WO2011152728A1

WO2011152728A1 - Method to fabricate a building by installing prefabricated elements

Info

Publication number: WO2011152728A1
Application number: PCT/NL2011/050392
Authority: WO
Inventors: Edwin Smit; Renze Schram
Original assignee: Laetitia Holding B.V.; Metropolis Iii Architekten B.V.; Van Strijp Holding B.V.
Priority date: 2010-06-03
Filing date: 2011-06-01
Publication date: 2011-12-08
Also published as: NL2006263C2

Abstract

Method for making a building, e.g. a block row housings of at least two storeys, by stacking two prefabricated elements with floor (2) and upright (3) walls. In the factory the walls obtain embedded vertical channels (5), the floor/ceiling obtains horizontal channels (5). Two of these elements of equal dimension are as a whole transported across the civil road to the building site and there stacked onto each other and the relevant foundation to provide two storeys. The element is transported across the civil road at a vehicle, mounted in a lifting and tilting frame. During the ride across the civil road while arriving at a the passage obstruction obstacle the element is tilted and lifted by moving the frame from a low level with horizontal floor/ceiling to a high level with vertical floor/ceiling and back again.

Description

Method to fabricate a building by installing prefabricated elements .

The invention relates to a building having at least a single building or living level. The building or living level comprises a prefabricated element of reinforced concrete or different initially form free casting material having stony like properties with a reinforcement, e.g. fibres, rods and/or net, fabricated within a mould in a factory remote from the building site. The prefabricated element comprises upright walls and a floor/ceiling and is e.g. tunnel or U shaped. The invention also relates to the prefabricated element.

Since long it is known to build the walls floors and ceilings of buildings and houses from units of reinforced concrete, prefabricated in the factory.

US4.606.878 (Day) discloses a method to fabricate a building from at least one prefabricated box type unit of reinforced concrete, wherein each unit provides a stand alone home. A dead-ended tunnel shaped unit (fig. 1) is cast in a mould and is made from five walls providing floor, ceiling, front, back and one of the sides, respectively. After dismantling a separately produced wall is installed providing the second side, and the box type unit is now completed to be transported across the public roads to the location where the building is established. The box like unit has a depth (the distance between the front and back gable) less then one third of its width, and its depth equals its height. During transport across the road one of the sides is directed in the driving direction. The provided dimensions are too small for a single family dwelling and merely adapted for a single person household.

NL6617920 (Patent Concern) discloses assembling single family row housings from for each level three or more in depth direction of the house behind each other located, prefabricated and at both ends open tunnel shaped units.

The disclosure of NL1037624 (123Huis) is comparable to NL6617920, however the prefabricated units are U shaped in cross section .

From practice is it is known to prefabricate a box like unit of reinforced concrete in the factory, designed for installation underground as a cellar or parking garage. Such units are too small to be labelled occupied zone according to the building and different regulations. Thus such units can not be used for the production of occupied zones.

The object of the invention is to further rationalise the production of for habitation and/or different function adapted elements having a gross floor area of at least 30 or 50 square meter per building or living level, spread over 1, 2 or more building or living levels.

Thus the invention proposes to fabricate a building or living level of a building, e.g. a row housing, preferably single family dwelling, of at least two levels above ground, to be made from a prefabricated element such dimensioned that it covers the complete floor surface of the main volume, or at least 75% of it, of the relevant building or living level, while the element covers the complete width of the building or living level and preferably the complete depth, or at least 75% of it, of the relevant building or living level, while the relevant building or living level is at least 4.5 metre wide and at least 6 metre deep, while the upright walls of the element have a height such that the headroom of the relevant building or living level is at least 2.0 metre, preferably at least 2.4 metre, more preferably at least 2.6 metre. As a rule the upright walls will thus have a height substantially equal to the headroom. A minimum headroom of 2.6 metre is presently required for occupied zones according to the regulations in Holland and also in other parts of Europe. A smaller headroom could be allowed in other countries for occupied zones.

