Abstract
The present disclosure relates to components and methods for a modular building system, used for high-rise residential and office building, to pre-fabricate and assemble the system quickly, easily and simply. More particularly, it relates to a building temporary self-supporting panel system invention that includes formwork, structural rebars and insulated panels for the purpose of wall, floor and roof, also for the structure and enclosure. The building system is composed of a number of layers and a temporary-structural frame, integrating all constructive elements needed: temporary structural capacity, thermal and acoustical insulation, impermeability and pre-installations; designed considering operation, function, fabrication and assembling.
Claims
1. A kit, comprising: a slab panel that is self-supporting; a first wall panel that is self-supporting, the first wall panel configured to be connected to the slab panel or a second wall panel via a reinforcement, the first wall panel configured to be casted in concrete such that reinforced concrete connects the first wall panel and at least one of the slab panel or the second wall panel, an exterior of the first wall panel forming a surface of permanent wall of a building.
2. The kit of claim 1, wherein the reinforcement of the first wall panel is structural corrugated steel configured to reinforce on site cast concrete.
3. The kit of claim 1, wherein the reinforcement of the first wall panel is rebar configured to reinforce on site cast concrete.
4. The kit of claim 1, wherein the slab panel includes corrugated steel configured to be casted in concrete.
5. The kit of claim 1, wherein: the first wall panel is a bottom wall panel; the reinforcement is a first reinforcement; and the second wall panel is a top wall panel configured to be disposed above the bottom wall panel, the second wall panel defining an interior volume that contains a second reinforcement configured to couple the top wall panel to the first reinforcement of the bottom wall panel, the top wall panel configured to be permanently joined to the bottom wall panel by reinforced concrete by casting concrete into the interior volume of the top wall panel and the interior volume of the bottom wall panel.
6. The kit of claim 1, wherein the second wall panel is prefabricated to include at least one of a plumbing or electrical installation.
7. The kit of claim 1, wherein the slab panel and the first wall panel are each prefabricated and configured to be transported to a construction location.
8. The kit of claim 1, wherein the slab panel and the first wall panel are each prefabricated, configured to be transported to a construction location, and configured to be hoisted to a permanent location at the construction location.
9. The kit of claim 1, wherein the reinforcement is a first reinforcement, the kit further comprising: a truss panel that is self-supporting, the truss panel configured to be connected to at least one of the first wall panel or the slab panel via a second reinforcement, the truss panel configured to be casted in concrete such that reinforced concrete permanently connects the truss panel and the at least one of the first wall panel or the slab panel, the truss panel configured to be coupled to an exterior curtain wall.
10. (canceled)
11. The kit of claim 1, further comprising: a kitchen module that is self-supporting and configured to be connected to at least one of the first wall panel or the slab panel, the kitchen module including a non-structural, self-supporting wall and a cabinet.
12. The kit of claim 1, further comprising: a kitchen module that is self-supporting and configured to be connected to at least one of the first wall panel or the slab panel, the kitchen module including a functional layer containing a plumbing fixture and a pipe.
13. The kit of claim 1, wherein the reinforcement is a first reinforcement and the first wall panel is configured to be connected below the slab panel such that the slab panel forms a ceiling for a room containing the first wall panel, the kit further comprising: a third wall panel that is self-supporting, the third wall panel configured to be connected above the slab panel via a second reinforcement, the third wall panel configured to be casted in concrete such that reinforced concrete connects the slab panel and the third wall panel and such that the slab panel forms a floor for a room containing the third wall panel.
14. A method, comprising: installing a first wall panel on a slab by coupling a reinforcement disposed in an interior volume of the first wall panel to a connection point of the slab; coupling a second wall panel to the first wall panel, the second wall panel being self-supporting such that the second wall panel remains in place without external support once coupled to the first wall panel; and casting the first wall panel in concrete such that reinforced concrete permanently connects the first wall panel to the slab, an exterior of the second wall panel forming a surface of a permanent wall of a building.
15. The method of claim 14, wherein the second wall panel is prefabricated to include at least one of a plumbing or electrical installation.
16. The method of claim 14, wherein the reinforcement is rebar and installing the first wall panel on the slab includes coupling the rebar to the connection point.
17. The method of claim 14, wherein the reinforcement is a first reinforcement, the method further comprising: installing a third wall panel above the first wall panel by coupling a second reinforcement disposed in an interior volume of the third wall panel to the first reinforcement disposed in the interior volume of the first wall panel; and casting the third wall panel in concrete to permanently couple the third wall panel to the first wall panel with reinforced concrete.
18. The method of claim 14, wherein the reinforcement is a first reinforcement, the method further comprising: installing a truss panel on the slab by coupling a second reinforcement disposed in an interior volume of the truss panel to the slab and by coupling the second reinforcement to the first reinforcement, the truss panel being self-supporting such that the truss panel remains in place without support once installed on the slab; and casting the truss panel in concrete such that reinforced concrete permanently couples the truss panel to the first wall panel and the slab.
19. The method of claim 14, wherein: the slab is a first slab panel and the first wall panel is installed above the first slab panel, the method further comprising: installing a second slab panel above the first wall panel by coupling rebar disposed in the interior volume of the first wall panel to a connection point of the second slab panel.
20. The method of claim 14, wherein the slab is a first slab panel and the first wall panel is installed above the first slab panel, the method further comprising: installing a second slab panel above the first wall panel by coupling the reinforcement disposed in the interior volume of the first wall panel to a connection point of the second slab panel; and casting the second slab panel in concrete such that reinforced concrete permanently couples the second slab panel to the first wall panel.
21. The method of claim 14, further comprising: filling gaps between the first wall panel and the slab panel with a sealant before casting the first wall panel in concrete.
22. A method, comprising: installing a slab panel at a construction site, the slab panel being self-supporting and manufactured at a location remote from the construction site; installing a wall panel on the slab panel by coupling a reinforcement disposed in an interior volume of the wall panel to a connection point of the slab panel, the wall panel being self-supporting such that the wall panel remains in place without support once installed on the slab panel, the wall panel being manufactured at the location remote from the construction site; and casting the wall panel in concrete such that reinforced concrete permanently couples the wall panel to the slab panel, an exterior of the wall panel forming a surface of a permanent wall of a building.
23. The method of claim 22, further composing casting the slab panel in concrete before installing the wall panel.
24. The method of claim 22, wherein the slab panel is a first slab panel and the wall panel is installed above the first slab panel, the method further comprising: installing a second slab panel above the wall panel by coupling the reinforcement disposed in an interior volume of the wall panel to a connection point of the second slab panel, the second slab panel being self-supporting and manufactured at the location remote from the construction site.
25. The method of claim 24, further comprising casting the second slab panel in concrete such that reinforced concrete permanently couples the second slab panel to the truss panel.
26. The method of claim 22, wherein the slab panel is a first slab panel, the reinforcement is a first reinforcement, and the wall panel is a first wall panel installed above the first slab panel, the method further comprising: installing a second slab panel above the wall panel after casting the first wall panel in concrete by coupling the first reinforcement disposed in an interior volume of the first wall panel to a connection point of the second slab panel, the second slab panel being self-supporting and manufactured at the location remote from the construction site; and installing a second wall panel above the second slab panel by coupling a second reinforcement disposed in an interior volume of the second wall panel to a connection point of the second slab panel, the second wall panel being self-supporting such that the second wall panel remains in place without support once installed on the second slab panel, the second wall panel being manufactured at the location remote from the construction site; and casting the second wall panel in concrete such that reinforced concrete permanently couples the second wall panel to the second slab pane, an exterior of the second wall panel forming a surface of a permanent wall of a building.
