|
(11) | EP 4 074 908 A1 |
| (12) | EUROPEAN PATENT APPLICATION |
|
|
|
|
||||||||||||||||||||||||
| (54) | CONSTRUCTION SYSTEM AND METHOD FOR PUTTING SAME INTO PRACTICE |
| (57) The invention consists of a construction system for building homes and the like wherein
the elements involved in the system exhibit a high degree of industrialization, allowing
homes to be built in a shorter time, reducing time frames and waste generation, increasing
safety and having optimum finishing. To that end, the system involves a series of
prefabricated elements such as prefabricated columns (1), prestressed beams (2), precast
slabs (3), prefabricated walls (4) with plumbing and raceway systems (14), prefabricated
façades (5), roof parapets (6), PVC joinery (7), glass panels (8), plasterboards,
prefabricated home electrical panels (9), prefabricated chimneys (11), prefabricated
bathrooms (12), as well as prefabricated balconies (13).
|
TECHNICAL FIELD
[0001] The present invention relates to a construction system for building homes and the like wherein the elements involved in the system exhibit a high degree of industrialization, which allows obtaining benefits in terms of time frame, sustainability, safety, and labor integration.
[0003] As a guideline, the system of the invention, previously industrialized elements involved in the system entail a value of the order of 64.8% of the total budget of the construction, with the subsequent cost reduction therein.
BACKGROUND OF THE INVENTION
[0004] As is known, when constructing buildings, the expected time frames are usually very long, where delays due to unforeseen circumstances are relatively frequent, very negatively affecting both building times and construction costs.
[0005] In order to avoid these problems, modular homes are known which, although drastically reduce the building times as well as the costs associated therewith, are very specific structures that are, accordingly, not very versatile.
DESCRIPTION OF THE INVENTION
[0006] The construction system that is recommended solves the aforementioned problems in a completely satisfactory manner, based on a simple but effective solution.
[0007] To that end, and more specifically, the system of the invention involves a series of industrialized elements which allow drastically reducing construction times, with the consequent and beneficial repercussion that this entails.
[0008] More specifically, the elements involved in the construction system are the following:
- Prefabricated columns.
- Prestressed beams.
- Precast slabs.
- Prefabricated walls.
- Prefabricated façades.
- Roof parapets.
- PVC joinery.
- Glass panels.
- Plasterboards on profiles.
- Installations.
- Home electrical panel.
- Metal baseboard.
- Coping.
- Chimneys.
- Prefabricated bathrooms.
- Covering for wet areas.
- Vinyl flooring.
- Prefabricated balconies.
[0009] The prefabricated columns are obtained in reinforced concrete of variable cross section connected to footing by means of an injected steel casing. The columns have a smooth finish and are painted in the color of choice.
[0010] The prestressed beams constitute prefabricated T-shape type prestressed concrete elements, with connections and support apparatus with columns included. Like the columns, they have a smooth finish and are painted in the color of choice.
[0011] The precast slabs consist of 25+5 precast top slabs with lightened polystyrene filler blocks, formed by a prefabricated reinforced concrete plate, top slab tensile reinforcements and ties. They are characterized by quick placement and concreting.
[0012] In terms of prefabricated walls, they will be self-supporting, have a variable thickness with B500S steel reinforcement and a smooth finish, and they will be painted in the color of choice. This type of wall is placed both in garages as containment, as well as in stairwells and communication centers.
[0013] In turn, the prefabricated façades will be made up of an outer bearing wall with a 5 cm thick visible concrete finish, a continuous rigid XPS insulation in the intermediate layer, and a 15 cm inner structure layer of concrete with inner plasterboard paneling on profiles and rock wool.
[0014] The roof parapets consist of concrete walls prefabricated for parapets, whereby brick placement is spared and a greater structural stability is obtained.
[0016] The glass panels have a double glazing formed by a colorless glass panel having a thickness according to the project and a second glass panel having a thickness according to the project and the dehydrated air chamber has a variable thickness with double perimeter sealing and aluminum separator profile.
[0018] With respect to the installations, the prefabricated walls internally include the installations of plumbing and raceway system.
[0019] The home electrical panels are partially assembled in factory with the entire switchgear provided only for connecting the points. It is supplied in a ready-for-placement plasterboard structure.
[0020] As mentioned above, another one of the prefabricated constructive elements is the metal baseboard, which will be hung on the metal profile acting as a slate sheet finishing profile in urbanization.
[0021] The use of metal copings with concealed mechanical fixing system has been envisaged in urbanization and parapets. The system circumvents silicone seals by having waterproof neoprene strips under the attachment, making the coping completely water-tight, avoiding maintenance of any type.
[0022] In turn, the chimneys are completely assembled from factory with a concealed structure for a quick and waste-free assembly. An inner metal fitting structure intended for that purpose is made.
