WO2023094732A1

WO2023094732A1 - Bathroom module and method for manufacturing of bathroom module

Info

Publication number: WO2023094732A1
Application number: PCT/FI2022/050790
Authority: WO
Inventors: Jorma KILPELÄINEN
Original assignee: Ssa Rakennus Oy
Priority date: 2021-11-26
Filing date: 2022-11-25
Publication date: 2023-06-01
Also published as: FI20216213A1

Abstract

The invention is related to a bathroom module (1), which comprises a cast base slab (11) that forms a floor, and at least three cast walls (12), in which case the building service components are arranged inside the cast structures, - water removal means (2) and floor heating elements (3) are arranged inside the base slab (11), - electric sockets (40), electrical cables (41) and/or electrical conduits and/or provisions for them for electrification are arranged inside the wall, and also water pipes (5) and/or lead- ins for water pipes and/or provisions for them for water supply to the water fittings, in which case said walls (12) and base slab (11) are of a single cast piece (10). The invention is also related to a method for the manufacturing of bathroom module (1).

Description

Bathroom module and method for manufacturing of bathroom module

[0001] The invention is related to a bathroom module according to the preamble of claim 1.

[0002] The invention is also related to a method for the manufacturing of a bathroom module, according to the preamble of claim 13.

[0003] One of the current trends in building is that building employs modules to an increasing degree, because when performed in the correct manner, this can be a cost-effective way to shift building work from building site conditions to a factory-like environment, to manageable, dry and well-illuminated conditions with even temperature. Modules are subject to various types of requirements; for example, the modules must have precise dimensions and keep their shape.

[0004] There can be modules with various degrees of completion. Precast concrete elements are most typical modules of a low degree of completion, as are various types of base slabs, on top of which walls are built at the building site. Modules to be put together of precast concrete elements at the building site are difficult to install, and in practice they cannot be water-proofed or surface-coated in advance so that they would be ready, but instead, much of the work remains to be carried out at the building site. This applies in particular to bathrooms and other corresponding sanitary facilities. Casting the base of the module and building of walls on top of the cast floor takes working time, and the structure will have several seams of different materials. Moreover, the modules are subject to the stress of weather conditions during transport and installation.

[0005] End users wish to have stone walls in a bathroom, because they are associated with high quality and a long-term structure in the minds of people. They also have many useful technical features: good insulation capacity and load-bearing capacity, incombustibility, dimensional accuracy etc. The walls of modules intended for bathrooms are typically not concrete walls. [0006] The purpose of the invention is to elevate prior art in the industry by presenting a bathroom module that can be used to minimise problems encountered in the technology already known in the industry.

[0007] The objective of the invention is to accomplish a bathroom module that enables the efficient and reliable building of a bathroom to be done in a short time frame, such as hotel building or building of blocks of flats, where a single building project involves many similar bathrooms.

[0008] Another objective of the invention is to accomplish a method that can be used to manufacture a bathroom module according to the invention in an efficient and simple manner.

[0009] The objectives of the invention are primarily achieved in a manner described in more detail by the independent claims 1 and 10 as well as other claims.

[0010] One embodiment of the invention is a bathroom module, which comprises a cast base slab that forms a floor, and at least three cast walls, in which case the building service components are arranged inside the cast structures,

- water removal means and floor heating elements are arranged inside the base slab,

- electric sockets, electrical cables and/or electrical conduits and/or provisions for them for electrification are arranged inside the wall, as well as water pipes and/or lead-ins for water pipes and/or provisions for them for water supply to the water fittings, in which case said walls and base slab are of a single cast piece, in which case the height of the wall essentially defines the inner height of the bathroom.

[0011] In connection with this invention, bathroom refers to such a space that is intended for and suited to the washing of people and to the taking care of other personal hygiene. The functional element in a bathroom is typically a washbasin and shower, shower cubicle and/or bath tub for washing, and possibly a toilet seat or equivalent. One special feature in the building of a bathroom is that in most countries the building regulations require a structure that prevents the access of water from the bathroom to other facilities through routes other than a sewer. In practice, this means a multilayer solution in the surfaces, where at least one of the layers is watertight, a so-called waterproofing layer. The specific purpose of the bathroom module which the invention concerns is to serve building, where the objective is the efficient manufacturing of compact-sized structures that are easily transferrable during the building stage.

