US20080022609A1

US20080022609A1 - Mobile manufacturing plants for producing prefab elements

Info

Publication number: US20080022609A1
Application number: US11/460,865
Authority: US
Inventors: Valente Carmine FRANCO; Peccolo MAURIZIO
Original assignee: BIT Tech Ltd
Current assignee: BIT Tech Ltd
Priority date: 2006-07-28
Filing date: 2006-07-28
Publication date: 2008-01-31

Abstract

The present invention concerns a mobile plant for producing prefab elements for the building industry. The mobile plant comprises a covering canopy structure (A) that can be dismantled, such as a large tent or a hall, assembly tables (1, 1.1, 1.2, 1.3) for producing elements in brick material and mortar, an installation (14) for preparing the reinforcing irons for the panel elements of brick and mortar, a concrete mixer plant (3) for supplying the mortar, and/or a plant for generating auxiliary means (steam, electric current, compressed air, etc.) and/or a service container (7) for the personnel and for managing the plant. All these equipment elements are mounted on trailers and/or in containers that can be transported by road or by rail to the building site or the buildings to be erected. The main advantage of the mobile plant is seen in the maximum work rationalisation that yields considerable savings in time and in means.

Description

BACKGROUND OF THE INVENTION

1. Field of the Invention
The present invention concerns an autonomous manufacturing plant, called “mobile plant” in the following, for producing prefab elements, according to the introductory part of the claim 1.
2. Discussion of Background Information
The term prefab elements in this context is understood in particular as building elements of brick material and cement mortar for producing panels for the building industry (residential and industrial buildings) such as e.g. described in the European patent application EP-01810973.6 published as EP-1273729 A2 on the 21 Aug. 2003.

SUMMARY OF THE INVENTION

In this specific case elements of brick material are concerned that can be assembled, using reinforcing irons and cement mortar filled in, to form the most different types of prefab structures (box-type structures, walls, floors or ceilings, etc.).
It is to be underlined that the mobile plant described and claimed here in general is apt to produce “on the building site” just about every type of prefab structure consisting of elements of brick material (or tile material) interconnected using cement mortar in order to form a rigid structure of any form and application desired.
The “mobile plant” thus is created as required for the task, apt to generate a large number of prefab elements in real time, and to reduce cost of transport of materials.
A new technology for high quality is concerned here, apt to activate a “door to door” industrial process directly on the building site where the buildings are to be erected.
It represents the realisation of matured direct experience in the field of prefabrication, for the benefit of all users, manufacturers and engineers.
The validity of the inventive idea can be comprehended also from the fact that the structures used in the present prefab element manufacturing practice were made use of in stationary and permanent work environments (e.g. halls), where the only advantage was gained from the repetition of the elements produced, but where the problems of transport and of assembly could not be dealt with. The present invention aims at eliminating all the problems once and for all concerning transport to, and assembly of the prefabricated elements on, the building site where the planned building is to be built.
For realising these objectives the inventive mobile plant is characterised in that it comprises a whole series of equipment devices, required in their combination, which constitute the characterising part of the claim 1. In its general concept the mobile plant thus comprises a covering canopy or roof erected temporarily, i.e. just for the time required for producing the prefab elements in close vicinity of the building site where the planned building is to be realised, under which canopy the equipment indispensably required for manufacturing the elements is placed. The equipment according to the present invention comprises at least one assembly table for producing single layer elements of brick material and cement mortar, equipment for preparing the reinforcing iron rods, a concrete mixing plant, facilities for generating auxiliary means (electric current, steam, compressed air, etc.) and possibly a service container with offices and personnel rooms as required.
A characteristic of the present invention is that the various equipment elements are mounted on trailers and/or in containers that can be transported, by road or by rail all the way to the building site where the planned building or buildings are to be erected, where the equipment can be arranged according to a suitable lay-out plan as required for rationalising the work process.
The equipment elements of the mobile plant are conceived for a number of production functions:

- Using the same assembly tables various element types can be produced,
- Panels of various thickness can be produced,
- On each trailer two operating units including their storage are transported,
- Production always is effected at a level above ground, damp and grimy conditions thus being avoided,
- Surfaces of up to 250 square meters or 450 square meters, respectively, can be produced per work day,
- The same equipment can be applied for traditional work methods,
- The plant structure is particularly suited for large building tasks such as e.g. entire developments or settlements, etc.

