WO2010041284A1

WO2010041284A1 - Prefabricated module, prefabricated structure and manufacturing method thereof

Info

Publication number: WO2010041284A1
Application number: PCT/IT2008/000640
Authority: WO
Inventors: Guido Montini; Gian Francesco Biancon
Original assignee: Polifar S.R.L.
Priority date: 2008-10-10
Filing date: 2008-10-10
Publication date: 2010-04-15
Also published as: HRP20120865T1; EP2195494A1; EP2195494B1; SI2195494T1

Abstract

The present invention concerns a prefabricated module (4) for structures and in particular for the construction of walls and/or floor slabs through a dry mechanical connection between the elements also separately produced. The prefabricated module (4) comprises a supporting frame (8), at least one concrete slab (16) and a mesh (20) at least partially submerged in the said slab (16). Module (4) is characterised by the fact to comprise mechanical means of connection (24, 26) that mechanically connect the slab (16) to the supporting frame (8) by means of bushings (44).

Description

DESCRIPTION

"Prefabricated module, prefabricated structure and manufacturing method thereof"

[0001] The present invention relates to a prefabricated module, prefabricated structure and related embodiment method .

[0002] In the building sector it is known to make prefabricated modules to form, once assembled together, an entire prefabricated structure. [0003] In particular, the said modules include a supporting frame, in high resistant laminated wood for example, and a concrete slab, preferably reinforced, enclosed by the frame.

[0004] The prior art solutions consist in assembling the frame beforehand on the slab and subsequently pouring the concrete or conglomerate with various aggregates and binders, even synthetic, between the frame elements so as to fill the volume identified by the frame elements and sink the frame itself into the casting. [0005] In this way the connection between the frame and the slab of concrete or conglomerate of aggregates and binders occurs through incorporation following the solidification of the concrete or mix.

[0006] The prior art solutions exhibit numerous problems and inconveniences. [0007] In fact, the pouring of the binding element, be it concrete or conglomerate, does not permit to verify the connection and the correct filling of module's entire volume . [0008] Furthermore, following the solidification of the binder, conglomerate or concrete, misalignments inevitably occur due to shrinkage stresses that undermine both the aesthetics as well as the structural resistance of the module itself. [0009] It should be noted that the casting technique of the prior art foresees that the casting takes place on the frames that are pre-assembled on the structure; in this manner the casting is carried out on a hyper-static structure and the shrinkage stress can reach considerable values such to cause numerous cracks, in correspondence with the interface between the casting and the frame. [0010] In other words solidified slabs loose planarity and trigger high residual shrinkage stresses . The loss of planarity gives the module a low aesthetic impact and residual stresses threaten to establish the formation of cracks .

[0011] The use of conglomerates also determines issues related to moisture and corrosion leading to the deterioration not only of the casting material but also its frame, often made of laminated wood. [0012] The problem at the basis of the present invention is to provide a prefabricated module which should solve the disadvantages mentioned above with reference to the prior art. [0013] Such disadvantages are solved by a device in accordance with claim 1, by a structure in accordance with claim 20 and by a method in accordance with claim 22 [0014] Other embodiments of the device according to the invention are described in the subsequent claims [0015] Further features and the advantages of the present invention will appear more clearly from the following description of preferred non-limiting embodiments thereof, wherein: [0016] figure 1 is a perspective view, partly cut-away, of a module according to a further embodiment of the present invention;

[0017] figure 2 is a perspective view, partly cutaway, of the module in figure 1, from the side of arrow II of figure 1; [0018] figure 3 is a plan view, in separate parts, of the module in figure 1, from the side of arrow III of figure 1;

[0019] figures 4-5 are a plan view of parts of the module in figure 1; [0020] figure 6a is a plan view of another part of the module in figure 1;

[0021] figure 6b is a cutaway view of the part in figure

6a;

[0022] figures 7-8 are a perspective view of the parts in figure 6a in a subsequent assembly phase;

[0023] figure 9 represents an application of the module in figure 1 for the construction of a floor slab; [0024] figure 10 is a side view of the module in figure 9, from the side of arrow X of figure 9. [0025] With reference to the above figures, reference number 4 generally denotes a prefabricated module for the creation of structural walls and/or floor slabs. [0026] Module 4 includes a supporting frame 8 which comprises for example, a pair of uprights 10 [0027] According to an embodiment, the uprights 10 are made of high resistance wood, such as laminated wood for example, and comprise a volume 12 suitable to be occupied, at least in part, by a slab 16. According to further embodiment, the uprights 10 are made of metallic and/or polymer materials .

