WO2009147509A2

WO2009147509A2 - Method for prefabricated modular building of walls and panel walls, in particular made of simple- or reinforced-concrete conglomerate

Info

Publication number: WO2009147509A2
Application number: PCT/IB2009/005843
Authority: WO
Inventors: Claudio Luchini
Original assignee: Nuova Ceval S.R.L.
Priority date: 2008-06-05
Filing date: 2009-06-04
Publication date: 2009-12-10
Also published as: WO2009147509A3; ITTO20080430A1

Abstract

Method for prefabricated modular building of walls (M) and panel walls, comprising the steps of: positioning a series of first panels (3) so as to form a delimitation wall (26) facing a reference wall and set at a predefined distance therefrom; connecting the first panels (3) to the reference wall by means of respective means of constraint (15, 16); and making a casting of cementitious conglomerate or mortar in the gap delimited between the first panels (3) and the reference wall; the method moreover comprises, prior to the step of making the casting, the step of positioning in the gap a series of insulating plates (30) made of a material with low thermal conductivity so as to form a further wall (28) parallel to the wall (26) of first panels (3).

Description

METHOD FOR PREFABRICATED MODULAR BUILDING OF WALLS AND PANEL WALLS, IN PARTICULAR MADE OF SIMPLE- OR REINFORCED-CONCRETE CONGLOMERATE

TECHNICAL FIELD

The present invention relates to a method for prefabricated modular building of walls and panel walls, in particular made of simple- or reinforced-concrete conglomerate.

BACKGROUND ART

In the building sector, there is increasingly felt the need to make walls and panel walls using prefabricated modular panels, the quality of which can be controlled in the factory and assembly of which can be made in a highly flexible, manual, simple, and rapid way.

There is moreover increasingly felt the need to make walls of residential dwellings that present a high degree of thermal and acoustic insulation in regard to the external environment.

Currently, the construction of a load-bearing wall made of insulated reinforced-concrete requires at least three constructional steps to be carried out at different times: a first constructional step for making the load-bearing structure made of reinforced concrete, a subsequent step of provision of an insulating layer on the outer side of the aforesaid load-bearing structure, and a final step of protection of the insulating layer with a layer of levelling plaster reinforced with a mesh made of metal or plastic material .

Furthermore, fixing to the wall thus made of the components of the necessary technological systems, such as for example wiring systems, heating systems, telecommunications systems, etc., is made in view on the surface of the wall itself which in use faced the inside of the premises delimited thereby, or else within an additional layer of wall (for example, made of bricks or other materials) built up on said surface.

DISCLOSURE OF INVENTION

The aim of the present invention is to provide a method for prefabricated modular building of walls and panel walls, which is particularly simple, fast and economically advantageous and, at the same time, enables both of the needs specified above to be met.

The aforesaid aim is achieved' by the present invention, in so far as it relates to a method for prefabricated modular building, as defined in Claim 1.

BRIEF DESCRIPTION OF THE DRAWINGS

For a better understanding of the present invention, some preferred embodiments are described in what follows, purely by way of non-limiting examples and with reference to the annexed drawings , wherein:

Figure 1 illustrates, in exploded perspective view, an example of components used in the method forming the subject of the present invention;

Figure 2 illustrates, in partially sectioned perspective view and at an enlarged scale, some components of Figure 1, in particular a finishing panel and an insulating plate used for formation of a prefabricated module in the method forming the subject of the present invention;

- Figure 3 illustrates, in a partially sectioned perspective view and at an enlarged scale, an example of wall made according to the method forming the subject of the present invention;

- Figure 4 illustrates, in a partially sectioned perspective view, a possible variant of the insulating plate of Figures 1 to 3;

- Figures 5 and 6 illustrate in cross section two different types of wall made according to the method forming the subject of the invention and using insulating plates of the same type as the one illustrated in Figure 4;

- Figure 7 illustrates, in partially sectioned perspective view, another possible variant of the insulating plates of Figures 1 to 4; and

- Figures 8 and 9 illustrate in cross section two different types of wall made according to the method forming the subject of the invention and using insulating plates of the same type as the one illustrated in Figure 7.

BEST MODE FOR CARRYING OUT THE INVENTION

Illustrated by way of example in Figure 1 are two prefabricated modules 1 used in the method forming the subject of the present invention for building a wall M (Figure 3 ) , which are designed to be set alongside one another to enable then mutual connection thereof by respective means of constraint 2.

