WO2022168109A1

WO2022168109A1 - An improved method for manufacturing / constructing single cast concrete construction modular buildings

Info

Publication number: WO2022168109A1
Application number: PCT/IN2021/050579
Authority: WO
Inventors: Sandesh Rane
Original assignee: Sandesh Rane
Priority date: 2021-02-05
Filing date: 2021-06-14
Publication date: 2022-08-11

Abstract

The present invention relates to an improved method for manufacturing / constructing buildings using single cast concrete prefinished modules which is cost and time efficient and at the same time is robust. The method includes the steps of providing a layout, studying the layout, modularizing the layout to obtain S3C modules, 3D modelling of S3C modules, designing a structural system for each of the S3C modules, designing mechanical, electrical and plumbing for each of the S3C modules, designing a formwork assemblies, finishing and fitout design for each of the S3C modules, preparing site erection and commissioning drawings, manufacturing each of the S3C modules, transporting the manufactured S3C modules to a building site, and erecting and commissioning S3C modules by hooking, hoisting and placement of the S3C modules in pre-defined formation above a plinth level.

Description

TITLE OF THE INVENTION

AN IMPROVED METHOD FOR MANUFACTURING / CONSTRUCTING SINGLE

CAST CONCRETE CONSTRUCTION MODULAR BUILDINGS

FIELD OF THE INVENTION

The present invention relates to an improved method for manufacturing / constructing buildings using single cast concrete prefinished modules and more specifically relates to the construction of high-rise as well as low height buildings using such single cast concrete pre-cast, pre-finished, and volumetric (3D) modules manufactured in factories.

BACKGROUND OF THE INVENTION

One of the basic human needs is shelter. Since ancient times, humans have tried to build a withstanding shelter that would provide not only shelter but also protect from various environmental factors including sunlight, wind, and rainfall.

With the advent of the modern age, the requirement of shelter still remains and has become more important and at the same time more challenging. The shelters or houses of the contemporary times demand that several factors be taken into consideration, which not only include protection from environment but also provide or facilitate several amenities which may include thermal insulation, provision of electricity, water supply, hygiene etc. Further, it is also desirable that the shelters are easy to build, easy to operate, and maintain. Still further, it is also desired to have shelters which are economically viable to build and maintain.

Attempts have been made in the known art to provide shelters or buildings which provides one or more of the above-mentioned characteristics. However, still there are certain drawbacks or lacune in the existing shelter types, their way of making or building, and their economic viability etc.

One way to build houses or shelters or buildings is employing pre-fabricated components, which are, as the name indicates, pre-fabricated in a factory setting, and then assembled at the site to complete the building structure which is then finished for its plaster painting, tiling, electricals, plumbing, hardware etc at site itself.

However, it is observed that employing the existing pre-fabrication technology, several aspects are untouched or not considered. For example, the pre-fabrication technology is not cost effective, and time effective as there are too many components to be assembled at site with precision, accuracy, and speed. Also finishing works are still carried out at site which essentially forms a substantial component of the costs involved in constructing a building. The houses build from the pre-fabrication technology may not be earthquake resistant, and corrosion resistant.Further, higher through put may not be obtained by employing the existing conventional pre-fabrication technology. Thus, there is felt a need for overcoming one or more drawbacks associated with the conventional pre-fabrication technology, and provide an improved method for manufacturing / constructing buildings using 3D single cast concrete prefinished modules and more specifically to provide the construction of high-rise as well as low height buildings using such single cast concrete pre-cast, pre-finished, and volumetric (3D) modules manufactured in factories.

OBJECTS OF THE INVENTION

Some of the objects of the presently disclosed invention, of which at the minimum one object is fulfilled by at least one embodiment disclosed herein are as follows:

An object of the present invention is to provide an alternative, which overcomes at least one drawback encountered in the existing prior art;

Another object of the present invention is to provide an improved method for manufacturing / constructing single cast concrete construction based modular buildings

Yet another object of the present invention is to provide an improved method for manufacturing / constructing single cast concrete construction based modular building, wherein the method enables a circulation system, for the modular buildings, which is robust, time wise, cost wise and availability wise more effective due to provision of vertical circulation method as compared with the conventional horizontal circulation system of traversing modules through work stations;

Still another object of the present invention is to develop an improved method for manufacturing / constructing single cast concrete construction based modular buildings which are economical and portable;

Still another object of the present invention is to develop a method for manufacturing I constructing single cast concrete construction based modular buildings which is less time consuming; and .

Another object of the present invention is to develop an improved method for manufacturing / constructing single cast concrete construction based modular buildings which saves natural resources such as water and also minimizes wastage of material.

Other objects and benefits of the present invention will be more apparent from the following description which is not intended to bind the scope of the present invention. SUMMARY OF THE INVENTION

The present invention relates to an improved method for manufacturing / constructing buildings using single cast concrete prefinished modules. More particularly, the present invention relates to the construction of high-rise as well as low height buildings using such single cast concrete pre-cast, pre-finished, and volumetric (3D) modules manufactured in factories.

In accordance with the present invention, an improved method for manufacturing a single cast concrete construction based modular building is disclosed. The method comprising the following steps, which include providing a layout for the building to be constructed, studying the layout, modularizing the layout in terms of S3C modules, 3D modelling of S3C modules, designing a structural system for each of the S3C modules, as well of the entire building with all modules assembled, designing mechanical, electrical and plumbing for each of the S3C modules, as also the dropdown connectivity to UGT / OHT as required for the entire building once all modules get assembled, designing FDBS philosophy based patented formwork assembly for each of the S3C modules, finishing and fitout design for each of the S3C modules, preparing site erection and commissioning drawings, manufacturing each of the S3C modules based on the design in compliance with the steps herein above, transporting the manufactured S3C modules to a building site, and erecting and commissioning S3C modules by hooking, hoisting, placement and grouting of the S3C modules using epoxy grouting material in pre-defined formation above the in-situ cast plinth level.