[0028] Module 4 comprises at least one slab 16, in concrete and/or conglomeration of various aggregates and binders, even synthetic, being that the said slab 16 is mechanically linked to the frame 8. [0029] The frame 8 has the supporting function for module 4, as well as the mechanical connection of module 4. In applications on vertical walls the slab 16 also has a wind bracing function. [0030] According to an embodiment, module 4 comprises a mesh 20 at least partially embedded in the said concrete and/or conglomerate slab 16.

[0031] Advantageously, the module 4 comprises a mechanical connection means 24 that mechanically connects the slab 16 to the supporting frame 8. The said mechanical means of connection 24 are distinct from the slab 16 and the frame 8; in other words, they are means of connection created separately from the slab 16 and subsequently inserted through the slab 16 to block the latter to the frame 8. [0032] According to an embodiment , the mechanical connection means 24 comprise threaded means of connection 26 that at least partially screw onto the uprights 10 of the said supporting frame 8. [0033] According to a further embodiment , the mechanical connection means 24 comprise expansion dowels and pins suitable to be driven with interference between the slab 16 and the frame 8 to create the related mechanical connection. [0034] Preferably, the threaded means of connection 26 are inserted into sections of the said mesh 20, so as to block the mesh 20 to the supporting frame 8. [0035] For example, the mesh 20 comprises fixing eyelets (not illustrated) and the threaded means of connection 26 pass through the said fixing eyelets. [0036] According to a preferred embodiment, the mesh 20 comprises bars 32 arranged in a longitudinal direction Y- Y, parallel to the uprights 10 and in a crosswise direction X-X, perpendicular to the longitudinal direction Y-Y, to exhibit a rectangular grid. [0037] The bars 32 therefore comprise openings 36 to insert the threaded means of connection 24,26. According to an embodiment, the openings 36 are parallel to the longitudinal direction Y-Y. [0038] According to an embodiment, the mesh 20 comprises pairs of parallel bars 32 and placed together to create rails 40 that delimit the opening 36 for the passage of the mechanical means of connection 24,26 and related fixing of the mesh 20 to the frame 8. [0039] The openings 36 are preferably continuous and interrupted by the related bars 32 arranged in a crosswise direction X-X. Thanks to the continuity of the openings 36 the positioning of the mechanical means of connection can be positioned in a continual manner so that the anchorage points of the slab 16 to the frame 8 can be moved at will. [0040] Advantageously, module 4 comprises bushings 44 positioned between the removable means of 24,26 and the mesh 20, said bushings 44 being at least partially- submerged in the concrete and/or conglomerate of aggregate and various binders, also synthetic of the slab 16.

[0041] According to an embodiment, the bushings 44 comprise a bushing body 48, with predominant extension Z-Z, suitable to create a restraint between the bushing 44 and the mesh 20 and a closure cap 52 suitable to secure a chamber 56 internally delimited by the bushing body 48. In an assembly configuration of the bushing body 48 on the mesh 20, the prevalent direction Z-Z is perpendicular to the longitudinal direction Y-Y and crosswise direction X-X.

[0042] According to an embodiment, the bushing body 48 comprises a groove 60 suitable to block itself axially in the opening 36 of the mesh 20, the said groove 60 being delimited by a pair of undercuts 64. [0043] Advantageously, the groove 60 has a thickness, along the predominant extension Z-Z, not less than the thickness of the mesh 20 bars 32 so that is can house the bars. [0044] According to an embodiment, the bushing body 48 comprises a coupling section 68 suitable to be inserted in the said opening 36 of the mesh 20, following a predetermined angular orientation in relation to the predominant extension Z-Z, and a fixing section 72 with greater dimensions to the said opening 32 of the mesh 20. [0045] In other words, the groove 60 is axially delimited, along the predominant extension Z-Z, by the coupling section 68 and the fixing section 72 respectively, the sections of which comprise the undercuts 64 for the groove 60. [0046] Preferably, the groove 60 comprises at lease one splay 76 to facilitate the rotation of the bushing body 48 inside the opening 36 so as to rotate in a predefined closure position, in which the coupling position 68 has an angular orientation that prevents the extraction of the bushing 44 from the mesh 20 (figure 8) .

