WO2009118480A2

WO2009118480A2 - Method for making buildings from prefabricated modules

Info

Publication number: WO2009118480A2
Application number: PCT/FR2009/000239
Authority: WO
Inventors: Françoise DAURON
Original assignee: Dauron Francoise
Priority date: 2008-03-18
Filing date: 2009-03-06
Publication date: 2009-10-01
Also published as: IL208192A0; FR2928944B1; EP2257677A2; WO2009118480A3; FR2928944A1

Abstract

The invention relates to a method for making buildings from prefabricated modules comprising filtering formworks each including at least two bearing structures (S1, S2) each comprising two walls located in intersecting or parallel planes (P11, P12, P21, P22), each including fittings (111, 121, 211, 221, 112, 122, 212, 222) arranged in two intersecting or substantially orthogonal directions, said walls (P11, P12, P21, P22) being maintained at a required distance by struts (31, 32), provided that the two bearing structures (S1, S2) are hinged relative to each other by a rotary link including a fitting (111) of one of said parallel walls (P11) of the first bearing structure (S1) and one of said struts (3) of the second bearing structure (S2).

Description

METHOD FOR PRODUCING BUILDINGS FROM PREFABRICATED MODULES

The present invention relates to a method of making buildings from prefabricated modules.

This process applies in particular to the construction of buildings that meet the requirements of economic development and respect for the environment.

In fact, new housing needs, estimated only in France, are estimated, according to sources, at 1 million or even 3 million; they must, of course, meet the sustainable environmental constraints, knowing that specialized labor is in sharp decline, that the cost of labor is increasing, that materials are becoming more expensive and that purchasing power of housing applicants is falling.

In a general way, we know that the way of prefabrication makes it possible to reconcile these imperatives; nevertheless, in heavy prefabrication, the advantages are destroyed by the constraints of supply, assembly and implementation of prefabricated products on the site.

Moreover, the realization of cast concrete wall requires, before pouring concrete to define the volume in which the material will be poured using formwork walls; to ensure the tensile strength of the concrete, it is known to house concrete reinforcing bars which, assembled together, constitute a reinforcement. Although the technique of pouring concrete using shuttering is widely used, a few years ago the technique of lost filtering formwork appeared on the market; this technique has the advantage of allowing the evacuation of excess water from the concrete which ensures the mobility of the solid aggregates of the concrete during the mixing and the implementation in the formwork.

Thus, thanks to the filtering wall, the concrete contained in the formwork no longer behaves like a fluid creating a hydrostatic pressure, which is proportional to the height of concrete poured above the level considered and therefore, the forces developed by this concrete are much weaker.

This technique therefore makes it possible to use lightweight forms that can be put in place without the need for a lifting device. By this filtering arrangement, the skeleton of the formwork, which must withstand the filling forces, is considerably reduced (in a ratio of 1/90, for example). It is therefore more interesting to recover this skeleton formwork, but on the contrary judicious to integrate it into the book. This skeleton can be constituted by a three-dimensional assembly made of standard high adhesion steels used in reinforced concrete technique, which will constitute the desired reinforcement of the final work.

In the embodiments known to date, this filtering form is in the form of two walls: - obtained by assembling permeable panels retaining the aggregates and allowing the water to escape, the panels being, for example expanded metal, and ,

- Maintained by a supporting structure consisting of two parallel walls, each formed of fittings arranged in two substantially orthogonal directions, these walls being maintained at the required spacing by spacers. Considering the low mass of these filtering forms, it is possible to associate with them the specific servitudes of the housing, namely, the technical ducts including plumbing, electricity, heating, as well as the insulating walls and any reinforcements.

Thus, said filter forms, equipped with their easements, can be made in the factory, then transported on site; as for the concrete, it will, of course, be poured on site. But as the technology does not require dismantling of formwork, the concrete may be of a slower setting than the concretes traditionally used.

Nevertheless, this pre-equipped filtering formwork technique requires the positioning and assembly of the various filter forms, in accordance with the desired structure, on the site; in a general way, one proceeds to the positioning of the formwork of the slab then to the assembly of the forms of the vertical walls; these on-site operations must be carried out with precision, especially in the case of collective buildings.

