System of prefabricated elements made of structural light concrete and of reinforced concrete for the total erection of 1 to 8 storey buildings

Abstract

 This constructive system allows you to erect buildings for any type of use, especially for residential use. It foresees self-supporting panels for the various types perimetral walls, lintels for windows and doors, partition walls, slabs with or without balcony aggregates, two-or three-flight stairs with or without elevator, roofs complete with relevant coverings.
This system also foresees various types of foundation elements - rectilinear, angular, T-shaped and cross-shaped - that are connected one another by means of male and female profiles and steel tie rods.
The panels used for the perimetral and supporting walls can also be connected one another by means of steel tie rods.
The slabs have: dap joint profiles made of cold-rolled steel sheet metal which will be connected one another by means of intermitted welding; PVC or steel pipes buried into them for the passage of household systems piping.

Description

[0001] The building industrialization has allowed the erection of industrial buildings and perfecting the prefabrication of structures and stopper panels, but the same application criterium as not been achieved in the design and construction of residential buildings of any type such as one-family houses, detached houses, terraced houses, few-story buildings and to the construction of non-residential buildings such as hospitals, schools, hotels, etc.

[0002] A system which only employs prefabricates in the total construction of the desired type of building is required in order to reach this degree of application.

[0003] With the application of the aforementioned system we want to achieve the following targets:

• Design rapidity
• Possibility of adapting the system to different projects
• Homogeneity in making the structural mixtures able to grant the declared characteristics that are the prerogatives of a prefabricated elements system
• Fast assembly of all the elements
• Possibility of making different types of new housing conglomerates in a short time
• Capability of the system to resist seismic stress
• Certainty of making a realistic expenses
• Possibility of designing different types of residential buildings and also of buildings for non-residential uses. One-family house, terraced houses, two/three/four-family houses, few-story and up to 8-story buildings with apartments of different sizes, hospitals, schools, office district and trading center buildings.

ELEMENTS OF THE SYSTEM

FOUNDATION BEAMS MADE OF CONCRETE

[0004] 

FIG.1 Rectilinear beam

FIG.2 Angular beam

FIG.3 T beam

FIG.4 Cross beam

SELF-SUPPORTING PANELS MADE OF STRUCTURAL LIGHT CONCRETE

[0005] 

FIG.5 Panel with longitudinal groove-and-tongue joints

FIG.6 Panel with longitudinal female-female dap joints

FIG.7 Panels with longitudinal male-male dap joints

FIG.8 Panel with groove-and-tongue joint with seating for lintel

FIG.9 Panel with tongue-and-groove joint with seating for lintel

FIG.10-Panel with male-male dap joint with seating for lintel

FIG.11-Lintel for doors and windows

FIG.12 Lintel for balcony

FIG.13 Panel for window sill

FIG.14-Composition of outside wall with windows

FIG.15 Angular panel

FIG.16- T-shaped panel

FIG.17- Cross panel

FIG.18- Panel for vertical passage of ducts

FIG.19- Panel with opening for sewage or for housing the heating system radiators

FIG.20- Panel for vertical and horizontal passage of ducts

ELEMENTS FOR PARTITION WALLS

[0006] 

FIG.21 Panel with groove-and-tongue joint

FIG.22 Panel ½FIG.21 with groove-and-tongue joint

FIG.23 T-shaped panel with springers for doors lintels

FIG.24 Reduced (smaller) panel with shutter springer for lintel

FIG.25 Lintel

FIG.26 Vertical masonry structure for door

FIG.27 Panel as FIG.21 with vertical masonry structure on the longitudinal axis

FIG.28 Panel as FIG.21 with openings for ducts passage

SLAB ELEMENTS

[0007] 

FIG.29- Element with one span with incorporated curb

FIG.30 Element with two spans with incorporated curb

FIG.31- Element with one span with curb and cantilevered slab for balcony

FIG.32 Element with two spans with curb and cantilevered slab for balconies

Fig.33 Element with one span with no incorporated curbs

Fig.34- Element with two spans with no incorporated curbs

[0008] Some elements can also be made with a size half in width

ELEMENTS FOR PEAKED ROOF

[0009] 