[0047] Preferably, the fixing section 72 has a concave cup configuration and encapsulates the said chamber 56, so that the mechanical means of connection 24,26 can be housed . [0048] The bushing body 48 comprises an axial hole 80 to pass the mechanical means of connection 24,26. In particular, the bushing body 48, in correspondence with the axial hole 80, comprises a threaded section 81, suitable to permit the screwing of the mechanical means of connection 24,26 and/or the lifting means for the module .

[0049] Preferably, the closure cap 52 is connected in a removable manner to the bushing body 48 in order to selectively close the chamber 56 inside the bushing body 48.

[0050] Preferably, the closure cap 52 is connected in a removable manner to the bushing body 48 by means of a suitably shaped coupling so as to rotate the body itself, by means of the closure cap 52 , in relation to the said predominant extension Z-Z. According to a further embodiment, the bushing body 48 has protuberances or notches on the outer side surfaces to allow the external clasping and rotation. [0051] The rotation of the bushing body 48 also determines the rotation of the coupling section 68 that prevents subsequent extraction through the opening 36. [0052] According to a preferred embodiment, the bushing 44 is made of a polymeric material and/or metallic material. According to a further embodiment, the bushing 44 comprises a metallic core at least partially covered internally or externally in a plastic/polymeric material to prevent direct contact between the metal and concrete or the conglomerate of aggregate and binders, also synthetic, as well as to prevent direct contact between the bushing and connectors if the covering is internal. The bushing 44 can also be made of several parts to allow the fixing to the mesh 20 without having to insert it and then rotate it inside the opening 36 but by acting on the two opposite ends of the bars 32 and inserting the two opposite parts of the bushing 44, in the opening 36, so as to make is solid by means of a coupling. [0053] According to a further embodiment , the closure cap 52 is made of a synthetic or organic material. [0054] The modules 4 can be connected together in correspondence with the uprights 10 of the related frames 8 so as to construct a prefabricated structure for the attainment of constructions in general, such as walls, floor slabs (figures 9-10) and roofing. [0055] The realization method of a prefabricated module and a prefabricated structure according to the invention shall now be described.

[0056] In particular, the method comprises the preparation phases of a preformatted formwork for a prefabricated module 4, the formwork having at least one closed outer structure, with a shape and dimension already existent or specifically constructed both horizontally and vertically, suitable to be set on a supporting surface, such as a pallet. [0057] Thereby the mesh 20 is placed on the formwork, and a number of bushings 44 are inserted into the mesh so as to bilaterally restrain the groove 60 of the bushing 44 in the appropriate opening 36 of the mesh 20 (figure 4) . [0058] In particular, the introduction of the bushings 44 in the opening 36 of the mesh 20 is made by orientating edgeways the coupling section 68 of the bushing body 48 until connecting the groove 60 with the bars 32 of the mesh 20 (figure 7) and then rotating the bushing body 48, by means of the related closure cap 52, so as to prevent subsequent extraction of the bushing from the opening 36 (figure 7-8) .

[0059] Note that the coupling section 68 creates the spacing function of the mesh 20 from the casting surface. In this way the mesh 20 is positioned in the approximate center of the thickness of the subsequent slab 16. [0060] The method therefore comprises the phase of making a cast of conglomerate and/or concrete on the mesh 20 so as to submerge the mesh 20 and the bushings 44. [0061] Following solidification, the mesh becomes incorporate in the slab 16 and the rotation of the bushings is blocked inside the slab. The thickness of the cast is such to not surpass the closure cap 52 to allow the subsequent removal of the cap itself.

[0062] Following the complete solidification of the casting the closure caps 52 of the bushings 44 that prevent the casting substance from filling the camber 56 of the bushing body 48 can be removed.

[0063] After the closure caps 52 have been removed, the chamber 56 of the bushing body is therefore empty and the mechanical means of connection 24,26 can be housed inside it.

[0064] To permit the lifting and movement of the module 4, a number of eyelets or eyebolt (not illustrated) can be inserted and screwed into the threaded section 81 of the bushing 44 and hooded for example to the hood of a site crane .