In accordance with one embodiment of the present invention, the step of studying the layout includes the sub-steps of calculating built-up and carpet area of each units of the layout, studying of wet areas of the building, ingress or egress areas of the inhabitants, materials, and vehicles, utility, and services related requirements of the building, calculating load acting on the building, the load being selected from the group consisting of dead load, live load, dynamic load, determining and differentiating load bearing structures, and non-load bearing structures, designing structural symmetry and continuity of the S3C modules to achieve compatibility of the S3C modules, determining reinforcements and concrete mix ratios based on the calculated load acting, and designing joineries based on loads selected from the group consisting of seismic load, wind load, live load, dead load, structural forces including in-plane and out-of-plane bending moments during seismic activity. The above- mentioned steps are applicable to any building design. A specially designed building with the single cast concrete construction technology or any standard building design in the market can be manufactured using this technology. The steps involved remain unchanged irrespective of the building design.

In accordance with one embodiment of the present invention, the step of modularizing includes the sub-steps of sizing the S3C modules in compliance with the regional transport office norms, preparing exploded modular drawings, and preparing drawings of each individual modules of S3C modules.

In accordance with one embodiment of the present invention, the structural design is matched with the reinforcements and the structural design.

In accordance with one embodiment of the present invention, the formwork is selected from the group consisting of a flat form, angular form, cover form, normal form, pouring form, texture, and combinations thereof, the flat form is a flat shutter having plain sheet on one side and stiffeners on the other side thereof, the flat form being employed for smooth surfaces the angular form being employed for connecting wall to wall, the angular form being one selected from the group consisting of corners, and corbels, the corbel form being connected at wall top end and cast a shape of corbel, the cover form being employed to connect internal and external assemblies, the cover form is one selected from the group consisting of window cover, door cover, wall joinery cover, slab joinery cover, top cover, and combinations thereof, normal form is flat form employed to create a flat surface, pouring form is provided with an opening for pouring pre-mixed concrete therein and covered with a flap, texture form being employed for configuring predetermined texture on the wall surfaces, and the formwork is designed with tolerance to maximum displacement and corrosion factors.

In accordance with one embodiment of the present invention, the step of designing of formwork assembly includes the sub-stepsassembling a lower most section of the formwork which being a floor form, assembling a door form operatively above and coupled to the floor form, disposing a beam form operatively above and coupled to the door form in both internal and external formwork sub-assemblies, disposing a soldier form which being disposed in balance spaces, covering non-covered areas between modules employing custom forms, creating sub-assemblies by splitting formworks from 3 -dimensions to 2-dimension, wherein the sub-assemblies are selected from the group consisting of walls, floors, and combinations thereof, and integrating the sub-assemblies on a master-frame to obtain the formwork assembly, wherein the step of assembling the forms on the master-frame for each of the S3C modules based on symmetric.

In accordance with one embodiment of the present invention, the step of finishing the S3C modules including wet module, and dry module, and wherein the step of finishing and fitout design for each of the S3C modules includes the sub-steps of completion of all fitout and finishes of the module area other than at the joints followed by identification and listing of free issue material, which being supplied along with the S3C modules, wherein the free issue material is one selected from the group consisting of titles, tiles grout, joinery grouting material, paint, door platform, window platform, kitchen platform and combinations thereof.

In accordance with one embodiment of the present invention, the step of manufacturing each of the S3C modules including the sub-steps oflifting the master-frame, transferring the master-frame to a workstation, cleaning the master-frame at the workstation, assembling multiple sub-assemblies of the external formwork and securing the same to the master-frame, applying a releasing agent to an internal surface of the formwork which being in contact with the pre-mixed concrete, placing reinforcement cages, concealed pipes, and cables, within the formwork, assembling multiple sub-assemblies of the internal formwork, pouring the pre-mixed concrete within the formwork from a pre-mixed concrete batching plant employing a boom placer, compacting the poured pre-mixed concrete employing vibrators thereby allowing the pre-mixed concrete to settle therein, curing the pre- mixed concrete poured within the formwork, the curing being carried out by disposing the formwork with the pre-mixed concrete in a heating chamber to obtain a cured product, removing the cured product along with the formwork from the heating chamber followed by cooling to obtain a cooled product, disassembling the formwork, cleaning the dis-assembled formwork for further reuse, fitting doors, windows, and other hardware, painting the internal and external surfaces of the walls, tiling the floor, the kitchen, the bathroom, and toilet walls to obtain the S3C modules within the factory premises, fitting fit-outs, the fit-outs being one selected from electrical switches, and B22 holders, and performing testing of the S3C modules and components fitted thereto, the testing including one test selected from the group consisting of electrical megger test, water pressure test, dimensional fitting, inspection of doors, windows, and tiles, paint thickness and combinations thereof.

In accordance with one embodiment of the present invention, wherein each of the S3C modules being tagged with a unique radio-frequency identification for each of the S3C module, and a space identification number, wherein the space identification number provides the area of placement of the S3C module thereby preventing incorrect placement of the S3C module.

BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWING

The present invention will now be described with the drawings of the accompanying specification and referred to by the numerals appropriately for understanding of the invention wherein,

Figure 1 represents the architectural layout of the building to be constructed using the S3C technology according to the present invention.

Figure 2 represents the modular breakdown of figure 1 according to the present invention.