FIG.77-Triangular element with flat slab and double-pitch sloping roof with insulation system and incorporated tiles

FIG.78 Triangular elements with slab with two spans and double- pitch sloping roof, with insulation system and incorporated tiles

ELEMENTS FOR TWO-FLIGHT STAIRS

[0010] 

FIG.41- Plan of the stairs

FIG.42 Element with incorporated steps and landing for first flight (plan)

FIG.43 Element without steps for first flight (plan)

FIG.44 Element with incorporated steps and landing for first flight (longitudinal section)

FIG.45 Element without steps for first flight (longitudinal section)

FIG.46 Element with incorporated steps and landings for second flight (plan)

FIG.47 Element without steps for second flight (plan)

FIG.48 Element with steps and landing for second flight (longitudinal section)

FIG.49 Element without steps for second flight (longitudinal section)

FIG.50 - Longitudinal sectional view of the stairs for out of the ground three-storey buildings

FIG.51-Cross section of the element with steps and landing FIG.42

FIG.52 Cross section of the element without steps FIG.43

FIG.53-Cross section of the element with steps and landing FIG.46

FIG.54- Cross section of the element without steps FIG.47

FIG.55- Cross section of the element for third flight with steps and landing

FIG.56- Cross section of the element for third flight without steps

FIG.57- Cross section of the element for fourth flight with steps and landing

FIG.58- Cross section of the element for fourth flight without steps

FIG.59- Cross section of the element of the last storey above FIG 57

FIG.60- Cross section of the element of the last storey above FIG.58

ELEMENTS FOR THREE-FLIGHT STAIRS WITH ELEVATOR SHAFT

[0011] 

FIG.61 Element with first, second and third flight

FIG.62 Element without steps with landing, to be coupled with FIG.61

FIG.63 Element with fourth, fifth and sixth flight coupled with element FIG.62

FIG.64 Plan of the three-flight stairs with elevator shaft

FIG.65 Plan of the base of the elevator shaft

FIG.66 Section of the stairs FIG.64 with elevator shaft

FIG.67.Elements for elevator shaft

DESCRIPTION OF THE ELEMENTS WHICH COMPOSE THE SYSTEM

[0012] All of the elements are made of structural light concrete, composed of expanded clay grains with different diameters, thoroughly washed sand and water in the correct ratio in order to obtain concrete which is consistent, processable, compact and semi-impermeable.

[0013] An optimal structural light concrete composition could be:

Cement: Rck 425 375 Kg/mc

Sand: 0-3 mm 470 Kg/mc

Expanded clay: 0 3-8 mm 0,850 mc

Water: 160 1/mc

[0014] The absorbed water depends on the absorbing power of the expanded clay which can be evaluated to be 50-60 1/mc

[0015] Metal formworks placed on vibrating surfaces or (depending on the type of elements) formworks placed vertically - with vibrating devices on the walls if one wants smooth and not float finished walls - are required for making the element.

FOUNDATION BEAMS

[0016] The foundation beams FIG.1-FIG.2-FIG.3-FIG.4- are made of normal concrete with vibrated 3 ql/mc cement.

[0017] The size will be determined by the load incidence and the ground and subsurface resistance. In order to illustrate this system these elements can for example have the following dimensions: cm 50x50h with a cm 10x5 upper rectangular dap joint and groove-and-tongue joint at the extremity (which changes according to the foundation height) which in our case we hypothesize to be cm . 5-20-5. This element rests on an underpinning which lays perfectly flat horizontally and which has an impression as wide as the foundation beam. The element in section shows four holes on both the upper and lower parts; in fact, no. 8 35x3 mm pipes with end flanges, which measure 60x8 mm, are buried in concrete to allow the passing of the steel tie rods used for tightly consolidating the various elements of the foundation. To consolidate the perpendicular elements, you have to insert the steel tie rods either through the inside or outside holes. The steel tie rods are composed of steel rods threaded at the end. The tightening will occur by means of hexagon nuts which are very high.