[0065] Subsequently, the slab is rested on the uprights 10 of the frame 8 and self-tapping screws are inserted, or other mechanical connections, through the slab 16 in order to engage the means of connection 24,26 in the uprights 10 of the frame 8 and to fix the slab 16 to the frame 8.

[0066] It is then possible to complete the module by applying a layer of plaster 82 for example, or a finish for exposed faces, in correspondence with an external face 84 and if necessary applying a layer of thermal or acoustic insulation material 86 in correspondence with an internal face 88.

[0067] As can be seen from the description, the prefabricated module according to the invention allows overcoming the disadvantages of the prior art. [0068] In particular, the module can be made separately, or rather directly on the structure under construction on site, or in the factory, in an extremely fast and economic manner, with fully mechanised assembly. [0069] For example, a single module can be made in an average time of 10 minutes and at extremely reduced costs.

[0070] The implementation operation guarantees greater safety for the personnel, both in terms of duration of the assembly as well as the automation and planning of the assembly.

[0071] The implementation is also independent from atmospheric conditions; therefore the overall assembly times are reduced and the implementation of the structure can be performed without seasonality.

[0072] Furthermore, the assembly of the prefabricated modules can be carried out dry: in this way greater precision, quality and assembly easy can be guaranteed, as well as an improved stability of the structure made in this way.

[0073] In fact, as already explained, the separate construction of the modules allows the control of the dimensional tolerances of the slab, its level of finish, as well as limiting the residual stress due to the solidification of the casting. [0074] The use of mechanical means of connection guarantees greater stability and resistance of the structure assembled in this manner.

[0075] The only operations that can be carried out on site or directly on the panel during assembly are related to the application of external plaster, of the concrete face in structural panels for walls; whereas modules for floor slabs the application can be performed on the part beneath the slab (from the formwork side) , of a finish even coloured to finish the element. Panels can be connected to the internal part of both elements, for example with plasterboard and/or insulating material, both for the thermal -acoustic insulation of the structure as well as protection against fire. [0076] Advantageously, the polymeric and/or plastic bushing, also with a metallic core, creates a thermal barrier between the concrete and the mechanical means of connection, and avoids that the difference in temperature inside the module creates condensate in the wood that constitutes the supporting structure of the module.

[0077] In other words, the bushings create a thermal and electrostatic barrier and also avert the rusting of metal parts, such as the screws and mesh. [0078] Furthermore, thanks to the presence of the bushing, the screws apply a force on the elements of the metal mesh avoiding direct action on the concrete and cause it damage .

[0079] A man skilled in the art may make several changes and adjustments to the modules, the structure and the methods described above in order to meet specific and incidental needs, all falling within the scope of protection defined in the following claims.

Claims

1. Prefabricated module (4) for walls, floor slabs, roofs and constructions in general, comprising a supporting frame (8) , at least on slab (16) of concrete and/or conglomerate of various aggregates and binders, also synthetic, said slab (16) being connected to the said frame (8) , a mesh (20) at least partially submerged into the slab (16) , characterised in that the module (4) comprises mechanical means of connection (24,26), separate from the slab (16) and the frame (8), said mechanical means of connection mechanically unite the slab (16) to the supporting frame (8) .

2. Module (4) according to claim 1, wherein the mechanical means of connection (24,26) comprise threaded means of connection (26) screwed at least partially in the uprights (10) of the said supporting frame (8) .

3. Module (4) according to claim 2, wherein the mechanical means of connection (24,26) are inserted into a section of the said mesh (20) , to directly block the mesh (20) to the supporting frame (8) .

4. Module (4) according to claims 1, 2 or 3, wherein the said mesh (20) comprises fixing eyelets and the mechanical means of connection (24,26) pass through the said fixing eyelets.

5. Module (4) according to any one of the previous claims, wherein the mesh (20) comprises bars (32) arrange in a longitudinal direction (Y-Y) and a crosswise direction (X-X) , perpendicular to the longitudinal direction (Y-Y) , to exhibit a rectangular grid, said bars (32) comprise openings (36) to insert the mechanical means of connection (24,26) .

6. Module (4) according to claim 5, wherein the mesh (20) comprises a pair of parallel bars (32) and brought together to create tracks (40) that delimit the opening (36) to insert the mechanical means of connection (24,26) and the related fixing of the mesh (20) and frame (8) .