Each module 1 comprises a pair of panels 3, 4 with rectangular profile, facing, and parallel to, one another, delimiting a gap 5 for the casting of cementitious conglomerate or mortar, and connected together by the aforesaid means of constraint 2; each panel 3, 4 is delimited by first mutually opposite horizontal side edges 6 and by second mutually opposite vertical side edges 7, the latter having a smaller length as compared to the edges 6 and extending between respective ends of the edges 6 themselves .

The panels 3, 4 can be made of different types of materials, such as for example cemetitious conglomerate, of a normal or lightened or lightened-insulating type, cellular concrete, etc., and the gap 5 is designed to be filled with cemetitious conglomerate, which is also of a normal or lightened or lightened-insulating type, or else mortar.

Each panel 3, 4 is moreover delimited, on the side opposite to - A -

the one facing the gap 5, by a rectangular surface 8, the quality of finishing of which can be controlled in the factory prior to the installation of the module 1.

In the case in point, the panels 3 are designed to be set on the side of the wall M facing in use the inside of the residential building. Advantageously, the panels 3 can be provided with arrangements for the fixing and passage of components of technological systems, such as for example wiring systems and/or telecommunications systems, and/or heating systems, and/or ventilation systems, and/or heat- recovery systems.

Indicated by way of example in Figure 3 are cavities C designed to house electrical boxes Cl, telephone boxes C2 , and cables C3 for connection of said boxes with the remaining part of the corresponding systems.

In the examples illustrated, the panels 3 have a thickness greater than that of the panels 4 and can preferably be made of materials with insulating characteristics both from the thermal and from the acoustic standpoint, for example cellular concrete, lightened- concrete, or wood-cement.

Alternatively, the arrangements for fixing and passage of the components of the technological systems can be made on site, by making appropriate cuts in the panels 3.

Preferably, the side edges 6 of the panels 3, 4 of each module 1 have respective mutually aligned longitudinal grooves 9, and the side edges 7 of the panels 3, 4 of each module 1 have respective mutually aligned longitudinal grooves 10, which intersect the corresponding grooves 9 at the respective ends and are transversely staggered with respect thereto.

The means of constraint 2 are preferably made of metal material, for example stainless steel, and comprise first anchorage elements 15, engaging in hide-away fashion the grooves 9 of corresponding panels 3, 4 of adjacent modules 1, and second anchorage elements 16, engaging in hide-away fashion the grooves 10 of corresponding panels 3, 4 of adjacent modules 1 and intersecting transversely the respective anchorage elements 15.

Each anchorage element 15 comprises a pair of mutually parallel rectilinear bars 17, each engaging corresponding halves of grooves 9 of respective panels 3, 4 set alongside one another of adjacent modules 1, and a plurality of cross members 18 (in the case illustrated, four) , extending orthogonally between the bars 17 and each having a pair of substantially rectangular through openings 19 designed to be engaged in use by respective vertical reinforcement bars 20.

Likewise, each anchorage element 16 comprises a pair of mutually parallel rectilinear bars 21, each engaging corresponding halves of grooves 10 of respective panels 3, 4 set alongside one another of adjacent modules 1, and a plurality of cross members 22 having a flattened shape (in the case in point two) , extending orthogonally between the bars 21 themselves .

As may be seen in Figures 1 to 3 , the formation of the wall M is made by setting horizontally alongside one another and stacking vertically on top of one another the modules 1 with manual movement and constraining them together by means of the anchorage elements 15 and 16.

In particular, the first operation consists in arranging a plurality of anchorage elements 15 mutually aligned on the resting surface of the wall M. Next, a first horizontal row of modules 1 is mounted, by setting the bottom grooves 9 of the panels 3 , 4 engaged in the corresponding bars 17 of the anchorage elements 15; in this way, the panels 3, 4 have the respective outer surfaces 8 mutually aligned. The grooves 10 of each pair of panels 3, 4 in contact with one another are, instead, engaged throughout half their length by a corresponding anchorage element 16, which is consequently set orthogonal to the corresponding anchorage element 15 and projects vertically throughout another half with respect to the panels 3 , 4 themselves .