The mobile plant can be managed technically for production control from outside using particular software programs conceived for organising production on a fixed basis, not just for planning but also for production control and the assembly of the elements.
The principles described of the present invention refer to an innovative technique in the field of building construction based on the production concept.
The essential characteristics of the novel method of assembling are known according to the state of the art e.g. from a particular element of brick material (the European Patent Application EP-12737729A2 cited above), using which it was possible already to reach a series of advantages described in detail in the document cited.
Practical experience has shown that assembly of all these types of wall or ceiling elements can be effected owing to particular equipment elements, which can be transported easily to the building sites where the equipment is placed and rendered operative within a few hours.
The manufacturing facility is laid out in such a manner that a certain number of elements of brick material amalgamated with cement mortar and reinforcing iron can be stored, which are the panel elements ready to be used (transport and mounting).
The assembly concepts shown here thus are aimed at eliminating the inconveniences caused by transports, and by the lack of trained personnel.
The objective of the present invention thus is to be understood as an improvement of the known techniques in building construction, known as traditional, as well as production of prefab elements in stationary plants.
The result obtained owing to the application of the constructive concept cited, known from the state of the art, from the element in brick material cited in the EP-1273729A2, permits e.g. assembly of up to 15 types of panel elements not only differing from each other but also of different thickness.
These objectives are met owing to studies of the particular elements of equipment, used also within the frame of the present invention, and which constitute a revalidation of the use of commonly known materials and yield cost reductions owing to the application of a novel construction process.
The mobile plant according to the present invention thus represents the consequent improvement of the rationalised assembly of elements that constitute the prefab element.
Work times required are optimised and independent of inconvenient weather conditions, particularly during winter time, the problems created by transports and building sites thus being eliminated.
The present invention thus permits production of large number of panel elements directly on the spot, all of which are obtained at better quality, profits and speed.
The “mobile” plant preferentially is laid out in the sense of a one way street, where the starting materials enter on one side and where the assembled product leaves on the opposite side.
Using the proposed production system with the particular equipment the “mobile” plant offers the following principal advantages:

- Standardised production process for all types of prefab elements (e.g. the ones described in EP-1273729A2);
- Possibility of obtaining larger panel dimensions in length and in width, all inconveniences caused by transports being avoided;
- Homogenous load bearing structures, or filling or dividing structures are assembled using one single assembly process for high quality;
- A large number of flat panel surfaces are produced without specialised operators, owing to a controlled production process.
- Absolute control of the production and of the quality of all products assembled.

BRIEF DESCRIPTION OF THE DRAWINGS

The present invention is described in more detail in the following with reference to illustrated realisation examples. It is shown in the:

FIG. 1 A canopy or roof (tent, transportable roof structure with steel struts and cover panels, etc.) protecting against adverse weather influences covering the following equipment elements, seen from above and from the side;

FIG. 2 Lay-out of the mobile plant with its basic equipment;

FIG. 3 Lay-out of the mobile plant with its basic equipment, seen in a section;

FIG. 4 A schematic plan of the equipment transport;

FIG. 4.1 A schematic plan of operation of the equipment;

FIG. 5 A schematic production plan for the mobile plant;

FIG. 6 A plan, side view and section of an assembly table for producing walls with double layer elements of brick material, mounted on a trailer, during the transport phase;

FIG. 6.1 A plan, side view and section of an assembly table for producing walls with double layer elements of brick material, mounted on a trailer, during the working phase on the ground;

FIGS. 7 and 7.1 A plan, side view and section of a container for preparing reinforcing rods;

FIG. 8 A plan, side view and section of the complete mobile plant for preparing concrete mortar.

DETAILED DESCRIPTION OF THE PRESENT INVENTION

In the FIG. 1 a canopy A or covering roof is shown in the form of a large tent 1. It easily can be imagined as a circus tent, but it is obvious that according to the invention any suitable cover structure that can be dismantled (e.g. a structure of steel struts and cover plates) could be used as well.
The form and the dimensions of the canopy A are chosen in function of the size of the mobile plant to be realised. Of importance is just the fact that the canopy can be easily dismantled and transported.
In the FIG. 2 an imaginable lay-out plan is shown of the inventive mobile plant in a practical form of realisation. The reference numbers in the Figure indicate the following working elements:

1. Pivotable and tiltable assembly table,
1.1 Assembly table for tunnel system,
1.2 Assembly table for pillars,
1.3 Assembly table for stairs,
1.4 Various productions,
1.5 Electric lifting winch.