[0018] The variable length of the elements is required to avoid that the joints of the panels ever coincide with the joints o the foundations.

SELF-SUPPORTING PANELS MADE OF STRUCTURAL LIGHT CONCRETE

[0019] The panels (FIG.1-FIG.2-FIG.3) have been designed for environments with an inside finished height of 2.70 meters but can also be of a different height if needed.

[0020] The panel can have these measures: width 1.20 m, thickness 0.30 m, height 2.75 m (slab substructure) plus a border with a height of 0.25 m or more (this depends on the height of the slab) a width of 1.20 m and a thickness of 5 cm. which allows the curb of the slab to be covered without any other additions. The same series can also be without border.

[0021] If used in an earthquake zone, the panels, which are obviously reinforced, will have stronger reinforcements depending on the seismicity of the area.

[0022] The panels FIG.1,FIG.2,FIG.3, as you can see from the list of elements which compose the system, have different dap joints to facilitate the coupling when there is an incompatibility problem of the dap joint profile as per the windows and the doors. The coupling profiles are slightly trapezoidal.

[0023] In order to face the problem of the openings, different elements are foreseen. The panels FIG.8,FIG.9 and FIG.10 have dap joints for the lintels FIG.11.and FIG.12. These lintels have the same dap joint to the right and to the left with a width of 10 cm and a length of 20 cm per side. On the upper part there is always a channel of cm. 10x5 in depth to seat the profile beneath the slab curb, and the border as for the panels in the case of the lintel of FIG.11 .The lintel of FIG.12 does not have the border because it will be used when a slab element with aggregate for making a balcony FIG.31 or FIG.32 is used.

[0024] There is also the panel FIG.13 for a 120 x 100h sill.

[0025] 35x3 mm. steel pipes with flanges at the ends are buried in all the panels for tie rods passing. Every section of the panel has 4 pipes, two in the upper part in the lintel area and two in the lower part one at 10 cm. from the base and the other at 70 cm. from the base.

[0026] There are other panels for the stability of the comers, of the tee joints and crossings, that act as big pillars and facilitate the assembly from the start. These are the angular panels FIG.15, the T panel FIG.16 and the perpendicular cross panel FIG.17.

[0027] Some panels FIG.18,FIG.19,FIG.20, have seatings for the passage of ducts, hydraulic and heating systems. They facilitate the installation and also allow inspection in case of faults, if any.

THE PARTITION WALLS

[0028] The elements for building partitions are made of C.L. composed of expanded clays, cement, and sand (with reinforcement for some types), properly plastered and gesso finished. They can be easily stuccoed after the installation.

[0029] The elements are 8: FIG.21 with groove-and-tongue joint, FIG.22 half panel with groove-and-tongue joint, FIG.23 T panel with springer for the lintels of the doors, FIG.24 reduced panel for lintel springer, FIG.25 lintel for door, FIG.26 vertical masonry structures for door to be used in special cases, FIG.27 panel with vertical masonry structure in the middle, FIG.28 panel as FIG.21 with openings for the passage of ducts.

[0030] It is obvious that the construction of a building with prefabricated elements cannot be made using the same criterium used for conventional buildings, since in our case everything must be planned respecting some priorities. The partitions must be constructed at the same time of the supporting structures along the perimeter, so that when the slabs are installed the partitions are complete being careful that the coplanarity of the slab positioning plane is respected.