The width of the element is preferably not more then 8.0 metre, preferably not more then 7.5 metre. The depth of the element is preferably not more then 15.0 metre, wherein the maximum length preferably depends from the width - depth ratio of the building or living level.

The element has at least two, three of four upright walls and at least one flat wall (floor/ceiling) . Preferably one or more of the following applies: all upright and/or flat walls are substantially rectangular; to at least two, three of four sides of a flat wall an upright wall connects; each to a side of a flat wall connecting upright wall extends along

substantially the completely said side; the height of all to the sides of a flat wall connecting upright walls is substantially equal; the dimension of the flat walls is substantially equal.

E.g. for a single family dwelling the element has merely the floor and thus has an open top since the floor of the unit above simultaneously provides the ceiling for the unit below. For a condominium the element has e.g. both, such that the vertical dwelling separation (floor) can be easily made sufficient thick.

The prefabricated element is made in the factory and transported across the civil road to the building site by a transport vehicle. Preferably the transport vehicle is provided with tilting means, e.g. a tilting frame in which the element is mounted and carried. With the tilting frame the element, while mounted in the tilting frame, can be tilted around an in the travel direction extending axis between a horizontal and vertical attitude. Thus during transport the element can be tilted between the attitudes WIDE and LONG. When WIDE, obstructions with small driving height, like a viaduct, can be passed. When LONG, road narrowings can be passed.

When WIDE, the floor or ceiling plate is horizontal.

The transport vehicle is possibly provided with lifting means, e.g. provided in a lifting tilting frame, such that the element mounted in the vehicle can be both tilted by the tilting means and lifted by the lifting means, and both these movements preferably substantially simultaneously, such that during tilting the unit always has sufficient floor clearance.

Preferably when the element is WIDE, the lifting tilting frame is LOW, while the element is LONG, the lifting tilting frame is HEIGH.

The element is preferably loaded onto the vehicle such that the depth direction of the element extends in the driving direction. The transport is in such case at least 4.5 metre and even to 7.5 or 8.0 metre wide, obviously too wide for typical road transport (in Holland limited to 3.5 metre wide) . Special transport from 4.5 metre wide can not use each civil road. Due to the tilting possibility this problem is solved, since when LONG the transport width can be kept below 3.5 metre.

By limiting the width to 7.5 or 8.0 metre and depth to 15 metre it is possible to apply the lifting and tilting feature without damage during transport .

The transport vehicle with the lifting and/or tilting means, e.g. the tilting or lifting tilting frame is also part of the invention. The invention also covers the making of two, three or more single family dwellings in a row, of which the two or more living levels are made by applying for each house and for each building or living level a single element according to the invention. In the same manner a condominium can be made by locating onto and next to each other each time a single element according to the invention, wherein each element provides a separate/distinct apartment with each time a living, bedroom(s), kitchen, toilet room, bath room.

The prefabricated element preferably comprises the floor and/or the ceiling (deck) , the house separating walls and the gable walls and preferably embedded and recessed provisions for installations, preferably according to a fixed outline in the upright and/or flat walls, while in the gable walls the fame recesses are made and in the floor and/or deck e.g. recesses for stairwell and channels are made. The separating walls or space dividers within the complete unit for partitioning the building or living level into e.g. kitchen, toilet and living or two r three bedrooms, bathroom and landing, can also already be provided in the factory.

It is preferred to embed in the factory conduit cavities and conduit channels within the element, preferably according to a dense pattern such that the decision for the location of a electricity socket, switch or illumination appliance at a wall or ceiling can still be made during the finish the dwelling, simply by striking of such embedded conduit cavity or channel, thus without the need for machining a gap. The upright walls, particularly the house separating walls, are for that reason preferably provided with embedded internal vertical channels, and the flat walls are preferably provided with embedded internal horizontal channels, in an along the length of the wall extending, repeating pattern having a spacing less then 1 metre, e.g. 60 centimetre, and which channels are relatively close below the wall surface, anyhow remote from the centre of the wall thickness, such that easy striking is possible. NL1025886 (VBI) already discloses integration of conduit channel in prefab panels, from which panels the upright walls of a building are assemble, such that a regular pattern of vertical conduit channels with a spacing of 60 centimetre in the upright walls is provided. This invention goes

substantially beyond NL1025886. The big difference is that with this invention a complete assembly of both horizontal and vertical embedded internal elements is provided, wherein horizontal and vertical channels according the same outline extend and thus provide mutual continuation.