[0023] In terms of the bathrooms, they will also be prefabricated, with an enveloping system of concealed metal structure and direct plasterboards with insulation to be left prepared on site so as to not open until delivery, leaving the installation points to be connected.
[0024] The covering for wet areas consists of a composite system received with high moisture-resistant glue for placement in kitchen and shower stall fronts. A cleaner, completely water-tight finish that does not generate tiling waste is achieved. This covering can have the desired design or drawing because a photograph is submitted and printed to the desired size.
[0025] A system for setting up a compression layer by means of directly polishing the finish to place the vinyl flooring on top has also been envisaged. This flooring is changed slat by slat without having to lift long wythes. With this mixed system, the implementation of mortar screed is spared, avoiding a large amount of waste.
[0026] Lastly, the involvement of prefabricated balconies is envisaged in the construction system, said balconies having metal fittings completely finished in factory including the outdoor wooden flooring with a water collection tray and connected by means of mechanical anchoring to the metal structure of the top slab.
[0027] Based on this structure, the construction method starts with setting up different on-site auxiliary installations and resources for the workers.
[0028] After the corresponding phase of moving the earth, the foundation and containment are set up by means of using the prefabricated concrete walls described above, which significantly reduces operating times.
[0029] Next, the underground sewage network is made by making the corresponding trenches and making bases and beddings for assembling the pipes and accessories associated therewith.
[0030] In terms of the below-ground structure, the prefabricated columns and beams described above are set up, such that once they are placed and before supporting horizontal elements thereon, a gravel paving process is performed to subsequently make the floor slab.
[0031] Top slabs, on which the corresponding compression layer is applied, are obtained in a quick and simple manner from the precast slabs described above.
[0032] In terms of making the stairs, this is done while climbing up the structure. It is made up of a prefabricated concrete box in which the stairs are supported on brackets by simply supporting them on top of one another.
[0033] As mentioned above, the façades are formed in a quick and simple manner by means of mechanical anchoring systems based on the prefabricated façades envisaged in the system, including therein the PVC joinery as well as the glass panels described above, thereby obtaining a fully finished and water-tight façade.
[0034] After placing the walls, the top slabs will be placed and the compression layer made, with the described operation being repeated until the desired height of the building is obtained.
[0035] In a subsequent phase, the prefabricated bathrooms are installed, and inner partitioning and installation connection are set out, all of which taking a much shorter operating time as a result of the prefabricated nature of most of the elements involved in the system.
[0036] Following the construction process set forth in the description, once reaching the last top slab, the roof must be tackled as soon as possible so as to make the building completely water-tight, with there being two different types of roofs to be obtained; trafficable and non-trafficable roofs.
[0037] In parallel, and in the cases in which it is envisaged, the prefabricated chimneys will be installed in this phase.
[0038] In parallel, vertical coverings will be applied, false ceilings obtained, and surfaces painted.
[0039] Once this phase has ended, the wood joinery and metal fittings will be installed, to lastly proceed with the laying out of flooring.
[0040] Therefore, and as mentioned above, the construction time frames, as well as the waste generated during construction, are significantly reduced, increasing safety, sustainability, and labor integration.
DESCRIPTION OF THE DRAWINGS
[0041] As a complement to the description that will be provided herein, and for the purpose of helping to make the features of the invention more readily understandable, according to a preferred practical exemplary embodiment thereof, said description is accompanied by a set of drawings constituting an integral part thereof in which, by way of illustration and not limitation, the following is represented:
Figure 1 shows a perspective view of one of the columns involved in a construction system carried out according to the object of the present invention.
Figure 2 shows a perspective view of a prestressed beam involved in the construction system of the invention.
Figure 3 shows a perspective view of a precast slab involved in the construction system of the invention.
Figure 4 shows a perspective view of a prefabricated wall involved in the construction system of the invention.
Figure 5 shows a perspective view of a prefabricated façade involved in the construction system of the invention.
Figure 6 shows a perspective view of a roof parapet involved in the construction system of the invention.
Figure 7 shows a perspective view of a detail of the PVC joinery involved in the construction system of the invention.
Figure 8 shows a perspective view of the glass panels involved in the construction system of the invention.
Figure 9 shows a detail of the plumbing and raceway system installations included in factory inside the prefabricated walls.
Figure 10 shows a perspective view of the prefabricated home electrical panel involved in the construction system of the invention.
Figure 11 shows a perspective view of a metal coping involved in the construction system of the invention.
Figure 12 shows a perspective view of a prefabricated chimney involved in the construction system of the invention.
Figure 13 shows a perspective view of a prefabricated bathroom involved in the construction system of the invention.
Figure 14 shows a perspective view of a prefabricated balcony involved in the construction system of the invention.
PREFERRED EMBODIMENT OF THE INVENTION
[0042] In view of the mentioned figures, it can be seen how the following elements are involved in the construction system of the invention:
- Prefabricated columns (1).
