WO2021064215A1 - A concrete dwelling with prefabricated building elements - Google Patents

A concrete dwelling with prefabricated building elements Download PDF

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Publication number
WO2021064215A1
WO2021064215A1 PCT/EP2020/077730 EP2020077730W WO2021064215A1 WO 2021064215 A1 WO2021064215 A1 WO 2021064215A1 EP 2020077730 W EP2020077730 W EP 2020077730W WO 2021064215 A1 WO2021064215 A1 WO 2021064215A1
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WO
WIPO (PCT)
Prior art keywords
prefabricated building
building elements
dwelling
wall
elements
Prior art date
Application number
PCT/EP2020/077730
Other languages
French (fr)
Inventor
Haim David Fisher
Fabio Bettazzi
Original Assignee
Fisher, Laura Micol
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Fisher, Laura Micol filed Critical Fisher, Laura Micol
Publication of WO2021064215A1 publication Critical patent/WO2021064215A1/en

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Classifications

    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04BGENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B5/00Floors; Floor construction with regard to insulation; Connections specially adapted therefor
    • E04B5/16Load-carrying floor structures wholly or partly cast or similarly formed in situ
    • E04B5/32Floor structures wholly cast in situ with or without form units or reinforcements
    • E04B5/36Floor structures wholly cast in situ with or without form units or reinforcements with form units as part of the floor
    • E04B5/38Floor structures wholly cast in situ with or without form units or reinforcements with form units as part of the floor with slab-shaped form units acting simultaneously as reinforcement; Form slabs with reinforcements extending laterally outside the element
    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04BGENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B2/00Walls, e.g. partitions, for buildings; Wall construction with regard to insulation; Connections specially adapted to walls
    • E04B2/84Walls made by casting, pouring, or tamping in situ
    • E04B2/86Walls made by casting, pouring, or tamping in situ made in permanent forms
    • E04B2/8611Walls made by casting, pouring, or tamping in situ made in permanent forms with spacers being embedded in at least one form leaf
    • E04B2/8617Walls made by casting, pouring, or tamping in situ made in permanent forms with spacers being embedded in at least one form leaf with spacers being embedded in both form leaves