27. The method of claim 22, wherein the reinforcement is a first reinforcement and the slab panel is a first slab panel and the connection point is a first connection point, the method further comprising: installing a truss panel above the first slab panel by coupling a second reinforcement disposed in an interior volume of the truss panel to a second connection point of the first slab panel, the truss panel being self-supporting and manufactured at the location remote from the construction site; casting the truss panel in concrete such that reinforced concrete permanently couples the truss panel to the first slab panel; hoisting a second slab panel above the truss panel, the second slab panel being self-supporting and manufactured at the location remote from the construction site; installing the second slab panel above the truss panel by coupling the second reinforcement to a connection point of the second slab panel.
28. The method of claim 27, wherein a curtain wall is configured to be coupled to the truss panel.
29. The method of claim 22, wherein a connection between the reinforcement disposed in the interior volume of the wall panel and the connection point of the slab panel is reversible prior to casting the wall panel in concrete.
30. The method of claim 22, wherein the connection point is a first connection point, the further comprising: installing a kitchen module on the slab panel by coupling the kitchen panel to the wall panel, the kitchen module being self-supporting, the kitchen module including a functional layer containing a plumbing fixture and a pipe.
31. The method of claim 22, further comprising: installing a stair element by coupling the stair element to the slab panel, the stair element being self-supporting and manufactured at the location remote from the construction site, the stair element having a plurality of prefabricated stairs, the stair element defining an internal structure having a C-profile and a U-profile; and casting the stair element in concrete such that the concrete fills the C-profile and the U-profile and permanently connects the stair element to the slab panel.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] The drawings described herein are for illustration purposes only and are not intended to limit the scope of the present disclosure in any way.
[0018] FIG. 1 is a front elevation of the wall panel Bottom, showing the internal lightweight structure and the internal substructure formed by cold-formed steel profiles, consistent with some embodiments of the present disclosure;
[0019] FIG. 2 is a transversal section of the wall panel Bottom, consistent with some embodiments of the present disclosure;
[0020] FIG. 3 is a front elevation of the wall panel Bottom, showing the finishing panels, consistent with some embodiments of the present disclosure;
[0021] FIG. 4 is a plan-view cross-section of the wall panel Bottom, showing the completed panel (internal lightweight structure, corrugated steel rebar, substructure and finishing), consistent with some embodiments of the present disclosure;
[0022] FIG. 5 is a top-view of the wall panel Bottom, showing the completed panel (internal lightweight structure, corrugated steel rebars, substructure and finishing), consistent with some embodiments of the present disclosure;
[0023] FIG. 6 illustrates an axonometric view of the wall panel Bottom, showing the total volume of the panel, consistent with some embodiments of the present disclosure;
[0024] FIG. 7 illustrates an axonometric view of the wall panel Bottom, showing the different exploded layers of the panels; consistent with some embodiments of the present disclosure;
[0025] FIG. 8 is a front elevation of the wall panel End Wall Bottom, showing the internal lightweight structure and the internal substructure formed by cold-formed steel profiles, consistent with some embodiments of the present disclosure;
[0026] FIG. 9 is a transversal section of the wall panel End Wall Bottom, consistent with some embodiments of the present disclosure;
[0027] FIG. 10 is a front elevation of the wall panel End Wall Bottom, showing the finishing panels, consistent with some embodiments of the present disclosure;
[0028] FIG. 11 is a plan-view cross-section of the wall panel End Wall Bottom, showing the completed panel (internal lightweight structure, corrugated steel rebar, substructure and finishing), consistent with some embodiments of the present disclosure;
[0029] FIG. 12 is a top-view of the wall panel End Wall Bottom, showing the completed panel (internal lightweight structure, corrugated steel rebars, substructure and finishing), consistent with some embodiments of the present disclosure;
[0030] FIG. 13 illustrates an axonometric view of the wall panel End Wall Bottom, showing the total volume of the panel, consistent with some embodiments of the present disclosure;
[0031] FIG. 14 illustrates an axonometric view of the wall panel End Wall Bottom, showing the different exploded layers of the panels; consistent with some embodiments of the present disclosure;
[0032] FIG. 15 is a front elevation of the wall panel Top, showing the internal lightweight structure and the internal substructure formed by cold-formed steel profiles, consistent with some embodiments of the present disclosure;
[0033] FIG. 16 is a transversal section of the wall panel Top, consistent with some embodiments of the present disclosure;
[0034] FIG. 17 is a front elevation of the wall panel Top, showing the finishing panels, consistent with some embodiments of the present disclosure;
[0035] FIG. 18 is a plan-view cross-section of the wall panel Top, showing the completed panel (internal lightweight structure, corrugated steel rebars, substructure and finishing), consistent with some embodiments of the present disclosure;
[0036] FIG. 19 is a top-view of the wall panel Top, showing the completed panel (internal lightweight structure, corrugated steel rebars, substructure and finishing), consistent with some embodiments of the present disclosure;
[0037] FIG. 20 illustrates an axonometric view of the wall panel Top, showing the total volume of the panel, consistent with some embodiments of the present disclosure;
[0038] FIG. 21 illustrates an axonometric view of the wall panel Top, showing the different exploded layers of the panels, consistent with some embodiments of the present disclosure;
[0039] FIG. 22 is a front elevation of the wall panel Top w/Opening, showing the internal lightweight structure and the internal substructure formed by cold-formed steel profiles, consistent with some embodiments of the present disclosure;
[0040] FIG. 23 is a transversal section of the wall panel Top w/Opening, consistent with some embodiments of the present disclosure;
[0041] FIG. 24 is a front elevation of the wall panel Top w/Opening, showing the finishing panels, consistent with some embodiments of the present disclosure;
[0042] FIG. 25 is a plan-view cross-section of the wall panel Top w/Opening, showing the completed panel (internal lightweight structure, corrugated steel rebars, substructure and finishing), consistent with some embodiments of the present disclosure;
[0043] FIG. 26 is a top-view of the wall panel Top w/Opening, showing the completed panel (internal lightweight structure, corrugated steel rebars, substructure and finishing), consistent with some embodiments of the present disclosure;
[0044] FIG. 27 illustrates an axonometric view of the wall panel Top w/Opening, showing the total volume of the panel, consistent with some embodiments of the present disclosure;
[0045] FIG. 28 illustrates an axonometric view of the wall panel Top w/Opening, showing the different exploded layers of the panels; consistent with some embodiments of the present disclosure;
[0046] FIG. 29 is a front elevation of the wall lintel, showing the internal lightweight structure and the internal substructure formed by cold-formed steel profiles, consistent with some embodiments of the present disclosure;
[0047] FIG. 30 is a transversal section of the wall lintel, consistent with some embodiments of the present disclosure;
[0048] FIG. 31 is a front elevation of the wall lintel, showing the finishing panels, consistent with some embodiments of the present disclosure;
[0049] FIG. 32 is a plan-view cross-section of the wall lintel, showing the completed panel (internal lightweight structure, substructure and finishing), consistent with some embodiments of the present disclosure;
[0050] FIG. 33 illustrates an axonometric view of the wall lintel, showing the total volume of the panel, consistent with some embodiments of the present disclosure;
[0051] FIG. 34 illustrates an axonometric view of the wall lintel, showing the different exploded layers of the panel; consistent with some embodiments of the present disclosure;
[0052] FIG. 35 is a top view of the slab panel Unit, showing the internal lightweight structure and formwork constituted by cold-formed steel profiles, consistent with some embodiments of the present disclosure;
