GB2434594A

GB2434594A - Modular building system

Info

Publication number: GB2434594A
Application number: GB0601442A
Authority: GB
Inventors: Mehdi Robert Teers
Original assignee: Individual
Current assignee: Individual
Priority date: 2006-01-25
Filing date: 2006-01-25
Publication date: 2007-08-01
Also published as: GB0601442D0

Abstract

A complete building system of pre-cast components connected by dry fixing connectors. The system comprises foundation components C, vertical D and horizontal E support components and hollow core infill panels G for floor, ceilings and walls. The connectors may be double dovetail wedge connectors fitting in tapered channels in the components. Buildings formed from the system can be dismantled for re-use of the components. The components may have channels L for air flow formed in them so as to provide for heating and cooling throughout a building constructed from the system. Solar energy may be utilised to this end. A building formed from the system may function as a flood barrier, road barrier or other heavy security barrier.

Description

APPLiCATION FOR PATENT IN v iJN lIONS

Title of the Invention: A BUILDING AND/OR BUILDING

METI IOD USING PRECAST CONCRETE ELEMENTS

WITH DRY FIXED' ASSEMBLY COUPLING.

SPEC I FICATION (1 to7) 11115 itiveiltiOn relates to a pi'ecist concrete mO(IUIUF building system having fou ndations, telescopic colu inns, 1)I'e-stressed beams, pre-stresseci hollow-core 11001). nels, hollow-core wiil I pIIle1s that hecone totally i uteri CkE( lorm a rigid structure u p to medium height level', when Ii opposing elements become locked together by the inventive devices as described in the technical description tge herewith atlache(1, (1 to 1 2).

2. The precast invention relates to the field of bui ldiiig construction, more specilically to tile construction ol bui Idi ng structures using factory engineered precast modular elements iii solid concrete or hybrid. Present day methods of assembi i rig building rilodLiles are fixed together to form a peI'111neI1t structure, which, is both time consuming and waste, as no recycling capability is allowed for, leaving demolition as tlìe only means of removing Unwanted buildings.

A Ii igh quality precast concrete structure has a life expectancy of 1 O() years or more, recycling must therefore form plrt of' its design and nianu lacturi ng concept' which, my nvCI1tJVe devccs have allowed br.

. In addi 11011 to the incorporation of m.y n.iodule coLll)I i rig dcv ices, I ILl it! ici claiiii a iiiethod of circulating air throughout i hui kling si ructure when both tloor and wall elements are oF 1101 low-core (les1!n and are il'iterconnecle(l by fllCiiIl5 of' coupling the duct eleiiicnts to panel ends ( I)g 12 F) and inserting iieoprene (or similar material) lullilels into each circular void (see Dg 12 C) to lorill a tight Fit that allows warm or cold air to circulate in any oh red ion t Ii roughout tile cnn re structure, with 1)1-c lerence to solar poWer energy for which this invention has been created for, by the inventor.

4. In a broad aspect, the present invention relates to a building structure, preterahly a medium-rise building', that is laclory produced to lre-dete!minedl dimensions that would provic.lc entire buildings to be available Irom Factory ES sloe 1K ite fl5 f( ) immediate iiistallation by means of a rapid dry-forni' of' assembly to a clo5e(l state', in a fraction of the time aiid cost C(.)mpared to all other 1K nown methods of building similar structures.

. 13y i ilCorpOrali ng a totally volumetric self-powered air flow system throughout the entire bid Iding, in the manner so described in my sketches I)g I () of 1 2' air conditioning operatiilg costs would be ([rasl.ical ly reduced.

Public delnan(.l for such a bui ldiiig supply service is lorever increasing, due to hui icling land shortage -escalating material and labour costs, i nl]ated costs for demolishing, jlus ever increasing house buying, costs, etc. 6. Jo erect and complete each bLiikling project in modular form to completion stage necessities the make and fit services ol several established manufacturers, who will also incorporate the new inventive clement coupling devices plus the new inventive method of air conditioning, to such bui Idi ligs and to the standards laid down by the huropcaii Building Federation.

7. Fach element or module will he engineered to fine Ii mits to enable a composite building to be efficiently and rapidly site asscmnblcd, wlthoLit waste of mnaterials and time, that wou Id permit occupation to take effect in Just days -1101 months or years as in the case of' most large project bui idi ngs being carried on I I ( )day by pre-dieterl u ned formulas.