Further it is preferred to provide in the factory in the element embedded recessed plinth channels at the location of the connection between an upright wall part and floor, which channels extend horizontally and are flush within the wall surface and into which vertical and/or horizontal embedded channels debouch. Wiring can afterwards be threaded through the plinth channels and the vertical and horizontal embedded channels, which increases the flexibility of the electrical installation. During finishing the dwelling these plinth channels are covered by a plinth and thus covered from sight. Possibly the plinth channels are located at close distance from in stead of at the wall surface, such that striking thereof is reguired to get access.

Since the prefabricated element is a monolithic cast piece, for the first time the possibility is created to avoid separations in the embedded and recessed conduits / channels in the prefabricated element, and they thus are unitary, such that couplings are absent and the conduits / channels extend free from interruptions across the complete depth of the building or living level. These embedded features can not only be used for the electrical installation, but also for the transport of tap and heating water.

Thus with the invention building e.g. a block single family row housings can be made substantially cheaper. By deciding for levels from a single piece of concrete, channels to contain installation conduits can be obtained effectively, without loosing flexibility of the layout of the dwelling house, and problems during installing the elements are avoided. Lifting and tilting allow transport across the civil roads, without which the making within the factory of storeys from a single piece of concrete would indeed be feasible, however due to unavoidable transport problems economically unrealistic.

A further independent invention relates to a method for transporting across the civil road of a prefabricated element by mounting it in a lifting and/or tilting frame of the vehicle and during the ride across the civil road tilting and/or lifting it, preferably wherein the element with its end is mounted to the frame and in between has a substantially free span.

The by way of example added drawing shows in:

Fig. 1 the from US4.606.878 (Day) known house unit;

Fig. 2 in perspective an example of a building according to the invention;

Fig. 3 the prefabricated elements, located next to and on top of each other, for the building of fig. 2;

Fig. 4 in detail the joint between upright and flat walls;

Fig. 5 in top view the street level;

Fig. 6 in top view the first floor;

Fig. 7 the different views of the building;

Fig. 8 two views of the building;

Fig. 9 and 10 perspective views of a truck.

The in fig. 2-7 illustrated row housings are made since for each house a single prefabricated element is located onto a foundation, and on top of this element a next single prefabricated element is located, wherein of both elements the flat walls have equal dimensions of at least 30 square metres. In the factory each element is provided with all four upright walls, such that each element is a box, with or without a deck (ceiling) and possibly open topped.

Thus none of the two building levels of a house have an across the complete height of the building layer extending vertical joint, and such vertical joints are merely present between two joining houses of the row.

The detail of fig. 4 shows the embedded recessed plinth channels 4 at the location of the joining between the upright and flat walls 1, 2, 3, and also the location just below the face of the vertical and horizontal embedded internal channels 5.

Fig. 8 shows the outline of the vertical embedded internal channels 5 in the upright walls. The outline of the horizontal embedded internal channels in the flat walls is thus in line. Fig. 8A shows the side view, fig. 8B the front view of two stacked elements to obtain a single family row housing with storey.

Fig. 9 and 10 show an element 6 during transport, mounted in the lifting tilting frame of the truck. Arrows P illustrate lifting and tilting. With the element in the position WIDE, the frame is located LOW. If the element is brought from the position WIDE to LONG, the frame goes to HIGH. Appreciate that the element with its ends is mounted in the frame and there between has a substantial free span.