[0053] FIG. 36 is an elevation view cross-section of the slab panel Unit, showing the completed panel with the different layers, consistent with some embodiments of the present disclosure;
[0054] FIG. 37 is a top view of the slab panel Unit, showing the completed slab including corrugated steel sheets and the attached corrugated steel rebars, consistent with some embodiments of the present disclosure;
[0055] FIG. 38 is an elevation-view transversal-section of the slab panel Unit, showing the material layers and the internal structure, consistent with some embodiments of the present disclosure;
[0056] FIG. 39 illustrates an axonometric view of the slab panel Unit, showing the internal prefabricated structure of steel profiles and corrugated steel bars, consistent with some embodiments of the present disclosure;
[0057] FIG. 40 illustrates an axonometric view of the slab panel Unit, showing the total volume of the panel, consistent with some embodiments of the present disclosure;
[0058] FIG. 41 illustrates an axonometric view of the slab panel Unit, showing the exploded different layers of the panels, consistent with some embodiments of the present disclosure;
[0059] FIG. 42 is a front elevation of the truss/facade Core Bottom, showing the internal lightweight structure formed by cold-formed steel profiles and the attached corrugated steel rebars, consistent with some embodiments of the present disclosure;
[0060] FIG. 43 is a transversal section of the truss/facade Core Bottom, consistent with some embodiments of the present disclosure;
[0061] FIG. 44 is a front elevation of the truss/facade Core Bottom, showing the internal substructure formed by cold-formed steel profiles and the window panels, consistent with some embodiments of the present disclosure;
[0062] FIG. 45 is a top-view of the truss/facade Core Bottom, showing the completed element, consistent with some embodiments of the present disclosure;
[0063] FIG. 46 is a plan-view cross-section of the truss/facade Core Bottom, showing the completed element (internal lightweight structure, corrugated steel bars, substructure and window panels), consistent with some embodiments of the present disclosure;
[0064] FIG. 47 illustrates an axonometric view of the truss/facade Core Bottom, showing the internal lightweight structure and corrugated steel bars, consistent with some embodiments of the present disclosure;
[0065] FIG. 48 illustrates an axonometric view of the truss/facade Core Bottom, showing the total volume of the element, consistent with some embodiments of the present disclosure;
[0066] FIG. 49 illustrates an axonometric view of the truss/facade Core Bottom, showing the different exploded layers of the panels; consistent with some embodiments of the present disclosure;
[0067] FIG. 50 is a front elevation of the truss/facade Core Top, showing the internal lightweight structure formed by cold-formed steel profiles and the attached corrugated steel rebars, consistent with some embodiments of the present disclosure;
[0068] FIG. 51 is a transversal section of the truss/facade Core Top, consistent with some embodiments of the present disclosure;
[0069] FIG. 52 is a front elevation of the truss/facade Core Top, showing the internal substructure formed by cold-formed steel profiles and the window panels, consistent with some embodiments of the present disclosure;
[0070] FIG. 53 is a top-view of the truss/facade Core Top, showing the completed element, consistent with some embodiments of the present disclosure;
[0071] FIG. 54 is a plan-view cross-section of the truss/facade Core Top, showing the completed element (internal lightweight structure, corrugated steel bars, substructure and window panels), consistent with some embodiments of the present disclosure;
[0072] FIG. 55 illustrates an axonometric view of the truss/facade Core Top, showing the internal lightweight structure and corrugated steel bars, consistent with some embodiments of the present disclosure;
[0073] FIG. 56 illustrates an axonometric view of the truss/facade Core Top, showing the total volume of the element, consistent with some embodiments of the present disclosure;
[0074] FIG. 57 illustrates an axonometric view of the truss/facade Core Top, showing the different exploded layers of the panels; consistent with some embodiments of the present disclosure;
[0075] FIG. 58 is a front elevation of the truss/facade Long Bottom, showing the internal lightweight structure formed by cold-formed steel profiles and the attached corrugated steel rebars, consistent with some embodiments of the present disclosure;
[0076] FIG. 59 is a transversal section of the truss/facade Long Bottom, consistent with some embodiments of the present disclosure;
[0077] FIG. 60 is a front elevation of the truss/facade Long Bottom, showing the internal substructure formed by cold-formed steel profiles and the window panels, consistent with some embodiments of the present disclosure;
[0078] FIG. 61 is a top-view of the truss/facade Long Bottom, showing the completed element, consistent with some embodiments of the present disclosure;
[0079] FIG. 62 is a plan-view cross-section of the truss/facade Long Bottom, showing the completed element (internal lightweight structure, corrugated steel bars, substructure and window panels), consistent with some embodiments of the present disclosure;
[0080] FIG. 63 illustrates an axonometric view of the truss/facade Long Bottom, showing the internal lightweight structure and corrugated steel bars, consistent with some embodiments of the present disclosure;
[0081] FIG. 64 illustrates an axonometric view of the truss/facade Long Bottom, showing the total volume of the element, consistent with some embodiments of the present disclosure;
[0082] FIG. 65 illustrates an axonometric view of the truss/facade Long Bottom, showing the different exploded layers of the panels, consistent with some embodiments of the present disclosure;
[0083] FIG. 66 is a front elevation of the truss/facade Long Top, showing the internal lightweight structure formed by cold-formed steel profiles and the attached corrugated steel rebars, consistent with some embodiments of the present disclosure;
[0084] FIG. 67 is a transversal section of the truss/facade Long Top, consistent with some embodiments of the present disclosure;
[0085] FIG. 68 is a front elevation of the truss/facade Long Top, showing the internal substructure formed by cold-formed steel profiles and the window panels, consistent with some embodiments of the present disclosure;
[0086] FIG. 69 is a top-view of the truss/facade Long Top, showing the completed element, consistent with some embodiments of the present disclosure;
[0087] FIG. 70 is a plan-view cross-section of the truss/facade Long Top, showing the completed element (internal lightweight structure, corrugated steel bars, substructure and window panels), consistent with some embodiments of the present disclosure;
[0088] FIG. 71 illustrates an axonometric view of the truss/facade Long Top, showing the internal lightweight structure and corrugated steel bars, consistent with some embodiments of the present disclosure;
[0089] FIG. 72 illustrates an axonometric view of the truss/facade Long Top, showing the total volume of the element, consistent with some embodiments of the present disclosure;
[0090] FIG. 73 illustrates an axonometric view of the truss/facade Long Top, showing the different exploded layers of the panels, consistent with some embodiments of the present disclosure;
[0091] FIG. 74 is a front elevation of the truss/facade Short Bottom, showing the internal lightweight structure formed by cold-formed steel profiles and the attached corrugated steel rebars, consistent with some embodiments of the present disclosure;
[0092] FIG. 75 is a transversal section of the truss/facade Short Bottom, consistent with some embodiments of the present disclosure;
[0093] FIG. 76 is a front elevation of the truss/facade Short Bottom, showing the internal substructure formed by cold-formed steel profiles and the window panels, consistent with some embodiments of the present disclosure;
[0094] FIG. 77 is a top-view of the truss/facade Short Bottom, showing the completed element, consistent with some embodiments of the present disclosure;
[0095] FIG. 78 is a plan-view cross-section of the truss/facade Short Bottom, showing the completed element (internal lightweight structure, corrugated steel bars, substructure and window panels), consistent with some embodiments of the present disclosure;
[0096] FIG. 79 illustrates an axonometric view of the truss/facade Short Bottom, showing the internal lightweight structure and corrugated steel bars, consistent with some embodiments of the present disclosure;
[0097] FIG. 80 illustrates an axonometric view of the truss/facade Short Bottom, showing the total volume of the element, consistent with some embodiments of the present disclosure;