The invention more particularly aims to eliminate these disadvantages. For this purpose, it proposes a method of producing buildings involving bearing structures consisting of two walls, formed of brackets arranged in two substantially orthogonal directions, these walls being maintained at the spacing required by spacers; according to the invention, this method consists in associating at least two of said support structures by a rotary connection consisting of a fitting of one of said parallel walls of the first supporting structure and one of said spacers of the second supporting structure. Thus, this rotary connection makes it possible to associate two supporting structures, which rotary connection can be reproduced as many times as necessary.

The invention particularly relates to a method of producing buildings from prefabricated modules consisting of filtering forms each comprising at least two supporting structures, each having two walls located in different planes and for example parallel, each comprising fittings arranged in two intersecting or substantially orthogonal directions, these walls being maintained at the spacing required by spacers, it being understood that the two supporting structures are articulated to one another by a rotary connection comprising a fitting of one of said walls parallel of the first carrier structure and one of said spacers of the second carrier structure.

Advantageously, the aforesaid rotary connection may allow to associate two carrier structures and thus one of said carrier structures may be associated with a third carrier structure by a second rotary link; the axis of rotation of the second rotary connection may be parallel, orthogonal, or oblique with respect to the axis of rotation of the first rotary connection, depending on whether the second rotary connection is made from a fitting of one said parallel walls of the second supporting structure and one of said spacers of the third supporting structure; the fitting of one of said parallel walls of the second supporting structure may be parallel, orthogonal or oblique with respect to the axis of rotation of the first rotary link.

Thus the combination of several supporting structures by means of parallel and orthogonal rotary links may constitute a set of filtering forms, which filtering forms will be equipped with the corresponding servitudes and will constitute prefabricated modules; these prefabricated modules will be assembled beforehand and positioned in the factory face against face for transport, then deployed in a pre-established sequence on site, to result in the constitution of the frame of an individual dwelling or a collective housing element; it will then suffice to fill the filtering forms of said prefabricated modules with concrete compatible with said filtering forms.

One embodiment of the method according to the invention will be described below, by way of nonlimiting example, with reference to the accompanying drawings in which:

Figure 1 is a schematic representation of a carrier structure;

Figure 2 shows two planar bearing structures, positioned at right angles;

Figure 3 shows two planar bearing structures, positioned at substantially an angle of 45 °;

Figure 4 shows two planar bearing structures positioned face to face;

Figure 5 is a schematic representation of a set of prefabricated modules assembled and positioned face to face;

Figure 6 shows the set of prefabricated modules in the deployment position of the floor slab;

FIG. 7 represents the set of prefabricated modules in the deployed floor slab position; FIG. 8 represents the set of prefabricated modules in deployment position of the partitions;

FIG. 9 represents the set of prefabricated modules in deployment position of the partitions;

FIG. 10 represents the set of prefabricated modules in deployment position of the partitions;

FIG. 11 represents the set of prefabricated modules in the position of deployed partitions;

Figure 12 shows the set of prefabricated modules during the filling of the formwork;

Fig. 13 is a schematic representation of a finished individual housing; and

Figure 14 is a schematic representation of a finished collective dwelling.

In the example shown in FIG. 1, a carrier structure S consists of two parallel walls P1, P2; each of said walls P1, P2, consists of fittings arranged in two directions, for example orthogonal, respectively 11, 12 and 21, 22; thus said brackets 11 and 21 are of parallel directions; it is the same of said brackets 12 and 22. The spacings separating the fittings 11 of the wall Pl are, in this example, constant and equal to the spacings separating the fittings 21 from the wall P2. The spacings separating the fittings 12 from the wall P1 are in this example constant and equal to the spacings separating the fittings 22 from the wall P2.

A set of spacers 3, located in a secant plane and here orthogonal to the plane defined by said walls P1, P2, maintain the two walls P1, P2 at a defined spacing; these zig-zag shaped spacers, bypass the hardware 11 of the partition Pl then 21 of the wall P2, and so on; each of said spacers 3 are spaced apart by a spacing equivalent to the spacing of the fittings 12 and 22.

