixes the final width of the gap, (0) placing the tie members under tension while holding the panel and end structure in a fixed position, and (d) after the filling has set, anchoring the end of the tie members in the end structure so that the latter is biased towards the end of the panel.
  • the tension should be at least sufficient to hold the joint firm and to prevent the filling from being stressed in tension.
  • One embodiment of this method comprises the sequential steps of (a) effecting such relative movement between the end structure and panel as will enter the tie members into the holes but leaving an over-size gap between the end structure and the adjacent end structure of the panel, (b) introducing the setting filling into the over-size gap, (0) adjusting the panel and structure to their final positions and thereby narrowing the gap to its final width, (d) holding them in their final positions while the filling sets or hardens, and (e) anchoring the tie members under tension to the end structure.
  • the gap may be brought to its final width before the setting filling is introduced into it.
  • Important subsidiary features of the invention are the acceleration of the setting of the filling by heat supplied by a resistance-heating element buried in it, or by an external high frequency generator, or the use of a quick-freezing metal as the filling, the molten metal being introduced into the gap after the latter has been brought to its final width.
  • FIG. 1 is a sectional elevation through adjacent parts of the floor panel and end structure showing the joint;
  • FIG. 2 is a view similar to FIG. 1 showing a modified joint
  • FIG. 3 is a section taken on the line 33 in FIG. 2;
  • FIG. 4 is a sectional'elevation of a further joint
  • FIG. 5 is an elevation of the end structure looking from the left in FIG. 4;
  • FIG. 6 is a sectional elevation showing a still further joint
  • FIG. 7 is a perspective view of the lower part of the structure in FIG. 6;
  • FIG. 8 is a perspective view of one corner of a floor panel and the adjacent column of an end structure, and illustrates the use of high frequency heating
  • FIG. 9 is a perspective view of one end of a structural unit according to this invention.
  • FIG. 10 is a perspective view illustrating the fabrication of the structural unit in ajig according to US. Pat. No. 3,460,308.
  • FIG. 1 there is shown in vertical section a representative end portion of a precast reinforced concrete floor panel 1 and a precast reinforced concrete end structure 2.
  • Component 2 is representative of a wall which extends across the end of the floor panel or one of a pair of vertical loadbearing pillars or columns located adjacent opposite corners of that end of the panel.
  • FIG. 9 shows an end structure 2 consisting of two vertical columns 2a and an integral cross beam 2b.
  • FIG. 1 there is a pair of joint elements each of which consists of a screw-threaded rod 3 precast into the floor panel 1 by means of an anchoring element or abutment 4 to which the buried end of the rod is fastened by a nut 5.
  • Corresponding anchoring elements or abutments 4 are precast into the structure 2. It will be seen that the rods 3 are spaced apart in the vertical direction within the thickness of the panel 1.
  • each rod 3 extends through a tube (or channels) 6 which is precast into the floor panel.
  • the rods 3 protrude from the end face of the panel 1 and are received in clearance holes (or channels) in the structure 2 which are defined by tubes 5 precast into the component and leading to the elements 4.
  • the elements 4 and 4' need not be welded or otherwise fixed to the reinforcements (not shown) of the panel I and structure 2. It is sufficient that some of the reinforcements surround the elements 4, 4 in a well understood manner so that the concrete in the zone between the reinforcements and the elements 4, 4' respectively is stressed in compression when transmitting any tension forces in the rods 3 to the elements 4, 4.
  • the structure 2 and the floor panel are moved relatively in the general plane of the latter until the protruding ends of the rods 3 enter the tubes 5 and the anchorage elements 4', rubber sealing rings 8 having first been placed around the rods.
  • a gap 9 is left between the end of the floor panel 1 and the face of the structure 2, its width at this stage being greater than its final width.
  • This gap is occupied by a layer of dry mortar 9' which may be applied to the panel 1 and structure 2 while they are still separated or may be subsequently introduced into the gap 9.
  • the component 2 is thereupon moved into its predetermined final position in which it is held rigidly until the mortar is hardened to a compressive strength, of for example, about Kg/cm This may take about one hour.
  • nuts 10 are screwed onto the ends of the rods 3 within pockets 11 in the structure 2 and are tightened so as to place the rods under a certain degree of tension.
  • the cavities are filled with a plastic or other suitable filler 11'.
  • a grouting or setting filling of cement slurry (preferably of a composition which will expand slightly on setting) is injected through the injection tubes 7 into the clearance between the interior of tubes 6 and 5 and the rods.
  • the chief difference between the construction shown in FIG. 1 and that shown in FIGS. 2 and 3 is the replacement of the rods 3 by the post-tensioning rods 12 which traverse the floor panel 1 in the longitudinal direction from end to end and are not fixed to the reinforcement. They are provided, in a manner known per se, with a coating which delays a firm bond between the rods and the surrounding concrete for, say, one or two weeks until after the post-tensioning has been carried out.