[0098] FIG. 81 illustrates an axonometric view of the truss/facade Short Bottom, showing the different exploded layers of the panels, consistent with some embodiments of the present disclosure;
[0099] FIG. 82 is a front elevation of the truss/facade Short Top, showing the internal lightweight structure formed by cold-formed steel profiles and the attached corrugated steel rebars, consistent with some embodiments of the present disclosure;
[0100] FIG. 83 is a transversal section of the truss/facade Short Top, consistent with some embodiments of the present disclosure;
[0101] FIG. 84 is a front elevation of the truss/facade Short Top, showing the internal substructure formed by cold-formed steel profiles and the window panels, consistent with some embodiments of the present disclosure;
[0102] FIG. 85 is a top-view of the truss/facade Short Top, showing the completed element, consistent with some embodiments of the present disclosure;
[0103] FIG. 86 is a plan-view cross-section of the truss/facade Short Top, showing the completed element (internal lightweight structure, corrugated steel bars, substructure and window panels), consistent with some embodiments of the present disclosure;
[0104] FIG. 87 illustrates an axonometric view of the truss/facade Short Top, showing the internal lightweight structure and corrugated steel bars, consistent with some embodiments of the present disclosure;
[0105] FIG. 88 illustrates an axonometric view of the truss/facade Short Top, showing the total volume of the element, consistent with some embodiments of the present disclosure;
[0106] FIG. 89 illustrates an axonometric view of the truss/facade Short Top, showing the different exploded layers of the panels, consistent with some embodiments of the present disclosure;
[0107] FIG. 90 is a front elevation of the truss/facade 100X34 Bottom, showing the internal lightweight structure formed by cold-formed steel profiles and the attached corrugated steel rebars, consistent with some embodiments of the present disclosure;
[0108] FIG. 91 is a transversal section of the truss/facade 100X34 Bottom, consistent with some embodiments of the present disclosure;
[0109] FIG. 92 is a front elevation of the truss/facade 100X34 Bottom, showing the internal substructure formed by cold-formed steel profiles and the window panels, consistent with some embodiments of the present disclosure;
[0110] FIG. 93 is a top-view of the truss/facade 100X34 Bottom, showing the completed element, consistent with some embodiments of the present disclosure;
[0111] FIG. 94 is a plan-view cross-section of the truss/facade 100X34 Bottom, showing the completed element (internal lightweight structure, corrugated steel bars, substructure and window panels), consistent with some embodiments of the present disclosure;
[0112] FIG. 95 illustrates an axonometric view of the truss/facade 100X34 Bottom, showing the internal lightweight structure and corrugated steel bars, consistent with some embodiments of the present disclosure;
[0113] FIG. 96 illustrates an axonometric view of the truss/facade 100X34 Bottom, showing the total volume of the element, consistent with some embodiments of the present disclosure;
[0114] FIG. 97 illustrates an axonometric view of the truss/facade 100X34 Bottom, showing the different exploded layers of the panels, consistent with some embodiments of the present disclosure;
[0115] FIG. 98 is a front elevation of the truss/facade 100X34 Top, showing the internal lightweight structure formed by cold-formed steel profiles and the attached corrugated steel rebars, consistent with some embodiments of the present disclosure;
[0116] FIG. 99 is a transversal section of the truss/facade 100X34 Top, consistent with some embodiments of the present disclosure;
[0117] FIG. 100 is a front elevation of the truss/facade 100X34 Top, showing the internal substructure formed by cold-formed steel profiles and the window panels, consistent with some embodiments of the present disclosure;
[0118] FIG. 101 is a top-view of the truss/facade 100X34 Top, showing the completed element, consistent with some embodiments of the present disclosure;
[0119] FIG. 102 is a plan-view cross-section of the truss/facade 100X34 Top, showing the completed element (internal lightweight structure, corrugated steel bars, substructure and window panels), consistent with some embodiments of the present disclosure;
[0120] FIG. 103 illustrates an axonometric view of the truss/facade 100X34 Top, showing the internal lightweight structure and corrugated steel bars, consistent with some embodiments of the present disclosure;
[0121] FIG. 104 illustrates an axonometric view of the truss/facade 100X34 Top, showing the total volume of the element, consistent with some embodiments of the present disclosure;
[0122] FIG. 105 illustrates an axonometric view of the truss/facade 100X34 Top, showing the different exploded layers of the panels, consistent with some embodiments of the present disclosure;
[0123] FIG. 106 is a transversal cross-section of the Shaft Cabinet element, showing the completed element, consistent with some embodiments of the present disclosure;
[0124] FIG. 107 is a front elevation of the Shaft Cabinet element, showing the completed element, consistent with some embodiments of the present disclosure;
[0125] FIG. 108 is a plan-view cross-section of the Shaft Cabinet element, showing the completed element, consistent with some embodiments of the present disclosure;
[0126] FIG. 109 illustrates an axonometric view of the Shaft Cabinet element; consistent with some embodiments of the present disclosure;
[0127] FIG. 110 is a transversal cross-section of the Stair Type 1 element, showing the completed element, consistent with some embodiments of the present disclosure;
[0128] FIG. 111 is a front elevation of the Stair Type 1 element, showing the completed element, consistent with some embodiments of the present disclosure;
[0129] FIG. 112 is a plan-view cross-section of the Stair Type 1 element, showing the completed element, consistent with some embodiments of the present disclosure;
[0130] FIG. 113 illustrates an axonometric view of the Stair Type 1 element, consistent with some embodiments of the present disclosure;
[0131] FIG. 114 is a transversal cross-section of the Stair Type 2 element, showing the completed element, consistent with some embodiments of the present disclosure;
[0132] FIG. 115 is a front elevation of the Stair Type 2 element, showing the completed element, consistent with some embodiments of the present disclosure;
[0133] FIG. 116 is a plan-view cross-section of the Stair Type 2 element, showing the completed element, consistent with some embodiments of the present disclosure;
[0134] FIG. 117 illustrates an axonometric view of the Stair Type 2 element, consistent with some embodiments of the present disclosure;
[0135] FIG. 118 is a transversal cross-section of the Bath Module element, showing the completed element, consistent with some embodiments of the present disclosure;
[0136] FIG. 119 is a front elevation of the Bath Module element, showing the completed element, consistent with some embodiments of the present disclosure;
[0137] FIG. 120 is a plan-view cross-section of the Bath Module element, showing the completed element, consistent with some embodiments of the present disclosure;
[0138] FIG. 121 illustrates an axonometric view of the Bath Module element, consistent with some embodiments of the present disclosure;
[0139] FIG. 122 is a transversal cross-section of the Bath Common Module element, showing the completed element, consistent with some embodiments of the present disclosure;
[0140] FIG. 123 is a front elevation of the Bath Common Module element, showing the completed element, consistent with some embodiments of the present disclosure;
[0141] FIG. 124 is a plan-view cross-section of the Bath Common Module element, showing the completed element, consistent with some embodiments of the present disclosure;
[0142] FIG. 125 illustrates an axonometric view of the Bath Common Module element, consistent with some embodiments of the present disclosure;
[0143] FIG. 126 is a transversal cross-section of the Kitchen Module element, showing the completed element, consistent with some embodiments of the present disclosure;
[0144] FIG. 127 is a front elevation of the Kitchen Module element, showing the completed element, consistent with some embodiments of the present disclosure;
[0145] FIG. 128 is a plan-view cross-section of the Kitchen Module element, showing the completed element, consistent with some embodiments of the present disclosure;
[0146] FIG. 129 illustrates an axonometric view of the Kitchen Module element, consistent with some embodiments of the present disclosure;
[0147] FIG. 130 is a transversal cross-section of the Elevators Doors Module element, showing the completed element, consistent with some embodiments of the present disclosure;