- Prestressed beams (2).
- Precast slabs (3).
- Prefabricated walls (4).
- Prefabricated façades (5).
- Roof parapets (6).
- PVC joinery (7).
- Glass panels (8).
- Plasterboards.
- Installations.
- Home electrical panel (9).
- Metal baseboard.
- Coping (10).
- Chimneys (11).
- Prefabricated bathrooms (12).
- Covering for wet areas.
- Vinyl flooring.
- Prefabricated balconies (13).
[0043] The prefabricated columns (1) are obtained in reinforced concrete of variable cross section connected to footing by means of an injected steel casing. The columns have a smooth finish and are painted in the color of choice.
[0044] The prestressed beams (2) constitute prefabricated T-shape type prestressed concrete elements, with connections and support apparatus with columns (2') included. Like the columns, they have a smooth finish and are painted in the color of choice.
[0045] The precast slabs (3) consist of 25+5 precast top slabs with lightened polystyrene filler blocks (3'), formed by a prefabricated reinforced concrete plate, top slab tensile reinforcements, and ties. They are characterized by quick placement and concreting.
[0046] In terms of the prefabricated walls (4), they will be self-supporting, have a variable thickness with B500S steel reinforcement and a smooth finish, and they will be painted in the color of choice. This type of wall is placed both in garages as containment, as well as in stairwells and communication centers.
[0047] In turn, the prefabricated façades (5) will be made up of an outer bearing wall with a 5 cm thick visible concrete finish, a continuous rigid outer XPS insulation, and a 15 cm inner structure layer of concrete with inner plasterboard paneling.
[0048] The roof parapets (6) consist of concrete walls prefabricated for parapets, whereby brick placement is spared and a greater structural stability is obtained.
[0050] The glass panels (8) have a double glazing formed by a colorless glass panel having a thickness according to the project and a second glass panel having a thickness according to the project and the dehydrated air chamber has a variable thickness with double perimeter sealing and aluminum separator profile.
[0051] In terms of the plasterboards, not depicted in the figures as they are conventional, said plasterboards allow obtaining a 15 mm thick inner plasterboard paneling.
[0052] With respect to the installations, as shown in Figure 9, the prefabricated walls (4) internally include the installations of plumbing and raceway system (14).
[0053] In turn, the home electrical panels (9) are partially assembled in factory with the entire switchgear provided only for connecting the points. It is supplied in a ready-for-placement plasterboard structure.
[0054] As mentioned above, another one of the prefabricated constructive elements is the metal baseboard, which will be hung on the metal profile acting as a slate sheet finishing profile in urbanization.
[0055] The use of metal copings (10), like the one shown in Figure 11, with concealed mechanical fixing system, has been envisaged in urbanization and parapets. The system circumvents silicone seals by having waterproof neoprene strips under the attachment, making the coping completely water-tight, avoiding maintenance of any type.
[0056] In turn, the chimneys (11) are completely assembled from factory with a concealed structure for a quick and waste-free assembly. An inner metal fitting structure intended for that purpose is made.
[0057] In terms of the bathrooms (12), and as can be seen in Figure 13, they will also be prefabricated, with an enveloping system of concealed metal structure and direct plasterboards with insulation to be left prepared on site so as not to open until delivery, leaving the installation points to be connected.
[0058] The covering for wet areas consists of a composite system received with high moisture-resistant glue for placement in kitchen and shower stall fronts. A cleaner, completely water-tight finish that does not generate tiling waste is achieved. This covering can have the desired design or drawing because a photograph is submitted and printed to size.
[0059] A system for setting up a compression layer by means of directly polishing the finish to place the vinyl flooring on top has also been envisaged. This flooring is changed slat by slat without having to lift long wythes. With this mixed system, the implementation of mortar screed is spared, avoiding a large amount of waste.
[0060] Lastly, the involvement of prefabricated balconies (13) is envisaged in the construction system, said balconies having metal fittings completely finished in factory including the outdoor wooden flooring with a water collection tray and connected by means of mechanical anchoring to the metal structure of the top slab.
[0061] In terms of the construction process, for on-site set up, auxiliary installations and resources will be provided for the workers. To avoid blocking public roads or interfering with construction works, a space within the plot of land has been chosen. The free spaces between blocks and the urbanization area are thereby reserved for the interior circulation of vehicles and for stockpiling, in the future shared interior urbanization area of the houses.
[0062] The stockpiling area is distributed in two accessible spaces, together with an area intended as a rebar workshop. It has been determined that these locations do not obstruct works and crane access areas.
[0063] The installation of construction offices provided with water, light, telephone connection, as well as IT and auxiliary resources, is considered necessary for proper construction planning and execution.
[0064] Furthermore, to prevent impacts that may be generated in the surroundings during the operative phase of these installations, the following preventive measures must be applied:
[0065] Temporarily fencing the construction areas to be occupied, putting up signs to indicate same and the transit roads, so as not to affect lands not related to the construction.
