MODULAR PANELS AND SYSTEM FOR USING SAID PANELS

Abstract

Construction panel and method for construction using said panel. Each construction panel comprises a lightweight structural element and insulation material sandwiched between a multilayer of lightweight boards which may have different types of finishing. The invention discloses an innovative system for rapid, more efficient and safer construction of building structures, resulting in lightweight yet resistant structures.

Claims

1. A modular construction system comprising: a plurality of structural elements, a plurality of pre-fabricated panels, comprising a plurality of lightweight boards and insulation; wherein said panels comprise a plurality of pre-fitted mechanical, electrical and plumbing (MEP) first fix and a label.

2. The system according to claim 1, wherein said structural elements comprise U-channels, C-channels, struts and beams.

3. The system according to claim 1, wherein said plurality of panels further comprise lightweight structural elements.

4. The system according to claim 1, wherein said label may be a barcode label.

5. The system according to claim 4, wherein said barcode label comprises information on project, site, location, position, orientation, dimensions, dates and composition of said panel.

6. The system according to claim 1 for use in construction of internal walls, external walls, load bearing walls and slabs.

7. The system according to claim 1, wherein said panels may be used vertically, horizontally or at any angle in between.

8. The system according to claim 1, wherein the structural elements and the panel composition are prepared according to building codes to withstand required seismic movement, weather conditions, fire, floods and load bearing.

9. A method for building a multi-story structure comprising the steps of: a. preparing a floor slab, b. preparing lightweight modular panels which comprise a plurality of lightweight boards and insulation, wherein said panels comprise a plurality of pre-fitted mechanical, electrical and plumbing (MEP) first fix and a label, c. assembling a structural building skeleton, d. fixing labeled lightweight modular panels according to the information contained on said label, wherein said label may be a barcode label which comprises information on project, site, location, position, orientation, dimensions, dates and composition of said panel, e. filling and sealing gaps between said panels and between said panels and floor, f. pouring or making ceiling slab, g. filling and sealing gaps between said panels and said ceiling slab, and h. applying finishing on said panels.

10. The method according to claim 8, wherein preparing said floor slab comprises marking the boundaries and positions of said panels.

11. The method according to claim 8, wherein the steps of a. to h. are repeated for each floor.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0028] The invention will be better understood from a reading of examples of embodiments, taken in conjunction with the accompanying figures in the drawings in which:

[0029] FIG. 1 illustrates a front and partially exploded isometric view of a construction panel system.

[0030] FIG. 2 shows a concrete foundation and its preparation.

[0031] FIG. 3 illustrates the building method of a traditional concrete foundation.

[0032] FIG. 4 shows the panel to floor detail.

[0033] FIG. 5 shows a 3D view of the erected floor.

[0034] FIG. 6 shows the installation of the MEP works on the panels.

[0035] FIG. 7 shows an example of linking two panels.

[0036] FIG. 8 illustrates a wall opening done using the panels.

DETAILED DESCRIPTION OF THE INVENTION

[0037] As disclosed above, the innovative system consists of a combination of structural steel construction and the use of pre-assembled wall panels that can constitute an auto formwork for the columns, pillars and peripheral beams. The panels are modular, factory pre-assembled, insulated, having an autoclaved high density cement board internal and external facia that can be finished with any type of finishing or that can be of stone or wood patterns, mass colored.

[0038] For simplicity and clarity of illustration, the drawing figures illustrate the general manner of construction, and descriptions and details of well-known features and techniques may be omitted to avoid unnecessarily obscuring the invention.

[0039] In one embodiment, a construction panel system comprises one or more modules. Each module or panel 100 comprises a lightweight structural element 101 and insulation material 102 sandwiched between a multilayer of lightweight boards 103 as shown clearly in FIG. 1.

[0040] In a preferred embodiment, the lightweight boards 103 are made of cement, cementitious fiber or any other acceptable such material currently in use or may become available for use in such conditions.

[0041] In another embodiment, the finishing surfaces can be plain or textured such as wood finishing, cement, PV panels, stone cladding among others.

[0042] In one embodiment, the lightweight structural element 101 can be made of steel, stainless steel, aluminum or any other metal or even material which provides similar characteristics for providing the desired structural features.

[0043] In one embodiment, additional layers of insulation 102 may be coupled to the lightweight structural element 101 from each side of the element to meet the architectural design or construction requirement. The insulation 102 layers may comprise one or more types of insulation material such as, but not limited to, foam, mineral wool and fiberglass among others. Alternative thicknesses and densities for insulation layers may be varied to achieve specific R-values for insulation. The different insulation layers may be used to also achieve sound or acoustic insulation which is achieved through the use of materials which reduce vibrations along the panels.

[0044] In one embodiment, a fire retardant insulation layer may be added to the system. Furthermore, a fire retardant paint layer may be applied to meet the requirement of the fire zoning.

[0045] In a preferred embodiment, the multilayer lightweight panels are water proof and water-resistant. They are unaffected by water and humidity, and may resist the impact of water under critical weather conditions.