At this point, set on the first row of modules 1 is a plurality of anchorage elements 15, which are positioned engaged with their own bars 17 in the corresponding top grooves 9 of the panels 3, 4 constituting the modules 1 themselves and intersect the anchorage elements 16. The construction of the wall M then proceeds by mounting in succession other horizontal rows of modules 1 connected together by corresponding first and second anchorage elements 15 and 16.

In practice, at the end of the operations described, two walls 26, 27 are obtained, arranged parallel and facing one another at a predefined distance and connected together by the anchorage elements 15, 16. Said walls 26, 27, which are formed respectively by the panels 3 and by the panels 4, delimit together the gap in which the casting of cemetitious conglomerate or of mortar will be made, said gap being consequently constituted by the set of the gaps 5 of the various modules 1 used.

Advantageously, before the casting of cemetitious conglomerate or of the mortar is made, a series of insulating plates 30 made of a material with low thermal conductivity, for example polystyrene, cork, glass fibre, etc., is positioned within the gaps 5 of the modules 1 so as to form a further wall 28 parallel to the walls 26, 27.

In the case illustrated in Figures 1 to 3 , each insulating plate 30 is inserted within the gap 5 of the corresponding module 1 during assembly of the module 1 itself. In this way, the insulating plates 30 are held in position by the anchorage elements 15, 16.

It is also possible, in order to ensure greater stability of the wall 28 constituted by the various insulating plates 30, to glue the latter together or else to the panels 4.

According to the preferred embodiment of the invention illustrated in Figures 1 to 3 , the insulating plates 30 are positioned against the wall 27 formed by the panels 4.

At this point, in the gap formed between the panels 3 and the insulating plates 30 the cemetitious conglomerate or the mortar is cast.

Preferably but not necessarily, prior to making the casting, the openings 19 of the cross members 18 of the anchorage elements 15 set mutually aligned in a vertical direction are engaged by the respective longitudinal reinforcement bars 20 (Figures 1 and 3 ) .

The panels 3, 4 can also be finishing panels of the wall M. In this case, the surfaces 8 of the panels 3, 4 can possibly be provided with decorations in relief or coupled with grit, stones, marble, and/or other finishing materials. According to a further possible alternative, the panels 3, 4 could also be made of completely different materials, for example, glass or plastic, in particular polymethyl methacrylate .

According to a possible variant (not illustrated) , the method forming the subject of the present invention can advantageously be adopted for making panel walls, i.e., coating walls for example for integrating existing constructions and foundations or for reinforcing deteriorated masonry works .

In this case, just one wall of panels 4 is provided in .a position facing the wall to be coated, which can be identified as reference wall, in the sense that the different anchorage elements 15, 16, in appropriately modified forms, are used for fixing the panels 4 themselves to said reference wall; in practice, the wall 27 of panels 4 that is formed is set facing, at a pre-set distance, the reference wall.

Prior to providing the casting of cemetitious conglomerate or of mortar, the insulating plates 30 are positioned in the gap that is formed between the panels 4 and the reference wall to be coated.

The insulating plates 30 are usually set in contact with the wall 27 of panels 4; the subsequent casting of cementitious conglomerate or mortar is made in the space between the reference wall and the insulating plates 30.

Also in this solution, the insulating plates 30 can be held in position within the gap in which the casting is made by means of the anchorage elements 15, 16; it is also possible that the various insulating plates 30 are glued together or else to the panels 4.

Figures 4 to 9 illustrate two possible variants of insulating plates 30', 30'', which can be used in the method forming the subject of the invention and two different types of walls M' , M' ' , which can be formed using the aforesaid insulating plates 30', 30''. In the ensuing treatment, the insulating plates 30', 30'' and the walls M', M'' will be described only to the extent in which they differ from the insulating plates 30 and the wall M; parts that are similar or equivalent to parts already described will be distinguished, where possible, by the same reference numbers . The insulating plate 30' illustrated in Figure 4 differs from the insulating plate 30 in that it comprises a plane portion 31', available in use parallel to the panels 3 and 4, and a plurality of elements in relief 32' projecting from the plane portion 31' and defined by rounded bodies set at a distance from one another both in a horizontal direction and in a vertical direction along the plane portion 31' itself.

As may be seen in Figures 5 and 6, the plates 30' are positioned with the elements in relief 32' in contact with corresponding panels 4 so as to delimit therewith a plurality of channels 33' for ventilation of the corresponding wall M'.