Definitions

  • the present disclosure relates to construction of buildings and more specifically to dwellings constructed of prefabricated building elements.
  • An object of the present disclosure is to provide a concrete dwelling with prefabricated building elements that offers a cost-effective solution
  • Another object of the present disclosure is to provide a concrete dwelling with prefabricated building elements that requires shorter construction time
  • Still another object of the present disclosure is to provide a concrete dwelling with prefabricated building elements that can be constructed by less skilled labor under minimal supervision;
  • the present disclosure relates to construction of dwellings and more specifically to dwellings constructed of prefabricated building elements.
  • the prefabricated building element comprises a flat planar rectangular body having a smooth or decorated outside surface and an inside surface in which a plurality of panel wires is partially embedded in a predefined pattern running from one end of said body to another end across said inside surface.
  • a plurality of prefabricated building elements placed vertically or horizontally in a spaced apart configuration with, operative inside surface facing each other and a plurality of clips configured to clip and position said prefabricated building elements in a spaced apart configuration with respect to each other, said spaced apart configuration to receive concrete for forming a wall or part of wall, a floor or part of floor, a slab or a part of slab of a dwelling.
  • a plurality of prefabricated building elements formed are clipped together along their edges to form a wall or a floor of the dwelling.
  • the prefabricated building elements are joined by panel clips in a manner along their edges such that a set of prefabricated building elements are substantially perpendicular to another set of prefabricated building elements to form a corner of the dwelling.
  • the panel wires meander along the length of said prefabricated building elements as they run across said inner surface. Panel wires meander along the length of said prefabricated building elements that are substantially parallel to each other in a waveform pattern.
  • the ratio of the panel wires embedded in the body and outside is approximately between thirty percent (30%) and eighty percent (80%), wherein the diameter of said panel wires could be approximately between five millimetres and ten millimetres and the thickness of the prefabricated building elements ranges approximately between 15 mm and 50 mm.
  • the inside surface is scored between said panel wires to define panel slots that facilitate cutting of said prefabricated building elements to fit the required measures of the specific building and for architectural purposes.
  • the wall or the floor or the slab as configured includes at least one reinforcing element secured within said space between two prefabricated building elements is selected from a trellis and a rebar.
  • the dwelling is constructed of plurality of prefabricated building elements arranged, to define the walls, the floor and the ceiling of dwelling. The prefabricated building elements are very simply cut out at the site to define openings for doors windows and ventilators.
  • Figure 1 illustrates an isometric view of a concrete dwelling pre-fabricated building element, in accordance with an embodiment of the present disclosure
  • Figure 2 illustrates a front view of the concrete dwelling pre-fabricated building element of Figure 1
  • Figure 3 illustrates a side view of the concrete dwelling pre-fabricated building element of Figure 1;
  • Figure 4 illustrates an isometric view of a concrete dwelling wall with pre-fabricated building elements, in accordance with another embodiment of the present disclosure
  • Figure 5 illustrates a side view of the concrete dwelling wall with pre-fabricated building elements of Figure 4;
  • Figure 6 illustrates a detail D of the concrete dwelling wall with pre-fabricated building elements of figure 4, in accordance with an embodiment of the present disclosure
  • Figure 7 illustrates an isometric view of the concrete dwelling with multiple pre-fabricated building elements interconnected in line with each other, in accordance with an embodiment of the present disclosure
  • Figure 8 illustrates a detail B of the concrete dwelling wall with multiple pre-fabricated building elements of figure 7, in accordance with an embodiment of the present disclosure
  • Figure 9 illustrates an isometric view of the concrete dwelling with multiple pre-fabricated building elements interconnected perpendicular to each other, in accordance with an embodiment of the present disclosure
  • Figure 10 illustrates a detail C of the concrete dwelling wall with multiple pre-fabricated building elements of figure 9, in accordance with an embodiment of the present disclosure
  • Figure 11 illustrates an isometric view of an alignment plate of the concrete dwelling with pre-fabricated building elements, in accordance with an embodiment of the present disclosure
  • Figure 12 illustrates a side view of an alignment plate of the concrete dwelling with pre fabricated building elements, in accordance with an embodiment of the present disclosure
  • Figure 13 illustrates a front view of an alignment plate of the concrete dwelling with pre- fabricated building elements, in accordance with an embodiment of the present disclosure
  • Figure 14 illustrates a top view of an alignment plate of the concrete building with pre fabricated building elements, in accordance with an embodiment of the present disclosure
  • Figure 15 illustrates an isometric view of the wall of the concrete dwelling with pre- fabricated building elements interconnecting the floor slab and ceiling slab, in accordance with an embodiment of the present disclosure
  • Figure 16 illustrates a detail E of figure 15, in accordance with an embodiment of the present disclosure
  • Figure 17 illustrates a detail F of figure 16, in accordance with an embodiment of the present disclosure
  • Figure 18 illustrates a side view of the temporary support element of the concrete dwelling with pre-fabricated building elements interconnecting the floor slab and ceiling slab, in accordance with an embodiment of the present disclosure
  • Figure 19 illustrates a detail G of figure 18, of the connection between the wall and the floor or ceiling slabs accordance with an embodiment of the present disclosure
  • Figure 20 illustrates a detail H of figure 18, in accordance with an embodiment of the present disclosure
  • Figures 21-26 illustrates sequence of construction of a floor of a dwelling, in accordance with an embodiment of the present disclosure
  • Figures 27-31 illustrates sequence of insertion of a clip into the prefabricated panel of the wall of a dwelling, in accordance with an embodiment of the present disclosure.
  • Embodiments, of the present disclosure will now be described with reference to the accompanying drawing. Embodiments are provided so as to thoroughly and fully convey the scope of the present disclosure to the person skilled in the art. Numerous details are set forth, relating to specific components, and methods, to provide a complete understanding of embodiments of the present disclosure. It will be apparent to the person skilled in the art that the details provided in the embodiments should not be construed to limit the scope of the present disclosure. In some embodiments, well-known processes, well-known apparatus structures, and well-known techniques are not described in detail.
  • first, second, third, etc. should not be construed to limit the scope of the present disclosure as the aforementioned terms may be only used to distinguish one element, component, region, layer or section from another component, region, layer or section.
  • Terms such as first, second, third etc., when used herein do not imply a specific sequence or order unless clearly suggested by the present disclosure.
  • Terms such as “inner”, “outer”, “beneath”, “below”, “lower”, “above”, “upper” and the like, may be used in the present disclosure to describe relationships between different elements as depicted from the figures.
  • FIGs 1-3 illustrate an embodiment of a prefabricated building element 100 of the present disclosure.
  • the prefabricated building element 100 has an inside surface 6 and an outside surface 8 which comprises of panel wires 4 that pass through the prefabricated building element 100 in a waveform pattern along its length, with intervals of panel wire 4 projections.
  • the waveform construction of panel wires 4 is such that the panel wires 4 project on the inside surface 6 only, while the outside surface 8 has a surface finish that facilitate elimination of extra finishing work.
  • the exterior walls of a dwelling built with the prefabricated building elements 100 also bear a surface finish as desired, which further eliminates extra finishing work.
  • Panel slots 10 provided on along the longitudinal direction of the prefabricated building element 100 divide the prefabricated building element 100 along the width, and hence accommodate customization of prefabricated building element size.
  • Figure 2 shows a side view of the figure 1 with intervals of panel wire 4 projections along the length of the panel wire 4
  • figure 3 shows an end view of figure 1 with regularly spaced panel wires 4 along the width of the prefabricated building element 100.
  • FIGs 4-6 illustrate the construction of a wall 1000 with the prefabricated building elements 100 integrated together by clips 9.