DESCRIPTION

I)g I Foundation modules -Factory produced to high standards to enable a complete building foundation base to he installed to carry all structural loads Lij) to medium height level for (lOIUestIc or coinmcrcu.il USe, to a prepared Foundation base.

Once laid out, as per engineers stipulations', floor panels are tlìcn lal(l into place, and first section ol telescol)IC columns are then inserted into prepared voids of toLinClation modules, ( I)g' s & 4) twin beams are then installed and bolted to column laces (1)g 10).

On complcl ion of first floor level beam assembly, first floor l1(.)l low-core floor panels are then installed, with master panels becoiiung interlocked by means of the coupling device ( I)g 2).

I)ucti rig modules are then inserted between floor panel edges 1)g 1 2E) and coupled together by inserting funnels into Floor panel edge voids (I)g 12 6 and 10).

Wall panels are installed by inserting head of panel between beams (L)g 9) with edges closed by tongue and groo/e configuration into recesses in column faces. The entire panel having two equal sides to permit direct entry. A butt floor strip is i nstal led on one side of the panel base, with detachable strips installed on panel entry side (Dg 10 H). All wall panels arc designed to he non-load bearing and detachable, plus being 50% lighter In weight coiiiparcd to h/c floor pamìels.

hxtcrior wall panels comprises of a sub Frame that houses the wall paiicls and is (lesigiled to be fixed to the mnainfraiiie as per (l) g 1!). which is detachable.

I i ft shafts and slai rs are at so designed as integrated part of' tIme mnam ri structui'al assembly, with both fixed to the main structure as illustrated in (l)g IJ).

This method of assembly is carried out in a methodical form to each floor level up to medium height.

Structure on the roof 101) level is designed to carry and support all necessary solar Panels and eqLlipment, plus proVi(li hg additional accommodation in the lorm of studios for its occupants to W( )Fk Ii'Oill home ii and when desired.

Constructi hg a mcdi u iii height l)LIi Ich ng structure iii ih 15 tOrlil amid as shown in attached sketches (1 to 12) enables the mainframe to carry all bearer loads to!oundalioiis, leaving all internal and external wall panels to be non load bearing, that can be removed independently ii required to create a wide range ol alteriiat ive desigii layouts.

It also Oilers the strongest resistance to shock loads and or external lorces from any direction, thus providing its occupants with the ma i mum pro1ect1o1 at all times.

It has been designed by the inventor to be rapidly site assembled to Final stage ot construction, with all modular elements being available From stock plus, be equally capable oF being dismantled!or onward use to create a wide range ol' alternative building designs if and when required, without waste.

DESCRIPTION OF ATTACHED DRAWINGS 1 TO 12

lii ()rdei' that the present i IlVeflti(.)n may he liii ly LinderStood an enihodi ment of the method of building PILLS a description of the (2OLIpli ng devices that create a monolithic di'y St1.LIclUre accordi I12, to the present iliveiltioll will he described, by way of exaiiiple in which: -I)g 1.is an exploded view ol a multi-storey StFLlCtUre that incorporates the main modular elements: -A. Foundation piles 13 & C louindatioii modules I). Telescopic columns F. Pre-stressed twin beams l. 1-lol low-core pre-sti'essed floor panels ( ;. 1-lol low-core wall panels II. Concrete trunking bearer modules I. Concrete hearer modules J. Lilt-shaft modules K. Stairs modules I. External wall panel modules Dg 2. Sets out the high yield steel coupling devices that are inserted into the hollow-core floor panel void ends (Dg 6) that become locked into position when a high yield steel bar is passed through l)iep.t1edl holes iii the panel end and through each bracket, then secured in ilace with ends l)iUecti ng outwards (l)g 6).

When two opposing master floor 1)anels are set i lito position as described in l)g, and the lock-wedge inserted iii both bracket ends, a positive locki iig action is created between both opposing floor paiiels afld column (Dg 5). To form a monolithic action to the main structure.

