WO2012021080A2

WO2012021080A2 - The procedure of building a metallic modular construction

Info

Publication number: WO2012021080A2
Application number: PCT/RO2010/000010
Authority: WO
Inventors: Georg Peter Steinhart; Ilie Udroiu
Original assignee: S.C. Pegeros Import Export Srl
Priority date: 2009-10-12
Filing date: 2010-07-14
Publication date: 2012-02-16
Also published as: WO2012021080A3; RO126214A2; RO126214A8; RO126214B1

Abstract

This invention refers to the procedure of building a metal modular construction in order to obtain residence houses or multifunctional constructions. The procedure conformable to the invention implies the montage of a basic polygonal frame on a reinforced concrete foundation, delimitating the exterior of the construction. The frame is fixed using one of the two ways: whether in the foundation with metal rods and chemical ampoules; or it is mounted on 4 collar poles fixed in the foundation placed in the ground and then the metal rods are fastened to the metal frame and the concrete of elevation is moulded for their fixation. After fixing the basic frame (1) using one of the two ways, the vertical resistance poles are fixed in the basic frame using screws and nuts, in the cuttings (d, d1) special provided for the basic frame. The resistance beams are mounted at the height of +3 and +6 m between the vertical poles. The vertical poles are mechanically fastened to the exterior beams by means of screws and nuts, fastening assured by carbon fibre rings whose rigidness was provided by the metal structure using special resin. The montage of structural elements at the corners of the building is made using various carbon fibre interpenetrated rings. Next the beams are mounted on the ceiling at the height of +3 and +6 m, 2 pieces back to back. Outside the metal structure the sandwich type panels with both metal sides and polyurethane core are vertically mounted and they are fastened to the structure by means of self-drilling metal screws; then the resistance pleated plate is mounted over the ceiling beams; outside the construction sandwich panels are placed and they are covered with polystyrene, polyester mesh and ornamental plaster; the framework is built of zinc metal structure and metal purlins are mounted over it along the water, fastened to a layer of pleated plate and tile plate over it or directly on the metallic structure of the roof framework are mounted sandwich panels with a type tile face; the direction of the electric, plumbing, and heating plants is mounted inside the construction, along the contour inside the metal structure. A coat of mineral wool is fixed over it and phonic-acoustic sandwich type panels or gypsum cardboards are mounted over it on the rigips type metal structure.

Description

The Procedure of Building a Metallic Modular Construction

This invention refers to the procedure of building a metal modular construction in order to obtain residence houses or multifunctional constructions.

Nowadays, the technologies for building metal structures constructions and combinations of metal structures with wooden structures are widely known. The disadvantages of these technologies refer to the usage as exterior wall panels of the sandwich type panels, made of oriented strand boards (OSB) and referred to as OSB in the rest of the presentation. These boards are fastened to the wooden poles or to the metal poles with screws, panels over which polystyrene and ornamental plaster are mounted; inside the construction, the wall panel is coated with mineral wool over which OSB boards are mounted, coated with boards of gypsum cardboard. This type of wall panels represents the condensation absorber for the mineral wool coat. In case of earthquake, the OSB boards can be pulled out of the screws, leading to the cracking of those wall panels. For these technologies, the metal poles are fixed directly in the foundation by means of the boards which are embedded in concrete, creating problems for the mounting procedure, like lack of preciseness regarding the vertical and horizontal alignment of the elements, or lack of preciseness in the case of the montage operations.

Another widely known procedure of building metal constructions is based on the use of basic metal structures with U profile, fixed in the same position with the small parallel wing, placed on the foundations and mounted poles every 50 cm, vertically fixed in the basic U profile, the fixation between the resistance elements being made with pop rivets or self-drilling metal screws. The floors of the construction are made up of metal U or C profiles, with a breadth of 1 mm, lattice beams type, on the metal structure of the interior and exterior walls, the boards being mounted with oriented fibres and a coat of mineral wool between them. Some reinforced screed is moulded, with an OSB board of 22 mm, over the metal structure of the floor, structure made of lattice beams. This procedure has various inconveniences, as well. The structure of the construction implies a lot of elements; it includes OSB boards both for the walls and for the floor, boards which are fastened to the metal structure and which, in case of earthquake, can be pulled out of the screws.

Also, big glazed surfaces and big cantilevered balconies or terraces cannot be made by using this procedure. For each type of construction, based on the mentioned procedure, the resistance calculations are repeated according to the openings of the rooms.