  • Clips 9 placed at regular intervals enable accurate positioning between two panels 100, thus defining a uniform thickness of the wall 100.
  • Clips 9 are typically round metal wires bent at their ends so that they can be hooked horizontally into the panel wire 4 projecting on the inside surface 6 of the prefabricated building elements 100, as shown by a sequence of construction in figures 27-31.
  • thickness of the wall 1000 can be customized as desired, as well as offering structural reinforcement to the wall 1000.
  • Filler material such as regular concrete or consisting of light weight concrete or any special concrete mix, such as combined with pieces of plastic, can be poured into the space formed between the prefabricated building elements 100 to complete the construction of the single wall 1000.
  • the process of pouring the concrete can be equal to what is normally done at any construction site, using mixing of the concrete at the site itself, mainly for small projects, or by mixers, that can pour at once the concrete to the entire floor.
  • the space between the prefabricated building elements 100 allows routing of piping, ducts or conduits in advance before the pouring filler material as required for accommodation for various purposes.
  • Figures 7 and 8 illustrates alignment of prefabricated building elements 100 at their respective edges facilitated with the use of alignment plates 12 and panel wedges 14.
  • Figure 8 shows a detail B of figure 7 where two prefabricated building elements 100 are in line with each other.
  • Alignment plate 12 is positioned between the edges of the two prefabricated building elements 100 that are to be joined together in line with each other.
  • Figures 9 and 10 illustrate alignment of prefabricated building elements 100 at their respective corners facilitated with the use of alignment plates 12 and panel wedges 14.
  • Figure 10 shows a detail C of figure 9 where two prefabricated building elements 100 are perpendicular to each other.
  • Alignment plate 12 is positioned between the edges of the prefabricated building elements 100 that are to be joined together that are perpendicular to each other.
  • Figures 11-14 illustrate construction of the alignment plate 12 with alignment plate bent faces 12a and alignment plate slot 12b.
  • Alignment plate bent faces 12a facilitates positioning of prefabricated building elements 100 with respect to each other while alignment plate slot 12b facilitates insertion of panel wedges 14.
  • Panel wedges can be hammered to position the prefabricated building elements 100 accurately with respect to each other.
  • Figure 15 illustrates construction of the wall 1000 into the floor slab 16.
  • Floor slab reinforcements 18 contained inside the floor slab 16 are pre-bent metal wires.
  • Horizontal rebars 20 can be inserted into the projections of the panel wires 4 which can be further connected to the floor slab reinforcements 18 to offer structural strength to the wall 1000 as well as the floor slab 16.
  • Figure 16 shows the detail E of figure 15 where trellis 22 clipped to the panel 100.
  • Trellis 22 are typically made of bent metal wires bent in the form of a wavy profile that run through the thickness of the wall 1000 in its longitudinal direction which facilitate enhanced structural strength to the construction.
  • Rebars 20 further augment the structural integrity of the wall 1000 by connecting to the floor slab 16 thus transferring loads.
  • Figure 17 shows detail F of figure 16 which illustrates the interwoven mesh structure of the trellis 22, the panel wire 4 and the horizontal rebar 20 with each other. This facilitates obtaining constraints that offer strength as well as ease of assembly to the unskilled laborers.
  • the horizontal rebars 20 pass through a gap opening formed between the panel wire 4 and trellis 22, as they are form a mesh together in a direction perpendicular to the horizontal rebars 20.
  • Figures 18 -20 illustrate an integral construction of the wall 1000 with the ground floor slab 16 and ceiling slab 24 with detail G showing the connection of ceiling slab 24 with the wall 1000 (as shown in figure 17) and detail H showing the connection of floor slab 16 with the wall 1000 (as shown in figure 18) respectively.
  • Such a construction requires less handling of construction materials than what is required by using conventional methods, as prefabricated building elements 100 are manufactured at the industry location.
  • This method of using prefabricated building elements 100 in constructing a dwelling reduces the challenges related to transportation, and eliminate the usage of heavy lifting equipment at site and the need for skilled staff. Additionally, this method requires simple and light weight elements, which are standardized and only need to be delivered to the construction site where filler material like concrete simply gets poured into the space between the panels 100 to form the wall 1000.
  • the procedure for constructing the walls 1000 will now be described with reference to figures 1-20. Initially the required amount of prefabricated building elements 100 are shipped to the dwelling location from the industry or from the local distributor. A wall 1000 being a standard concrete bearing wall as per the construction specifications is marked. The prefabricated building elements 100 that are light weight in construction are then simply held in position with manual means or other suitable supports that are handled by workmen on a floor 16. The plurality of clips 9 with suitable dimensions are then inserted into the plurality of panel wires 4 projecting from the inside surface 6 of each of the prefabricated building elements 100. This facilitates positioning of the wall 1000 and thus imparts structural continuity to the wall 1000. The dimensions of the clips 9 govern the desired wall 1000 thickness to be achieved.
  • a number of reinforcements in the form of rebars 20 and trellis 22 are inserted into the plurality of panel wires 4 that offer structural reinforcement to the wall 1000.
  • the panel slots 10 provided on each of the prefabricated building elements 100 facilitate weakenings for sectioning or cutting the prefabricated building elements 100, in order to bring the wall 1000 into conformity with the constructional specifications.
  • Surface finished prefabricated building elements 100 manufactured in the industry offer ease of manufacturing as compared to applying surface finish that is usually done manually by a specialized worker, at the construction location, as manufacturing inside an industry enables maintaining the desired controlled environment as well as is easy to employ skilled labor.
  • One of the walls 1000 is then secured with another wall 1000 in an in line configuration or an across configuration is accomplished via usage of trivial positioning tools such as alignment plates 12 that are made of metal which consist of bent faces 12a and provision for inserting panel wedges 14. Subsequently, the panel wedges 14 are fitted into alignment plate slot 12b and hammered.
  • Figures 21-26 show a sequence of steps in constructing the dwelling in accordance with an embodiment of the present disclosure.
  • Figure 21 shows a layer of net made of a soft material that has a mesh 26, typically of size equal to the width of the wall 1000 to be constructed for example 20cm x 20cm if this will be the final width of the wall 1000, that is be positioned on the ground floor slab, as a first step, allowing the builder to align the prefabricated building elements.
  • This facilitates elimination of measurement work needed to be carried out on the dwelling site, as the mesh 26 acts as a guidance, thereby reducing construction time significantly.
  • the mesh 26 is supplied, upon request, to the builder together with the pre-fabricated building elements 100 which enables even the less skilled labourers to identify the dwelling construction plan easily, as desired.
  • the supplier of the prefabricated building elements 100 offers a complete design solution for an entire dwelling that are already pre-cut and numbered to facilitate installation work and avoiding resizing of the pre-fabricated building elements 100 on the construction site, thereby preventing loss of construction time.
  • the construction of the dwelling begins with constructing the prefabricated building elements adjoining the door.
  • the rest of the walls 1000 are then constructed leaving a predetermined margin for the door frame of the dwelling.
  • the entire dwelling is constructed by connecting the multiple floors vertically over one another to their final position.
  • This method of using prefabricated building elements 100 as integrated in the final construction, is a “one-shot” form and does not allow the re-use of such prefabricated building elements 100 forms, however, the prefabricated building elements 100 avoid the cost of recuperating, handling, transportation, the storage and the further delivery of the forms, as occur is regular forms that are re-usable, and in the same time offers a complete integrated process by including the steel reinforcement works, offering also the final finishing of the walls, on the internal and external side of the building.
  • the foregoing description of the embodiments has been provided for purposes of illustration and not intended to limit the scope of the present disclosure. Individual components of a particular embodiment are generally not limited to that particular embodiment, but, are interchangeable. Such variations are not to be regarded as a departure from the present disclosure, and all such modifications are considered to be within the scope of the present disclosure.