[0148] FIG. 131 is a front elevation of the Elevators Doors Module element, showing the completed element, consistent with some embodiments of the present disclosure;
[0149] FIG. 132 is a plan-view cross-section of the Elevators Doors Module element, showing the completed element, consistent with some embodiments of the present disclosure;
[0150] FIG. 133 illustrates an axonometric view of the Elevators Doors Module element, consistent with some embodiments of the present disclosure;
[0151] FIG. 134 is a transversal cross-section of the Core Technical Floor element, showing the completed element, consistent with some embodiments of the present disclosure;
[0152] FIG. 135 is a front elevation of the Core Technical Floor element, showing the completed element, consistent with some embodiments of the present disclosure;
[0153] FIG. 136 is a top-view of the Core Technical Floor element, showing the completed element, consistent with some embodiments of the present disclosure;
[0154] FIG. 137 illustrates an axonometric view of the Core Technical Floor element; consistent with some embodiments of the present disclosure;
[0155] FIG. 138 illustrates an axonometric view of a typical casted in concrete level of Construction Module100X50, showing the optimal application of the building system; consistent with some embodiments of the present disclosure;
[0156] FIG. 139 illustrates an axonometric view of a typical level of Construction Module100X50, with the addition of the wall panels Bottom, showing the optimal application of the building system, consistent with some embodiments of the present disclosure;
[0157] FIG. 140 illustrates an axonometric view of a typical level of Construction Module100X50, with the addition of the trusses/facades Bottom, showing the optimal application of the building system, consistent with some embodiments of the present disclosure;
[0158] FIG. 141 illustrates an axonometric view of a typical level of Construction Module100X50, with the addition of all the different construction elements, showing the optimal application of the building system, consistent with some embodiments of the present disclosure;
[0159] FIG. 142 illustrates an axonometric view of a typical level of Construction Module100X50, with the casted in concrete phase of Bottom parts, showing the optimal application of the building system, consistent with some embodiments of the present disclosure;
[0160] FIG. 143 illustrates an axonometric view of a typical level of Construction Module100X50, with the addition of the wall panels Top, showing the optimal application of the building system, consistent with some embodiments of the present disclosure;
[0161] FIG. 144 illustrates an axonometric view of a typical level of Construction Module100X50, with the addition of the trusses/facades Top, showing the optimal application of the building system, consistent with some embodiments of the present disclosure;
[0162] FIG. 145 illustrates an axonometric view of a typical level of Construction Module100X50, with the addition of lintels and all the different construction elements, showing the optimal application of the building system, consistent with some embodiments of the present disclosure;
[0163] FIG. 146 illustrates an axonometric view of a typical level of Construction Module100X50, with the addition of Slab panels, showing the optimal application of the building system, consistent with some embodiments of the present disclosure;
[0164] FIG. 147 illustrates an axonometric view of a typical level of Construction Module100X50, with the casted in concrete phase of Top parts, showing the optimal application of the building system, consistent with some embodiments of the present disclosure;
[0165] FIG. 148 illustrates an axonometric view of a typical casted in concrete level of Construction Module100X34, showing the optimal application of the building system, consistent with some embodiments of the present disclosure;
[0166] FIG. 149 illustrates an axonometric view of a typical level of Construction Module100X34, with the addition of the wall panels Bottom, showing the optimal application of the building system, consistent with some embodiments of the present disclosure;
[0167] FIG. 150 illustrates an axonometric view of a typical level of Construction Module100X34, with the addition of the trusses/facades Bottom, showing the optimal application of the building system, consistent with some embodiments of the present disclosure;
[0168] FIG. 151 illustrates an axonometric view of a typical level of Construction Module100X34, with the addition of all the different construction elements, showing the optimal application of the building system, consistent with some embodiments of the present disclosure;
[0169] FIG. 152 illustrates an axonometric view of a typical level of Construction Module100X34, with the casted in concrete phase of Bottom parts, showing the optimal application of the building system, consistent with some embodiments of the present disclosure;
[0170] FIG. 153 illustrates an axonometric view of a typical level of Construction Module100X34, with the addition of the wall panels Top, showing the optimal application of the building system, consistent with some embodiments of the present disclosure;
[0171] FIG. 154 illustrates an axonometric view of a typical level of Construction Module100X34, with the addition of the trusses/facades Top, showing the optimal application of the building system, consistent with some embodiments of the present disclosure;
[0172] FIG. 155 illustrates an axonometric view of a typical level of Construction Module100X34, with the addition of all the different construction elements, showing the optimal application of the building system, consistent with some embodiments of the present disclosure;
[0173] FIG. 156 illustrates an axonometric view of a typical level of Construction Module100X34, with the addition of Slab panels, showing the optimal application of the building system, consistent with some embodiments of the present disclosure;
[0174] FIG. 157 illustrates an axonometric view of a typical level of Construction Module100X34, with the casted in concrete phase of Top parts, showing the optimal application of the building system, consistent with some embodiments of the present disclosure;
DESCRIPTION
[0175] The standard building system of the present disclosure contains various construction elements assembled on-site, aspects of the disclosed subject matter include different categories of panels: four categories of wall panels, one category of wall lintel, one category of slab panel and eight categories of truss/facade.
[0176] The standard building system of the present disclosure contains various prefabricated elements assembled on-site, aspects of the disclosed subject matter include different categories of elements: one category of shaft cabinet element, two category of stairs, two categories of bath modules, one category of kitchen module, one category of elevators doors module and one category of technical floor.
[0177] In some embodiments, a plurality of wall panels is provided as a kit wherein the plurality of the wall panels is of the same type. In some embodiments, a plurality of wall panels is provided as a kit, wherein wall panels come in a plurality of different types. In some embodiments, four different types are complementary in denomination, i.e., the wall panels could come in four types: a type with a door opening, a type without opening, a type with a closed end and a type with an opening without door. The size of each type of the wall panel is ultimately the decision of the user and depends upon the following non-limiting list of factors: human-scale, space quality, industrial sizes, and transportation margins.
[0178] Referring to FIG. 1, in some embodiments, the wall panels Bottom for using with the system of the present disclosure have internal structures configured to operate as a support skeleton. In some embodiments, the main internal structure is comprised of columns U-profiles 5 and C-profiles 6 which is configured as the formwork for in-site casted concrete. Referring to FIGS. 1, 4 and 5, secondary structure 15 is composed by C-profiles 4 and U-profiles 3. In some embodiments the secondary structure 15 referring to FIGS. 1 and 4 support the functional layer 19. Referring to FIGS. 2, 3 and 4, functional layer 19 comprises a thermal and acoustic insulation 14 and sideboard 13. In some embodiments, the panels are self-supporting during construction work. In some embodiments, the panels have a vertical crush resistance of at least 2000 pounds per linear foot; length of said wall panel when tested according to ASTM E72, and using a safety factor of 3. In some embodiments, the panels have a bending resistance when subjected to uniform loading in accord with ASTM E72 of up to 2000 pounds per square foot surface area.