It is to be noted here that in the FIG. 2 a mobile plant is represented, which is apt to produce a whole series of different elements of brick material. The arrangement of assembly tables 1 through 1.3, required according to the present invention, thus depends on the type of building construction to be realised and is easily adapted to the requirements. Also the size of the canopy A is to be chosen according to the specific requirements that can vary according to the buildings to be erected, be it an industrial building (large tent) or an urban residential building or a multi-storey building, etc.
A water tank reservoir is indicated with 2 (always required except in cases where a sufficient local water supply can be relied on, while 3 indicates a concrete mixer.
In the FIGS. 3.1 and 3.2 each a deposit for inert materials and a cement mortar distributor are shown, i.e. elements for work rationalisation in the mobile plant. In the FIG. 4 a storage deposit area is shown for the brick elements required for producing the various panel elements of brick material and mortar (compare the description in the EP-1273729A2 cited), whereas in the FIG. 5.1 a shop for preparing reinforcing iron rods for the panel elements of brick material and mortar is shown. In the FIG. 6 an installation is shown for generating auxiliary means (steam, electric current, compressed air, etc.), and in the FIG. 7 a container is shown for offices, sanitary installations, dormitories for workers, canteen, etc.
Evidently the presence of these services can depend on the local requirements where the building activity takes place. Conditions permitting dormitories for workers thus will be dispensed with, etc., and the facilities available locally will be relied on. In any case the mobile plant can be provided with all these services in such a manner that it can operate autonomously with respect to the working conditions in its environment. It is to be noted here also, that in the example of practical realisation according to the FIG. 2, also transportable floor planks 10 are provided permitting easier transport of the panel elements produced, and a lifting winch 11 for facilitating internal transport. It is clear that provision of such transport equipment elements will be adapted to each task of the mobile plant, of which in the FIG. 2 just a practical example is shown. All and any variation of the lay-out described here of a mobile plant for producing prefab elements must be considered as fitting into the frame of the present invention, under the condition that every equipment element, which is part of the mobile plant, be mounted on trailers and/or in containers transportable by road or by rail to the building site. This actually is the basic characteristic of the present invention.
In the FIG. 3 the lay-out of the mobile plant according to the FIG. 2 is shown schematically in a section demonstrating that the individual equipment elements 1, 1.1, 1.2, 1.3 are mounted onto trailers and thus can be easily transported by road. In the FIG. 4 the base plan of transport of the equipment shows that the assembly tables 1, . . . 1.3 can be transported by road in their transport configuration. An analogue solution easily can be imagined for transport by rail.
In the FIG. 4.1 a particular preferred realisation form of the present invention is shown, in which the assembly table 1 is mounted on a trailer 12 (compare also the FIG. 4) of a truck (not shown) and is provided with a horizontal hinge 13 permitting pivoting of the assembly table 1 from a vertical filling and transport position (FIG. 4) into a horizontal working and unpacking position indicated in the FIG. 4.1. This system facilitates work in the mobile plant.
In the FIG. 5 then a possible block plan is shown of the inventive mobile plant. This illustration is self-explanatory and shows the base constitution of the inventive mobile plant.
In the FIG. 6 a plan, a side view and a section are shown of an assembly table 1 for producing wall panels with double layer elements of brick material on the trailer 12, during transport, whereas in the FIG. 6.1 a plan, a side view and a section are shown of an assembly table 1 for producing wall panels with double layer elements of brick material on the trailer 12, during the working phase on the ground.
In the FIG. 7 a plan, a side view and a section are shown of a container for preparing the reinforcing iron rods for producing the panel elements of brick material and mortar. Also this container is provided with walls that tilt down and can be opened, which container contains e.g. the following items: reinforcing iron bender 15 (left), work bench 16, reinforcing iron bender 17 (right), reinforcing net cutter 18, reinforcing net bender 19.
In the FIG. 8 finally the complete concrete mixer plant is shown in a plan and in a side view, which also is mounted on a trailer 12 for easy transport to the building site according to the teachings of the present invention. In this Figure, shown at the upper right, a possible location is indicated of the equipment element 3 under the canopy structure A.
According to a preferred realisation form of the present invention it is provided that the equipment elements 1 through 6 be disposed under the canopy structure A in such a manner that the production of the panel elements of brick material and mortar is effected according to the one-way principle, where the starting materials enter at one side of the canopy structure A whereas the assembled panel elements of brick material and mortar emerge at the opposite side of the canopy structure A. This can be seen e.g. e.g. from the schematic block plan according to the FIG. 5, where the starting materials (brick material elements, etc.) enter at the left hand side whereas the finished panel elements emerge (towards the building site) at the right hand side in a straight linear flow. This procedure, rationalising the production process, certainly is not new as such, but is novel and original as applied in the framework of a mobile plant like the inventive one described.
The advantages of the inventive mobile plant basically are the rationalisation of the construction of residential and industrial buildings, especially if large building projects are dealt with (e.g. building of new settlements or residential developments for tourists, or rebuilding after nature disasters, etc.) with corresponding savings in building cost, owing to the fact that after completion of the buildings the mobile plant easily can be dismantled and be transported to another building site. Not to be neglected are the ecologic advantages owing to the elimination of transports otherwise required for bringing personnel and prefab panel elements built elsewhere to the installation site, in cases over hundreds of kilometres.