[0066] The engines of the machinery and loading vehicles will be regulated so that they comply with the legislation in force in terms of the emission of gases to the atmosphere. Likewise, effective mufflers approved by the competent organizations will be provided and the machinery shall comply with Directives 86/622/EEC and 95/27/EC on the limitations of noise emitted by the public work machinery at all times.
[0067] Periodic watering of discharge accesses and areas to prevent the emission of particles and dust.
[0068] Services in terms of the needs for water, light, and telephone connections will be from nearby points. Furthermore, and for movement around the construction site, there will be a mobile telephone phone system for an uninterrupted faultless communication.
[0069] The availability of electric power and particularly water, required for the operation of the installations, will be assured either by providing the required services or by installing generators and a potable water tank of sufficient capacity.
[0070] There will also be a fully equipped first-aid kit. Occasional or emergency care will be provided through the different public and/or private medical services existing in the area.
[0071] The selected units or sheds, as well as the access path, will be conditioned for setting up the following general services.
- Office
- Canteen
- Warehouse
- Dressing rooms
- Toilets
[0072] The worker installations, toilets, dressing rooms, canteens, and first-aid kit, as well as offices, will be modular prefabricated ones and transported to the construction site in a truck in modules measuring 6.00x2.40 m. If space requirements exceed availability in the plot of land, the sheds will be placed vertically. These modules do not require any foundation where there are placed, such they are raised on concrete supports and/or rough brick masonry, allowing multiple combinations in the arrangement thereof.
[0073] The services required, as well as the suitable lighting and heating, will be provided in all of them taking into account, in any case, their temporary character.
[0074] The technical-administrative office will have a series of work places, with a work place being prepared for the construction management. In all cases, air conditioning and heating will be provided.
[0075] The dressing rooms and toilets will be provided with lockers and sinks, toilet pans, and showers, respectively. Likewise, electric heaters will be provided in the toilets. In the canteen, in addition to the suitable tables and chairs, food heating elements will be provided.
[0076] The first-aid kit or treatment room will have the elements required to perform first aid, there being hospitals and health centers in the area for serious cases.
[0077] Once the installation of all the spaces has ended, construction works will be set out. Once construction works have started, all the other envisaged installations will be assembled.
[0078] In terms of the auxiliary installations, a compressed air installation will be established while construction is going on as an auxiliary element for operations such as concrete vibration, fretting, demolitions, cleaning, etc.
[0079] An electric power installation will also be set up for supplying the electric power necessary for shed installation and site installations which will come from the area's mains connection.
[0080] In each structure site, in order to prevent possible current losses and to prevent a "critical" site from shutting down, a 150 kVA generator, sufficient for those activities which, in the event of unforeseen circumstances, can be performed by taking power supply from the existing installations, such as exhaustions, use of welding equipment, vibration generators, etc., will be provided.
[0081] Both the medium-voltage line and the low-voltage line will be installed and operated according to the rules and regulations in force and those others established for this case.
[0082] The lines will generally be laid overhead, with said lines being able to be laid underground in the cases in which it is required either due to the characteristics of the terrain or to special situations, such as parallelisms, crossings, etc.
[0083] There will be provided in the different sites and installations motor control centers or power and lighting distribution panels which will be suitably protected both mechanically and electrically according to the type of service they must provide, i.e., fixed, semi-fixed, and mobile.
[0084] Independently of the protection against accidental direct contacts inherent to the laid overhead or underground lines in each case, suitable protections against overvoltages, short-circuits, overcurrent, etc., will be installed and they will be completed with other defect countercurrents and grounding meshes, so as to ensure maximum worker safety and service continuity at all times.
[0085] For supplying water in the area of the installations, water will suitably be drawn from the area's water mains, with a pressure group being provided in each one to ensure a suitable pressure at the points of use.
[0086] A mobile telephony network will be provided to allow communications between the different areas of the construction site, as well as between the sites and main installations.
[0087] An indoor telephone exchange having the capacity for several extensions and simultaneous connections will be installed. This unit will be installed in the main office, from where all the external cabling will branch out to different areas of the installations, and will be installed with battery equipment automatically connecting the accumulators when the mains voltage fails, thereby allowing service continuity.
[0088] For laying the overhead telephone lines, "urban self-supported"-type cable or simply "plastic urban" cable will generally be used, as the case may be. These cables are made of a copper conductor with PVC insulation and forming telephone pairs. The telephone apparatus will be of the "table-top" or "wall-mounted" type, and will be installed directly or inside soundproof cabins, as the case may be.
[0089] There will also be water mains with suitably located outlets, said water mains will be installed in the area of the offices and general warehouses, as well as electromechanical and rebar workshops as means for extinguishing fires.