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  • Engineering & Computer Science (AREA)
  • Architecture (AREA)
  • Physics & Mathematics (AREA)
  • Electromagnetism (AREA)
  • Civil Engineering (AREA)
  • Structural Engineering (AREA)
  • Conveying And Assembling Of Building Elements In Situ (AREA)

Abstract

The present disclosure relates to construction of buildings and more specifically to buildings constructed of prefabricated elements. The prefabricated building element (100) comprising a flat planar rectangular body (2) having a smooth outside surface (8) and an inside surface (6) in which a plurality of panel wires (4) are partially embedded in a predefined pattern running from one end of said body (2) to another end across said inside surface (6). The present invention facilitates cost reduction, time saving for construction and can be accomplished by less skilled labor.

Description

A CONCRETE DWELLING WITH PREFABRICATED BUILDING ELEMENTS
FIELD
The present disclosure relates to construction of buildings and more specifically to dwellings constructed of prefabricated building elements.
BACKGROUND
The background information herein below relates to the present disclosure but is not necessarily prior art.
At present, dwellings constructed solely of traditional concrete material, are costly and also require significant construction time, as raw material for construction is first brought to the construction site followed by a sequence of constructional activities. This problem further gets aggravated in developing countries where there is acute shortage of homes especially among the low-income families. So, in order to meet the increasing demand, it is desired that the construction is cost-effective and also takes place at a faster pace than the conventional type construction. Moreover, the conventional construction techniques require significant number of laborers that typically lack the required expertise, and constant supervision which renders the construction process time consuming as well as of low quality. Still further, the tools and equipment required by the construction workers in constructing dwellings are complex to handle with or often requires additional machinery. The construction of dwellings by conventional methods is rendered highly inefficient, as a lot of raw material and different products that need further processing are carried to the location as well as leads to increased construction time. Furthermore, as construction on dwellings require integration of different trades, coordination of activities at the location becomes difficult which results in substandard construction quality. Thus, cost of construction increases with conventional construction methods.
There is, therefore, felt a need to overcome the above said problems. OBJECTS
Some of the objects of the present disclosure, which at least one embodiment herein satisfies, are as follows:
An object of the present disclosure is to provide a concrete dwelling with prefabricated building elements that offers a cost-effective solution;
Another object of the present disclosure is to provide a concrete dwelling with prefabricated building elements that requires shorter construction time;
Still another object of the present disclosure is to provide a concrete dwelling with prefabricated building elements that can be constructed by less skilled labor under minimal supervision; and
Other objects and advantages of the present disclosure will be more apparent from the following description, which is not intended to limit the scope of the present disclosure.
SUMMARY
The present disclosure relates to construction of dwellings and more specifically to dwellings constructed of prefabricated building elements. The prefabricated building element comprises a flat planar rectangular body having a smooth or decorated outside surface and an inside surface in which a plurality of panel wires is partially embedded in a predefined pattern running from one end of said body to another end across said inside surface. A plurality of prefabricated building elements placed vertically or horizontally in a spaced apart configuration with, operative inside surface facing each other and a plurality of clips configured to clip and position said prefabricated building elements in a spaced apart configuration with respect to each other, said spaced apart configuration to receive concrete for forming a wall or part of wall, a floor or part of floor, a slab or a part of slab of a dwelling. A plurality of prefabricated building elements formed are clipped together along their edges to form a wall or a floor of the dwelling. The prefabricated building elements are joined by panel clips in a manner along their edges such that a set of prefabricated building elements are substantially perpendicular to another set of prefabricated building elements to form a corner of the dwelling. The panel wires meander along the length of said prefabricated building elements as they run across said inner surface. Panel wires meander along the length of said prefabricated building elements that are substantially parallel to each other in a waveform pattern. Further, the ratio of the panel wires embedded in the body and outside is approximately between thirty percent (30%) and eighty percent (80%), wherein the diameter of said panel wires could be approximately between five millimetres and ten millimetres and the thickness of the prefabricated building elements ranges approximately between 15 mm and 50 mm. Still further, the inside surface is scored between said panel wires to define panel slots that facilitate cutting of said prefabricated building elements to fit the required measures of the specific building and for architectural purposes. The wall or the floor or the slab as configured includes at least one reinforcing element secured within said space between two prefabricated building elements is selected from a trellis and a rebar. The dwelling is constructed of plurality of prefabricated building elements arranged, to define the walls, the floor and the ceiling of dwelling. The prefabricated building elements are very simply cut out at the site to define openings for doors windows and ventilators.
BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWING
The concrete dwelling with pre-fabricated building element of the present disclosure, will now be described with the help of the accompanying drawing, in which:
Figure 1 illustrates an isometric view of a concrete dwelling pre-fabricated building element, in accordance with an embodiment of the present disclosure;
Figure 2 illustrates a front view of the concrete dwelling pre-fabricated building element of Figure 1; Figure 3 illustrates a side view of the concrete dwelling pre-fabricated building element of Figure 1;
Figure 4 illustrates an isometric view of a concrete dwelling wall with pre-fabricated building elements, in accordance with another embodiment of the present disclosure; Figure 5 illustrates a side view of the concrete dwelling wall with pre-fabricated building elements of Figure 4;