[0012] The terms used in connection with this invention have the following meanings:

- Building service components refer in connection with this invention to the components required by heating, water supply and sewerage as well as electrification. Ventilation can also be considered to be included here, but ventilation components can be built, if that is desired, into the ceiling or other overhead structure, which does not necessarily have to be covered by the essential scope of protection of the bathroom module specified by this invention.

- Water removal means refer in connection with this invention to a floor drain, linear drain on the floor, water collection chute, hole in the floor for sewerage or other corresponding structure that leads away the water that is on the floor and further to a sewerage section possibly connected to it.

- Floor heating elements refer in connection with this invention to an ordinary arrangement used for the heating of the floor of the bathroom, the purpose of which is partially to keep the floor such that it gives a comfortable sensation when walked on barefoot, but partially also to keep the structures dry and to dry up the bathroom after use. This purpose is generally arranged by means of either electric heating, in which case the heating cable is inside the base slab, or alternatively floor heating with water circulation is used, where a heating water piping runs inside the floor. An alternative way to arrange floor heating is to use an infrared heater or blower other corresponding radiant heater or blower arranged in the facility, by means of which device the floor can be heated and dried by using warm air.

- Cast structure refers in connection with this invention to such a structure that is made by casting from a material and by removing the casting mould from around the structure after the casting has hardened, in which case the cast surface remains as the external interface of the piece with cast structure. The piece with cast structure will contain the components, potential support structure, such as reinforcement steel supporting or a support structure made of other corresponding reinforcement, placed in the casting mould before casting. Injection casting is also one available technique, which is why an injection-cast piece is considered to be a cast structure I cast piece. It is to be noted in particular that various types of pieces with a shell construction are not considered to be cast structures even though material could be cast inside the shells. Shell refers to a support structure that will remain as the surface of the piece formed.

- Electric sockets, electrical cables and/or electrical conduits and/or provisions for them for electrification are arranged inside the wall of the bathroom module. Bathrooms typically have lights, in addition to a ceiling light, for example, in connection with the mirror cabinet, as well as electric sockets for the use or charging of electric devices such as hair dryer, electric shaver and electric toothbrush. An aesthetically more appealing and better finalised bathroom is created by installing the necessary cables and electric sockets into the wall with flush mounting, as compared to a situation where electric cables or switches and sockets installed on the completed surface would be used. The objective in the building of a bathroom module according to the invention is to accomplish most of the work to be carried out at a factory, in which case at least said provisions are made in the wall of the bathroom module even though the actual cables and their connections would be made at the building site.

- Like electricity, also water pipes and/or lead-ins for water pipes and/or provisions for them for supplying water to the water fittings are arranged inside the wall, in other words they are built to the necessary completion before casting the bathroom module and are hence built at the factory.

[0013] The cast base slab, which constitutes the floor, and at least three cast walls are of a single cast piece. In this way, the bathroom module can be manufactured efficiently so that most of the work can be carried out industrially in factory conditions. As a result of this feature, the fastening of separate walls to the base slab can be avoided, in which case it is possible to design the structure to be very firm and stiff in relation to the mass of the bathroom module. It is possible to make various shapes in the casting mould, and the shapes are repeated exactly identically in each cast piece manufactured with the mould. As an example, it is possible to make exactly the correct types (for example, ones required by a tiling robot) of inclinations in the base slab, in other words in the floor, for guiding water to the water removal means. Another example that can be mentioned is a rebate possibly to be made in a doorway, enabling the precise and quick installation of a door/frame. Furthermore, a cast piece consisting of a single part enables waterproofing to be made over the entire necessary area without the need to make the waterproofing in the corner between the wall and floor only after the walls have been fastened.