Figure 3 represents the modular exploded view of the modules of figure 2 according to the present invention.

Figure 4 represents the individual module drawings of any of the modules from within figure 2 and/or 3 according to the present invention.

Figure 5 represents the 3D module of the S3C module according to the present invention.

Figure 6 shows the structural design showing reinforcement of the S3C module according to the present invention.

Figure 7 shows the electrical system of the individual S3C module according to the present invention.

Figure 8 shows the plumbing system of the individual S3C module according to the present invention.

Figure 9 shows the formwork assembly according to the present invention.

Figure 10 shows the formwork sub-assembly according to the present invention.

Figure 11 shows the fitout positions for the S3C module according to the present invention.

Figure 12 is erection drawings according to the present invention.

Figure 13 represents the Floor, Door, Beam and Soldier (FDBS) concept of formwork assembly. Figure 14 shows the factory set up of module joinery according to the present invention.

Figure 15 shows the site set up of module joinery according to the present invention.

Figure 16 shows the factory set up of wall, corbel, slab joinery according to the present invention.

Figure 17 shows the site set up of wall, corbel, slab joinery according to the present invention.

Figure 18 shows factory layout according to the present invention.

Figure 19 shows normal flat form according to the present invention.

Figure 20 shows pouring flat form according to the present invention.

Figure 21 shows comer angle form (wall to wall/ floor to wall) according to the present invention.

Figure 22 shows comer angle form (floor to two walls) according to the present invention.

Figure 23 shows corbel angle form according to the present invention.

Figure 24 shows door/window covers according to the present invention.

Figure 25 shows slab to slab joinery covers according to the present invention.

Figure 26 shows drawing of wall-to-wall joinery covers according to the present invention.

Figure 27 shows drawing of master-frame according to the present invention.

Figure 28 shows drawing of master-frame placement on rollers.

Figure 29 shows drawing of module external formwork placement on master-frame.

Figure 30 shows drawing of module external and internal formwork assembly on master-frame.

Figure 31 shows drawing of module formwork assembly with external, internal formwork and covers DETAILED DESCRIPTION

All the terms and expressions, which may be technical, scientific, or otherwise, as used in the present invention have the same meaning as understood by a person having ordinary skill in the art to which the present invention belongs, unless and otherwise explicitly specified.

In the present specification, and the claims, the articles “a”, “an”, and “the” include plural references unless the context clearly dictates otherwise.

The term “comprising” as used in the present specification and the claims will be understood to mean that the list following is non-exhaustive and may or may not include any other extra suitable features or elements or steps or constituents as applicable.

Further, the terms “about” or “approximately” used in combination with ranges relating to sizes of parts, or any other physical properties or characteristics, are meant to include small variations that may occur in the upper and/or lower limits of the ranges of the sizes.

The present invention relates to an improved method for manufacturing / constructing single castconcrete construction modular buildings.

In accordance with one embodiment of the present invention, the building design provided by the customer himself or can be designed for the customer based on his requirements. Once the building design is approved by the customer the further procedure of modularization and thereafter as stated below remains the same.

Accordingly, before modularizing the building layout, as required for the present invention, the layout is studied in detail to calculate abuilt-up and a carpet area for each of the units of the layout. Further, detailed studies are done taking into consideration the factors such as wet areas of the building; ingress/egress (access) of inhabitants, material, and vehicles; utility and services related requirements for every dwelling within the building. Once the study is complete the modularization is done taking into consideration the applicable RTO norms for transportation of the module from factory to the site. Following is the table showing the recommended and maximum dimensions as applicable for the modules to be transported-

Therefore, the maximum dimension for any modular unit shall not exceed the above maximum recommended size. It is clarified that if RTO changes the norms, then present invention is capable of increasing the module dimensions without departing from the scope of the invention. Further, according to the present invention all the calculations and detailed studies are required to finalize the load acting on the building i.e., Dead load, Live load, and Dynamic load. Thereafter, load bearing structures viz floor slabs, shear walls and non-load bearing structure such as partition walls are designed accordingly. Designing the structural symmetry and continuity of the modules are done in such a way that overall compatibility of the components is achieved so as to form the building. Further the reinforcements and concrete mix ratios are decided based on the acting loads and the ratios can be varied depending upon the loads applicable on the building.

Once the designs are finalized and concrete mix ratios are decided on the basis of the loads applicable on the building suitable joineries are designed in such a way that they are compatible with the seismic load, wind load, live load, dead load, and other structural forces such as in-plane and out of plane bending moments during seismic activity.

Once the above steps as described are finalized the exploded modular drawings of every unique floor as more particularly shown in figure 3 are prepared. Thereafter, detailed drawings of each of the individual modules are prepared as per figure 4. The detailed drawings of each individual modules are required for finalizing the dimensions, designing of the joineries and also that drawing acts as a base for 3D modelling of the module as per S3C technology. The 3D modelling can be done by using any available software. Presently, the present invention makes use of advanced CAD CAM software available in the market. However, it is not compulsory to use the same.

Once the 3D modelling is done, based on the 3D model design, reinforcement of floor, walls, column, and beam of each of the 3D modules are finalized. Utmost care has to be taken while doing the reinforcements so that the reinforcementsare in line with the structural design which was finalized as mentioned above. Once the reinforcementsare finalized and the same matches with the structural design, detailed MEP drawings are prepared taking into consideration electrical and plumbing conduiting and mechanical equipment fittings. Also, along with these, the dropdown connectivity to underground tanks and overhead tanks as per the requirement of the entire building is done once all the modules are assembled.