More precisely, a first spacer 3 bypasses an even-numbered fitting 11 of the wall P1, then an odd-order fitting of the wall P2, and so on; the second spacer 3 bypasses a bracket 11 of odd order of the wall Pl, then an even-order fitting of the wall P2, and so on.

By this arrangement, the forces in the steels are no longer transmitted by a welded type connection but by the total section of zigzag-shaped steels. This feature greatly increases the elastoplastic field of reinforced concrete and leads to very clear improvements for structures subjected to accidental loads (earthquakes, for example).

According to the example shown in FIG. 1, at the end of the carrier structure S, the fittings 12 of the wall P1 are folded at an exemplary angle of 180 ° in the direction of the fittings 22 of the wall P2 and at a spacing equivalent to distance separating the two walls P1, P2; it is the same of the fittings 22 of the wall P2 which are thus bent at an angle, for example by 180 ° in the direction of the fittings 12 of the wall P1 and at a spacing equivalent to the distance separating the two walls P1, P2 . The sections orthogonal to the walls P1, P2 of said fittings 12, 22 are spaced apart from the end fittings 11, 21 respectively from the walls P1, P2 of a value substantially equivalent to that between the fittings 11 and 21, and complies with the usual rules for the continuity of steels.

Thus, the carrier structure S constitutes an almost rigid assembly and has in the vicinity of one side which separates the two walls P1, P2, and perpendicular to the plane defined by the spacers 3, a rounded edge which will constitute the end associated with a connection rotation defined below.

In the example shown in FIG. 2, a carrier structure S1 consists of two parallel walls P1, P21; each of said walls PI 1,

P21, consists of brackets arranged in two orthogonal directions, respectively 111, 121 and 211, 221.

A set of spacers 31, located in a plane substantially orthogonal to the plane defined by said walls P1, P21, maintain the two walls P1, P21 at a defined spacing; these zig-zag shaped spacers, bypass the fittings 111 of the partition PI l and 211 of the wall P21, and so on; each of said spacers 31 are spaced apart by a spacing equivalent to the spacing of the fittings 121 and 221.

Similarly, a support structure S2 consists of two substantially parallel walls P 12, P 22; each of said walls P 12, P 22 consists of fittings arranged in two substantially orthogonal directions, respectively 112, 122 and 212, 222. A set of spacers 32, situated in a plane substantially orthogonal to the plane defined by said walls P 12, P22, maintain the two walls P 12, P 22 according to a defined spacing; these spacers of zigzag shape, bypass the fittings 112 of the partition P 12 and 212 of the wall P22, and so on; each of said spacers 32 are spaced apart at a spacing equivalent to the spacing of the fittings 122 and 222. Each of said carrier structures S1, S2 comprises, according to a small side, the bending of the fittings respectively 121 in the direction of the fittings 221 and vice versa, and fittings 122 in the direction of the fittings 222 and reciprocally.

A rotary connection between said carrier structures S1, S2 is obtained by ensuring that the end fitting 111 of the wall P1 of the carrier structure S1 replaces the end fitting 112 of the wall P12 of the support structure S2. . Thus, the two supporting structures Sl, S2 are made integral with each other along an axis of rotation Δ corresponding to the axis of the aforesaid end fitting 111 of the wall PI 1 of the supporting structure S 1.

According to the example shown in FIG. 2, said carrier structures S1, S2 are arranged substantially orthogonally.

In the example shown in FIG. 3, a carrier structure S1, consisting of two parallel walls P1, P21, is associated with a support structure S2 consisting of two parallel walls P12, P22; the rotary link, associating the two bearing structures Sl, S2, is represented by the axis Δ.

According to the example shown in Figure 3, said carrier structures Sl, S2, are positioned at substantially an angle of 45 °; thus, the aforesaid walls PI 1, P21, respectively supporting structures S1, S2 are opposite.

In the example shown in FIG. 4, a carrier structure S1, consisting of two parallel walls, for example parallel Pl1, P21, is associated with a carrier structure S2, consisting of two parallel walls P12, P22; the rotary link, associating the two bearing structures Sl, S2, is represented by the axis Δ. According to the example shown in FIG. 4, the said supporting structures S1, S2 are positioned face to face; thus, the aforesaid walls P1, P21, respectively supporting structures S1, S2, are against each other. All of said carrier structures S1, S2 constitute a pair of carrier structures folded on themselves.