Figure 6 illustrates a detail D of the concrete dwelling wall with pre-fabricated building elements of figure 4, in accordance with an embodiment of the present disclosure;
Figure 7 illustrates an isometric view of the concrete dwelling with multiple pre-fabricated building elements interconnected in line with each other, in accordance with an embodiment of the present disclosure;
Figure 8 illustrates a detail B of the concrete dwelling wall with multiple pre-fabricated building elements of figure 7, in accordance with an embodiment of the present disclosure;
Figure 9 illustrates an isometric view of the concrete dwelling with multiple pre-fabricated building elements interconnected perpendicular to each other, in accordance with an embodiment of the present disclosure;
Figure 10 illustrates a detail C of the concrete dwelling wall with multiple pre-fabricated building elements of figure 9, in accordance with an embodiment of the present disclosure;
Figure 11 illustrates an isometric view of an alignment plate of the concrete dwelling with pre-fabricated building elements, in accordance with an embodiment of the present disclosure;
Figure 12 illustrates a side view of an alignment plate of the concrete dwelling with pre fabricated building elements, in accordance with an embodiment of the present disclosure;
Figure 13 illustrates a front view of an alignment plate of the concrete dwelling with pre- fabricated building elements, in accordance with an embodiment of the present disclosure;
Figure 14 illustrates a top view of an alignment plate of the concrete building with pre fabricated building elements, in accordance with an embodiment of the present disclosure;
Figure 15 illustrates an isometric view of the wall of the concrete dwelling with pre- fabricated building elements interconnecting the floor slab and ceiling slab, in accordance with an embodiment of the present disclosure;
Figure 16 illustrates a detail E of figure 15, in accordance with an embodiment of the present disclosure;
Figure 17 illustrates a detail F of figure 16, in accordance with an embodiment of the present disclosure;
Figure 18 illustrates a side view of the temporary support element of the concrete dwelling with pre-fabricated building elements interconnecting the floor slab and ceiling slab, in accordance with an embodiment of the present disclosure;
Figure 19 illustrates a detail G of figure 18, of the connection between the wall and the floor or ceiling slabs accordance with an embodiment of the present disclosure;
Figure 20 illustrates a detail H of figure 18, in accordance with an embodiment of the present disclosure;
Figures 21-26 illustrates sequence of construction of a floor of a dwelling, in accordance with an embodiment of the present disclosure; and Figures 27-31 illustrates sequence of insertion of a clip into the prefabricated panel of the wall of a dwelling, in accordance with an embodiment of the present disclosure.
LIST OF REFERENCE NUMERALS
1000 wall 100 prefabricated building elements
2 flat planar rectangular body
4 panel wire
6 inside surface
8 outside surface
9 clips
10 panel slots
12 alignment plate
14 panel wedge
12a alignment plate bent faces
12b alignment plate slot
16 floor slab
18 floor slab reinforcement
20 rebars
22 trellis
24 ceiling slab
26 mesh
DETAILED DESCRIPTION
Embodiments, of the present disclosure, will now be described with reference to the accompanying drawing. Embodiments are provided so as to thoroughly and fully convey the scope of the present disclosure to the person skilled in the art. Numerous details are set forth, relating to specific components, and methods, to provide a complete understanding of embodiments of the present disclosure. It will be apparent to the person skilled in the art that the details provided in the embodiments should not be construed to limit the scope of the present disclosure. In some embodiments, well-known processes, well-known apparatus structures, and well-known techniques are not described in detail.
The terminology used, in the present disclosure, is only for the purpose of explaining a particular embodiment and such terminology shall not be considered to limit the scope of the present disclosure. As used in the present disclosure, the forms “a”, “an” and “the” may be intended to include the plural forms as well, unless the context clearly suggests otherwise. The terms “comprises”, “comprising”, “including” and “having” are open-ended transitional phrases and therefore specify the presence of stated features, integers, steps, operations, elements, modules, units and/or components, but do not forbid the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof. The particular order of steps disclosed in the method and process of the present disclosure is not to be construed as necessarily requiring their performance as described or illustrated. It is also to be understood that additional or alternative steps may be employed.
When an element is referred to as being “mounted on”, “engaged to”, “connected to” or “coupled to” another element, it may be directly on, engaged, connected or coupled to the other element. As used herein, the term “and/or” includes any and all combinations of one or more of the associated listed elements.
The terms first, second, third, etc., should not be construed to limit the scope of the present disclosure as the aforementioned terms may be only used to distinguish one element, component, region, layer or section from another component, region, layer or section. Terms such as first, second, third etc., when used herein do not imply a specific sequence or order unless clearly suggested by the present disclosure. Terms such as “inner”, “outer”, “beneath”, “below”, “lower”, “above”, “upper” and the like, may be used in the present disclosure to describe relationships between different elements as depicted from the figures.
Figures 1-3 illustrate an embodiment of a prefabricated building element 100 of the present disclosure. The prefabricated building element 100 has an inside surface 6 and an outside surface 8 which comprises of panel wires 4 that pass through the prefabricated building element 100 in a waveform pattern along its length, with intervals of panel wire 4 projections. The waveform construction of panel wires 4 is such that the panel wires 4 project on the inside surface 6 only, while the outside surface 8 has a surface finish that facilitate elimination of extra finishing work. The exterior walls of a dwelling built with the prefabricated building elements 100 also bear a surface finish as desired, which further eliminates extra finishing work. Panel slots 10 provided on along the longitudinal direction of the prefabricated building element 100 divide the prefabricated building element 100 along the width, and hence accommodate customization of prefabricated building element size. Figure 2 shows a side view of the figure 1 with intervals of panel wire 4 projections along the length of the panel wire 4, while figure 3 shows an end view of figure 1 with regularly spaced panel wires 4 along the width of the prefabricated building element 100.