Descnbes an example layout ol a building foundation wit Ii 1.3 ---C-and I) ill ustral i iig the three of I lie four di here nt designs requi re.1 to install a fully l)reparc(1 foundat ion base on which both the suspeiide.l ground floor can be laid with hollo\\ -

S

core panels, plus erection of P1 stage columns that are set into place iilt() prepared voids. All being connected t(.)gelLIer by means of the double dovetail wedge-bk (Dg 2).

Dg 4. Referring to drawings 3 and 4 denotes a precast ft)undation telescopic coliimii, cross beam assembly, with i nierniedi ate Hoor patiel asse nib I y, l)lL1s ground floor level. /-\ ii ol wli iclì have been calculated to carry and support all dead arid live loads to foundation level.

D 5. Is a description of the two sizes ol the telescoi)ic colu inns.

i.e. to assemble a single height storcy, and double height. that.

provides additional floor levels as desired.

I) 6. To accommodate wider span floor widths, two thicknesses ol hot low-core floor panels will be required -a 1 50mm and a 2( )Omm thick panel. Thus two di ITerent size of voids are created at factory level. Iwo different dej.ths of coupling brackets will he needed, as per my illustrations (0 and H. 6). The wedge-bk coupling will also be in iwo lengths. D06-C illustrates the cutout section in each of the floor panel end to fit round and to lock to the column, with (D) arid (I) presenting the coupling device action between opposing floor panel elements.

Dg 7. Illustrates a series of modules that partly make up the bui Idi rig structure, e.g. (A) being the master floor panel edge design. ( B) the pre-stressed twin beam member with prepared holes for fixing rods to p1 I hrongh both beam ends and coin niii, then bolted together with beams slotted iflt(.) lace ol colu inn ( Dg 10) to create a sot id locid ng action betweei'i col u mu, twin beams and master floor l)Inel (C.') Illustrates a yen ical comiuiection. -D shows a vertical hollow-core wall assembly section that enables wall panels to he asscuiiblcd liorutonial by between columns. Both precast side sLipponts are asseiiibled by inserting tLlhes into wall cores, then bowene(l iii posutioul into column recesses, with both beams providu mig a l( )ck u ui act ion to all connected wall panels that are m nsta lied by this method. (p

Dg 8. illustrates a side elevation beam to column coupling assembly, plus floor panel ends being coupled together by flkaflS of the!ork-lok ( Dg 8 E) with wall bearer/trunki ng module (F) that is inserted between beams with edges supported oii beam edges (Dg 8-F).

Ii a I So i II ustrates a II oor end pane 1-to-panel c)nflect ion to create a fully directional locking action i)etween all opposing elements when wedge-loks are inserted into bracket voids ( I)g A-B).

Incorporating double pre-stressed concrete beams i lito the hu i lding method Provides di sti iicti ye advantages over si iigle beam frame construction or single load bearing wall structures as, the hearer cumulative load surface are olten permitted wi lb a 1 00mm lb ick surface with 110 locking action applied, whereas the building method as herewith illustrated provides a hear level of 125111111 for each floor Panel plus becoming interlocked when coupled together as illustratec.l, by means 0! my coLipling device.

Any extreme lorce applied to such a structure is therefore controlled to a much higher degree compared to a conventional method 01 building.

Dg 9. Is an illustration of a wall pailci assembly. Wall pLiiiels are precast 1101 low-core non load hearing, having a thickness ol 92mm or thicker if sped lied.

Space between both beams is I 50mm that permits a sectional ised load bearing ducting modules T and C edges to he i iistal led in tile manner described. At one side of the base will be a Ii xed ski ni hg strip, to align wall pitiiels. Panels are inserted ilto 1)0111 sides of the column frame with edges i iiserted 11110 colu inn recess. Master central panel is then fitted and base plate installed 1(.) complete tile wall pallel itistal lation to required width.

W lien lower floor level wall pane Is have been installed as so described ah)vC. duct iii ii iodu les al-c tlìe ii lowered i 1110 ( )5 Iii)Il bet\\ ecu Hoor pah1L'l edges. with airflow' gasket couplitigs being fitted to the underside before slotting into position and or all funnels being inserted i flt() COreS in head of lower wall pane! (as shown ii 90). (1) 0 1-1 and I) illustrate the method of secun ug an external wall panel frame to the main frame. This method entai is the USC 0! the same coLipli ng bracket that locks floor JIt1cls together except that it is inserted into the side wall to enable the eOUl)l i ng end to project 35 showii (1) g II) to enable the coupling wedge to lock both the floor paiie I end and opposing wall panel together when assembled ill the nianner as so described. Top end of wall panel become locked to the mainframe by means of a coupling bracket as shown (11).

