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(11) | EP 1 065 324 A2 |
| (12) | EUROPEAN PATENT APPLICATION |
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| (54) | Prefabricated modular structure |
| (57) "PREFABRICATED MODULAR STRUCTURE", applicable to the building of construction units such as wall and mezzanine structures,
characterised by the wall structure being constituted on a foundation of balsa, with
lintel beams running throughout each wall, with anchors placed at equal distances
formed by a "U" shaped profile, to house electronically welded reinforcing bars, on
whose base a core of expanded polystyrene panels is prepared with a coping on its
lateral faces that form polygonal openings and crossing these panels are the support
profiles of an interior finishing plate, also providing an exterior mesh and fixing
for a concrete coat that completely fills the constricted openings; the mezzanine
structure has a concrete coat projected on a steel mesh, fixed on the polygonal openings,
and is provided with an electronically welded reinforcing bar and providing these
panels rectangular recesses of inclined wall, for the insertion of a prefabricated
concrete slab and reinforcement profiles. |
DESCRIPTION OF THE INVENTION
[0001] The objective of this invention, as expressed in the statement to this descriptive report, relates to a "PREFABRICATED MODULAR STRUCTURE", applicable to the production of both vertical construction units such as walls (supports and partitions) and horizontal or inclined units such as mezzanines, covered inclines, stairs, etc. of the type used in the construction of housing and other buildings.
[0002] Currently, construction projects relating to housing or similar buildings use metallic forms for the construction of heavy columns and panels covered in concrete on both faces, with this process being undertaken as a part of the project work.
[0003] For this, specialised labour is required that raises the final cost of the construction as well as the complexity of the labour teams involved.
[0004] The new prefabricated modular structure provides panels that are more flexible compared to the traditional heavy manufactured panels.
[0005] In addition, it can be easily adapted to the architectural demands of different projects, allowing any shape to be prepared including flat, curved or covered panels, up to four storeys in height.
[0006] It provides for optimal on-site construction, allowing for openings and different grooves for hydraulic, sanitary and electrical connections or any other hollow dimensions for doors and/or windows.
[0007] Once in place, concrete is applied to it, thus securing the jointing seams of the steel meshes to achieve a monolithic structure, with many advantages in terms of the speed and quality of the work.
[0008] With respect to the standard weight of the prefabricated structure, the panels with a variable weight of between 4 and 10 kg/m2, remain light until put into place, where the concrete is applied to it, which fulfils the aesthetic needs of the works. This characteristic ensures easy movement of the panels in all phases of construction up to the point at which they are put into place, which can be done directly by the person assigned, without the need for other tradesmen.
[0009] The setting of these innovative panels and their finish on-site with the application of structural concrete requires straightforward alignment and shoring teams; modest working teams with staff who are not specialised for the tasks in hand. For example, the application of the concrete on the external surface of the panels can be done directly by spraying mortar from a portable cement maker using a normal air compressor.
[0010] The typology of the panels, the distribution of the steel threads and the supplementary profile sections in expanded polystyrene allow, in a superior way to other similar methods, the optimisation of the use of structural components such as steel and concrete, as well as the correct use of the space concerned.
[0011] The structure of a building constructed with these innovative panels is monolithic in comparison with traditional structures.
[0012] The structural continuity between the horizontal and vertical surface elements that define the space available, is secured by meshes and reinforcements successively amassed in the concrete applied in the termination phase. Such characteristics offer notable advantages in terms of resistance in the behaviour of the structural joints in the event of conditions such as seismic torsional forces.
[0013] The monolithic feature can be without doubt, as well as the general thermal insulation of the building, free of thermal bridges for continuous insulation, a part of all of the surfaces in contact with the exterior.
[0014] The new panel provides a continuous structure with a more rational distribution of the long vertical loads, the support perimeter and with a notable cost advantage, in particular in the case of single plane buildings.