Figures 4-6 illustrate the construction of a wall 1000 with the prefabricated building elements 100 integrated together by clips 9. Clips 9 placed at regular intervals enable accurate positioning between two panels 100, thus defining a uniform thickness of the wall 100. Clips 9 are typically round metal wires bent at their ends so that they can be hooked horizontally into the panel wire 4 projecting on the inside surface 6 of the prefabricated building elements 100, as shown by a sequence of construction in figures 27-31. By altering the size of the panel positioning wired 9, thickness of the wall 1000 can be customized as desired, as well as offering structural reinforcement to the wall 1000. Filler material such as regular concrete or consisting of light weight concrete or any special concrete mix, such as combined with pieces of plastic, can be poured into the space formed between the prefabricated building elements 100 to complete the construction of the single wall 1000. The process of pouring the concrete can be equal to what is normally done at any construction site, using mixing of the concrete at the site itself, mainly for small projects, or by mixers, that can pour at once the concrete to the entire floor. Moreover, the space between the prefabricated building elements 100 allows routing of piping, ducts or conduits in advance before the pouring filler material as required for accommodation for various purposes.
Figures 7 and 8 illustrates alignment of prefabricated building elements 100 at their respective edges facilitated with the use of alignment plates 12 and panel wedges 14. Figure 8 shows a detail B of figure 7 where two prefabricated building elements 100 are in line with each other. Alignment plate 12 is positioned between the edges of the two prefabricated building elements 100 that are to be joined together in line with each other.
Figures 9 and 10 illustrate alignment of prefabricated building elements 100 at their respective corners facilitated with the use of alignment plates 12 and panel wedges 14. Figure 10 shows a detail C of figure 9 where two prefabricated building elements 100 are perpendicular to each other. Alignment plate 12 is positioned between the edges of the prefabricated building elements 100 that are to be joined together that are perpendicular to each other.
Figures 11-14 illustrate construction of the alignment plate 12 with alignment plate bent faces 12a and alignment plate slot 12b. Alignment plate bent faces 12a facilitates positioning of prefabricated building elements 100 with respect to each other while alignment plate slot 12b facilitates insertion of panel wedges 14. Panel wedges can be hammered to position the prefabricated building elements 100 accurately with respect to each other.
Figure 15 illustrates construction of the wall 1000 into the floor slab 16. Floor slab reinforcements 18 contained inside the floor slab 16 are pre-bent metal wires. Horizontal rebars 20 can be inserted into the projections of the panel wires 4 which can be further connected to the floor slab reinforcements 18 to offer structural strength to the wall 1000 as well as the floor slab 16. Figure 16 shows the detail E of figure 15 where trellis 22 clipped to the panel 100. Trellis 22 are typically made of bent metal wires bent in the form of a wavy profile that run through the thickness of the wall 1000 in its longitudinal direction which facilitate enhanced structural strength to the construction. Rebars 20 further augment the structural integrity of the wall 1000 by connecting to the floor slab 16 thus transferring loads.
Figure 17 shows detail F of figure 16 which illustrates the interwoven mesh structure of the trellis 22, the panel wire 4 and the horizontal rebar 20 with each other. This facilitates obtaining constraints that offer strength as well as ease of assembly to the unskilled laborers. The horizontal rebars 20 pass through a gap opening formed between the panel wire 4 and trellis 22, as they are form a mesh together in a direction perpendicular to the horizontal rebars 20.
Figures 18 -20 illustrate an integral construction of the wall 1000 with the ground floor slab 16 and ceiling slab 24 with detail G showing the connection of ceiling slab 24 with the wall 1000 (as shown in figure 17) and detail H showing the connection of floor slab 16 with the wall 1000 (as shown in figure 18) respectively. Such a construction requires less handling of construction materials than what is required by using conventional methods, as prefabricated building elements 100 are manufactured at the industry location. This method of using prefabricated building elements 100 in constructing a dwelling reduces the challenges related to transportation, and eliminate the usage of heavy lifting equipment at site and the need for skilled staff. Additionally, this method requires simple and light weight elements, which are standardized and only need to be delivered to the construction site where filler material like concrete simply gets poured into the space between the panels 100 to form the wall 1000.
The procedure for constructing the walls 1000 will now be described with reference to figures 1-20. Initially the required amount of prefabricated building elements 100 are shipped to the dwelling location from the industry or from the local distributor. A wall 1000 being a standard concrete bearing wall as per the construction specifications is marked. The prefabricated building elements 100 that are light weight in construction are then simply held in position with manual means or other suitable supports that are handled by workmen on a floor 16. The plurality of clips 9 with suitable dimensions are then inserted into the plurality of panel wires 4 projecting from the inside surface 6 of each of the prefabricated building elements 100. This facilitates positioning of the wall 1000 and thus imparts structural continuity to the wall 1000. The dimensions of the clips 9 govern the desired wall 1000 thickness to be achieved. As required a number of reinforcements in the form of rebars 20 and trellis 22 are inserted into the plurality of panel wires 4 that offer structural reinforcement to the wall 1000. The panel slots 10 provided on each of the prefabricated building elements 100 facilitate weakenings for sectioning or cutting the prefabricated building elements 100, in order to bring the wall 1000 into conformity with the constructional specifications. Once the skeleton of the wall 1000 is completed, the concrete mix is poured into the space apart prefabricated building elements 100 forming the wall 1000 followed by subsequent curing of said wall 1000. As the outside surface 8 of the wall 1000 bears a surface finish as desired by the occupants, finishing work is thus completely avoided rendering the walls 1000 ready for use immediately. Surface finished prefabricated building elements 100 manufactured in the industry offer ease of manufacturing as compared to applying surface finish that is usually done manually by a specialized worker, at the construction location, as manufacturing inside an industry enables maintaining the desired controlled environment as well as is easy to employ skilled labor. One of the walls 1000 is then secured with another wall 1000 in an in line configuration or an across configuration is accomplished via usage of trivial positioning tools such as alignment plates 12 that are made of metal which consist of bent faces 12a and provision for inserting panel wedges 14. Subsequently, the panel wedges 14 are fitted into alignment plate slot 12b and hammered.