[0014] Said walls and base slab of the bathroom module are cast from a purposeful structural material to become a uniform cast piece, such materials being, for example, concrete, concrete derivative or composite material, such as fibre-reinforced polymer. This gives the stone structure desired by the end users or a structure that appears as such, and the structure can be tiled or surface- coated with the desired surface material. Said structural materials are typically materials that insulate sound well, appear sturdy and are fire-resistant, and the necessary classifications required by the building regulations can be attained with them. In addition to ordinary structural concrete grades, possibly suitable materials include, for example, foam concrete, silicon oxide aerogel and of product names Betolar, for example. According to one preferred embodiment, the structural material is a waterproofing material in itself.

[0015] According to one embodiment of the invention, the bathroom module comprises at least three cast walls and one wall of another construction, or four cast walls. From the point of view of the efficiency of the manufacture of the bathroom module, four cast walls is likely the most efficient way of manufacture, by means of which it would be possible to make a great number of bathroom modules as quickly as possible. However, in some cases, due to various interior design or architectural reasons, the fourth wall of the bathroom module can be manufactured in a manner other than by casting in the same conjunction with the three other walls, without losing much of the benefits of the invention relating to production and technical solutions. In some cases, it is possible to use, for example, a glass wall, a wall with a light construction, or the bathroom module is installed against some other water-proofed wall, in which case only the water tightness of the joint seam is ensured.

[0016] According to one embodiment of the invention, the base slab and at least three walls of the bathroom module are provided with reinforcement steel supporting or otherwise supported inside the casting, such as a cast structure with lathwork supporting. The purpose of the reinforcement steel supporting is to stiffen the structure so that it is adaptable to its purpose and to allow the transport of the bathroom module manufactured at the factory to the building site and to allow it to be installed into place. Reinforcement steel supporting made of reinforcement steel together with concrete is a well-known and well-functioning combination, but with other materials reinforcement steel is not necessarily the best suited material. In this case, some other solution, such as lathwork supporting, may work best.

[0017] The reinforcement steel supporting or other supporting preferably comprises corner supports that extend inside the cast piece as well as inside the base slab and wall to a distance from the corner between the base slab and wall. One specific purpose of this feature is to accomplish such rigidity in the structure that the walls and base slab cannot move relative to each other. This type of movement between the walls and base slab is especially disadvantageous from the point of view of waterproofing, because waterproofing must not tear at any point of the production, installation or usage chain. Waterproofing must be watertight from manufacture to the entire planned service life of the bathroom module. In this way, a structure that enables an “opening” movement of the corner between the base slab and wall and contributes to the tearing of the waterproofing is detrimental from the point of view of the durability of the waterproofing. Such a detrimental movement can be prevented by means of corner supports that have a sufficiently sturdy structure.

[0018] The bathroom module preferably comprises a ceiling, which is of a piece different from said base slab and walls. From the point of view of manufacture, a structure that is open from the top is advantageous, because it enables easy accessibility to various operations that are needed during manufacture. These can include, for example, the use of tiling robots in the tiling of the walls and floor of the bathroom module, and the use of various lifters is easy, when the supplies and components to be installed can be lowered by means of a crane directly into the interior of bathroom module without having to carry them in through the doorway. Moreover, bathrooms often have a suspended ceiling, which is at a lower height than the ceiling in the other room facilities. Various systems included in ventilation, such as a heat recovery system or other air conditioning of ventilation equipment can be installed in the space between the suspended ceiling and the actual ceiling height. In the bathroom module according to the invention, the ceiling element can be manufactured as a separate work stage elsewhere or concurrently with the building of the interior of the bathroom module. When the interior is complete, the ceiling element that forms the ceiling is installed into place. The ceiling element can be installed between the walls and/or on top of the walls. Even though the height of the wall of the bathroom module essentially defines the inner height of the bathroom, the joint between the ceiling element and the walls of the bathroom module can be used for adapting the total height of the bathroom module by means of spacer pieces, such as spacer strips. The seam between the walls and ceiling of the bathroom module must be built in a manner conforming to the requirements in any case, but there are a considerable number of various implementation options for this, and these are not discussed in more detail here.