Of course, said supporting structures S1, S2 may include so-called second work servitudes, namely plumbing, electricity and heating; in addition, said carrier structures S1, S2 may include:

permeable panels holding the aggregates and allowing water to escape during the pouring of the concrete, the connection of which will be made by locking on the spacers 31,

insulating walls whose connection will be made by locking on the spacers 31,

- reinforcement walls, ...

Similarly, the supporting structures may include openings, such as those intended later for doors and windows.

These various elements, mentioned above, will be set up in the factory at each of the carrier structures, which carrier structures will then be made integral by at least one rotary link, as described above.

Thus, the combination of supporting structures, as described above, equipped, depending on the case, permeable panels, insulating walls, reinforcement wall, openings for the implantation of doors and windows, so-called servitudes finishing work, will constitute a set of prefabricated modules, reduced mass, dimensions compatible with the road gauge, and therefore transportable. Note that these bearing structures, consisting essentially of metal fittings, are electromagnetic screens, and thus the combination of these said screens can induce a so-called Faraday cage effect. Thus, during the establishment of these supporting structures, it will be necessary to connect them electrically to the ground.

In the example shown in Figure 5, a set of prefabricated modules is assembled and some positioned face to face; this set includes:

three prefabricated modules, Ml, M2, M3, constituting the future slab of the housing, which are arranged in a U-shape, the module M2 forming the foot of the U, the modules M1, M3 forming the wings of the U,

two sets of modules MA, MB, placed in the space formed by the modules M1, M3, the set of modules MA resting against the module M1, the set of modules MB resting against the module M3.

By way of example, if we consider that the three modules M1, M2, M3 as well as the sets of modules MA, MB, constitute the modules making it possible to construct a dwelling whose living space is estimated at 80 m ² , the total mass is between 2 and 4 tons, or 25 to 50 kg per m ² living space, and the total volume is compatible with the road gauge, equivalent to the volume of a container.

In the example shown in Figure 6, a set of prefabricated modules are in the deployment position of the floor slab; thus the module M2 being placed on the ground or on supports previously made, the module Ml and the set of modules MA on the one hand, the module M3 and all the MB modules, are progressively deployed on both sides. other of the M2 module; given the masses previously estimated, the total mass of the modules Ml and of all the modules MA is estimated between 0.5 tonnes and 1.5 tonnes; it is the same for the total mass of the modules M3 and all the modules MB.

In the example shown in Figure 7, a set of prefabricated modules are deployed floor slab position; Thus, the modules Ml, M2, M3 are placed on the ground, all the MA modules resting on the module Ml, the set of MB modules based on the module M3.

In the example shown in FIG. 8, a set of prefabricated modules are in the deployed position of the formwork elements which constitute the facades or gables; thus, all the modules of partitions

MA are arranged vertically, in the vicinity of the outer limit edge of the slab module Ml; likewise, all of the modules of form elements which constitute the facades or pinions MB are arranged vertically, in the vicinity of the outer boundary edge of the slab module M3; each of said sets of modules MA, MB may consist of subsets of modules; by way of example, the set of modules MB may consist of two subsets of modules, MB1, MB2; given the masses previously estimated, the individual mass of the MB 1 subset of modules is estimated at 400 kg.

In the example shown in Figure 9, a set of prefabricated modules are in the deployed position of the formwork elements which constitute the facades or gables; thus, the set of partition modules MA is deployed; the subset of partition modules MB 1 is also deployed; it is the same for the subset of partition modules MB2; for example, the individual masses of the partition modules are between 50 kg and 150 kg.

In the example shown in FIG. 10, a set of prefabricated modules are in the deployed position of the formwork elements which constitute the facades or gables; thus, the set of partition modules MA is fully deployed; it is the same for the subset of modules of the formwork elements which constitute the facades or pinions MB2; the subset of partition modules MB1 is partially deployed.