[0090] This water mains will be complemented with the corresponding manual extinguisher equipment located in visible and easily accessible places. These manual extinguishers may be "pressurized water", "chemical foam", "dry powder," or "carbon dioxide" extinguishers, depending on whether they are intended for extinguishing solid fuel fires that should not be affected by liquid foam, non-delicate solid fuels, combustible gases or flammable products and electrical equipment.
[0091] Likewise, lightning protection and storm proximity detection, consisting of lightning arresters and acoustic alarms, will be provided.
[0092] An electromechanical workshop with a work place for the workshop manager, a small storage room, and a separate exit for the electrical workshop, dressing rooms and toilets and the workshop itself, have also been envisaged next to the general installations.
[0093] A rebar workshop and a collection point which will help the operators in waste separation have also been envisaged.
[0094] The industrialized construction system reduces the need to perform works at height to a minimum due to its complete façade closure system.
[0095] Nevertheless, when the heights do not exceed 3-4 m, standardized fixed scaffolding with wheels will be used so as not to damage the flooring.
[0096] The movements of earth include clearing a 15 cm thick layer off the terrain and forming the void for making the basement and foundation. All earth moving works will be performed with mechanical means and excess earth will be brought to an authorized landfill.
[0097] In terms of the foundation and containment phase, prefabricated concrete walls will be used therein, such that the ground containment system is formed by the basement wall or the semi-prefabricated reinforced concrete containment wall made up of two parallel, 6 cm HA-25 concrete slabs and B-500-S steel therein.
[0098] The thickness of the wall is 30 cm and the height according to project plans, with vertical chamfered joints every 2.40 m or 1.20 m.
[0099] The phases of making the reinforced concrete containment walls are related to the following:
- 1) Excavating the grounds for the foundation: continuous or by foundation trenches (two-sided or single-sided walls).
- 2) Pouring blinding concrete on the support base of the wall
- 3) Calculating the footing of the wall and making same in the conventional way such that the metal feet or protruding rebars of the wall are introduced in the prefabricated sandwich.
- 4) Placing the prefabricated wall. The resistant steel of the wall elevation is incorporated in the prefabricated wall, so it is not necessary to place any rebar during construction, only filler concrete.
- 5) Pouring concrete into the wall.
[0100] Each panel is assembled independently from the rest, where 4 wooden wedges and a so-called double-effect post are necessary. No formwork is necessary and only one post per panel is required.
[0101] To assure that those walls are completely water-tight, they will be made with a PVC strip between different concreted parts.
[0102] The time it takes to make a conventional 6 m tall and 15 m long wall is 3 days since it involves the use of an over-scaffolding for making the second height of the wall. This wall system allows a 3 m high and 20 m long wall to be completed in a single day.
[0103] In terms of the foundation, this will be superficial, by means of insulated HA-25 reinforced concrete footings with steel casings for prefabricated columns.
[0104] In terms of the underground sewage network, for the installation of the tubes in the trench, several reference points are first fixed by means of stakes, nails, or any other method. Based on these points, the shaft of the pipe is placed at the bottom of the trench. It may also be suitable to set the pipe out directly at the bottom of the trench. After this, the trench is made, paying attention to the slopes. This will be made by means of a backhoe, transporting excess earth to a landfill with a three-axle truck.
[0105] If the presence of water is detected during emptying, a fishbone-type drainage network will be made.
[0107] The entire drainage system will be supplied by the same manufacturer who has developed all the elements. The watertightness thereof is thereby assured.
[0108] Finally, before making the floor slab, cleaning will be performed while inspecting with cameras so that any blockage can be dealt with in a quick and simple manner.
[0110] With the drainage system already made and the foundation finished, the gravel paving process begins. This process is extremely important and requires good manual compaction thereof to be performed. This is because the final floor slab will be arranged on this support base.
[0111] Since it does not require any posts, the system allows making the floor slab "in one go" with fewer problems; furthermore, it will allow starting works in the basement immediately without waiting for the time periods needed for the top slabs, the floor slab base, and the finishing layer to set, as well as for posts to be removed.
[0112] Once the verticality of the vertical elements is ensured, prefabricated T-shaped beams will be placed.
[0113] The top slabs chosen for the project are joist slabs and pre-cast slabs with lightened polystyrene filler blocks.
[0114] This top slab is placed in a quick and simple manner because it is allowed to fall on the supports at the ends and is ready for the placement of the rebar.
[0115] The compression layer for this top slab is envisaged with a thickness of 5 cm and is made without polishing unlike the top slabs for housing.
[0116] Having top slabs with prefabricated elements, joist slabs, or pre-cast slabs allows vertical construction to be performed, moving forward with the upper floors, and allowing gradually finishing the garage as posts are not needed.
[0118] The stairs are made while climbing up the structure. It is made up of a prefabricated concrete box in which the stairs are supported on brackets by simply supporting them on top of one another.
[0119] It is a quick process which assures that the workers will be safe on site since they do not have to walk on platforms.