[0019] According to one preferred embodiment, the floor and walls of the bathroom module are water-proofed with a waterproofing material at a factory. Performing waterproofing is one of the critical work stages in the manufacture of a bathroom, and it should be carried out in a manner that fulfils the requirements and with an as consistent quality as possible. Water-proofing made industrially in the production stage at a factory is one way to achieve consistent quality. In a factory-like process, it is easy to specify issues such as the sufficient and instructed drying times of the waterproofing materials or the sufficient cleanliness of the production facilities I absence of dust in the production facilities so as to ensure the adhesion of the materials. When manufactured industrially as factory work, it is easy to make sure that the floor and walls of the bathroom module are water-proofed at least to such height from the floor that is required by the building regulations or to a sufficient distance from a water supply point.

[0020] One wall or more walls of the bathroom module is/are preferably a wall between apartments or a load-bearing wall. A number of different building regulations apply to the walls between the various facilities of a building, such as between different apartments, between an apartment and a corridor, between an apartment and a storage facility or between an apartment and a technical facility. When at least three walls of the bathroom module according to the invention are cast structures, it is relatively simple to use them to fulfil the requirements required of the walls between the above-mentioned facilities. In this way, from the point of view of overall economy of building, it may be sensible to make one wall or two walls of the bathroom module to be a little sturdier, in which case it fulfils I they fulfil the building regulations concerning the case at hand.

[0021] According to one embodiment, the bathroom module is a partially complete product, in which case the fixtures, such as water fittings and/or other fittings are installed in the building stage at the building site. According to another embodiment, the bathroom module is complete when delivered from the factory, so that in the building stage at the building site the bathroom module is fastenable to a structure, and the interfaces to sewerage, water pipes, ventilation ducts and electricity network are connectable to operating condition. In practice, it is in other words possible to specify a certain minimum delivery scope that is deemed to be economically sensible, and a sufficiently large portion of the building work can be carried out at the factory. The other extreme of the degree of completion is a so- called Plug & Play type solution, where a fully complete bathroom module is delivered to the building site and installed into place, and the sewerage, water pipes, ventilation ducts and electricity are connected.

[0022] Furthermore, according to one embodiment the bathroom module comprises mounting points in the area of the base slab and walls, by means of which mounting points the bathroom module or cast piece can be lifted and/or turned around some axis and/or fastened in the building stage to a surrounding structure. In the production stage and later in the transport and installation stages, it is convenient if the bathroom module is already equipped with such mounting points that facilitate lifting, turning and moving. In this case, there is no need to separately start adapting various types of lifting slings or similar around the structure, but instead, these types of measures can be done with purposeful and safe equipment designed for the product. In connection with this invention, mounting points refer to such structures or structural details by means of which the bathroom module can be lifted, turned around some axis and/or fastened in the building stage to a surrounding structure, in which case the automation of manufacture is facilitated. These can be, for example, lugs, recesses, openings or similar.

[0023] The invention is also related to a method for the manufacture of a bathroom module, which comprises a cast base slab that forms a floor, and at least three cast walls, where the height of the wall essentially defines the inner height of the bathroom, in which case the building service components are arranged inside the cast structures,

- electric sockets, electrical cables and/or electrical conduits and/or provisions for them for electrification are arranged inside the wall, and also water pipes and/or lead-ins for water pipes and/or provisions for them for water supply to the water fittings, the method comprises the following stages:

- an inner mould is prepared for casting, with the inner mould comprising a negative of the shapes that correspond to the raw inner surfaces of the bathroom,

- the inner mould is coated in a liquid tight manner with a casting release material, such as with a waterproofing fabric or other corresponding waterproofing material,

- water removal means together with the sewer possibly connected to them are fastened to the inner mould, and these are supported to the inner mould for casting,

- electric sockets and electrical cables and/or electrical conduits and/or their provision components are fastened to the inner mould for electrification,

- water pipes and/or lead-ins for water pipes and/or provisions for them are installed in connection with the inner mould for supplying water to the water fittings,

- reinforcement steel supporting or other supporting that remains inside the casting is installed around the inner mould,

- the casting material is poured or injected,

- the casting is allowed to harden until a sufficient strength has been achieved, after which the casting mould or moulds is/are removed,

- the bathroom module is built to finished completion to a desired degree of completion.