Thereafter, based on the 3D modelling the formwork of each of the S3C module is finalized. The term form is used for the components used to create a temporary mould into which concrete is poured and formed. This is the step of designing the structural system for each of the S3C modules as well as that of the entire building with all modules assembled therein.

The formwork is assembly of the forms and is assembled for manufacturing of the individual S3C module by pouring the pre-decided concrete mix ratio as mentioned above. The forms are broadly categorized as Flat form, Angle form and Cover form.

Flat forms are flat shutters with plain sheet on one side and stiffeners on the other side. Flat forms are used to create a smooth surface like wall or floor. Various flat forms are joined together to form wall of required dimension. The flat side of the flat form comes in contact with the concrete. The sheet is supported by angles and stiffeners to provide strength. The flat forms are further classified as Normal form, Pouring form and Texture form. The normal form is a flat form and is used to create a flat surface. Opening is provided in the pouring form for pouring of the pre-mixed concrete in to the slab and thereafter covered with the flap. The Pouring form has a standard size of 600 mmx600 mm. The pouring forms are placed only on the floor as it is required for floor pouring only. The texture forms are used to create certain type of predetermined texture on the wall surfaces.

The angular forms are used to connect wall to wall, wall to floor and two or more walls to the floor, ft may be a two dimensional or three-dimensional angle. Angle forms are further classified as Corners, Corbels and Others. The two-dimensional comers are used to connect a wall to floor or two walls at right angles. The three-dimensional corners are used as block to connect two adjacent walls and floors. Another category of angle form is corbel. These forms are used to create a corbel on a structure. A corbel is the load bearing member for the module above it. The corbel forms are connected at wall top end and help cast the required shape of the corbel. This is a special purpose form according to the present invention. The last category in angles is “Others”, which includes all other types of angles that are application specific according to the present invention. Example of one such others category is the slope at the Over-Head Tank (OHT) bottom. The OHT bottom has a slope on the inside at comers and requires special shape of the form.

Cover forms are used to connect internal and external sub-assemblies. The covers are further classified as window and door covers, wall joinery covers, slab joinery covers and top covers. Window and door covers are used to create cavity of the required size. The internal and external sub-assemblies are connected by means of these covers. The wall and slab joinery covers are used to close end connections of the individual modules which are otherwise required for joining of the modules. These covers have holes to allow rebar protrusion through them. The top covers are mounted on the top side of the module to provide guideline and positioning of extruded rebars for the connection between lower and upper module.

According to the present invention, forms are either “Universal” or “Custom” by design. Universal forms used for the purpose of present invention are of 70 different variants and can be used in any of the formwork assembly and for very high number of repetitions. Whereas, Customs forms are application specific so as to meet the differential dimensions that vary from assembly to assembly. The technical specifications of the standard forms are as follows-

Technical Specifications of forms- 1. Standard Dimensions of Formwork

The following table describes the maximum and minimum sizes of the material used to manufacture the Formwork.

The following table describes the sizes of the various parts used in a formwork.

Parts Used in Formwork

2. Maximum Displacement

The following table describes the maximum displacement of a fixed (all side) rectangular plate under a uniformly distributed load.

Maximum Displacement

3. Corrosion

If a process includes use of certain corrosive chemicals such as oxygen, special considerations must be made for the materials. Additionally, environmental conditions such as salt from a nearby ocean should be considered. If corrosion is expected, the engineer should select the material accordingly.

Uniform corrosion is the most common type of corrosion and is considered the “general wastage of material,” while disregarding other sources of wear. Due to the nature of this type of corrosion, the corrosion rate can be predicted and experimentally determined. Corrosion testing is done to predict the penetration rate in mm per year. The following table shows the acceptable corrosion rates for low alloy steels.

Considering the corrosion penetration rate of 0.25 and reuse of shutters per year, each shutter can be reused for a minimum of 2000 times by ensuring systematic handling with caution and proper maintenance.

With corrosion rate of 0.15 mm per year and erosion of 1 micron per cycle, the thickness of sheet is reduced by 0.5 mm to 0.6 mm in 3 years giving a reusable cycle of more than 2000. This is because with 0.5 mm reduction, gradually the deflection in 2.5 mm sheet still fits within the permissible limits of displaces.

4. Sizing Strategy

As per the design of a module, the height of largest shutter is defined as 1800 mm.

80- 85% of the formwork will be of standard size (can be reused in any shape and size of module). 15- 20% of the formwork will be of non-Standard size (specific to a module requirement).

5. Material Specification

Shutters are manufactured using 3mm Thick HR Sheet and 50 x 50 x 5 mm HR

Angle.

6. Formwork Bolting

The following table describes the formwork bolting option.

Thereafter the formwork assembly of each of the S3C modules is designed using the

Universal form and non-standard spaces are occupied by designing and using Custom forms.