[0179] In some embodiments, panels are configured to be connected to other panels and/or a building foundation. In some embodiments, the connections are made via the internal structures of adjacent panels and via rebars 17. In some embodiments, the connection between the various panels and/or the connection between the panels and the foundation is reversible. In some embodiments, panels are connected directly to a foundation using any suitable means. In some embodiments, an interface is provided to stabilize the connection between a panel and the foundation.
[0180] Referring to FIGS. 1-7, 1 wall panels Bottom 57 is provided. Referring to FIG. 5, in some embodiments, U-profile 5 and C-profile 6 constitute the steel frame and act as the formwork 18 for in-site casted concrete 16. In some embodiments the steel frame comprises rebars 17 that allow for connection with panels installed above them, as will be discussed in the construction process below. In some embodiments wall panels are connected with other wall panels Bottom 57. In some embodiments wall panels are connected with other wall panels Top 72. In some embodiments wall panels are connected with slab panel unit 79. In some embodiments panels are connected with truss/facade Core Bottom 59. In some embodiments panels are connected with truss/facade Core Top 74.
[0181] Referring again to FIGS. 3-4, the wall panel includes at least two sideboards 13. In some embodiments, side boards are disposed on opposing sides of the interior space of wall panel. In some embodiments, side boards are comprised of at least one of wood, cement, fiber cement, drywall, suitable metal sheets, and the like. In some embodiments, the thickness of sideboards 13 is approximately 0.5-1 inches.
[0182] In some embodiments, wall panel further includes at least one acoustic insulation layer (such as Rockwool) 14. In some embodiments, the thickness and composition of Rockwool are configured to provide the desired level of sound insulation to wall panel. In some embodiments, the thickness of Rockwool is approximately 45-50 mm (2 inch) in each side. In some embodiments, the Rockwool is filled in the inner space of substructure 15.
[0183] The overall thickness of wall panel is the summation of at least the layers described in the above paragraphs. In some embodiments, the overall thickness of wall panel is adapted according to local needs, such as climate conditions, building codes, constructions budget, and the like. In some embodiments, the total thickness of wall panel is approximately 32 inches. In some embodiments, this thickness includes the internal structure. In some embodiments, the main internal structure is disposed between functional layers 19 and the substructure is disposed between formwork 18 and the sideboard 13.
[0184] In some embodiments, the wall panels have internal structure. In some embodiments, the internal structure includes a main structure and a substructure. In some embodiments, the main structure comprises some profiles such as U-profile 5 and C-profiles 4. In some embodiments, the main structure serves as formwork 18 for on-site casted concrete 16. In some embodiments, a plurality of prefabricated rebars 17 is contained in the formwork 18 for the possible connection to the upper panels. In some embodiments, the distance between two sides of the formwork 18 is 24 inches.
[0185] In some embodiments, the formwork 18 is held and fastened by one substructure 15 on each side. In some embodiments, any other functional layer 19 disposed are held between profiles such as U-profiles 3 and C-profiles 4 from FIG. 7. In some embodiments, these profiles form substructure 15 of panel. In some embodiments, the horizontal distance between two C-profiles 4 in the substructure is 2 feet. In some embodiments, the profiles in substructure along with the functional layers held there between defines a functional layer block that can be stacked with other functional layer blocks to fill the interior space of a panel. In some embodiments, two functional layer blocks are attached on both side of the structural formwork 18.
[0186] Referring to FIGS. 3, 4 and 6, the wall panel integrates a door 20. In some embodiments, the door 20 is a double flush door. In some embodiments, the door 20 is directly connected to the substructure 15.
[0187] Referring to FIGS. 8-14, the wall panels End Bottom 58 have similarities in internal structure, layers and differences in the structural opening and in the finished dimensions. In some embodiments, the internal structure of wall comprises profiles which form the main structural formwork 18. In some embodiments, substructures with functional layers are installed on both side of formwork 18 like the wall panel Bottom 57. In some embodiments, the components and order of functional layers in the wall panels End Bottom 58 are the same as those in wall panels Bottom 57.
[0188] Referring to FIGS. 15-21, the wall panels Top 72 have similarities in internal structure, layers and differences in the structural opening and in the finished dimensions. In some embodiments, the internal structure of wall comprises profiles which form the main structural formwork 18. In some embodiments, substructures with functional layers are installed on both side of formwork 18 like the wall panel Bottom 57. In some embodiments, the components and order of functional layers in the wall panels Top 72 are the same as those in wall panels Bottom 57.
[0189] Referring to FIGS. 22-28, the wall panels Top w/Opening 73 have similarities in internal structure, layers and differences in the structural opening and in the finished dimensions. In some embodiments, the wall panels Top w/Opening 73 integrate a structural opening 21. In some embodiments, the internal structure of wall comprises profiles which form the main structural formwork 18. In some embodiments, substructures with functional layers are installed on both side of formwork 18 like the wall panel Bottom 57. In some embodiments, the components and order of functional layers in the wall panels Top w/Opening73 are the same as those in wall panels Bottom 57.
[0190] Referring to FIGS. 29-34, the wall lintel 78 have similarities in internal structure, layers and differences in the structural dimensions. In some embodiments, the internal structure of wall comprises profiles which form the main structural formwork 18. In some embodiments, substructures with functional layers are installed on both side of formwork 18 like the wall panel Bottom 57. In some embodiments, the components and order of functional layers in the wall lintel 78 are the same as those in wall panels Bottom 57.
[0191] Referring to FIGS. 35-41, in some embodiments, a slab panel is provided: Slab Panel Unit 79. In some embodiments, slab panels unit are approximately 8 0 in width and approximately 39 0 in length. In some embodiments, slab panels unit are approximately 8 0 in width and approximately 32 0 in length. The size of slab panel is ultimately the decision of the user and depends upon the following non-limiting list of factors: structure feasibility, building code, human-scale, space possibility, industrial sizes, and transportation margins. In some embodiments, the slab panels have steel frame as seen in FIG. 37. In some embodiments, the steel frame includes an internal structure which are formed by steel profiles groups 22 which have a C-profile 2 jammed in a U-profile 1. In some embodiment, the internal structure is divided into five modules. In some embodiment a U-profiles 23 are connected on the periphery of the internal structure as the bottom of formwork for on-site casted concrete 26. In some embodiment a transversal U-profile 24 is connected between two parts as bottom of formwork for on-site casted concrete 26. Referring to FIGS. 36-38, in some embodiment, a plurality of metal corrugated sheet 25 are fixed upon the internal structure served as the formwork 28 of on-site casted concrete 26. In some embodiments, metal corrugated sheet 25 has a thickness of approximately 2-3 inches (54 mm). In some embodiments the steel frame comprises prefabricated rebars 27. Referring to FIG. 39-41, in some embodiment, the steel rebars could be attached on the slab panel and casted in concrete with the internal structure and profiles in-between. In some embodiment, the steel rebars in the slab panel could fasten with the rebars on wall panel. In some embodiments, the rebars could be casted in concrete on either side. In some embodiments, concrete 26 could cover the metal corrugated sheet 25 and the rebars 27 of slab panel.
[0192] Referring to FIGS. 42-49, in some embodiments, the truss/facade Core Bottom 59 for use with the system of the present disclosure have a structure configured to operate as a support skeleton. Referring to FIG. 42, in some embodiments, the main internal structure is composed by columns 33, diagonals 34 and horizontal 35. In some embodiments columns 33, diagonals 34 and horizontal 35 are comprised of U-profiles 7 and C-profiles 8 which is configured as the formwork of on-site casted concrete 30. In some embodiments, the secondary structure 36 referring to FIG. 44 integrate constructive elements needed such as steel frame, exterior curtain wall system 29 with window 37 and panel 38. In some embodiments, the trusses are self-supporting during construction work. In some embodiments, the panels have a vertical crush resistance of at least 2000 pounds per linear foot; length of said wall panel when tested according to ASTM E72, and using a safety factor of 3. In some embodiments, the trusses have a bending resistance when subjected to uniform loading in accord with ASTM E72 of up to 2000 pounds per square foot surface area.