[0015] The construction of the components that comprise the new panel is simplified, using contemporary methods, with the structural function of the thermal insulation.
[0016] The polystyrene panel can be measured accurately, in terms of its thickness and density in order to ensure that the building is comfortable in different climatic conditions.
[0017] The new prefabricated modular structure is available in a wall or mezzanine structure. In the case of a wall, it is available with a foundation of balsa, measured for each particular case, with lintel beams running throughout each wall, and anchors of corrugated steel fixed at equal distances in a "U" shape, to house the electronically welded reinforcing bars, formed by two long beams with transversal components in the form of a zigzag.
[0018] On this transversal base there is a core of expanded polystyrene panels placed consecutively on their sides, which provide a coping to form a constricted opening.
[0020] Crossing these polystyrene panels, are some reinforcement "J" profiles in galvanised steel, that carry out the function of supporting an interior wall finishing plate and for levelling and ensuring that the walls are vertical.
[0021] It also has a mesh of galvanised steel in the form of slightly rectangular grid squares that cover the exterior of the panels and serve as a setting for a concrete coat projected on the exterior surface.
[0022] In the case of a mezzanine structure, a concrete coat, projected on a mesh of galvanised steel, is provided, which is fixed on the polygonal recesses of the polystyrene panels. An electronically welded steel reinforcing bar with two long beams and transversal units in the form of a zigzag is also provided.
[0023] These panels, of a thickness slightly greater than the wall panels, provide on their upper part rectangular recesses for the insertion of a reinforced prefabricated cement slab, as well as reinforcement "J" profiles in galvanised steel that serve as a support for the upper termination plate and for their own reinforcement.
[0024] On an optional basis, a vapour barrier is also available on the polystyrene panels, using products that are compatible with the surface of the polystyrene plate.
[0025] The objective of the new prefabricated modular structure is to improve the existing system of construction, providing an optimal solution for the structural demands and home comforts, with economical advantages in the construction of housing.
[0026] The contribution of the insulating capability to energy savings is notable, when the climatic conditions require buildings with heating installations and/or installations suitable for other climatic conditions.
[0027] The fundamental concept is the construction of prefabricated modular structures for specific projects, with only the projected concrete being applied on site, thus including all of the advantages of this form of construction, such as: combination of structural solutions, acoustic and thermal insulation, speed in the execution of the project, general lightness of the building, easy manual assembly, dispensing with the need for hauling teams or heavy transportation.
[0029] As it is carried out right away, the exterior finishing is superior to any other prefabricated system.
DESCRIPTION OF THE DRAWINGS
[0030] In order to illustrate what we have explained so far, this descriptive report is accompanied by a page of drawings, which form an integral part of this report, in which a simplified and schematic representation of an example is provided which is intended to be illustrative only and does not limit the practical possibilities of the innovation.
In these drawings, figure 1 represents an isometric view of the detail of the joining of the innovative structure with the basic foundation.
Figure 2 shows a view of the appearance of the wall structure.
Figure 3 shows the finish of the front face of the flexible modular panel.
Figure 4 represents an isometric view in detail of the joining of the diaphragm panel with the slab and the closure in the case of the mezzanine structure.
Figure 5 represents a view of the appearance of the mezzanine panel joined to the upper concrete slab.
Figure 6 provides a view of the closure on the integral wall to the prefabricated slab.
DESCRIPTION OF A PRACTICAL CASE
[0031] The new prefabricated modular structure is available for a wall or mezzanine. In the case of a wall, it is provided on a foundation of balsa, measured for each particular case, with lintel beams (1) running throughout each wall where anchors of corrugated steel are positioned at equal distances in a "U shape, to hold electronically welded reinforcing bars, formed by two long beams with transversal elements in the form of a zigzag (2).
[0032] On this base, there is a core of expanded polystyrene panels (3) placed consecutively on their sides, which provide a coping to form a constricted opening (4).
[0033] In addition, on the upper face, polygonal recesses are provided for the perfect fit of the panels.