Claims

1. Method for making a building, wherein a building or living level of the building is made from a prefabricated element of reinforced concrete or different initially from free cast material with stony properties with a reinforcement, which element has at least two, three or four upright walls and a floor/ceiling, while this element has a dimension such that it covers the complete floor surface of the main volume, or at least 75% of it, of the relevant building or living level, while the element covers the complete width of the building or living level and preferably the complete depth, or at least 75% of it, of the relevant living or building level, and also the relevant building or living level is at least 4,5 metre wide and at least 6 metre deep, while the element provides a headroom of the relevant building or living level of at least 2.0 metre, preferably at least 2.4 metre, more preferably at least 2.6 metre, and wherein this element is fabricated remote from the building site and as a whole is transported across the civil road to the building site and there is located at the relevant foundation.

2. Method according to claim 1 to make a dwelling block ground level single family row housings of each at least two storeys above ground, wherein each row housing is made by stacking at least two prefabricated elements (6), wherein such a prefabricated element completely provides a living level of the row housing and is made from reinforced concrete, which element has at least the four housing separating upright walls (1) and a floor/ceiling (2) with stairwell recess, while this element is dimensioned such that it covers the complete floor surface of the relevant living level, while the element covers the complete width and the complete depth of the relevant living level, and also the relevant living level is at least 4.5 metre wide and at least 6 metre deep, while the element provides a headroom of the relevant living level of at least 2.6 metre, and wherein two of these elements, meaning a first and a second element, are fabricated remote from the building site in a factory such that they have equal width and depth and are completely, separately, transported across the civil road to the building site and there the first is located onto the relevant foundation and the second is located onto the first one which was already located onto the foundation, to make two storeys of a row housing and subsequently next to it the subsequent first and second elements are located in the same manner until of each of the block row housings all first and second elements are located at the desired location in the block, while in the factory the housing separating upright walls (1, 3) are provided with embedded internal vertical channels (5) , and the flat walls (2) are provided with embedded internal horizontal channels (5) , according to an along the length of the wall extending, repeating, and among the vertical and horizontal channels registered, pattern with spacing smaller then 1 metre, e.g. 60 centimetre, and which channels (5) are relatively close below the wall surface, in any case remote from the centre of the wall thickness, such that easy striking is possible, and in the factory in the element embedded recessed plinth channels (4) are provided at the location of the joining between an upright wall part (1) and floor (2), which channels extend horizontal and are flush with the wall surface and into which the vertical and horizontal embedded channels (5) debouch, and at the building site, after final locating of the elements (6), wiring and conduits for tap water and heating water are pulled through the plinth channels and the vertical and horizontal embedded channels (5) and during finishing the dwelling these plinth channels (4) are covered by a plinth and thus brought out of sight, and in the factory the prefabricated element (6) is cast as a monolithic part, such that separations in the embedded and recessed conduits / channels (4, 5) in the prefabricated element are absent and these conduits / channels (4, 5) are unitary, such that couplings are absent and the conduits / channels extend without interruption across the complete depth of the living level, while the following applies: all upright and flat walls are substantially rectangular; to all four sides of a flat wall an upright wall connects; each to a side of a flat wall connecting upright wall extends substantially along the complete said side; the height of all to the sides of the flat wall connecting upright walls is substantially equal the dimension of the flat walls is substantially equal.

3. Method according to claim 1 or 2, wherein each

prefabricated element, having a length not more then 7.5 metre and a depth not more then 15 metre, separately from the factory is transported across the civil road at a dedicated vehicle, during which transport a plurality the passage obstructing obstacles is passed if a fixed position of the element relative to the vehicle is maintained, for which the element is mounted in a lifting and tilting frame of the vehicle such that the element with its opposite ends is mounted in the frame and there between has a free span and with the depth direction according to the driving direction of the vehicle and during the ride across the civil road when a the passage obstructing obstacle is visited the element is tilted and lifted by moving the frame from a low level with horizontal floor/ceiling to a high level with vertical floor/ceiling and vice versa.

4. Prefabricated element for the method according to claim 1, 2 or 3.

5. Building, obtained by the method according to claim 1, 2, 3 or 4.