[0193] As shown in FIGS. 42-46, the internal structures component of the trusses provide space for the application of functional layers to endow each panel with not only structural stability, but desired properties derived from the composition of materials filling that space. In some embodiments, the panels can have different interior spaces based on the purpose of the panel and the needs of the system user. Some embodiments are discussed below in FIGS. 47-49.
[0194] In some embodiments, trusses are configured to be connected to other panels. In some embodiments, the connections are made via the internal structures of adjacent panels and via rebars 81. Referring to FIGS. 42-46, in some embodiments, U-profile 7 and C-profile 8 constitute the steel frame and act as the formwork 32 for on-site casted concrete 30. In some embodiments the steel frame comprises main rebars 31 and other rebars 81 that allow for connection with truss/facade Core Top 74 installed above them, as will be discussed in the construction process below. In some embodiments the profile 9 enables the connection with truss/facade Core Top 74 installed above them. In some embodiments truss panels are connected with possible wall panels 57, 72. In some embodiments truss panels are connected with possible slab panel unit 79. In some embodiments panels are connected with possible truss/facade panels 60, 74.
[0195] Referring again to FIGS. 47-49, the truss/facade panel includes at least a main internal structure. In some embodiments, main internal structure is composed by columns 33, diagonals 34 and horizontal beams 35. In some embodiments, columns, diagonals and horizontal are composed by U-profile 7 and C-profile 8. In some embodiments, main internal structure is configured as the formwork 32 of on-site casted concrete 20. In some embodiments, formwork 32 comprises main rebars 31 and other rebars 81 for structural connection.
[0196] In some embodiments, the truss/facade panel includes at least a substructure 36. In some embodiments, the substructure 36 is composed by U-profile 11 and C-profile 12. In some embodiments, a U-profile 9 is fastened to the substructure 36 to enable connection with other panels. In some embodiments, the substructure 36 is configured to operate as a support skeleton for the curtain wall system 29.
[0197] In some embodiments, truss/facade panel further includes an exterior curtain wall system 29 disposed on interior side. In some embodiments, curtain wall system 29 comprised of at least a window 37 and a panel 38. In some embodiments, window and panel can be customized according to code, climate needs and user like. In some embodiments, curtain wall system 29 is supported to internal substructure 36.
[0198] The overall thickness of truss/facade panel is the summation of at least the layers described in the above paragraphs. In some embodiments, the overall thickness of truss/facade panel is adapted according to local needs, such as climate conditions, building codes, constructions budget, and the like. In some embodiments, the thickness is 24 inches.
[0199] Referring to FIGS. 50-57, the truss/facade Core Top 74 has similarities in internal structure, layers and differences in the structural dimensions and in the dimension of the structural elements. In some embodiments, the internal structure of truss comprises columns, diagonals and horizontal which forms the main structural formwork 32. In some embodiments, substructure 36 and curtain wall system 29 are installed on interior side of formwork 32 like the truss Core Bottom 59. In some embodiments, a profile 10 is fastened to the substructure 36 to enable connection with other panels. In some embodiments, the components and other elements in the truss Core Top 74 are the same as those in trusses Core Bottom 59.
[0200] Referring to FIGS. 58-65, the truss/facade Long Bottom 60 has similarities in internal structure, layers and differences in the structural dimensions and in the dimension of the structural elements. In some embodiments, the internal structure of truss comprises columns, diagonals and horizontal which forms the main structural formwork 32. In some embodiments, substructure 36 and curtain wall system 29 are installed on interior side of formwork 32 like the truss Core Bottom 59. In some embodiments, a profile 9 is fastened to the substructure 36 to enable connection with other panels. In some embodiments, the components and order elements in the truss Long Bottom 60 are the same as those in trusses Core Bottom 59.
[0201] Referring to FIGS. 66-73, the truss/facade Long Top 75 has similarities in internal structure, layers and differences in the structural dimensions and in the dimension of the structural elements. In some embodiments, the internal structure of truss comprises columns, diagonals and horizontal which forms the main structural formwork 32. In some embodiments, substructure 36 and curtain wall system 29 are installed on interior side of formwork 32 like the truss Core Top 74. In some embodiments, a profile 10 is fastened to the substructure 35 to enable connection with other panels. In some embodiments, the components and order elements in the truss Long Top 75 are the same as those in trusses Core Top 74.
[0202] Referring to FIGS. 74-81, the truss/facade Short Bottom 61 has similarities in internal structure, layers and differences in the structural dimensions and in the dimension of the structural elements. In some embodiments, the internal structure of truss comprises columns, diagonals and horizontal which forms the main structural formwork 32. In some embodiments, substructure 36 and curtain wall system 29 are installed on interior side of formwork 32 like the truss Core Bottom 59. In some embodiments, a profile 9 is fastened to the substructure 36 to enable connection with other panels. In some embodiments, the components and order elements in the truss Short Bottom 61 are the same as those in trusses Core Bottom 59.
[0203] Referring to FIGS. 82-89, the truss/facade Short Top 76 has similarities in internal structure, layers and differences in the structural dimensions and in the dimension of the structural elements. In some embodiments, the internal structure of truss comprises columns, diagonals and horizontal which forms the main structural formwork 32. In some embodiments, substructure 36 and curtain wall system 29 are installed on interior side of formwork 32 like the truss Core Top 74. In some embodiments, a profile 10 is fastened to the substructure 36 to enable connection with other panels. In some embodiments, the components and order elements in the truss Short Top 76 are the same as those in trusses Core Top 74.
[0204] Referring to FIGS. 90-97, the truss/facade 100X34 Bottom 62 has similarities in internal structure, layers and differences in the structural dimensions and in the dimension of the structural elements. In some embodiments, the internal structure of truss comprises columns, diagonals and horizontal which forms the main structural formwork 32. In some embodiments, substructure 36 and curtain wall system 29 are installed on interior side of formwork 32 like the truss Core Bottom 59. In some embodiments, a profile 10 is fastened to the substructure 36 to enable connection with other panels. In some embodiments, the components and order elements in the truss 100X34 Bottom 62 are the same as those in trusses Core Bottom 59.
[0205] Referring to FIGS. 98-105, the truss/facade 100X34 Top 77 has similarities in internal structure, layers and differences in the structural dimensions and in the dimension of the structural elements. In some embodiments, the internal structure of truss comprises columns, diagonals and horizontal which forms the main structural formwork 32. In some embodiments, substructure 36 and curtain wall system 29 are installed on interior side of formwork 32 like the truss Core Top 74. In some embodiments, a profile 10 is fastened to the substructure 36 to enable connection with other panels. In some embodiments, the components and order elements in the truss 100X34 Top 77 are the same as those in trusses Core Top 74.
[0206] In some embodiments, a plurality of prefabricated elements is provided as a kit wherein the plurality of the elements is of the same type. In some embodiments, a plurality of elements is provided as a kit, wherein prefabricated elements come in a plurality of different types. In some embodiments, these different types are complementary in denomination. The size of each type of the elements is ultimately the decision of the user and depends upon the following non-limiting list of factors: human-scale, space quality, industrial sizes, and transportation margins.