[0034] Crossing these polystyrene panels, are reinforcement "J" profiles (5) in galvanised steel, that perform the function of supporting the interior wall finishing plate (6).
[0035] It also has a mesh of galvanised steel in the form of slightly rectangular grid squares (7) that cover the exterior of the panels and serve as a setting for a concrete coat (8) projected on the exterior surface which completely fills the constricted openings (4) of the panels (3).
[0036] In the case of the mezzanine structure, there is a concrete coat (8) projected on the mesh of galvanised steel (7), which is fixed on the polygonal openings (4) of the polystyrene panels (3). An electronically welded steel reinforcing bar with two long beams and transversal elements in the form of a zigzag is also provided.
[0037] These panels, of a thickness slightly greater than the wall panels, provide rectangular recesses (4) in the joining area, of its upper part, for the insertion of a reinforced prefabricated cement slab (9), as well as reinforcement "J" profiles (5) in galvanised steel that serve as a support for both the upper finishing plate and their own reinforcement and reinforcement grids of galvanised steel.
[0038] On an optional basis, a vapour barrier is available on the polystyrene panels, through the use of products that are compatible with the surface of the panel.
[0039] Having described the idea to which this report refers, it is necessary to emphasise that the details for putting the stated idea into practice may be subject to slight alterations, which will always be based on the fundamental principles of the idea, which are in essence those that are reflected in the paragraphs of the report.
[0040] In effect, the current Law of Patents establishes that changes in the form, dimensions, proportions and materials of an object already patented, cannot be patented, therefore establishing the criteria of the legislator which ensures that once an idea, which may give rise to a practical reality that may be industrialised, is patented, nobody shall, by introducing slight modifications, present it as a new and original idea.
[0041] On the basis of the above concept, vindication is drafted in the following note, thus establishing the innovations that may be vindicated:
NOTE
1. "PREFABRICATED MODULAR STRUCTURE", applicable to the production of both vertical construction units such as walls (supports
and partitions) and horizontal or inclined units such as mezzanines, covered inclines,
stairs, etc. of the type used in the construction of housing and other buildings,
essentially characterised by their conformation as a wall or mezzanine structure,
the wall structure being prepared, on a foundation of balsa, measured for each individual
case, with lintel beams (1) running along each wall, with anchors of corrugated steel
at equal distances in a "U" shape, to house electronically welded reinforcing bars,
formed by two long beams with transversal elements in the form of a zigzag (2), and
on this base there is a core of expanded polystyrene panels (3) placed consecutively
on their lateral faces, which provide a coping to form a constricted opening (4),
enabling its upper face to provide polygonal recesses for the perfect fit of the panels
and crossing these polystyrene panels, are reinforcement "J" profiles (5) in galvanised
steel supporting an interior wall termination plate (6) and for levelling and supporting
the verticality of the walls, also providing, a mesh of galvanised steel in the form
of slightly rectangular grid squares (7) that cover the panels for the exterior setting
of a concrete coat (8) which completely fills the constricted openings (4) of the
panels (3).
2. "PREFABRICATED MODULAR STRUCTURE", according to the above claim, characterised, in the case of the mezzanine structure,
by the provision of a concrete coat (8) projected on a mesh of galvanised steel (7),
which is fixed on the polygonal openings (4) of the polystyrene panels (3), being
provided also with an electronically welded steel reinforcing bar with two long beams
and transversal elements in the shape of a zigzag and such panels (3), which are slightly
heavier than the wall panels, providing in the joining area on the upper part, rectangular
recesses (4) of slightly inclined side panels, for the insertion of a reinforced prefabricated
cement slab (9), as well as reinforcement "J" profiles (5) in galvanised steel.
3. "PREFABRICATED MODULAR STRUCTURE", according to the above claims, characterised by the option of a vapour barrier on
the polystyrene panel through the use of products that are compatible with the surface
of the panel.