[0024] In other words, in practice the inner mould is used for creating the raw surfaces of the interior of the bathroom module, the floor with the necessary inclination and the walls that are ready to be tiled. The inner mould also serves as a kind of an installation jig, to which the building service components are fastened. A casting release material, which is most suitably a waterproofing fabric or other corresponding waterproofing material, is installed over the inner mould first. The waterproofing fabric is seamed to become watertight. The building service components can preferably be fastened to their correct places in the inner mould by means of screws, for example, when the inner mould is manufactured as an installation jig type solution, which already contains all the holes and grip points required by installation. After the building service components, a reinforcement steel supporting that has most suitably been pre-built is lifted around the inner mould, and the reinforcement steel supporting settles to a planned distance from the surface of the inner mould, in other words from the inner surface of the bathroom module after casting. Alternatively, the reinforcement steel supporting is lifted into place before the installation of the outer mould. Casting preferably takes place so that the bathroom module is formed upside down relative to its normal usage position, in other words with the floor facing up, in which case the dense surface of the cast material settles most suitably against the inner mould.

[0025] Once the casting mould and the preliminary preparations are ready, the casting material is poured or injected. In other words, it is possible to use here a two-sided inner mould - outer mould solution, or alternatively a one-sided injection casting technique, where a suitably stiff and quickly setting casting material is injected onto the surface of the inner mould. The casting is allowed to harden after casting until a sufficient strength has been achieved, after which the temporary fastenings of the building service components made for casting can be dismantled, and the casting mould or moulds is/are removed.

[0026] The other additional characteristic features of the invention are disclosed in the enclosed patent claims and in the below description of the embodiments of the figures.

[0027] In what follows, the invention and its functioning are described by making reference to the enclosed schematic figures, where:

Fig. 1 shows schematically one embodiment of the bathroom module according to the invention,

Fig. 2 shows schematically one embodiment of the cross section of the bathroom module according to the invention.

[0028] Fig. 1 shows schematically one embodiment of a bathroom module 1 according to the invention, which bathroom module 1 comprises a cast base slab 11 that forms a floor, and at least three cast walls 12, in which case the building service components are arranged inside the cast structures,

- water removal means 2 and floor heating elements 3 are arranged inside the base slab 11 ,

- electric sockets 40, electrical cables 41 and/or electrical conduits and/or provisions for them for electrification are arranged inside the wall, as well as water pipes 5 and/or lead-ins for water pipes and/or provisions for them for water supply to the water fittings, in which case said walls 12 and base slab 11 are of a single cast piece 10. Said walls 12 and base slab 11 are preferably cast from a purposeful structural material to become a uniform cast piece, such materials being, for example, concrete, concrete derivative or composite material, such as fibre-reinforced polymer. Fig. 1 illustrates how the bathroom module 1 comprises at least three cast walls 12. One of the walls (not illustrated in Fig. 1) can be of another structure, or alternatively the bathroom module can comprise four cast walls 12. [0029] Fig. 2 shows schematically a cross section of the bathroom module 1 according to one embodiment, which bathroom module 1 comprises a cast base slab 11 that forms a floor, and at least three cast walls 12, in which case the building service components are arranged inside the cast structures,

- electric sockets 40, electrical cables 41 and/or electrical conduits and/or provisions for them for electrification are arranged inside the wall, as well as water pipes 5 and/or lead-ins for water pipes and/or provisions for them for water supply to the water fittings, in which case said walls 12 and base slab 11 are of a single cast piece 10. The waterproof sealant 8 extends up to the walls 12 in accordance with the building regulations.