Universal Form Sizes-

Designing the formwork assembly of each of the S3C modules

Assembling the forms on master-frame for each of the S3C modules using floor, door, beam, and soldier concept (FDBS) as more particularly shown in figure 13. The concept FDBS is based on symmetric placement of formwork on the module. According to the present invention, in the process of designing the formwork assembly, the lower most section of formwork that is “floor forms” (as more particularly shown as 13.01 in figure 13) is assembled first. Attention to detail is required for external and internal formwork sub- assemblies of the module so that the top surface of the forms is maintained at equal height. The next assembly that is designed is “door forms” (as more particularly shown as 13.02 in figure 13) and is connected to the “floor forms”. The “door forms” of 1800 mm length are placed above the “floor forms” in both internal and external formwork sub-assemblies. The “beam forms” (as more particularly shown as 13.03 in figure 13) of 600 mm length are placed above the “door forms” in both internal and external formwork sub-assemblies. The “soldier forms” (as more particularly shown as 13.04 in figure 13) are necessary to occupy the balance spaces, in case the height of module / floor is changed. The height of the module is decided on the basis of building layout given by the customer and/or client and/or architect. During this entire process of placement of formwork, universal forms are used. In case, there remain any spaces due to change in the width and/or depth of the modules then custom forms are used to cover and/or occupy the remaining spaces of the formwork. Once the forms are placed by using the FDBS concept as mentioned above the end connections of the module are sealed by using “cover forms”. Thereafter, for ease of assembling the formwork, sub- assemblies are created by splitting the 3D formwork assembly to 2D sub-assemblies. The 2D sub-assemblies are independent walls, floor and any other component drawing as more particularly shown in Figure 10. Splitting the 3D formwork assembly to 2D sub-assemblies is necessary for the purpose of deciding the quantity and assembly sequence of the forms. It also simplifies the manufacturing process.

Final mould of forms is formed by integrating the sub-assemblies that are prepared at the sub-assembly area and is also called as “formwork assembly” and the formwork assembly is assembled on the master-frame. Master-frame which acts as the primary fixture for assembling the formwork where all sub-assemblies for a particular module design are assembled to form a complete formwork assembly for that particular module. It is necessary to maintain the stability of the formwork and therefore various tailored made props are used as support. The supports restrict the deflection of the formwork and maintain the formwork dimensions, line levels and the required shapes. Based on the module’s size and shape, the support placement is designed.

After completion of module curing, forms are dis-assembled according to the dis- assembly drawings for each of the S3C modules. The dis-assembly drawing acts as a guide thereby ensuring sequential dismantling of forms resulting in avoiding accidents and achieve pre-determined efficiency. After dis-assembling of forms the same are cleaned and reused for manufacturing further modules on the production line.

Once the 3D modelling of the module is completed, finishing drawings of each of the S3C modules are also prepared in pre-determined standards as elaborated in the layout. Thereafter, as per the finishing process module type is identified. The identified module type may include wet module or dry module. Below is a table showing the module types and their respective features according to the present invention-

Separate drawings are prepared for waterproofing, door/window fitouts, tiling, kitchen platform assembly, sanitary fitting, faucet fitting, wall treatment as more particularly shown in Figure 11 hereto.

Once the module drawings are completed, identification and listing of Free Issue Material (FIM) is done. The free issue material is to be supplied along with each of the S3C modules. According to the present invention, free issue material is a material used for finishing of the module at site once the structural connection between the modules is completed. The free issue material includes tiles, grouting material (tiles grout and joinery grouting material), paint, door/window/kitchen platform if applicable. Once the building modularization is completed, building erection drawings for the plinth are prepared as per the standard norms. Building erection drawings also contain details of connection between ground floor modules and plinth. Thereafter, the geo-spatial map of the building is prepared, wherein the location of each of the modules is fixed along the 3 coordinates. The geo-spatial map serves as an input to the site erection team for placement of modules at site.

MANUFACTURING PROCESS AS PER THE S3C MODULAR TECHNOLOGY-

CONVEYOR SYSTEM FOR S3C MODULE MANUFACTURING

The conveyor system type of manufacturing setup / process, for the purpose of manufacturing S3C modules within a specially designed factory for this purpose.

This involves a rolling system on which a large rectangularly cubical frame, moves from one pre-designated Work Station (WS) to the next. On completion of one cycle, the frame is lifted in a direction perpendicular to the ground and transferred to the first workstation for the next cycle. During this cycle, different activities related to formwork assembly, like placement of reinforcement cages and concealed pipes and cables, pouring of concrete, curing, followed by fitting doors, windows, and other hardware along with painting and tiling works, are completed to manufacture the S3C modules, all within the closed confines of the factory. The above step also includes assembling multiple sub-assemblies of the internal formwork. The Operations / Processes have been designed considering ample redundancies in the manufacturing. In case of any failures on one of the assembly line equipment, all the other lines can still manufacture and achieve the output planned for them. Thus, the assembly lines run independent of each other.

The factory production process begins with the creation of external sub-assemblies at the Formwork Sub-assembly workstation. Reinforcement cage required for the module is also assembled at the Rebar Sub-Assembly workstation. The external sub-assemblies are transferred to the workstation WS01 for assembly on the Master Frame. Post assembly of the external formwork on the Master Frame at WS01, the reinforcement cage from Rebar Sub- Assembly is shifted & fixed onto the Master Frame. Simultaneously, formwork internal sub- assemblies are assembled on the Formwork Sub-assembly workstation. The internal sub- assemblies are then transferred to the Master Frame for completing the module assembly. A batching plant prepares the concrete with the designated concrete mix ratio & the concrete is transferred to the pouring point via a boom placer at WS02. The boom placer pours this concrete into the created mould & is allowed to settle. The poured mould is then transferred to curing chamber for accelerated curing at WS03. On completion of curing, the module is de-shuttered i.e., the formwork assemblies are dis-assembled at WS04 and sent for cleaning and reused in the production process. However, the module proceeds with the further finishing activities that include waterproofing, door assembly, window assembly, kitchen platform assembly, primer application and electrical fitouts on WS04. On completion of these activities at WS04, the module moves to WS05 where the balance finishing work is carried out. It includes dado tiling, floor tiling and plumbing fitout assembly. The module is inspected at WS05 for the quality parameters as applicable. On successful quality check, the module is transferred to the finished goods area for storage & later on to despatch. The following table describes in brief each of the stages of assembly (at designated work stations), while more details on the operating procedure at each of the workstations is described in more details as under-

The sub-assembly areas that support the main production line-

A) Formwork sub-assembly area-

B) Reinforcement sub-assembly area

TRANSPORTATION TO SITE AND ERECTION and COMMISSIONING:

When the modules are being produced in the factory, the site is readied up to a plinth level at the building site. The plinth is readied as per the design details provided. The Modules are loaded on to a low bed trailer and shipped to site. When the modules arrive on site, the modules are stored for a while within the tower crane operating radius, before alignment for lifting and placing at the correct locations on the plinth and above thereafter. The modules are placed one over the other and grouted to complete the building. The step of grouting of the S3C modules is done by employing epoxy grouting material in pre-defined formation above the in-situ plinth level. UNIVERSAL FORMWORK SYSTEM-

The Universal Formwork System, designed with the intent to cast any shape and size of building modules using the same formwork components in the factory, thereby allowing for quick and cost-effective production.