[0120] The handrail is placed as the stair is made and lastly it is painted before delivery. The complete safety of the stair is therefore assured.
[0121] In terms of the above-ground structure, the structural system is based on load-bearing walls (where the top slabs and semi-load bearing walls rest, supporting the weight thereof and furthermore performing transverse bracing functions and other functions completing the structural scheme as a whole.
[0122] Said walls will be installed naturally, being supported on one another and using mechanical anchoring systems for this purpose.
[0123] Some walls are intended for separating houses or interior spaces and other walls furthermore constitute the façade in line with their structural function.
[0124] The walls contain:
- Incorporated laminated gypsum board.
- Façade insulation.
- Installations built into walls.
- Installed doors and windows (PCV joinery).
- Glass panels.
[0125] The advantage of this system is that the façade elements and party walls, i.e., the entire structure and enclosure of the construction, can be made in factory, regardless of the weather condition.
[0127] In this sense, fully finished façade walls will be placed, party walls will be placed between houses, and lastly the top slab will be placed on the walls.
[0128] The walls are attached by means of mechanical systems, dispensing with liquid elements which make the construction thereof slower and messier, with the attachment being an attachment that reduces waste and speeds up the process.
[0129] The construction is carried out with tower cranes which allow said construction to be performed without having to occupy roads as a result of requiring mobile cranes.
[0130] After placing the walls, the top slabs are placed and the compression layer which, in this case is semi-polished, is made without requiring screed mortar.
[0132] Once the ceiling panels of the houses are placed and the compression layer concreted, certain activities such as the setting out of partitioning, inner partitioning (that did not come together with the walls) and the connection of installations can then be performed, with the rest of the activities also being carried out.
[0133] In terms of the roofs, two different roofs can be obtained, i.e., trafficable roofs and non-trafficable roofs.
[0134] The sheet considered for both roofs is of a state-of-the-art, synthetic, non-adherent TPO type.
[0135] It is placed with heaters or automated machines which, depending on the room temperature and the degree of humidity, apply the suitable temperature on the waterproofing overlaps. The reason is to prevent degradation due to overheating and to ensure that it does not lack heat for an optimal welding.
[0136] In the case of a non-trafficable roof (except for maintenance activities), the order of the non-trafficable roof is as follows:
- 1. Slopes
- 2. Geotextile
- 3. Waterproofing sheet
- 4. Geotextile
- 5. 14 cm XPS
- 6. Geotextile
- 7. 5 cm gravel
[0137] The order of the trafficable roof is as follows:
- 1. Slopes
- 2. Geotextile
- 3. Waterproofing
- 4. Geotextile
- 5. Mortar protective layer
- 6. Flooring
[0138] The synthetic TPO sheet system used has the particularity that there is placed at the lower part of the parapets a distribution bar which causes strains to be distributed without creating localized stresses on the sheets, which could be a problem in the future.
[0139] In terms of the divisions, they may be below or above ground depending on the area in which they are located.
[0140] If they are below-ground, one of the premises of the industrialized system is the elimination of the large format with gypsum, which usually causes a lot of cracking problems during construction. Thus, a 20 cm exposed concrete block is proposed in the sectorization areas and a 10 cm block in the storage room divisions. This block is placed like the exposed brick and has a very good finish.
[0141] In the case of above-ground divisions, it must be indicated that 30% of the partitioning are made in factory, since the entire facade paneling, as well as the housing divisions that are made up of a structural wall, already have the laminated gypsum board installed in factory.
[0142] The laminated gypsum board partitioning work is started by the officer who sets out the site, beginning with the assembly of the supporting structure, with the placement of the horizontal lower and upper channels, as appropriate, to then proceed with the vertical pillars placed every 40 or 60 cm and inserted into these channels. The door pre-frames will also be placed therewith.
[0143] From this point on, in the case of partitions, the first plate will be screwed on one of the faces thereof followed by the second plate in a staggered manner.
[0144] The installers will pass all the raceway systems and lines that will be housed therein, and once this is done this end will be closed on the other face with the assembly of the two corresponding plates. Finally, with an adhered tape covering the joint and a special paste, the joints will be sealed and all the nuts and bolts covered.
[0145] In the case of stairs, vertical sandwich panels which provide a cleaner finish than the conventional rough brick with painted gypsum, will be used.
[0146] For the assembly of this panel that has been described, a metal fitting substructure, which will be assembled in factory and must simply be inserted during the structural phase through the opening intended as the air well, is required.
[0147] The sandwich panel base is then placed so that the panels serving as a support when erecting the installations can be placed.
[0148] Once all the installations are in place, the closure panels with their registers are placed in compliance with the regulation.