Figures 21-26 show a sequence of steps in constructing the dwelling in accordance with an embodiment of the present disclosure. Figure 21 shows a layer of net made of a soft material that has a mesh 26, typically of size equal to the width of the wall 1000 to be constructed for example 20cm x 20cm if this will be the final width of the wall 1000, that is be positioned on the ground floor slab, as a first step, allowing the builder to align the prefabricated building elements. This facilitates elimination of measurement work needed to be carried out on the dwelling site, as the mesh 26 acts as a guidance, thereby reducing construction time significantly. The mesh 26 is supplied, upon request, to the builder together with the pre-fabricated building elements 100 which enables even the less skilled labourers to identify the dwelling construction plan easily, as desired. In an alternate embodiment, the supplier of the prefabricated building elements 100 offers a complete design solution for an entire dwelling that are already pre-cut and numbered to facilitate installation work and avoiding resizing of the pre-fabricated building elements 100 on the construction site, thereby preventing loss of construction time.
As shown in figure 22 the construction of the dwelling begins with constructing the prefabricated building elements adjoining the door. The rest of the walls 1000 are then constructed leaving a predetermined margin for the door frame of the dwelling. In this way the entire dwelling is constructed by connecting the multiple floors vertically over one another to their final position.
This method, of using prefabricated building elements 100 as integrated in the final construction, is a “one-shot” form and does not allow the re-use of such prefabricated building elements 100 forms, however, the prefabricated building elements 100 avoid the cost of recuperating, handling, transportation, the storage and the further delivery of the forms, as occur is regular forms that are re-usable, and in the same time offers a complete integrated process by including the steel reinforcement works, offering also the final finishing of the walls, on the internal and external side of the building. The foregoing description of the embodiments has been provided for purposes of illustration and not intended to limit the scope of the present disclosure. Individual components of a particular embodiment are generally not limited to that particular embodiment, but, are interchangeable. Such variations are not to be regarded as a departure from the present disclosure, and all such modifications are considered to be within the scope of the present disclosure.
TECHNICAL ADVANCEMENTS
The present disclosure described herein above has several technical advantages including, but not limited to, the realization of a concrete dwelling with prefabricated building element that:
• saves construction time;
• offers better quality of buildings;
• offers almost complete flexibility in terms of logistics;
• offers an egg-shell concrete continuous structure, that is of a higher structural strength, mainly for seismic areas;
• offers a low-cost alternative in construction of dwellings; and
• enables construction of dwellings with less skilled labor as well as under minimal supervision.
The foregoing disclosure has been described with reference to the accompanying embodiments which do not limit the scope and ambit of the disclosure. The description provided is purely by way of example and illustration.
The embodiments herein and the various features and advantageous details thereof are explained with reference to the non-limiting embodiments in the following description. Descriptions of well-known components and processing techniques are omitted so as to not unnecessarily obscure the embodiments herein. The examples used herein are intended merely to facilitate an understanding of ways in which the embodiments herein may be practiced and to further enable those of skill in the art to practice the embodiments herein. Accordingly, the examples should not be construed as limiting the scope of the embodiments herein.
The foregoing description of the specific embodiments so fully reveal the general nature of the embodiments herein that others can, by applying current knowledge, readily modify and/or adapt for various applications such specific embodiments without departing from the generic concept, and, therefore, such adaptations and modifications should and are intended to be comprehended within the meaning and range of equivalents of the disclosed embodiments. It is to be understood that the phraseology or terminology employed herein is for the purpose of description and not of limitation. Therefore, while the embodiments herein have been described in terms of preferred embodiments, those skilled in the art will recognize that the embodiments herein can be practiced with modification within the spirit and scope of the embodiments as described herein.
The use of the expression “at least” or “at least one” suggests the use of one or more elements or ingredients or quantities, as the use may be in the embodiment of the disclosure to achieve one or more of the desired objects or results. Any discussion of documents, acts, materials, devices, articles or the like that has been included in this specification is solely for the purpose of providing a context for the disclosure. It is not to be taken as an admission that any or all of these matters form a part of the prior art base or were common general knowledge in the field relevant to the disclosure as it existed anywhere before the priority date of this application. The numerical values mentioned for the various physical parameters, dimensions or quantities are only approximations and it is envisaged that the values higher/lower than the numerical values assigned to the parameters, dimensions or quantities fall within the scope of the disclosure, unless there is a statement in the specification specific to the contrary.
While considerable emphasis has been placed herein on the components and component parts of the preferred embodiments, it will be appreciated that many embodiments can be made and that many changes can be made in the preferred embodiments without departing from the principles of the disclosure. These and other changes in the preferred embodiment as well as other embodiments of the disclosure will be apparent to those skilled in the art from the disclosure herein, whereby it is to be distinctly understood that the foregoing descriptive matter is to be interpreted merely as illustrative of the disclosure and not as a limitation.