The formwork components for the purpose of casting on the frames as described in the above section are specially designed with a view to achieve the following objective

JOINERY SOLUTIONS-

The Joinery Solutions (Shear Keys, Twin Dowels and overlap philosophy along with the grouting access) to suit seismic levels suitable even for seismic Zones 3, 4 etc. and to allow for easy and simplified joinery work at site. Simple and Effective Joinery System

Like in every precast system, there are joints that need to be made between two or more modules that are to be joined and placed at site.

For a modular design proposed here the following points are of importance here -

1. The number of joints in a volumetric precast element as here, are far lesser in number as compared to the 3D (volumetric) modules discussed here.

2. The joints in a 3D module are assisted by the monolithic fusion of the floor and wall elements to each other, with respect to tensile force handling. In a way there is an opposite moment / reaction provided by such monolithic joints to the in-plane / out-of-plane bending moments created during seismic reverberations.

3. The proposed 3D Modules are cast with a twin shear key and dowel philosophy. Twin key means two TMT rebars, one each on the two sides of every wall thereby allowing for each tensile member (read the TMT rebar) to bear the two probable tensile stresses induced due to highly volatile seismic activity (specified as in seismic zones 3 and 4) - In-plane and Out-Of-Plane Bending Moments.

4. Properly planned joints for every type of joint within the possible building structure - a. Slab to Slab (as per standard norms) b. Slab to Wall (as per standard norms) c. Wall to Wall (as per standard norms) d. Twin shear key system

Twin Shear Key system a) Lower module to upper module

Factory set up-

For joining of two modules vertically special provision is made in the drawings of the module. As shown in figure 14, every module will have a set of half grout couplers installed on the rebars from the wall at the top (inside the wall). The grout injection holes of the coupler are aligned to the formwork assembly to enable cavity creation at injection points. During casting, the couplers get embedded within the walls.

Site set up-

The lower module is erected at its designated position. The upper module has the embedded couplers installed from the factory. Rebars from the lower module are inserted into the coupler through a cavity at the bottom. The grout injection holes are located in the upper module and are connected to the grout pump via a hose pipe. Grout is pumped into the cavity through the lower injection hole and is allowed to flow out through the upper injection hole. Once the grout flows out through the upper injection hole, grout pumping is stopped and the holes are plugged to arrest the grout flow. The grout is allowed to cure. The same is more particularly shown in figure 15. b) Wall + Corbel + Slab ioint-

Factory set up-

For a wall to slab joint, rebars shall protrude horizontally from slab end and the wall as well. The slab shall have a configuration similar to that shown in figure 16. However, for the wall, rebars shall be bent inside the wall at the required slab thickness. Rebars from the corbel shall protrude through the top of the module for joining at site. During finishing of module in factory, metal spacers and backer rods shall be fixed at the respective locations as specified in the drawing

Site set up-

The lower module with a corbel is erected first. Next, the module with vertical wall to wall joinery is assembled. The rebars from the upper module are straightened out. The rebars from the corbel top are also aligned with the upper wall. The slab is then placed on the corbel. The rebars from the corbel and the adjacent wall are bent into the slab cavity. These rebars are then tied to the rebars in the slab. Epoxy grout is filled in the cavity between the corbel and the top modules. Similarly, grouting is filled in the slab cavity and allowed to cure. The same is more particularly shown in figure 17.

MODULE IDENTIFICATION AND RETRIEVAL APPLICATION (MITRA)-

It is very important that every module manufactured must be identified (tagged) uniquely so that retrieval and placement of the right module in the right place at site happens error free. This becomes even more relevant in high rises because all modules that are placed one above the other look similar in size and shape, however are different in load bearing capacities depending upon which floor they are designed for. This is typically done for the purpose of optimising load management for the lower floor, which needs to lift floors above it. Any mistake in placing a module not intended to carry the designated load is fatal.

A solution in this regard in designed with the following features - i. Every module is tagged with an RFID number at the time of production. This RFID number is unique to that module. ii. The finished goods storage area is a fairly large one and therefore has every module placement area, predefined based on size and is also allotted a unique SPACE ID. iii. The finished Module is placed on to the allotted SPACE ID and thus the system now knows as to which RFID number is mapped to which SPACE ID, thereby revealing which module is placed where. This helps in easy retrieval and despatch planning. iv. The Trailers used for despatch are also mapped and hence it also becomes easy to track the exact status of each Module Despatched and its location status and other relevant transportation details. v. At site, every building that is ready for Erection and Commissioning of the delivered modules is Geo-fenced on its perimeter line and also the vertical height basis to identify the exact location of not just the ground floor module, but also every other module which is to be placed at higher floors. vi. On any mismatch in the pre-defined matrix related to every geo spatial position ID and the MODULE REID Number, there is an alarm which rings loud at the site, thereby informing about the possible error in a wrong module being lifted for erection at that geo spatial ID. vii. Such a solution thus allows for no human error in placement of modules, especially for high rises where there are multiple number of similar looking modules to be handled and placed in position for commissioning. viii. The solution is a combination of RFID, GPS mapping, and an application that computes and resolves the correct / incorrect pairing of the RFID tagged module at site while it is being lifted in air to be placed at the designated in place. Such resolution of the dynamic position of the moving module on real time basis is resolved by the software to match with the pre-defined position with the module space IDs for every building. Any anomaly to that effect gets enunciated at site in the form of an alarm.