From the RO 113264 patent, a construction with a simple structure, made of typified metal profiles, with the section in I, U, L, T on the poles and floors with prefabricated wall panels and ceiling is also known. The fixation of the basic panels between the consecutive metal poles, fixed in the foundation of the construction, is made by means of purlins and sealing material, inside and outside the construction. This blending is covered with decorative boards; for the montage of the floors, on the poles there are fixed at a certain distance beams and profiles, perpendicular to each other and fixed by means of welding, placing a panel in every quadrilateral thus formed.

There is also known from the RO 114989 patent about a stratified panel and a resistance structure used for building houses or industrial buildings, panel which is made of a U bent profile frame in which there are introduced a board of asbestos-cement, a board of expanded polystyrene or any other simple insulator and a medium-density fibreboard, boards which are glued with polyvinyl acetate. The resistance structure of the construction made with the panel presented above includes the prefabricated metal elements, from the U profile, a reinforced angle, bent at a low temperature, made of steel band in which there are mounted by gliding the stratified prefabricated panels, the reinforcing being made by means of points welding. These panels imply special plants for the procedure of building and the plants have a high level of energy consumption; the panels do not have high thermo-insulating characteristics. The technical problem which is solved by the present invention consists in the safely and precisely building of a metal construction, the easiness of mounting the structure elements, which are interchangeable, valid for all buildings versions and sizes, and also increasing the resistance of the combinations of metal structure and the improvement of the thermal resistance of the walls.

This problem is created by conceiving a process of building some metal modular constructions which imply the montage on the reinforced concrete foundation of the construction of one of the polygonal basic frame for precision control regarding the montage of the structure elements, frame which delimitates the exterior of the construction. This frame is fixed on the foundation of the construction using one of two ways: by means of threaded metal rods and chemical ampoules or by fixing 4 collar poles in the concrete of the foundation in the ground. Then the polygonal frame is fixed on the 4 collar poles, the metal rods are fixed on the frame and the elevation is moulded. After fixing the base frame through one of the methods presented above, by means of screws, nuts and washers, the vertical resistance poles are mounted, in the special cuttings made for the basic frame. Between the vertical poles resistance beams are mounted at a height of +3m and +6. The beams are mechanically fastened by means of screws and nuts, fastening provided additionally by some carbon fiber rings reinforced by the metal structure by means of a special resin. In the corners of the building the fixation of the elements is made by means of more intertwined carbon fibre rings. Furthermore, the ceiling beams are mounted, at a height of +3m and +6m, two pieces placed back to back. In the exterior of the metal structure there are mounted, on the vertical, sandwich panels with two metal sides and polyurethane core, panels which are fastened to the structure with self-drilling metal screws; moreover, over the ceiling beams there is mounted pleated resistance plate, over which there are placed sandwich panels. In the exterior of the construction, polystyrene, polyester mesh are mounted and an ornamental plaster coat is applied on the wall sandwich panels; the zinc metal structure framework is made, over which there are moulded metal purlins along the water, on which a layer of pleated plates is fastened and then some tile board is added. Inside the construction, on the contour of the walls inside the metal construction, the directions of the plumbing, heating, electric plants are set, over which a coat of mineral wool is fixed and over which boards of gypsum cardboard or phonic-acoustic sandwich panels are mounted.

The procedure of building a metal modular construction according to the invention has the following advantages:

allows the construction of a multifunctional building, using interchangeable structure elements;

leads to the precision of the metal structure montage;

the construction is easily and fast built;

dry materials, without concrete, lime, etc are used in the procedure.

To continue, an example of building the invention it is presented, regarding the pictures 1-13, which represent:

Picture 1 - schematic horizontal section in the building which has a metal modular construction;

Picture 2 - top view of the frame and of the element for mounting the field pole;

Picture 3 - top view of the frame and of the element for mounting the corner pole;

Picture 4 - Z-Z section of the basic frame and its fastening with the collar poles;

Picture 5 - M-M section of the basic frame, the fastening of the frame with metal rods and chemical ampoules;

Picture 6 - N-N section of the basic frame - fixation in the concrete of the elevation;

Picture 7 - schematic detail regarding the fixation of the structure elements with carbon fibre rings on the corner poles; Picture 8 - top view of picture 7;

Picture 9 - supplementary fixation of the structure elements combination;

Picture 10 - 0-0 section of picture 9;

Picture 11 - detail of a carbon fibre ring;

Picture 12 - partial section of a vertical wall panel.

Picture 13 - fixation of the frame with the collar poles and the fastening rods - fixation in the concrete of the elevation.