  • the rods 12 can be laid as in FIG. 1, in tubes (or channels) which are cast into the floor panel and which are filled with a cement slurry after post-tensioning. As will be seen from FIG. 2 the rods 12 are slightly inclined upwards towards their ends (which are received in clearance holes 14 in each end structure 2).
  • the metal rods which transmit any tension forces between the floor panel and the end structure, are positively secured in both. These forces are not transmitted across a weld or across an adhesive cement layer stressed in shear, and the joints are therefore safe and fireproof.
  • both of the foregoing embodiments suffer from the drawback that, after assembly, a considerable time must elapse until the dry mortar in the gap 9 has hardened.
  • a resistance-heating element comprising an electrically conducting mesh 25 cut to size is introduced into the gap where it is position by the rubber rings 26.
  • This mesh may consist of galvanized wire rods; e.g., welded wire rods 1mm in diameter at a pitch of 12 X 12mm.
  • the top and bottom ends of the mesh are suitably connected at 18 and 118' to an electrical power supply which heats the wires and therefore greatly shortens the setting time of the mortar filling the gap. Good results have been obtained by applying power at about 3Kw and a voltage between 4 and 8.
  • a very suitable mortar consists of:
  • the setting time is reduced from at least one hour to only about 15 minutes. After this time lapse the mortar is hard enough to take in compression the stresses imposed on it by the tension rods.
  • the water content of the mortar can be reduced by reducing the amount of clay, say from percent to 6 percent, and reducing the water glass (or its water content) to a minimum to give a drier mix.
  • FIGS. 6 and 7 The alternative method illustration in FIGS. 6 and 7 is applicable to the joint shown in FIG. 1 and to that shown in FIGS. 2 and 3.
  • a U-shaped resilient gasket 19 (of for example, neoprene rubber) is positioned at the middle region of the gap to define a cavity 20 through which the rings 26 extend.
  • a low melting alloy is poured into this cavity, which alloy freezes rapidly by loss of heat to the concrete faces of the gap.
  • a relatively inexpensive and suitable alloy consists of lead with the addition of, for example, 4 percent antimony.
  • the alloy cools and hardens to such an extent that it is capable of taking the tension forces exerted by the rods after post-tensioning, without yielding.
  • the yield point of the alloy may vary between 200 and 500 Kg/cm" according to the antimony content and the total area of the cavity must be adjusted accordingly.
  • the volume of the gap other than that enclosed by the gasket 19 is filled with dry mortar as described above which will set in the course of the subsequent manufacturing stages. The alloy layer is thereby firmly insulated and fireproofed.
  • FIG. 8 illustrates the accelerated curing of the mortar joint 9' in the gap 9 between an end of the floor panel I and a pillar of the end structure 2, copper electrodes 21 connected to a highfrequency generator are applied to the components so as to close the vertical edges of the over-size gap and to act as shuttering for the mortar.
  • the bottom edge of the gap is closed by a strip of adhesive tape 22.
  • Type BBC 10 (Brown-Boveri product) Output l0 kw Frequency l3.6 MHZ lnput 380 V 50 CPS 3-Phase Full load demand 19 kw.
  • the area of the void (between the base of each column or pillar 2a and the end face of the floor panel) is 220 X 350 mm and its width is about 10mm.
  • the assembly and positioning of the floor panel and each end structure may be carried out by the method and by use of a jig which forms the subject of US. Pat No. 3,460,308.
  • FIG. 10 is a view corresponding to FIG. 1 to that Patent and shows the fabrication, in the jig, of a structural unit comprising the floor panel l and an end structure 2 rigidly attached to each end of the panel at the base of each vertical column 2a.
  • a high frequency generator is shown at 24, supplying electrodes 21 (FIG. 8) through leads 28.
  • the manner in which the end structures and panel are relatively positioned by the jig, while they are being permanently connected in such manner that all linear and angular dimensions of the finished units have a high degree of accuracy irrespective of the manufacturing tolerances of the three components will be appreciated from the said Patent.
  • each end structure can be adjusted along the protruding ends of the tie rods to positions determined by limit stops in the jig, and the fact that said protruding ends are received in clearance holes in the end structures permits the heightwise and widthwise location of the end structures in relation to the panel, and the angular attitude of each end structure in its own plane and also in relation to the surface of the panel, also to be fixed by limit stops in the jig.
  • a method for the manufacture of a structural unit for a transportable prefabricated room element comprising the steps of:
  • tie members protruding from the floor panel being positioned in corresponding channels in the base of the end structure
  • the method of claim 1 further comprising the step of positioning retaining means in the gap, the retaining means defining a cavity, and filling the cavity with the setting filler.
  • the method of claim 9 further comprising the step of adjusting the width of the gap to a final predetermined width after the gap is filled with a setting filler.
  • a method for the manufacture of a structural unit for a transportable prefabricated room element comprising the steps of:

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  • Engineering & Computer Science (AREA)
  • Architecture (AREA)
  • Physics & Mathematics (AREA)
  • Electromagnetism (AREA)
  • Civil Engineering (AREA)
  • Structural Engineering (AREA)
  • Floor Finish (AREA)
  • Manufacturing Of Tubular Articles Or Embedded Moulded Articles (AREA)
  • Joining Of Building Structures In Genera (AREA)
US00105835A 1970-01-17 1971-01-12 Prefabricated buildings Expired - Lifetime US3762122A (en)

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Application Number Priority Date Filing Date Title
GB239870 1970-01-17

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US3762122A true US3762122A (en) 1973-10-02

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US00105835A Expired - Lifetime US3762122A (en) 1970-01-17 1971-01-12 Prefabricated buildings

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US (1) US3762122A (enrdf_load_stackoverflow)
BE (1) BE761675A (enrdf_load_stackoverflow)
CA (1) CA956133A (enrdf_load_stackoverflow)
CH (1) CH518422A (enrdf_load_stackoverflow)
DE (2) DE2101593A1 (enrdf_load_stackoverflow)
FR (1) FR2080912B1 (enrdf_load_stackoverflow)
GB (1) GB1333743A (enrdf_load_stackoverflow)
NL (1) NL7100533A (enrdf_load_stackoverflow)
SE (1) SE385932B (enrdf_load_stackoverflow)
ZA (1) ZA71212B (enrdf_load_stackoverflow)

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20110265403A1 (en) * 2010-04-28 2011-11-03 Seo Ji Kim Precast concrete structure and method of constructing the same

Families Citing this family (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB1478964A (en) * 1973-06-21 1977-07-06 Credelca Ag Buildings

Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US446511A (en) * 1891-02-17 Pipe-coupling nipple
US2075633A (en) * 1936-05-27 1937-03-30 Frederick O Anderegg Reenforced ceramic building construction and method of assembly
US3111569A (en) * 1958-06-20 1963-11-19 Rubenstein David Packaged laminated constructions
US3319387A (en) * 1963-10-03 1967-05-16 Edeltraud Polonyi Roof structure of concrete blocks having wave-shaped passages containing stressed reinforcing
US3473273A (en) * 1964-07-11 1969-10-21 Dietrich Gunkel Pre-assembled,sub-enclosure,building section

Family Cites Families (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
FR1452292A (fr) * 1965-08-20 1966-02-25 Elcon Ag Perfectionnements dans la fabrication d'unités structurales
FR1461555A (fr) * 1965-10-25 1966-02-25 Perfectionnement à la construction de bâtiments

Patent Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US446511A (en) * 1891-02-17 Pipe-coupling nipple
US2075633A (en) * 1936-05-27 1937-03-30 Frederick O Anderegg Reenforced ceramic building construction and method of assembly
US3111569A (en) * 1958-06-20 1963-11-19 Rubenstein David Packaged laminated constructions
US3319387A (en) * 1963-10-03 1967-05-16 Edeltraud Polonyi Roof structure of concrete blocks having wave-shaped passages containing stressed reinforcing
US3473273A (en) * 1964-07-11 1969-10-21 Dietrich Gunkel Pre-assembled,sub-enclosure,building section

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20110265403A1 (en) * 2010-04-28 2011-11-03 Seo Ji Kim Precast concrete structure and method of constructing the same

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Publication number Publication date
FR2080912A1 (enrdf_load_stackoverflow) 1971-11-26
BE761675A (fr) 1971-07-01
ZA71212B (en) 1971-10-27
NL7100533A (enrdf_load_stackoverflow) 1971-07-20
CH518422A (de) 1972-01-31
SE385932B (sv) 1976-07-26
DE2166505A1 (de) 1974-05-09
DE2101593A1 (de) 1971-08-19
FR2080912B1 (enrdf_load_stackoverflow) 1975-01-17
CA956133A (en) 1974-10-15
GB1333743A (en) 1973-10-17

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