INBUILT REDUNDANCY and ENABLEMENT OF 24 x 7 FACTORY OPERATIONS-

Unlike the Previous system where the factory operations could be severely impacted due to a failure within the assembly line function or any other critical components of the manufacturing process, viz. Batching Plant, Circulation system, Curing Chamber I Boiler System, Power Supply, the proposed FURTHER IMPROVED MANUFACTURING DESIGN ensures ample redundancy across the entire operation. Redundancy has been provided in this design at the following points within the factory end to end systems -

1. Circulation System - with multiple assembly lines (8x) in the factory shed and each line being independently operational, the factory production will remain available at least 87.5% of the times in case one of the circulation line experiences a bottleneck / failure.

2. Cranes - with lx 45 Ton and 2x 4 Ton cranes per bay there is a 50% worst case availability between two assembly lines in a bay of 25% between 4 bays.

3. Boiler and Curing Chamber - with 2x boilers and 8x Curing Chambers the system provides 50% redundancy between the Boilers and 87.5% redundancy between the retractable curing chambers 4. Concrete Delivery System - with 2x Batching plants, 2x Concrete Pumps and Boom Placer pairs the system provides a 50% availability for production in the worst case.

5. Formwork Cleaning System - 4x form-work cleaning stations provide for a high availability of 75% in the remote possibility of one of these failing at a time.

The design thus provides in general a worst-case scenario of 50%+ type of high availability under situations where any of the critical components were to break down.

Also, it also will allow for a 365-day 24x7 operation with the flexibility now available to carry out preventive maintenance on a single assembly line at a time.

Further, it is to be noted that the above-mentioned steps are applicable to any building design. A specially designed building with the single cast concrete construction technology or any standard building design in the market can be manufactured using this technology. The steps involved remain unchanged irrespective of the building design.

TECHNICAL ADVANCES AND ADVANTAGES OF THE INVENTION

The presently disclosed invention, as described herein above, provides several technical advances and advantages:

- With the efficient manufacturing process, it only takes a module 30 hrs from Formwork Assembly to Finished Goods Storage providing Fast Delivery to its customers.

- Factory Finish and Quality - leading to perceptibly high value at lesser costs in the eyes of the customers.

- RCC Based - Provides the same strength, ruggedness, and flexibility that Conventional Construction provides.

- Earthquake Resistant - Joinery and Reinforcement designed to withstand seismic activity in Zone 3 and 4.

- Caters to all types of building requirements - from bungalows to high rises.

- Improves the economics for the real estate industry, thereby bringing about a sea change in the current day practises related to pricing in the sector delivering true affordable homes to the needy. - The Bay-wise expansion Capability makes the factory design customizable and easy to implement.

- Each bay consists of 2 Assembly lines that deliver an output of 16 modules per day.

- The Factory consists of 4 bays with 8 Assembly Lines, thus producing an output of 64 modules per day.

- Unidirectional nature of the Assembly Lines eases the man, material, and vehicle flow in the factory.

- Perpendicular to Ground Circulation of the Master-frame from WS05 to WS01 eliminates the need of on-floor transfer of the frame.

- Each Assembly line functions independently and the production output remains unhampered.

- 2 Batching Plants supply concrete continuously to the 8 assembly lines to achieve the 64 Modules per day output.

- Boiler systems provided on each side of the shed supply steam to the Curing Chamber that helps in faster curing of the modules. 1 Boiler system caters to 4 assembly lines.

- Each bay has a set of LT panels that supply power to the manufacturing stations and the respective equipment.

- Process plan with maximum output and ample redundancy in Operations / Processes.

- The Business Processes set are ERP Ready.

- The Floor-Door-Beam-Soldier concept of the Formwork assembly on a module ensures manufacturing of any shape and size module to suit the customer requirements.

- The Module Identifications Tagging and Retrieval Application (MITRA) is an all-round solution for error free Module placement and erection at site. With this application in place, the problem of incorrect module assembly becomes redundant. - Simplified Concrete Delivery to Moulds is achieved through the Remote- Controlled Boom Placer coupled to the Batching Plant. This Remote-controlled operation provides speed and accuracy required for the job.

- Each line consists of 5 workstations that perform all the operations required to manufacture a module within a span of 30 hours.

- Each Frame is capable of holding 2x or more modules.

- Each workstation has a fixed takt time of 6 hours to provide enough time to complete job work assigned.

- Each workstation has been State of the Art Workstation Management system. - 24x7 uninterrupted factory operations providing for 365-day shift planning.

- Centralised Network Operations Centre (NOC) to be available to monitor and control all critical systems responsible for throughput of the factory

Claims

I claim:

1. An improved method for manufacturing a single cast concrete construction based modular building, the method comprising the following steps: a. providing a layout for the building to be constructed; b. studying the layout; c. modularizing the layout in terms of S3C modules; d. 3D modelling of S3C modules; e. designing a structural system for each of the S3C modules along with that of the entire building having all modules assembled therein; f. designing mechanical, electrical and plumbing for each of the S3C modules, along with dropdown connectivity to underground tanks and overhead tanks in congruence with the requirement for the entire building; g. designing a formwork assembly for each of the S3C modules; h. finishing and fitout design for each of the S3C modules; i. preparing site erection and commissioning drawings; j. manufacturing each of the S3C modules based on the design in compliance with the steps (c) to (g); k. transporting the manufactured S3C modules to a building site; and l. erecting and commissioning S3C modules by hooking, hoisting, placement, and grouting of the S3C modules using epoxy grouting material in pre-defined formation above an in-situ plinth level.