Claims

Claims:
1. A prefabricated building element 100 comprising a flat planar rectangular body 2 having a smooth or decorated finished surface outside side of the building 8, and an inside finished surface 6 in which a plurality of panel wires 4 are partially embedded in a predefined pattern running from one end of said body 2 to another end of said body 2 across said inside surface 6.
2. A plurality of prefabricated building elements 100 as claimed in claim 1 placed vertically or horizontally in a spaced apart configuration with,
• said operative inside surfaces 6 facing each other;
• a plurality of clips 9 configured to clip and position said prefabricated building elements 100 in a spaced apart configuration with respect to each other, said spaced apart configuration adapted to receive concrete for forming a wall 1000 or part of wall, a floor 16 or part of floor, a slab 24 or a part of slab of a dwelling.
3. The prefabricated building elements 100 as claimed in claim 2, wherein a plurality of prefabricated building elements 100 elements formed as defined in claim 2 are clipped together along their edges to form a wall 1000 or a floor 16 of the dwelling.
4. The plurality of prefabricated building elements 100 as claimed in claim 2, wherein said prefabricated building elements 100 are joined by alignment plates 12 in a manner along their edges such that a set of prefabricated building elements 100 are substantially perpendicular to another set of prefabricated building elements 100 to form a corner of a dwelling.
5. The prefabricated building elements 100 as claimed in claim 1, wherein the panel wires 4 meander along the length of said prefabricated building elements 100 as they run across said inner surface 6.
6. The prefabricated building elements 100 as claimed in claim 1, wherein said panel wires 4 meander along the length of said prefabricated building elements 100, and are substantially parallel to each other.
7. The prefabricated building elements 100 as claimed in claim 1, wherein the panel wires 4 meander in a waveform pattern running along the length of said prefabricated building elements 100.
8. The prefabricated building elements 100 as claimed in claim 1, wherein the ratio of the panel wires 4 embedded in the body could vary between 30 and 80 percent.
9. The prefabricated building elements 100 as claimed in claim 1, wherein the diameter of said panel wires 4 is approximately between five millimetres and ten millimetres.
10. The prefabricated building elements 100 as claimed in claim 1, wherein thickness of the prefabricated building elements 100 ranges between 15mm and 50 mm.
11. The prefabricated building elements 100 as claimed in claim 1, wherein said inside surface 6 is scored between said panel wires to define panel slots 10 that facilitate cutting of said prefabricated building elements 100 to fit the required measures of the specific building and for architectural purposes.
12. The prefabricated building elements 100 as claimed in claim 1, wherein said wall 1000 or said floor 16 or said slab 24 as configured in accordance with claim 2 includes at least one reinforcing element secured within said space between two prefabricated building elements 100.
13. The prefabricated building elements 100 as claimed in claim 12, wherein at least one of said reinforcement elements is selected from a trellis 22 and a rebar 20.
14. The prefabricated building elements 100 as claimed in claim 1, wherein a dwelling is constructed of said plurality of prefabricated building elements 100 arranged as claimed in any of the claims 1-13, said prefabricated building elements 100 define said walls 1000, said ground slab 16 and said floor/ceiling slab 24 of said dwelling.
15. The prefabricated building elements 100 as claimed in claim 14, wherein said walls 1000 are cut out at a dwelling location according to the final measures of the building and to define openings for doors windows and ventilators or can be pre-cut by the manufacturer according to the drawings of the required dwelling.
16. A method of constructing walls 1000, said method comprises: i. Gathering of prefabricated building elements 100 to the dwelling location, followed by supporting two of said prefabricated building elements 100 in position, as per construction plan of dwelling along a floor 16; ii. Clipping a plurality of clips 9 with suitable dimensions into a plurality of panel wires 4 projecting from the inside surface 6 of each of said prefabricated building elements 100, facilitating positioning of said wall 100 and imparting structural continuity to said wall 1000; iii. Inserting reinforcements in the form of rebars 20 and trellis 22 into said plurality of panel wires 4 for offering structural reinforcement; iv. Sectioning or cutting said prefabricated building elements 100 along panel slots 10 to bring dimensions of said wall 1000 within construction specifications of the wall 1000; v. Pouring concrete mix between said prefabricated building elements 100 followed by subsequent curing of concrete mix to form said wall 1000 allowing the entire floor to be of a continuous concrete structural egg-shell system, as per the construction specifications; vi. Securing one of said wall 1000 to another said wall 1000 that is in line or across with each other as per dwelling construction plan.
PCT/EP2020/077730 2019-10-02 2020-10-02 A concrete dwelling with prefabricated building elements WO2021064215A1 (en)

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Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP0298008A1 (en) * 1987-07-01 1989-01-04 Juan Antonio Martinez Baena Building element comprising prefabricated panels
EP3309312A1 (en) * 2016-10-14 2018-04-18 Lesage Developpement S.A.S. Method of manufacturing a balcony and balcony obtained
KR20190018453A (en) * 2019-02-01 2019-02-22 김태준 The all-in-one PC panel structure with improved safety

Patent Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP0298008A1 (en) * 1987-07-01 1989-01-04 Juan Antonio Martinez Baena Building element comprising prefabricated panels
EP3309312A1 (en) * 2016-10-14 2018-04-18 Lesage Developpement S.A.S. Method of manufacturing a balcony and balcony obtained
KR20190018453A (en) * 2019-02-01 2019-02-22 김태준 The all-in-one PC panel structure with improved safety

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