The procedure of building a metal modular construction according to the invention consists of the following building phases:

An (A) foundation of reinforced concrete is made, according to the classic procedures. A polygonal basic frame (1) is mounted on this foundation, frame which delimitates the exterior of the construction. The basic frame (1) is made up of the profile type C 200 mm of a 3.5 mm board, thermally zinc board. The metal frame (1) has some cuttings (d) on its four sides, every 4 m in which there are mounted the vertical resistance poles (2), and at the corners of the building the corner poles (3) in some cuttings are mounted, being made in the basic frame which has a profile according to the poles. The fastening of the poles (2,3) is made with cover plates, screws and nuts.

On the four sides of the frame (1), on one of the small wings of the C profile, there are made o apertures with a diameter of 22 mm, an opening of 600 mm, in which there are introduced metal rods (4) M20x300 mm with chemical ampoules (5).

For strong winds having between 150 and 250 km per hour, the basic frame (1 is fastened to the (A) foundation with metal rods (4) M20 with the lejngth of 500-700 mm, according to the pictures 4 and 13, the frame being supported horizontally and vertically by 4 collar poles (6), fixed in the concrete of the foundation placed in the ground. After having fixed the frame (1 , on the four poles (6) there are fixed the metal rods (4) M20x500 mm and the elevation is moulded. Now the rods (4) are fixed in the concrete of the elevation.

Frame (1) is placed with one of the wings of the C profile on the foundation, having the opening between the small wings of the profile towards the interior of the construction.

Next to the vertical poles (2) and corner poles (3), in the superior wing of the frame (1) profile, there are made some cuttings (d1) of 201x60 mm, thus providing the precision of the montage of the interchangeable elements.

Horizontally, on the contour of the construction, between the vertical resistance poles(2) there are mounted the resistance beams (7) made up of the profile type C200, at the height of +3 m and +6 m, the construction having vertically the resistance elements of 3 m multiple. After mounting the poles vertically, between the poles the exterior beams(8 of profiles type C200 mm are mounted, at a height of +3 m and +6 m. In the corners of the construction, between the vertical poles (2) and the exterior beams

(8) , apart from the mechanical fastening with screws and nuts, the reinforcement of the elements is provided by means of some carbon fibre rings (9). In the section, such a ring

(9) is made of a group of carbon fibre whose rigidness was provided by the metal structure by means of a special resin. Thus, the resistance of the respective combination for wind of 150-250 km per hour is increased.

After the supplementary rigidness of the poles (2,3), the ceiling beams (10) are mounted, beams which are also made up of the profile type C200 mm, at a height of +3 m and +6 m, two pieces placed back to back. On the exterior side of the metal structure thus created from the interchangeable elements, the wall panels (11) are vertically mounted. The panels (1 1) are of sandwich type, with a breadth of 100 mm, having both metal sides of 0.5 mm and polyurethane core. The fastening of the panels ( 1) with metal structure is made by means of self- drilling metal screws, and fixed with an additional profile type L, caught by the metal structure, stiffening the panels with metal structures.

Over the metal ceiling beams (10) there are mounted resistance pleated plates

(12) , with a breadth of 1.5 mm over which there are mounted some sandwich panels

(13) , with two metal sides having a breadth of 0.5 mm, panels which have a breadth of 60 mm.

All the elements of the resistance structure, beams, connector poles, are perforated in the manufactory, on specialized plants, providing the precision necessary for the inter-changeability. The montage of the structure elements is made by means of connectors, with zinc M14 screws, nuts and lock washers.

At the exterior, the metal modular construction has mounted on the wall panels (1 1) a polystyrene coat (14) of 50 mm, a polyester mesh (15, fixed with polifix adhesive, and a coat (16) of ornamental plaster. The fastening of the polystyrene on the metal sides of the wall panels (11) is made by means of mushroom head screws and with dowels.

Furthermore, the framework is built of zinc metal beams, over which metal purlins are mounted along the water, fastened with the resistance pleated plate with a breadth of 1.5 mm, as roof boarding, over which the tile plate is mounted or, directly to the roof metal framework are fixed with screws sandwich panels with a tile type face

Inside the metal construction, more exactly inside the metal structure, there is an empty space of 60 mm on all the inner walls surfaces where the plumbing, heating, electric plants and the Internet facilities are mounted. At the same time the resistance poles 2 and (3) are equipped with transit apertures, vertically placed from 150 to 150 mm, for the running across in the direction of the plants.