2. The method as claimed in claim 1, wherein the step (b) of studying the layout includes the sub-steps of: i. calculating built-up and carpet area of each units of the layout; ii. studying of wet areas of the building, ingress or egress areas of the inhabitants, materials, and vehicles, utility, and services related requirements of the building; iii. calculating load acting on the building, the load being selected from the group consisting of dead load, live load, dynamic load; iv. determining and differentiating load bearing structures, and non-load bearing structures; v. designing structural symmetry and continuity of the S3C modules to achieve compatibility of the S3C modules; vi. determining reinforcements and concrete mix ratios based on the calculated load acting; and vii. designing joineries based on loads selected from the group consisting of seismic load, wind load, live load, dead load, structural forces including in-plane and out- of-plane bending moments during seismic activity.

3. The method as claimed in claim 1, wherein the step (c) of modularizing includes the sub-steps of: i. sizing the S3C modules in compliance with the regional transport office norms; ii. preparing exploded modular drawings; and iii. preparing drawings of each individual modules of S3C modules.

4. The method as claimed in claim 2, wherein the structural design is matched with the reinforcements and the structural design.

5. The method as claimed in claim 1, wherein

- the formwork is selected from the group consisting of a flat form, angular form, cover form, normal form, pouring form, texture, and combinations thereof;

- the flat form is a flat shutter having plain sheet on one side and stiffeners on the other side thereof, the flat form being employed for smooth surfaces

- the angular form being employed for connecting wall to wall;

- the angular form being one selected from the group consisting of comers, and corbels;

- the corbel form being connected at wall top end and cast a shape of corbel;

- the cover form being employed to connect internal and external assemblies;

- the cover form is one selected from the group consisting of window cover, door cover, wall joinery cover, slab joinery cover, top cover, and combinations thereof; - normal form is flat form employed to create a flat surface;

- pouring form is provided with an opening for pouring pre-mixed concrete therein and covered with a flap;

- texture form being employed for configuring predetermined texture on the wall surfaces; and

- the formwork is designed with tolerance to maximum displacement and corrosion factors.

6. The method as claimed in claim 5, wherein the step (g) of designing of formwork assembly includes the sub-steps:

- assembling a lower most section of the formwork which being a floor form;

- assembling a door form operatively above and coupled to the floor form;

- disposing a beam form operatively above and coupled to the door form in both internal and external formwork sub-assemblies;

- disposing a soldier form which being disposed in balance spaces;

- covering non-covered areas between modules employing custom forms;

- creating sub-assemblies by splitting formworks from 3 -dimensions to 2- dimension, wherein the sub-assemblies are selected from the group consisting of walls, floors, and combinations thereof; and

- integrating the sub-assemblies on a master-frame to obtain the formwork assembly; wherein the step of assembling the forms on the master-frame for each of the S3C modules based on symmetric.

7. The method as claimed in claim 1, wherein the step (h) of finishing the S3C modules including wet module, and dry module; and wherein the step (h) of finishing and fitout design for each of the S3C modules includes the steps of completion of all fitout and finishes of module area other than joints followed by identification and listing of free issue material, which being supplied along with the S3C modules, wherein the free issue material is one selected from the group consisting of titles, tiles grout, joinery grouting material, paint, door platform, window platform, kitchen platform and combinations thereof.

8. The method as claimed in claim 1, wherein the step (j) of manufacturing each of the S3C modules including the sub-steps of:

- lifting the master-frame;

- transferring the master-frame to a workstation;

- cleaning the master-frame at the workstation;

- assembling multiple sub-assemblies of an external formwork and securing the same to the master-frame;

- applying a releasing agent to an internal surface of the formwork which being in contact with the pre-mixed concrete;

- placing reinforcement cages, concealed pipes, and cables, within the formwork, assembling multiple sub-assemblies of internal formwork;

- pouring the pre-mixed concrete within the formwork from a pre-mixed concrete batching plant employing a boom placer;

- compacting the poured pre-mixed concrete employing vibrators thereby allowing the pre-mixed concrete to settle therein;

- curing the pre-mixed concrete poured within the formwork, the curing being carried out by disposing the formwork with the pre-mixed concrete in a heating chamber to obtain a cured product;

- removing the cured product along with the formwork from the heating chamber followed by cooling to obtain a cooled product;

- disassembling the formwork;

- cleaning the dis-assembled formwork for further reuse;

- fitting doors, windows, and other hardware ;

- painting the internal and external surfaces of the walls;

- tiling the floor, the kitchen, the bathroom, and toilet walls to obtain the S3C modules within the factory premises; - fitting fit-outs, the fit-outs being one selected from electrical switches, and B22 holders; and

- performing testing of the S3C modules and components fitted thereto, the testing including one test selected from the group consisting of electrical megger test, water pressure test, dimensional fitting, inspection of doors, windows, and tiles, paint thickness and combinations thereof.

9. The method as claimed in claim 1, wherein each of the S3C modules being tagged with a unique radio-frequency identification for each of the S3C module, and a space identification number, wherein the space identification number provides the area of placement of the S3C module thereby preventing incorrect placement of the S3C module.