[0149] In parallel, a vertical enclosure of the open stairwell formed by a sandwich panel 35 mm thick and 1100 mm wide has been envisaged, formed by two smooth galvanized steel sheet walls with an external thickness of 0.5 mm and an internal thickness of 0.5 mm, and an insulating polyurethane core having a mean density 40 kg/m3, with a concealed fastening system.
[0150] With respect to the vertical coverings, they are divided into below-ground and above-ground coverings.
[0151] In the case of below-ground coverings, the uncovered, exposed block solution provides a better termination by eliminating works implying the same element.
[0152] In the case of above-ground coverings, a paneling system for showers and kitchens with a gluing treatment and a composite-like sheet that is completely waterproof and offers the best performance is chosen. This finish will be placed at the end of the work as if it were the furniture, so that it will be used for the first time when the owner moves in.
[0153] The operation is as follows:
Placement of the composite paneling covering:
- 1. Cleaning the plasterboard support
- 2. Applying a special glue according to the manufacturer's indications
- 3. Placing the already measured and previously machined panel
- 4. Placing finishing elements at the ends and corners
- 5. Sealing joints between the shower plate and corners.
[0154] The false ceilings both in homes and in common areas are 13 mm plasterboards with insulation in bathrooms, kitchens, and areas required by the project.
[0155] The following types of false ceiling will be placed:
- For homes: laminated gypsum board false ceiling and vinyl drop ceiling
- For common areas: smooth false ceiling with riser, soundproof acoustic false ceiling, continuous false plaster ceiling.
[0156] As a condition for its assembly, all the installations running through the interior thereof must have been carried out so as to avoid subsequent breakages that may affect the construction process, and the laminated gypsum paneling and partitions must have been made.
[0157] This is made prior to the flooring so as to prevent the flooring from being damaged as a result of the movement of the scaffolding, even if they have wheels, and of the materials and tools possibly falling.
[0158] In terms of the construction process, in the continuous false ceiling, the steps to be followed will be similar to the laminated gypsum partitions and paneling, since the same systems are used, but in a horizontal position.
[0159] The envisaged heights will be marked on the walls with laser levels. The perimeter profiles will then be placed. After that, the main and secondary profiles will be placed. The boards will be screwed and the joints sealed as explained above. Finally, the curtain rods will be installed.
[0160] In terms of the painting process, it is the last task to be performed because it cannot be carried out in advance due to its fragility. Nevertheless, works can be organized so that they can be carried out in two stages, in the first stage, sanding and elimination of imperfections can be performed, followed by the application of a coat of primer with diluted plastic, plastification, and general mechanical sanding.
[0161] Wooden doors will be supplied in a duly identified manner in accordance with the carpentry reports to facilitate their placement and subsequent assembly. They will be distributed by floors and, in turn, by houses. The frames will be assembled with fittings for putting up the doors.
[0162] Finally, the leaves will be placed and the installation of the closure mechanisms will come to an end. Given the final finish of these doors (lacquered), they must be duly protected, since they will be difficult to repair in the event of an impact and would have to be replaced. They will be assembled prior to the flooring.
[0163] With respect to cabinets, they will be acquired from a workshop since they are modular elements, such that there is only a need to place them in their final position on site.
[0164] In terms of flooring, polished concrete will be used if it is below-ground. Compared to ceramic flooring, this finish is durable and requires minimal maintenance, and it is impeccable as it is made without any posts.
[0165] Polished concrete will be made when making the bottom slab and will be used to start works on exposed block.
[0166] If the flooring is above-ground, the use of vinyl flooring coupled by clipping has been envisaged.
[0167] In terms of the chimneys, and as mentioned above, they are prefabricated elements that are assembled on site. This chimney has been developed with a system for anchoring to the top slab in those of small dimensions and embedded in those of larger dimensions to finish off the waterproofing against its base without having to make brick parapets.
[0168] In turn, the outer baseboards will be detachable metal baseboards hanging from an element adhered to the wall and held in the lower portion thereof to prevent movement. This hanging baseboard allows absorbing small tolerances that are generated during construction, providing a completely flat finish.
[0169] In parallel, the use of metal copings without silicone seals in joints, copings mechanically fixed to the wall by an attachment element under the joint between parts and with a waterproof element preventing the sealing thereof, has been envisaged.
[0170] With respect to projecting balconies, they constitute another industrialized element that arrives on site ready for assembly at the right time.
[0171] They are balconies made with a metal structure with an attachment element acting as a holding structure embedded in the top slab and mechanically fixed to the completely finished 3D balcony including flooring, handrail, false ceiling, and water collection system. This allows adapting the design of the balcony to the architect's design for this development and any others that may arise. It is a standardized type of construction solution.
[0172] As a general rule and as explained, the installations must be adapted to other processes, such as partitioning, ceilings, flooring, etc.
[0173] In the garage, and since the system of the present invention does not have any posts, the entry of the ceiling networks and the trays thereof can be done immediately after the concreting of the lower floor compression layer, and it is necessary to set out the partitions and make the floor slab to work in optimal conditions.