[0046] In another embodiment, the panels 100 may be labeled during the fabrication process. Said labels may include information such as indications on the location, position, and level where said panel 100 is to be installed on site. Said labeling comprises the use of QR coding, bar coding, RFIDs or any other currently existing technology and technology which may be developed in the future and is compatible with the present invention.

[0047] In a preferred embodiment, the dimensions of the panels 100 may be variable in order to meet the needs of the project under construction, the structural element being reinforced to go beyond the restrictions in the dimensions of traditional wall panels.

[0048] In one embodiment, the panels 100 may also be used as siding panel or façade panels. In another embodiment, the panels 100 may be used as roof panels. In yet another embodiment, the panels 100 may be used as floor slabs.

[0049] In a preferred embodiment, the skeleton of the building may be a traditional structural steel. In such a preferred system, first the support structures used to support the structural steel body are erected, the support structures are typically formed from steel columns, beams or trusses, or from reinforced concrete. The next step would be erecting a series of vertically oriented steel elements spaced apart as needed or required to define a general shape of the building, floor or space as shown in FIG. 2.

[0050] In one embodiment, the skeleton of the building may be made of reinforced concrete or any other acceptable construction material deemed to be able to bear the required load. First, all the support columns, beams and trusses are erected. the next step would be erecting a series of vertically oriented elements made of reinforced concrete or any other acceptable construction material.

[0051] In a preferred embodiment, as shown in FIG. 3, the panels 100 are laid on a concrete base slab. After being poured, the concrete base is prepared with marking the boundaries and the panels positions. The structural steel building body is then erected. The panels 100 are then placed in position. After disposing the panels, these are fitted and aligned to ensure straight and flat surfaces. Alternatively, the panels are may be fitted and positioned at any preferred angle to obtain the shape and style required based on architectural drawings or design.

[0052] In one embodiment, the panels 100 are fixed to the floor and upper slab using bolts fastened into U channels already laid in the concrete as shown in FIG. 4. While the use of U channels may be a preferred embodiment of the present invention and as shown here merely for the purpose of description, other means that U channels may be used to secure the panels solidly in place.

[0053] In a preferred embodiment, the gaps and joints between the panels are filled using mesh tape followed by cement mortar. Not to limit this step to the use of mesh tape and cement mortar, the gaps and joints may be filled and sealed as needed with any currently existing material available for use or may become available and which may provide similar characteristics to those desired form the use of mesh and mortar.

[0054] In one embodiment, the panels 100 and the skeleton body would form a complete floor as shown on FIG. 5. The structural integrity formed by the skeleton of the building and the lightweight structural element of the panels can withstand seismic loads and offers better behavior than traditional construction due to its lightweight characteristics and fixation details. The system would meet earthquake resistance requirements taking into account wind and seismic lateral forces applied. Design based on minimum peak ground acceleration 2.5 m/sec2 (or as per project location requirement), in compliance with ACI318, IBC and UBC 97 standards. All of this resulting in less human and material damage and abiding by the highest standards of safety and security.

[0055] In a preferred embodiment, the formwork may be used for the columns and a beam may be made from the panels 100. The traditional formwork would not be needed and a finishing level would be obtained in the early stages of construction, cutting down on both cost and time.

[0056] In another embodiment, the panels 100 may be overlapping and are linked together using different techniques like zinc self-tapping screws as shown in FIG. 7. For the purposes of illustrations, this is used as an example however, this in no way limits the use of other systems or techniques for linking together the overlapping panels.

[0057] In a preferred embodiment, as shown in FIG. 6, the panels 100 are fabricated with surface and/or internal grooves and/or linkage spots to fit the first fix of all MEP works, such as electrical conduits, electrical boxes, water, gas and drainage pipes and all frames related to the plumbing fixtures.

[0058] Going forward, FIG. 8 illustrates different elements aligned to assemble a wall-opening. Wall-opening structure can be used to create an opening that can be used, for example, to attach windows to construction panel system.

[0059] The wall-opening structure may comprise construction panels 801, 802, 803, and 804, similar to the construction panel shown in FIG. 1. In the embodiment of FIG. 8, construction panels 801 and 802 are larger than construction panels 803 and 804 and such difference in size allows the opening to be formed when construction panels 801, 802, 803 and 804 are coupled together. The dimensions, height, length and width of said panels in the present disclosure may all be pre-fabricated and labeled for rapid and accurate fitting so as to maximize construction speed accurately and without human error or confusion.

[0060] In one embodiment, in case of design changes, the installed panels may be easily dismantled, removed and replaced with newly fabricated and labelled ones.

[0061] Although the invention has been described with reference to specific examples, it will be appreciated by those skilled in the art that the invention may be embodied in many other forms. It should also be understood that the various aspects and embodiments of the invention as described can be implemented either independently, or in conjunction with all viable permutations and combinations of other aspects and embodiments. All such permutations and combinations should be regarded as having been herein disclosed.