After setting the direction of these plants, mineral wool type (17) is mounted on walls with a breadth of 63 mm of the walls metal structure, then gypsum cardboards (19) or phonic-acoustic sandwich type panels with a breadth of 60 mm are mounted, covering it with a.

Modular constructions built in this manner have 2 sides, covered platforms with a width of 2.5 cm at every level, platforms also built of zinc modular elements.

Sandwich type wall panels allow the covering with particular ornamental plasters outside the construction.

Due to the phonic and thermal super-insulations, polystyrene and sandwich panels on the exterior metal structure, mineral wool on the metal structure thickness and sandwich panels on the inside or rigips, a substantial power save is assured regarding buildings exploitation, by means of a thermo-isolation equivalent to a brick wall of 1.5 m.

Thus the thermal conductivity coefficients and thermal resistance of the walls obtained in this manner are:

λ = 0.03 W/m²K for polystyrene, breadth of 50 mm

λ = 0.02 W/m²K for sandwich type panel, breadth of 100 mm

λ = 0.033 W/m²K for mineral wool, breadth of 50 mm

The procedure conformable to the invention allows the increasing of the interchangeable elements structure montage speed so that the modular construction can be built within a period of 20 to 60 days, obtaining a multitude of modular constructions of horizontally multiple of 4m and vertically multiple of 3m.

Claims

1. The procedure of building a modular metal construction, characterized by the fact that:

a basic polygonal frame (1) is mounted on the reinforced concrete foundation (A), which delimitates the exterior of the construction;

the basic frame (1) is fixed using one of the two ways: whether in the foundation with metal rods (4) and chemical ampoules (5); or it is mounted on 4 collar poles (6) fixed in the foundation placed in the ground and then the metal rods (4) are fastened to the metal frame (1) and the concrete of elevation is moulded for their fixation;

after fixing the basic frame (1) using one of the two ways, the vertical resistance poles (2, 3) are fixed in the basic frame using screws and nuts, in the cuttings (d, d1) special provided for the basic frame (1)

the resistance beams (7) made up of profiles type C200 are mounted horizontally, on the contour of the construction between the vertical resistance poles (2) at the height of +3 and +6 m;

the exterior beams (8) made up of profiles type C200 mm are mounted between the vertical poles at the height of +3 and +6 m;

supplementary rigidness of elements is assured by means of carbon fibre rings (9) at the corners of the construction, where the vertical poles (3) and the exterior beams (8) meet; next the beams (10) are mounted on the ceiling, at the height of +3 and +6 m, 2 pieces back to back;

outside the metal structure, sandwich type wall panels (1 ) are vertically mounted with both metal surfaces and polyurethane core, panels which fasten to the structure with self-drilling metal screws and additional, over the panels, is fixed a profile L-type with metal structure;

resistance pleated plates (12) are mounted over the ceiling beams and the sandwich type panels (13) are placed over it;

outside the construction polystyrene (14), polyester mesh (15) are mounted on the sandwich type wall panels (11), covered with a coat of ornamental plaster (16) the metal zinc structure framework is built; the metal purlins along the water are mounted over it, fastening with a layer of pleated plates and over it with tile plates or sandwich type panels with pleated plate are mounted;

the direction of the plumbing, heating, electric plants is set along the contour of walls, inside the metal structure strengthened with a coat of mineral wool (17) and gypsum boards (19) on rigips type metal structures or phonic-acoustic sandwich type panels.

2. Procedure conformable to the first requirement, characterized by the fact that the basic frame (1) is made up of profile type C 200 mm of thermal zinc compact plate of 3.5 mm on its 4 corners, being equipped with some cuttings (d) from 4 to 4 m; the frame (1) is equipped with some cuttings (d1) and on its sides it has some apertures (o) with a diameter of 22 mm, with a distance of 600 mm.

3. Procedure conformable to the first requirement, characterized by the fact that outside the wall panels (11) have a polystyrene coat (14) of a breadth 50 mm, a polyester mesh (15), fixed with polifix adhesive and a coat of ornamental plaster (16) and inside the surface dedicated to the direction of specific plants a coat of mineral wool (17) of a breadth of 63 mm was placed, covered by gypsum carton plates ( 9) fixed on rigips type metal structure or phonic-acoustic sandwich type panels with a breadth of 60 cm.

4. Procedure conformable to the first requirement, characterized by the fact that the vertical poles (2, 3) and the exterior beams (8) are reinforced with carton fibre rings (9) consisting of a bundle of carbon fibre whose rigidness was provided by the metal structure by means of a special resin.