[0174] In the houses, as the different enclosures are constructed, the piping, trays, and raceway systems, particularly the installations that will be embedded in the enclosures in factory and in the laminated gypsum partitions and paneling, will be gradually installed.
[0175] As indicated above, the installations are incorporated in the prefabricated walls and then connected and complemented with the rest of the installation made "in situ".
[0176] The false ceilings will be made once all the installations running through the interior thereof have been made.
[0177] After the ceilings, the terminal elements (grating, light fixture, detectors, etc.) can be installed. Finally, upon the conclusion of painting works, the mechanisms and their decorative components will be assembled, with the connection boxes being previously installed.
1. A construction system, characterized in that it involves the following prefabricated elements:
• Prefabricated columns (1)
• Prestressed beams (2)
• Precast slabs (3)
• Prefabricated walls (4) with plumbing and raceway systems (14)
• Prefabricated façades (5)
• Roof parapets (6)
• PVC joinery (7)
• Glass panels (8)
• Plasterboards
• Home electrical panel (9)
• Metal baseboard
• Coping (10)
• Chimneys (11)
• Prefabricated bathrooms (12)
• Covering for wet areas
• Vinyl flooring
• Prefabricated balconies (13)
2. The construction system according to claim 1, characterized in that the prefabricated columns (1) are obtained in reinforced concrete of variable cross
section connected to footing by means of an injected steel casing, having a smooth
finish and a paint coat.
3. The construction system according to claim 1, characterized in that the prestressed beams (2) are made as prefabricated T-shape type prestressed concrete
elements, with connections and support apparatus with columns (2') included, having
a smooth finish and a paint coat.
4. The construction system according to claim 1, characterized in that the precast slabs (3) are made as top slabs with lightened polystyrene filler blocks
(3'), formed by a prefabricated reinforced concrete plate, top slab tensile reinforcements,
and ties.
5. The construction system according to claim 1, characterized in that the prefabricated walls (4) are self-supporting, have a variable thickness with B500S
steel reinforcement and a smooth finish and paint.
6. The construction system according to claim 1, characterized in that the prefabricated façades (5) are made up of an outer bearing wall with a 5 cm thick
visible concrete finish, a continuous rigid outer XPS insulation, and a 15 cm inner
structure layer of concrete with inner plasterboard paneling.
7. The construction system according to claim 1, characterized in that the roof parapets (6) are made as concrete walls prefabricated for parapets.
8. The construction system according to claim 1, characterized in that the PVC joinery (7) is made as 76 mm deep PVC windows with 5 chambers.
9. The construction system according to claim 1, characterized in that the glass panels (8) have a double glazing formed by a colorless glass panels and
an intermediate dehydrated air chamber with double perimeter sealing and aluminum
separator profile.
10. The construction system according to claim 1, characterized in that the plasterboards are 15 mm thick.
11. The construction system according to claim 1, characterized in that the home electrical panels (9) are partially assembled in factory with the entire
switchgear provided only for connecting the points, incorporating a plasterboard structure
for direct placement.
12. The construction system according to claim 1, characterized in that the metal baseboard is hung on a metal profile.
13. The construction system according to claim 1, characterized in that the metal copings (10) include a concealed mechanical fixing system.
14. The construction system according to claim 1, characterized in that the prefabricated chimneys (11) include a concealed structure for a quick and waste-free
assembly by means of an inner metal fitting structure.
15. The construction system according to claim 1, characterized in that the prefabricated bathrooms (12) include an enveloping system of concealed metal
structure and direct plasterboards with insulation to be left prepared on site, with
installation points to be connected.
16. The construction system according to claim 1, characterized in that the covering for wet areas consists of a composite system received with high moisture-resistant
glue for kitchen and shower stall fronts.
17. The construction system according to claim 1, characterized in that the prefabricated balconies (13) have metal fittings completely finished in factory
including the outdoor wooden flooring with a water collection tray and means for mechanical
connection to the metal structure of the top slab.
18. A method for putting the system according to claim 1 into practice, characterized in that the following operative phases are established therein:
a) Setting up on-site auxiliary installations and resources for the workers
b) Moving earth
c) Setting up the foundation and containment by means of using prefabricated concrete walls (4)
d) Making the underground sewage network
e) Setting up prefabricated columns (1), prestressed beams (2), gravel paving, and setting up the floor slab
f) Installing the top slabs from the precast slabs (3) and obtaining a polished compression layer
g) Making stairs
h) Forming façades by means of mechanical anchoring systems from the prefabricated façades (5), PVC joinery (7), and glass panels (8)
i) Repeating steps f, g, and h until the desired height of the building is obtained
j) Setting out inner partitioning and installation connection
k) Installing roofs
l) Applying vertical coverings, and obtaining false ceilings, and painting surfaces
m) Installing the wood joinery
n) Laying out flooring