REFERENCE NUMERALS

A canopy (tent, temporary hall)
1,1.1,1.2,1.3 pivotable and tiltable assembly table
2 water tank, reservoir
3 concrete mixer plant
4 storage area of brick elements
5 office and storage
5.1 installation for preparing reinforcing irons
6 plant for generating auxiliary means
7 containers for personnel and management
10 transportable foot planks
11 lifting winch
12 trailer
13 horizontal assembly table hinge
14 container for preparing reinforcing items
15 reinforcing iron bender (left)
16 work bench
17 reinforcing iron bender (right)
18 reinforcing net cutter
19 reinforcing net bender
20 storage area for assembled elements

Claims

1. Mobile plant for producing prefab elements of brick material and cement mortar for the construction of residential and industrial buildings comprising at least the following equipment elements:

a covering canopy (A) as a roof that can be dismantled,

one or more assembly tables (1, 1.1, 1.2, 1.3) for producing panel elements of brick material and cement mortar,

a plant (14) for preparing the reinforcing irons for the panel elements of brick material an cement mortar,

a concrete mixing plant (3) for preparing the cement mortar to be supplied to the assembly tables (1, 1. 1, 1.2, 1.3),

and/or a station (6) for generating auxiliary means such as steam, electric current, compressed air, with the corresponding pumps,

and/or a service container (7) for offices, sanitary stations, dormitories for workers, and the canteen,

where the individual equipment elements are mounted on trailers and/or in containers transportable by road or by rail to the building site where the buildings are to be realised, and which can be arranged according to a suitable lay-out plan for producing prefab panel elements.

2. Mobile plant according to the claim 1, characterised in that

the covering canopy is a large tent (A).

3. Mobile plant according to the claim 1 characterised in that

the covering canopy is a steel strut structure with covering plates, that can dismantled.

4. Mobile plant according to the claim 1, characterised in that

the equipment elements (1 through 6) are arranged within the covering canopy (A) in such a manner that the production of the panel elements of brick material and concrete mortar can be effected according to a principle of one-way direction, the starting materials entering at one side of the canopy (A) and the assembled panel elements emerging at the opposite side of the covering canopy (A).

5. Mobile plant according to the claim 1, characterised in that

the assembly table (1) is mounted on a trailer (12) of a truck and is provided with a horizontal hinge (13) permitting pivoting of the assembly table (1) from a vertical transport and filling position to a horizontal working and unpacking position.

6. Mobile plant according to the claim 5, characterised in that

on a trailer (12) two assembly tables (1, 1.1) are mounted on each longitudinal side of the trailer (12), each of which can be pivoted about its own horizontal hinge (13) from a of the a vertical transporting and filling position to a horizontal working and unpacking position.

7. Mobile plant according to the claim 5, characterised in that

the vertical filling position of the assembly table also is its transporting position on a trailer (12) of a truck.

8. Mobile plant according to the claim 1, characterised in that

it contains different types of assembly tables such as:

assembly tables for flat panels (1, 1. 1),

assembly tables for posts and pilasters (1.2)

assembly tables for stairs (1.3),

other types of assembly tables for producing different element types (1.4).

9. Mobile plant according to the claim 1, characterised in that

within the covering canopy (A) or in its close vicinity furthermore a storage area (20) is provided for the assembled individual elements of brick material and mortar.

10. Mobile plant according to the claim 6, characterised in that