THE SLAB

[0031] The element of the slab, which is part of the system, is composed of a beam, which is 1.20 m wide, 25 cm. high, or higher when the calculation requires it, and of an element, which is 0.60 m. wide. Since these elements have an incorporated curb and the panels are 1.20 m. wide, the joints of the panels will not correspond with the joints of the slab elements and therefore the continuity of the vertical lines is interrupted when you compose the slab. The elements of the slab can therefore have either incorporated curbs or only the reinforcements corresponding to the curbs which can in this case be made at site. The length can change according to the design with e 4 to 6 meters span if with only one span. If it has two spans the first span will be 5 to 6 meters and the second span from 4 to 5 meters.

[0032] In the section it shows 6 plastic pipes with a diameter of 120 - 140 mm or thin steel pipes with a diameter of 120 mm. They allow the passage of household ducts and of air conditioning ducts if required. Longitudinally it has male-female profiles, FIG.36, made of 2 - 2.5 mm steel sheet metal that allows the elements to be placed very closely. They will then be consolidated by intermittent welds which are 5 cm long and at 40 - 50 cm. from one another.

[0033] The longitudinal reinforcements made with steel rods with a diameter of 8, 10 mm, will be made according to the span and the capacity and will be consolidated one to the other by means of perpendicular bracketings.

[0034] These elements have 6 more holes on the longitudinal side with pipes to allow the passage of the 20 to 24 mm steel tie rods. The extremities of the tie rods are threaded so as to allow the use of long nuts to compact the elements. These tie rods strengthen the slabs and cooperate in the distribution of the loads. Also the joint profiles FIG.36 cooperate in the distribution of the loads. Any type of floor, to be anchored using products available on the market, can be installed on the slab surface.

[0035] Beneath the slab, the profiles FIG.36 are not visible because their lower wing is buried in mix to facilitate the plastering. The elements can be already plastered and only the stuccoing of the ceiling will be required in this case.

THE COVERING

[0036] The covering can be of the terrace- or roof-type. If the design foresees a terrace type of covering, the same slabs will be used with insulating layers, waterproof mantles, slab leveling layer with normal slope if required, to be installed at site and which must be suitable for the installation of elements that can be stepped on.

[0037] Two elements have been studied for a roof type of covering: FIG.77 and FIG.78 with sloping planes already equipped with insulation and tiles of any type being careful that mobile elements can be positioned in the joints between the elements: these mobile elements will be fixed, at the site, above the tiles near the joints. A waterproof and elastic rubber cement will be put between one element and the other: this rubber cement must not be damaged by temperature variation.

[0038] These elements also bear the holes of the passage of the tie rods.

STAIRS

[0039] Also the stairs with or without elevator are inserted in the system in the view of total prefabrication. This prefabricated system foresees two- and three-flight stairs with or without elevator shaft depending on the height of the building, and two-flight stairs with gallery and elevator if there are 4 apartments per storey (floor). The stairs form an integral part of the system. The two-flight stairs per floor, illustrated in the FIG.41 plan, is composed of one element with incorporated steps and landing for the first flight FIG.42 (Plan) FIG.44 (Longitudinal section),FIG.51 (Cross section), of one element without steps for first flight FIG.43 (Plan) FIG.45 (Longitudinal section), FIG.52 (Cross section), of one element with incorporated steps and landing for the second flight FIG.46 (Plan) FIG.48 (Longitudinal section),FIG.53 (Cross section), and of one element without steps for second flight FIG.47(Plan),FIG.49 (Longitudinal section),FIG.54 (Cross section). The elements with steps and the adjacent ones without steps are consolidated by tie rods that also consolidate the landings of the following flights, i.e. the top landing of the first flight will be consolidated with the bottom landing of the second flight.

[0040] The third flight FIG.55, has a bottom landing to be consolidated with the top landing of the second flight and a top landing to be consolidated with the bottom landing of the fourth landing FIG.57. FIG.50 shows the longitudinal section of two-flight stairs in a three-storey building.