[0030] Fig. 2 shows an embodiment, where the bathroom module comprises a ceiling 7, which is of a piece different from said base slab 11 and walls 12. A ventilation system 9 is arranged inside the ceiling. Fig. 2 also shows one embodiment for the joint between the ceiling element that forms the ceiling 7, and the walls 12 of the bathroom module; the ceiling is adapted inside the walls 12 as a so-called suspended ceiling, in which case the walls 12 extend higher than the lower surface of the ceiling 7. In this way, it is also possible to adapt the total height of the bathroom module 1 to the desired height by means of spacer pieces 70, such as spacer strips. In a solution according to one preferred embodiment, the height of the wall 12 of the bathroom module 1 essentially determines the inner height of the bathroom. In this case, the cast walls 12 continue in the vertical direction up to the interface of the ceiling 7. In some special cases, however, there may, for example, windows or other light openings, glass blocks etc. at the very top, but in these cases, too, the cast wall preferably extends up to the window structures.

[0031] Fig. 2 further shows one embodiment, where the base slab 11 and at least three walls 12 of the bathroom module 1 are provided with reinforcement steel supporting 6 or otherwise supported inside the casting, such as a cast structure with lathwork supporting. For illustration purposes, the reinforcement steel supporting 6 in Fig. 2 is only shown as a few reinforcement steel supports 6 in the direction of the image plane, but it is understandable to a person skilled in the art that the quantity of the reinforcement steel supporting 6 is that which is required by the strength of the structure in each individual case, and there is reinforcement steel supporting 6 both lengthwise and longitudinally relative to the perspective of Fig. 2. Fig. 2 also shows one embodiment, where the reinforcement steel supporting 6 or other supporting comprises corner supports 61 that extend inside the cast piece 10 as well as inside the base slab 11 and wall 12 to a distance from the corner between the base slab 11 and wall 12. The purpose of these corner supports is to reinforce the area of the corner between the base slab 11 and walls 12 and to prevent the cracking of the cast piece 10 in the manner described above. One wall or more walls 12 of the bathroom module

I is/are preferably a wall between apartments or a load-bearing wall.

[0032] Furthermore, Fig. 2 shows how, according to one embodiment, the bathroom module 1 comprises mounting points 62 in the area of the base slab

I I and walls 12, by means of which mounting points 62 the bathroom module 1 or cast piece 10 can be lifted and/or turned around some axis and/or fastened in the building stage to a surrounding structure, such as to the frame of the building. In other words, the purpose of the mounting points 62 is to facilitate the automation of building work and to make the bathroom module 1 or cast piece 10 suitable for automation. One example of work that could advantageously be automated is tiling, which is demanding when performed manually and requires considerable accuracy from the person performing the work. The ceramic tiles that form the final inner surface of the bathroom are fastened by means of mortar to the floor/wall, and seamed. It is in no way self-evident that this work stage can be performed in a clean manner and always identically in building site conditions. The mortar used for fastening the tiles must be spread to each point with exactly the same layer thickness and with identical viscosity. Factors such as the position of the notched mortar spreading trowel and the residence time of the mortar in the mortar bucket are factors that are susceptible to change constantly in tiling work that is performed manually. If the person performing tiling cannot control and standardise these, the tiles will set at different heights relative to each other from the surface. The planar position of the tiles relative to each other is also very accurate so that the seams of the tiles would not appear to be meandering. Such tiling work can also be automated, in which case tiling always takes place in the same manner, but the use of a tiling robot in building site conditions is not usually profitable. This work stage or function can be automated in an industrial facility. In this case, however, it is most advantageous if the piece to be tiled can be turned so that tiling always takes place in the horizontal plane. The automation of the manufacture of the bathroom module 1 according to the invention is facilitated if mounting points 62 have been arranged in the cast piece 10, preferably as early as at the initial stage and/or as part of the reinforcement steel supporting 6, by which mounting points 62 it is possible to grip the cast piece 10 and turn it to the desired position.

[0033] In the manner described above, the floor 11 and walls 12 of the bathroom module 1 are water-proofed with a waterproofing material 8, most preferably as early as at the factory. According to a preferred embodiment, the floor 11 and walls 12 of the bathroom module 1 are water-proofed with a waterproofing material 8 at least to such height from the floor 11 that is required by the building regulations or to a sufficient distance from a water supply point 5.