7. Module (4) according to any one of the previous claims, comprising of at least one bushing (44) placed between the mechanical means of connection (24,26) and the mesh (20) , said bushing (44) being alt least partially submerged in the casting.

8. Module (4) according to claim 7, wherein the said bushing (44) comprises a bushing body (48) , with predominant extension (Z-Z) , suitable to create a restraint between the bushing (44) and the mesh (20) and a closure cap (52) suitable to block a chamber (56) internally delimited by the bushing body (48) .

9. Module (4) according to claim 8, wherein the bushing body (48) comprises a groove (60) suitable to axially block into the opening (36) of the mesh (20) , said groove (60) being delimited by a pair of undercuts (64) .

10. Module (4) according to claim 8 or 9, wherein the bushing body (48) comprises a coupling section (68) suitable to be inserted into the said opening (36) of the mesh (20) , following a predetermined angular orientation in respect to the predominant extension (Z-Z) , and a fixing section (72) with greater dimensions to the said opening (36) of the mesh (20) .

11. Module (4) according to claim 10, wherein the groove (60) is delimited by opposite parts, along the predominant extension (Z-Z) , of the coupling section (68) and of the fixing section (72) .

12. Module (4) according to claim 10 or 11, wherein the groove (60) comprises at least one splay (76) suitable to ease the rotation of the bushing body (48) inside the opening (36) so as to rotate into a predefined fixing position, wherein the coupling section (68) assumes an angular orientation that prevents the extraction of the bushing (44) from the opening (36) of the mesh (20) .

13. Module (4) according to claim 10, 11 or 12, wherein the fixing section (72) has a concave cup configuration, to house the mechanical means of connection (24,26) .

14. Module (4) according to any one of the claims from 8 to 13, wherein the bushing body (48) comprises an axial hole (80) to pass the mechanical means of connection (24,26) .

15. Module (4) according to claim 14, wherein the bushing body (48) , in correspondence with the axial hole (80) , comprises a threaded section (81) suitable to allow the screw connection of the mechanical means of connection (24,26) and/or the lifting means for the module .

16. Module (4) according to any one of the claims from 8 to 15, wherein the closure cap (52) is connected in a removable manner to the bushing body (48) to selectively close the chamber (56) inside the bushing body (48) .

17. Module (4) according to any one of the previous claims, wherein the closure cap (52) is connected in a removable manner to the bushing body (48) by means of a coupling suitable to rotate the bushing body (48) , by means of the closure cap (52) , in respect to said predominant extension (Z-Z) .

18. Module (4) according to any one of the claims from 7 to 17, wherein the bushing (44) is made of a polymeric material .

19. Module (4) according to any one of the claims from 7 to 18, wherein the bushing (44) is made of a plastic or metallic material, at least partially • coated by a polymeric material.

20. Prefabricated structure comprising a number of modules (4) in accordance with any one of the claims from 1 to 19.

21. Structure according to claim 20, wherein the said modules (4) are set side by side in correspondence with the uprights (10) of the related frames (8) , to create building walls or floor slabs.

22. Embodiment method of a prefabricated module (4) in accordance with any one of the claims from 1 to 19, comprising the following phases:

- prepare a pre- formatted formwork for a prefabricated module (4) ,

- lay a mesh (20) on the said formwork,

- insert a number of bushings (44) into the mesh (20) in order bilaterally restrain the bushings (44) in special openings (36) of the mesh (20) ,

- perform a casting of conglomerate and/or concrete so as to submerge the mesh (20) and the bushings (44) .

23. Method according to claim 22, comprising the following phases: apply the closure caps (52) to the bushings (44) before performing the casting, and remove the closure caps (52) from the bushing (44) once the casting has solidified.

24. Method according to claim 22 or 23, comprising the phase of inserting a number of eyelets or eyebolts in the bushings (44) to allow the lifting and movement of the module (4) following the solidification of the casting.

25. Method according to claim 22, 23 or 24, comprising the phase of resting the solidified module onto a frame

(8) equipped with uprights (10) , insert the mechanical means of connection (24,26) into the bushing bodies (48), to engage the said mechanical means of connection (24,26) in the uprights (10) of the frame (8) and fix the slab (16) to the frame (8) .