THREE-FLIGHT STAIRS

[0041] The three-flight stairs with elevator shaft are composed of one element FIG.61 with first, second and third flight and intermediate landings, of element FIG.62 without steps and landings on the ground and first floors. These two elements are consolidated one with the other by means of tie rods which pass through flanged pipes. The last step of the third flight is housed in the seat of landing in FIG.62 where the seat for the first step of the fourth flight is also located. The element FIG.68 (cross section) with fourth, fifth and sixth flight with intermediate landings and following flights, element FIG.70 without steps with landing for the second floor and following.

[0042] This type of stairs is arranged with an elevator pit which is composed of two elements that are the subgrade FIG.65 and the concrete pit element FIG.67

Claims

1. System of prefabricated elements for the construction of buildings, characterized by a vertical structure composed of panels made of structural light cement which in turn is made of expanded clay, high resistance cement and sand in the right proportions.

2. System of prefabricated elements as per claim no. 1, characterized by panels having groove-and-tongue joints, female-female dap joints, male-male dap joints, all slightly trapezoidal

3. System of prefabricated elements as per claim nos. 1 and 2, characterized by the fact that the upper part of the panels is equipped with a border which is required in order to cover the incorporated or made at site curb.

4. System of prefabricated elements as per claim nos. 1, 2, 3 characterized by the fact that there are three panels, with seatings for lintel, for making the window. One panel has the seating to the right, one to the left while the third panel has a seating to the right and one to the left.

5. System of prefabricated elements as per claim nos. 1, 2, 3, 4 characterized by the fact of having panels with the seating for WP and systems piping that can be easily inspected.

6. System of prefabricated elements as per claim nos. 1, 2, 3, 4, 5 characterized by the fact of having three different types of panels for making wall knot. The panels are the following: angular panel, T panel and cross panel.

7. System of prefabricated elements as per claim nos. 1, 2, 3, 4, 5, 6, characterized by the fact that all of the elements (panels, window sills, lintels) have flanged pipes buried into them which are needed for the passage of the tie rods that consolidate the panels.

8. System of prefabricated elements as per claim nos. 1, 2, 3, 4, 5, 6, 7 characterized by the fact that the slab (horizontal structure) is composed of elements having one or two spans. The slab has the following characteristics: it is made of structural light mix as the panels; it has PVC or thin steel sheet metal pipes buried into it; it has male and female longitudinal metal profiles which can be put close together and welded; it has a reinforcement that varies according to the load.

9. System of prefabricated elements as per claim nos. 1, 2, 3, 4, 5, 6, 7, 8, characterized by the fact that the elements of the slab can have an incorporated curb.

10. System of prefabricated elements as per claim nos. 1, 2, 3, 4, 5, 6, 7, 8, 9, characterized by the fact of having a two-flight stair composed of 4 elements, two with incorporated steps and two without steps, for the ground floor and 4 elements, two with incorporated steps and two without steps, for the first and following floors.

11. System of prefabricated elements as per claim nos. 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, characterized by the fact that three-flight stairs with elevator shaft are used for prefabricated buildings with three or more storeys. These stairs are composed of 4 elements: one with three flights on the ground floor; one with landing; one with three flights from the first floor and following floors; one with only one landing from the first floor and following floors.

12. System of prefabricated elements as per claim nos. 1, 2, 3, 4, 5, 6, 7, 8, 9, 10 11, characterized by the fact of having sloping pitch covering elements which are already equipped with insulation and elements such as tiles of any type.

13. System of prefabricated elements as per claim nos. 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, characterized by the fact that the covering elements have flanged steel pipes for the passage of tie rods buried into them crosswise.

14. System of prefabricated elements as per claim nos. 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, characterized by the fact that the panels can be surface finished in any way (baked bricks or different type, mosaic finish, plastering, etc.) before installation.

15. System of prefabricated elements as per claim nos. 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13,14, characterized by the fact of having linear, angular, T-shaped and cross-shaped foundation elements which can be coupled with one another by means of a coupling profile with rectangular section.

16. System of prefabricated elements as per claim nos. 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, characterized by the fact that the foundation elements have 8 steel pipes buried into them for the passage of the tie rods needed for consolidating the foundation elements.

Drawing