[0034] In what follows, a method for the manufacture of the bathroom module 1 presented in Fig. 1 and Fig. 2 is presented, which bathroom module 1 comprises a cast base slab 11 that forms a floor, and at least three cast walls 12, in which case the building service components are arranged inside the cast structures,

- electric sockets 40, electrical cables 41 and/or electrical conduits 41 and/or provisions 41 for them for electrification are arranged inside the wall, as well as water pipes 5 and/or lead-ins 5 for water pipes and/or provisions 5 for them for water supply to the water fittings, wherein the method comprises the following stages:

- an inner mould (not illustrated in the figures) is prepared for casting, with the inner mould comprising a negative of the shapes that correspond to the raw inner surfaces of the bathroom,

- the inner mould is coated in a liquid tight manner with a casting release material, such as with a waterproofing fabric 8 or other corresponding waterproofing material 8,

- water removal means 2 are fastened to the inner mould together with the sewer possibly connected to them, and these are supported to the inner mould for casting,

- electric sockets 40 and electrical cables 41 and/or electrical conduits 41 and/or their provision components 41 are fastened to the inner mould for electrification,

- water pipes 5 and/or lead-ins 5 for water pipes and/or provisions 5 for them are installed in connection with the inner mould for supplying water to the water fittings,

- reinforcement steel supporting 6 or other supporting that remains inside the casting is installed around the inner mould,

- the casting material is poured or injected,

- the bathroom module 1 is built to finished completion to a desired degree of completion.

[0035] According to one embodiment, an outer mould (not illustrated in the figures) is prepared for casting,

- the casting material is poured between the inner mould and outer mould,

- the casting material/mould is vibrated so that the casting settles tightly in the mould and any air bubbles can escape. Alternatively, the method is carried out so that the outer mould is the actual mounting base for the building service components, and the inner mould is only for forming the inner shape of the bathroom. In this case, the installations described above are made in the outer mould, and the outer mould is used as an installation jig. The reinforcement steel supporting is preferably prepared to be completely finished, after which the reinforcement steel supporting 6 is lifted into place before the installation of the outer mould. Alternatively, if using a technique where the outer mould is first, the reinforcement steel supporting is installed into place before the installation of the inner mould. The installation of the reinforcement steel supporting to be done after the installation of both moulds is not recommended, because the reinforcement steel supporting can easily damage the building service components which have already been installed into place. For this reason, the order of installation must always be planned on a case by case basis.

[0036] It is to be noted that what has been described above only includes some most preferred embodiments of the invention. It is therefore clear that the invention is not limited to the above embodiments alone, but it can be applied in many ways within the enclosed patent claims. The features described in conjunction with the various embodiments can also be used in conjunction with the other embodiments within the basic idea of the invention and/or various entities can be combined of the features presented if this is to be desired and the technical facilities for this exist.

[0037] Reference numbers used in the figures:

1 bathroom module

10 cast piece 11 base slab, floor

12 wall

2 water removal means

3 floor heating elements

40 electric sockets 41 electrical cables and/or electrical conduits and/or provisions for them

5 water pipes and/or lead-ins for water pipes and/or provisions for them

6 reinforcement steel supporting

61 corner support

62 mounting point 7 ceiling

70 spacer pieces

8 waterproofing material

9 ventilation system

Claims

1. A bathroom module (1), which comprises a cast base slab (11) that forms a floor, and at least three cast walls (12), in which case the building service components are arranged inside the cast structures,

- water removal means (2) and floor heating elements (3) are arranged inside the base slab (11),

- electric sockets (40), electrical cables (41) and/or electrical conduits and/or provisions for them for electrification are arranged inside the wall, and also water pipes (5) and/or lead-ins for water pipes and/or provisions for them for water supply to the water fittings, characterised in that said walls (12) and base slab (11) are of a single cast piece (10), in which case the height of the wall (12) essentially defines the inner height of the bathroom.

2. A bathroom module (1) according to claim 1 , characterised in that said walls (12) and base slab (11) are cast from a purposeful structural material to become a uniform cast piece (10), such materials being, for example, concrete, concrete derivative or composite material, such as fibre-reinforced polymer.