Dg 10. Description o! both illustrations show an internal wall panel assembly with base stops.

Lower sketch shows the beam to column assembly, for a multi-storey structure.

I)g 1 I Illustrates an external wall assembly 1110 which a rei n!'orced cage is fixed to a steel subl.rame with a Stone or brick effect façade. The mainframe is designed to accommodate ai most any form of façade panel within the Size of the frame void and is fixed to the mainframe as so described.

Dg 1 2. Illustrates a floor to wail shape structure through which coiitro!led temperature air can he circulated in all dimensions.

F and F) representing the trunking section that is fitted wit Ii lu nnel led tubes that are inserted into roLind floor cores (I)g 1 and C).

I nstal kit ion COLI p1 i ng procedure is carried out by fixing h wer in inel strIp i lito concrete duct element before iowcri hg Into 1)05111011 onto beam ledges. S ide funnel strips are i nserte(l iii t( (mci cores then pressed 1110 side wall round cores and into floor cores. An adhesive solution to be applied to floor core just be lore con p1 ng duct i ng blocks to ft)rnl an airtight coil ilecI 101 10 all 01)1)051 ng elements.

DETAILED CONSTRUCTION OF AN EXAMPLE

BUILI)ING CompresSiVe stress of Foundation 500 kg I cm2 iciiiforced concrete Precast concrete 50() kg / cm2 lci n Forcing bars SR24 (round steel) S I)3() detormed round steel bars Allowable bean i cal)acltY So Ions per m2 Col u nins Precast concrete dimensions -350 x 350mm -350/400mm l3eam -1 50mm wide x 220mm depth l.eiigtli -4-6 m 1)epih oF Face rebate -75 mm I leiglit of column section (lower = 3.9m -higher = 7.5m)(l'wo-slorey) I lollow-core Floor panels -4.5m -6.Om-7.2m and 1 ()m in length 1 50 mm and 220mm thick I lollow-core wall ianels -2.6 -2.8 -3. 0 high (I iiteriial) -92mm -1 50mm thick -0.6m and 1. .2m wide Exterior wall la me -4.2 m wide GiIvinized steel Frame -2.6m high -150mm thickl200nìin (.oii ned i oiis I ou ndat ion -clove tail wedge strips C(.)lumns -sell' sul)pOFted m preiarcd \ o1d Beams -stainless steel bolts Floor and wall panels -steel coupling wedge locking device

Claims

CLAIMS

1. A building structure comprising foundation elements, vertical support elements, horizontal bearer elements, floor and ceiling bl1Ollow_core elements, plus hollow-core wall elements, each element being adapted to become securely attached to at least one other element, when coupled together by means of one or more ol' my inventive devices.

2. A structure according to claim 1 wherein each said element (when manufactured) to the specific design and dimensions as described creates a monolithic structure up to medium height, when assembled by means of my dry lix' couplings as so described in drawings 1-12 that also permit total demountability.

3. A structure according to claim 2 the foundation modules are laid to prepared Ibundation, vertical supporting elements (precast columns) are inserted into foundation modules, horizontal bearer elements (precast beams) are inserted into column walls and bolted together, hollow-core floor and wall panels are laid and installed (as illustrated in Dg's I to 17 and secured together by means of the locking wedge devices (as shown in Dg 2) is inserted to integrally lock them together, forms a fully directional locking action between all opposing modules, to create a monolithic structure.

4. 1 further claim that by incorporating precast ducting elements with funnel strips as so described on page 12 (B F & G) into hollow-core floor and wall panel circular prepared cores, selected temperature controlled air can be circulated within floor and wall panel cores in any direction, when generated, throughout an entire building.

5. I further claim that this part of the invention enables a self-generated facility to be created when connected to solar l)O%'er.

which will form l)art of the structural design.