In the solution of Figure 5, by providing at least one opening 34' in one of the panels 4 of the lowest horizontal row and at least one opening 35' in one of the panels 4 of the highest horizontal row, it is possible to generate an external flow of air, i.e., a flow directed towards the outside of the environment delimited by the wall M' , which, starting from the opening 34', traverses the channels 33' and then comes out of the opening 35' .

Said flow of air can be a simple natural flow or else can be a forced flow created by one or more fans appropriately provided at one or both of the openings 34', 35'.

This type of external ventilation can be used for evacuating possible accumulations of heat on the external panels 4 of the wall M' and for reducing the effect of solar radiation on the masonry.

The solution of Figure 6 differs from that of Figure 5 in that the openings 34' and 35' are made on corresponding panels 3 of the lowest horizontal row and highest horizontal row, respectively. In this case, by providing corresponding bottom and top openings 36', 37' through the casting and through the insulating plates 30', it is possible to generate an internal flow of air, i.e., a flow directed towards the inside of the environment delimited by the- wall M' , which, starting from the opening 34', traverses the corresponding bottom openings 36', 37' and the channels 33' and then comes out through the opening 35' passing first through the corresponding top openings 36', 37'.

This type of internal ventilation can be used for heating the air as it passes between the channels 33' defined by the elements in relief 32'. Said heating effect can be enhanced by providing heating pipes along the ventilation channels 33' or also by integrating the external panels 3 with solar panels or with panels designed to create a sort of "greenhouse effect" (for example, made of glass, particular plastics, such as polymethyl methacrylate, etc.) in the gap between the panels themselves and the insulating plate 30'.

The insulating plate 30'' illustrated in Figure 7 is of the same type as the plate illustrated in Figure 4; i.e., it is also formed by a plane portion 31'' and by a plurality of elements in relief 32'' projecting from the plane portion 31'' itself. The only difference lies in the fact that the elements in relief 32'' are defined by vertical ribbings set at equal distances apart from one another in a horizontal direction.

As may be seen in Figures 8 and 9, also in this case, the plates 30'' are positioned with the elements in relief 32'' in contact with corresponding panels 4 so as to delimit therewith a plurality of vertical channels 33'' for ventilation of the corresponding wall M' ' .

In the solution of Figure 8, the plates 30'' of the lowest horizontal row and those of the highest horizontal row can be provided with respective continuous horizontal grooves 40'', 41'' designed to set in communication the channels 33'', respectively, with an opening 34'' made in one of the panels 4 of the lowest horizontal row and with an opening 35'' made in one of the panels 4 of the highest horizontal row; in this way, it is possible also in this case to generate am external flow of air, which, starting from the opening 34'', traverses in succession the horizontal groove 40'', the channels 33'', and the horizontal groove 41'', finally coming out through the opening 35 ' ' .

The solution of Figure 9 is altogether similar to that of Figure 6 and differs from that of Figure 8 in that the openings 34'' and 35'' are made on corresponding panels 3 of the lowest horizontal row and highest horizontal row, respectively .

In this case, by making corresponding bottom and top openings 36'', 37'' through the casting and through the insulating plates 30'', it is possible to generate an internal flow of air, which, starting from the opening 34'', traverses in succession the corresponding bottom openings 36'', 37'', the groove 40'', the channels 33'', and the groove 41'', and then comes out through the opening 35'' passing first through the corresponding top openings 36'', 37''.

According to a possible variant not illustrated, the internal and external ventilation described with reference to Figures 4 to 9 could be obtained by providing the elements in relief 32', 32'' directly on the panels 3 (for example by making them integrally with the panels 3 themselves) and using in contact therewith insulating plates 30 that are completely plane.

From an examination of the characteristics of the method forming the subject of the present invention the advantages that it affords are evident.

In particular, the modular building system described and illustrated herein enables provision, in a highly flexible way, of walls M, M' , M' ' or panel walls with a high degree of thermal insulation and designed to be cut on site or in the factory to provide the various arrangements C for fixing and passage of components Cl, C2, C3 of the technological systems normally present in residential buildings .

In the case of use of the method according to the invention for providing a wall M, M' , M' ' made of insulated reinforced concrete, the latter can be constructed in a single constructional step, i.e., directly during building of the load-bearing structure.