3. A bathroom module (1) according to claim 1 or 2, characterised in that the base slab (11) and at least three walls (12) of the bathroom module (1) are provided with reinforcement steel supporting (6) or otherwise supported inside the casting, such as a cast structure with lathwork supporting.

4. A bathroom module (1) according to claim 1 , 2 or 3, characterised in that the bathroom module (1) comprises at least three cast walls (12) and one wall (12) of another construction, or four cast walls (12).

5. A bathroom module (1) according to claim 3, characterised in that the reinforcement steel supporting (6) or other supporting comprises corner supports (61) that extend inside the cast piece (10) as well as inside the base slab (11) and wall (12) to a distance from the corner between the base slab (11) and wall (12).

6. A bathroom module (1) according to any one of the preceding claims, characterised in that the bathroom module comprises a ceiling (7), which is of a piece different from said base slab (11) and walls (12).

7. A bathroom module (1) according to any one of the preceding claims, characterised in that the bathroom module (1) comprises mounting points (62) in the area of the base slab (11) and walls (12), by means of which mounting points (62) the bathroom module (1) or cast piece (10) can be lifted and/or turned around some axis and/or fastened in the building stage to a surrounding structure.

8. A bathroom module (1) according to any one of the preceding claims, characterised in that the floor (11) and walls (12) of the bathroom module (1) are water-proofed with a waterproofing material (8) at a factory.

9. A bathroom module (1) according to claim 7, characterised in that the floor (11) and walls (12) of the bathroom module (1) are water-proofed with a waterproofing material (8) at least to such height from the floor (11) that is required by the building regulations or to a sufficient distance from a water supply point (5).

10. A bathroom module (1) according to any one of the preceding claims, characterised in that the one wall or more walls (12) of the bathroom module (1) is/are a wall between apartments or a load-bearing wall.

11. A bathroom module (1) according to any one of the preceding claims, characterised in that the bathroom module (1) is a partially complete product, in which case the fixtures, such as water fittings and/or other fittings are installed in the building stage at the building site.

12. A bathroom module (1) according to any one of the preceding claims, characterised in that the bathroom module (1) is complete when delivered from the factory, so that in the building stage at the building site the bathroom module (1) is fastenable to a structure, and the interfaces to sewerage, water pipes, ventilation ducts and electricity network are connectable to operating condition.

13. A method for the manufacture of a bathroom module (1), which comprises a cast base slab (11) that forms a floor, and at least three cast walls (12), where the height of the wall (12) essentially defines the inner height of the bathroom, in which case the building service components are arranged inside the cast structures,

- electric sockets (40), electrical cables (41) and/or electrical conduits (41) and/or provisions (41) for them for electrification are arranged inside the wall, and also water pipes (5) and/or lead-ins (5) for water pipes and/or provisions (5) for them for water supply to the water fittings, characterised in that the method comprises the following stages:

- the inner mould is coated in a liquid tight manner with a casting release material, such as with a waterproofing fabric (8) or other corresponding waterproofing material (8),

- water removal means (2) are fastened to the inner mould together with the sewer possibly connected to them, and these are supported to the inner mould for casting,

- electric sockets (40) and electrical cables (41) and/or electrical conduits (41) and/or their provision components (41) are fastened to the inner mould for electrification,

- water pipes (5) and/or lead-ins (5) for water pipes and/or provisions (5) for them are installed in connection with the inner mould for supplying water to the water fittings,

- reinforcement steel supporting (6) or other supporting that remains inside the casting is installed around the inner mould,

- the casting material is poured or injected,

- the casting is allowed to harden until a sufficient strength has been achieved, 21 after which the casting mould or moulds is/are removed,

- the bathroom module (1) is built to finished completion to a desired degree of completion.

14. A method according to claim 13, characterised in that an outer mould is prepared for casting,

- the casting material is poured between the inner mould and outer mould,

- the casting material/mould is vibrated so that the casting settles tightly in the mould and any air bubbles can escape.

15. A method according to claim 13, characterised in that the outer side of the inner mould is cast by injection.

16. A method according to claim 13, characterised in that the reinforcement steel supporting (6) is lifted into place before the installation of the outer mould.