6 1 Ilirther claim that by creating and producing a column as so described in sections that fit into each other to lorm a Lelescopic I0 column of reinforced precast concrete to support all building loads to prepared modular foundations, can he manufactured also as stock elements' that would be fully capable of SUp)OI'ting totally plecast concrete structures up to medium level'.

7. 1 Further clai 111 that all main structural modules as so described Iii drawiiigs 1 o 12 aiid iiic!uding bathroom and kitchen pods' would bccoiiie aVailable to the public as stock items' that can be selected Iroin a catalogue to create almost any size oi' shape of bLli ldiiìg to provide a very quick delivery and installation service by the manu Facturer, at greatly reduced costs.

. I further claim that such a building StrLtctLu'e as so clescri bed and is made and assembled in the manner as set out in drawings ( I to 1 2) oilers a higher degree of security and protection to its occ Li pants compared to most Other bu i Idi rig methods of coii t ru cii on.

I Further claim that a building structure as Sc) described in drawings (1 to 12) ensures a 100% recycling capability, piLls being capable ot being recreated to form almost any shape or building design, without waste.

9. 1 Further claim that a biii iding as so described in drawings (1 to 1 2) is capable ot providi rig its own power when solar energy is applied and generated throughout entire buildings through a series of tubular cores in all floor and wall panels that transmit selected tcm')erature o1 airflow (hot or cold' throuohout all huildino areas I / 1 0. I Further clai ni that the airflow ducting precast concrete elements beconie installed as illustrated on pages 9-10 and 11 oF t lie tttched draw i rigs' when set onto beam ledges and with Flex iNc funnels inserted into wall and floor panel circular holes, an eFFicient arid eFfecti ye sell' generated air conditioning system is created t Ii rotighout I lie entIre bui Idi ng.

I I I Further c I ai iii that iiiy particular modular bu i Idi ng systeli 1 as so described iii attache(I drawings 1 to 12 and iii particular to (1rdwii1 (7 F' and ( ) in which is set out additional uses. as liv Ii example a flood harrier, or a traffic barrier, or defence barriers, by a)lying the same principles ol assembly as property building hut with pretei-isioned wall panels being inserted horizontally as per sketch (70) that are slotted into pi'epirecl voids iii column walls and beam supported laterally by fixing one top beam and fixing sUPl)Ort jacks to opposing side 0! beam voids, with all coupling 011115 UPI)' ied with a water repellent creates a very effective flood baiTier, in a very qLlick space of time, that can also be in! ly di s mantled in hoLirs.

I
2. 1 also clai ni that as a traffic barrier it would oiler a much higher degree of protection compared to today's harriers. By example, the foundation concrete module would be taking first impact which will he at most immovable', followed by the second line of force being absorbed by the pre-teiisioned concrete wall up to 2 to meters high, which could also act as an anti dazzle and sound barrier, cacti bay having a bay width of up to tell meters and several meters high in sections of I.2m. In addition, a heated air flow transmitted through hollow-core wall panels in the same manner with cores formed in colLlmn/post to transfer air from panel to panel then ejected into traffic lanes at vehicle level, would dissipate fog blankets that could prevent disastrous traffic 1i Ic-ups on motorways for which I also claim the i iivention for. It woutld also offer a very high degree of containment ability, as a cross over barrier, with a lifespan of over fi fly years.

\1FNI)\IENTS TO TIlE (1, I\I II \F 111.1 \ FILFI) %. 101 I O\ S ADDED CLAIM -13 I further claim that a multiple building structure that is designed to support precast concrete floor and wall panels that enables temperature controlled circulating air to pass through both vertical and horizontal directions, can be created in both precast concrete, or, steel frame structure. i.e. HYBRID, as so described in sketch lB of 12, and assembled in the same method as so described in my description in a concrete frame, page 1 of 7 -paragraph
3.

Shape of airflow transmission coupling is different to that used in concrete but both providing the same purpose.

Dg lB -Description 13.

A-B-C Steel forms to be used.

D-E-F Perspectives of steel frame elements.

G-H Perspectives of hollow-core concrete panels with holes to underside for air tube connection.

J Air flow tube connector.

:.:::. i Perspective of mainframe to floor assembly.

K Through section of floor and wall panel assembly with airflow connectors to permit controlled air to be transmitted in both horizontal and vertical directions that enables required air to be recycled throughout this particular form of building structure.