In the example shown in FIG. 11, a set of prefabricated modules are in the position of deployed partitions; the subset of partition modules MB2 is fully deployed; thus, the deployment operations being carried out, the pouring of the concrete is carried out in the three slab modules Ml, M2, M3.

In the example shown in Figure 12, a set of prefabricated modules are being filled forms; the pouring of the concrete being carried out in the three slab modules M1, M2, M3, the partition modules are filled.

In the example shown in FIG. 13, an individual housing according to the invention is finished, and

In the example shown in Figure 14, a collective housing according to the invention is completed.

Thus, the operation of supporting structures, consisting of two parallel walls, each formed of brackets arranged in two orthogonal directions and maintained at the spacing required by spacers, which can be associated with each other by a rotary connection, makes it possible to form forms pre-equipped and pre-combined filters in the factory; the presence of rotational links between the different filter forms allows the folding of these for transport, and the deployment on site. Given the reduced masses of said filtering forms, and the possibility of folding, the transport of these is carried out under better conditions and their deployment on site is achieved without the intervention of powerful handling means.

The modules thus formed meet the standards of durability thanks to reinforced concrete, and are resistant to accidental and especially earthquake-resistant overloads thanks to the reinforcements and the ductility of the supporting structures.

They also meet environmental standards thanks to the presence of integrated insulation, the thermal inertia of the whole, the reduction of energy consumed by transport and the use of abundant resources. As for the potential diversity of the design shapes by acting on the distribution of the fittings 11 and 21 and / or that of the fittings 12 and 22, it is easy to give the sails "S" the desired single or double curvatures. This process is thus in compliance with aesthetic and environmental constraints.

They also respond to economic constraints; indeed, most of the structural work as well as the second work, are made in the factory according to industrial methods, and of course without constraints due to inclement weather; on-site labor is therefore reduced.

Thus, the method according to the invention must be able to respond to: - the needs of new buildings,

- sustainable environmental constraints, knowing that the specialized workforce is in sharp decline, that the cost of labor is increasing, that materials are increasingly expensive and that the purchasing power of candidates housing is down.

Claims

1. A method of producing buildings from prefabricated modules consisting of filtering forms each comprising at least two supporting structures (Sl, S2), each having two walls located in intersecting or parallel planes (PI 1, P 12, P 21, P22), each comprising fittings (111, 121, 211, 221, 112, 122, 212, 222) arranged in two intersecting or substantially orthogonal directions, these walls (PI 1, P 12, P21, P22) being maintained at spacing required by spacers (31, 32), characterized in that the two supporting structures (Sl, S2) are articulated to each other by a rotary connection comprising a fitting (111) of one of said walls (PI l) of the first carrier structure (Sl) and one of said spacers (3) of the second carrier structure (S2).

2. Method according to claim 1, characterized in that the aforesaid carrier structure (Sl, S2) further comprises:

permeable panels holding the aggregates and releasing the excess mobility water during pouring of concrete, and / or

insulating walls, and / or reinforcing walls.

3. Method according to claim 1, characterized in that the aforesaid carrier structure (Sl, S2) further comprises servitudes called second work.

4. Method according to claim 1, characterized in that the aforesaid carrier structure (Sl, S2) further comprises openings for doors and windows.

5. Method according to claim I ₉ characterized in that the aforesaid carrier structure (Sl, S2) comprises an electrical ground of said metal fittings (111, 121, 211, 221, 112, 122, 212, 222).

6. Method according to claim 1, characterized in that the aforesaid prefabricated modules consist of filtering forms are assembled in the factory and positioned face to face for on-site transport.

7. A method according to claim 6, characterized in that the aforesaid prefabricated modules consist of factory-assembled filter casings and positioned face to face for transport, are then deployed on site.

8. Method according to claims 6 and 7, characterized in that the aforesaid prefabricated modules consist of filtering forms deployed on site, constitute the supporting structure forming part of the final work and therefore not disassembled, is filled with a mixture of taking can be slow.

9. Method according to the preceding claims, characterized in that the aforesaid prefabricated modules consist of filtering forms deployed on site and filled with concrete, are intended for the building of private homes and / or collective housing.