Thanks to the presence of the grooves 9, 10 and to the simplicity of the conformation of the anchorage elements 15, 16, mounting of the modules 1 is carried out by making successive fixed joints and is consequently particularly simple and rapid and above all does not require any operation of dismantling of the means of constraint once the casting has assumed the right consistency.

Furthermore, thanks to their relatively reduced dimensions and weight, the panels 3, 4 and the insulating plates 30, 30', 30'' do not require the presence of specialized installers or powerful hoisting means, but rather they can be moved and positioned in a completely manual way.

Finally, thanks to the reduction of the operations to be executed on site, the quality controls can be made to a major extent in the factory to provide the modules 1, with considerable advantages of an economic nature.

Finally, it is clear that modifications and variations may be made to the modular-building method described previously, without thereby departing from the sphere of protection defined by the claims .

Claims

1.- A method for prefabricated modular building of walls (M, M', M'') and panel walls, comprising the steps of:

- positioning a series of first panels (4) so as to form a delimitation wall (27) facing a reference wall and set at a predefined distance therefrom;

- simultaneously with said positioning step, connecting said first panels (4) to said reference wall by means of respective means of constraint (15, 16); and

- making a casting of cementitious conglomerate or mortar in the gap delimited between said first panels (4) and said reference wall; characterized in that it comprises, prior to said step of making said casting, the step of positioning in said gap a series of insulating plates (30, 30', 30'') made of a material with low thermal conductivity so as to form a further wall (28) parallel to said wall (27) of first panels (4) .

2.- The method according to Claim 1, characterized in that said insulating plates (30, 30', 30'') are held in position by said means of constraint (15, 16) .

3.- The method according to Claim 1 or Claim 2, characterized in that said insulating plates (30, 30', 30'') are glued together or else to said first panels (4) .

4.- The method according to any one of the preceding claims, characterized in that said insulating plates (30, 30', 30'') are positioned against said first panels (4) so that the casting is made between said insulating plates (30, 30', 30'') and said reference wall .

5.- The method according to any one of the preceding claims, characterized in that said reference wall (26) is made simultaneously with construction of said wall (27) of first panels (4) by positioning a series of second panels (3) in a position facing and parallel to the corresponding said first panels (4) and by connecting said first and second panels (4, 3) together by means of said means of constraint (15, 16) .

6.- The method according to Claim 5, characterized in that said second panels (3) are provided with arrangements (C) for the fixing and passage of components (Cl, C2, C3 ) of technological systems.

7. - The method according to Claim 6, characterized in that said technological systems comprise wiring systems and/or telecommunications systems, and/or heating, systems, and/or ventilation systems, and/or heat-recovery systems.

8.- The method according to any one of Claims 5 to 7, in which said first panels (4) define an outer surface of said wall

(M', M'') and said second panels (3) define an inner surface of said wall (M' , M' ' ) , characterized in that said steps of positioning said first panels (4) and of positioning said insulating plates (30, 30', 30'') comprise the steps of using first panels (4) or insulating plates (30', 30'') provided integrally with elements in relief (32', 32'') and arranging said first panels (4) and said insulating plates (30, 30', 30'') in contact with one another via said elements in relief

(32', 32'') so as to define a plurality of channels (33', 33'') for ventilation of said wall (M', M'') .

9.- The method according to Claim 8, characterized in that said elements in relief (32', 32'') project integrally from plane portions (31', 31'') of said insulating plates (30', 30'') and are set at a distance from one another at least in a horizontal direction.

10.- The method according to Claim 8 or Claim 9, characterized in that it comprises the step of making, in at least one of said first panels (4) of a bottom row and in at least one of said first panels (4) of a top row, respective openings for bringing about a flow of air through the channels (33', 33'') defined by said elements in relief (32', 32'') .

11.- The method according to any one of Claims 8 to 10, characterized in that said first panels (4) are made of a material designed to create a sort of greenhouse effect in the gap between the first panels (4) themselves and said insulating plates (30, 30', 30'') .

12.- The method according to any one of the preceding claims, characterized in rectangular panels (3, 4) are used, each having, on its own horizontal and vertical side edges (6, 7) , respective grooves (9, 10), which are transversely staggered and are joined together only at their ends.