[0207] Referring to FIG. 106-109, a Shaft Cabinet 65 is provided as a prefabricated element. In some embodiments, the shaft cabinet is 20 0 in length, 7 2 in width and approximately 8 6 in height. In some embodiments, the shaft cabinet includes a plurality of non-structural self-supporting walls. In some embodiments, the walls of shaft cabinet include an internal structure and at least one functional layer 39. In some embodiments, the functional layer 39 includes thermal and acoustic thermal insulation 41 and cement board as finishing layer 40, similar as the functional layer in wall panels. In some embodiments, the internal structure is comprised of C-profiles 44 and U-profiles 45. In some embodiments, two installation cabinets and two doors 46 are integrated in the shaft cabinet. In some embodiments, the shaft cabinets include the floor steel structure, comprised of C-profiles 44, U-Profiles 45 and corrugated metal sheet 43. In some embodiments, the piping 47, ducts 48 or conduits 49 correspondent to the installation are partly hold in the functional layer and partly fixed in the installation cabinet. In some embodiments the installation cabinet is accessible via a cabinet door 46. In some embodiments, two access door 52 are integrated in the walls of the Shaft Cabinet 65 elements. In some embodiments, the Shaft Cabinet element includes a corrugated metal sheet 43 for the on-site casted concrete in the construction process. The shaft cabinet can be applied in construction modules, as seen in FIGS. 138-157.
[0208] Referring to FIG. 110-113, a Stair Type 1 63 is provided as a prefabricated element. In some embodiments, the Stair Type 1 element is 20 0 in length, 4 4 in width and approximately 8 6 in height. In some embodiments, the Stair Type 1 element includes a plurality of non-structural self-supporting walls. In some embodiments, the walls of Stair Type 1 element include an internal structure and at least one functional layer 39. In some embodiments, the functional layer 39 includes thermal and acoustic insulation 41 and cement board as finishing layer 39, similar as the functional layer in wall panel. In some embodiments, the internal structure is comprised of C-profiles 44 and U-profiles 45. In some embodiments, one prefabricated stair is integrated in the Stair Type 1 element. In some embodiments, the prefabricated stair is composed of a plurality of prefabricated steps 50 and prefabricated landing 51. The Stair Type 1 element can be applied in construction modules, as seen in FIGS. 138-157.
[0209] Referring to FIG. 114-117, a Stair Type 2 64 is provided as a prefabricated element. In some embodiments, the Stair Type 2 element is 20 0 in length, 4 4 in width and approximately 8 6 in height. In some embodiments, the Stair Type 2 element includes a plurality of non-structural self-supporting walls. In some embodiments, the walls of Stair Type 2 element include an internal structure and at least one functional layer 39. In some embodiments, the functional layer 39 includes thermal and acoustic insulation and cement board as finishing layer 40, similar as the functional layer in wall panel. In some embodiments, the internal structure is comprised of C-profiles 44 and U-profiles 45. In some embodiments, two access door 52 are integrated in the walls of the Stair Type 2 element. In some embodiments, one prefabricated stair is integrated in the Stair Type 2 element. In some embodiments, the prefabricated stair is composed of a plurality of prefabricated steps 50 and prefabricated landing 51. The Stair Type 2 element can be applied in construction modules, as seen in FIGS. 138-157.
[0210] Referring to FIG. 118-121, a Bath Module 66 is provided as a prefabricated element. In some embodiments, the bath module is 15 3 in length, 9 0 in width and approximately 7 6 in height. In some embodiments, the bath module includes a plurality of non-structural self-supporting walls. In some embodiments, the walls of bath module include an internal structure and at least one functional layer 39. In some embodiments, the functional layer 39 includes thermal and acoustic thermal insulation 41 and cement board as finishing layer 40, similar as the functional layer in wall panels. In some embodiments, the internal structure is comprised of C-profiles 44 and U-profiles 45. In some embodiments, plumbing fixtures 53 are integrated in the bath module. In some embodiments, the piping 47 correspondent to the installation are partly hold in the functional layer and partly fixed in the installation cabinet. In some embodiments the bath module is accessible via a door 52. In some embodiments, three access door 52 are integrated in the walls of the Bath Module 66 element. The shaft cabinet can be applied in construction modules, as seen in FIGS. 138-157.
[0211] Referring to FIG. 122-125, a Bath Common Module 67 is provided as a prefabricated element. In some embodiments, the bath common module is 10 0 in length, 4 0 in width and approximately 7 6 in height. In some embodiments, the bath common module includes a plurality of non-structural self-supporting walls. In some embodiments, the walls of bath common module include an internal structure and at least one functional layer 39. In some embodiments, the functional layer 39 includes thermal and acoustic thermal insulation 41 and cement board as finishing layer 40, similar as the functional layer in wall panels. In some embodiments, the internal structure is comprised of C-profiles 44 and U-profiles 45. In some embodiments, plumbing fixtures 53 are integrated in the bath common module. In some embodiments, the piping 47 correspondent to the installation are hold in the functional layer. The bath common module can be applied in construction modules, as seen in FIGS. 138-157.
[0212] Referring to FIG. 126-129, a Kitchen Module 68 is provided as a prefabricated element. In some embodiments, the kitchen module is 15 3 in length, 9 0 in width and approximately 7 6 in height. In some embodiments, the kitchen module includes a plurality of non-structural self-supporting walls. In some embodiments, the walls of kitchen module include an internal structure and at least one functional layer 39. In some embodiments, the functional layer 39 includes thermal and acoustic thermal insulation 41 and cement board as finishing layer 40, similar as the functional layer in wall panels. In some embodiments, the internal structure is comprised of C-profiles 44 and U-profiles 45. In some embodiments, plumbing fixtures 53 are integrated in the kitchen module. In some embodiments, a plurality of cabinets 54 are integrated in the kitchen module. In some embodiments, the piping 47 correspondent to the installation are partly hold in the functional layer and partly fixed in the installation cabinet. The kitchen module can be applied in construction modules, as seen in FIGS. 138-157.
[0213] Referring to FIG. 130-133, a Elevators Doors Module 69 is provided as a prefabricated element. In some embodiments, the Elevators Door Module element is 15 3 in length, 6 in width and approximately 8 0 in height. In some embodiments, the wall of Elevators Doors Module element includes an internal structure and at least one methacrylate layer 42. In some embodiments, the internal structure is composed of galvanized profiles 45. In some embodiments, two elevator doors 55 are integrated in the internal structure of the Elevators Doors Module element. The Elevators Doors Module element can be applied in construction modules, as seen in FIGS. 138-157.
[0214] Referring to FIG. 134-137, a Core Technical Floor 70 is provided as a prefabricated element. In some embodiments, the Core Technical Floor element is 15 3 in length, 5 8 in width and approximately 1 0 in height. In some embodiments, Core Technical Floor element include a steel frame structure. In some embodiments, the steel frame structure is comprised of C-profiles 44 and U-profiles 45. In some embodiments, the Core Technical Floor element includes a corrugated metal sheet 43 for the on-site casted concrete in the construction process. The Core Technical Floor element can be applied in construction module, as seen in FIGS. 138-157.
[0215] Referring now to FIGS. 138-147, in the construction module 100X50, wall panels, wall lintel, trusses/facades, slab panel and prefabricated elements are connected via rebars and other connections. In some embodiments, vertical rebars in all the element panels are connected to horizontal rebars from other element panels. In some embodiments, on-site concrete unifies the rebars on different panels and the entirety.
[0216] In some embodiments, the present disclosure is directed to a method of assembling modular panels to produce a building or interior space. In some embodiments, the modular panels are self-supporting, so individual panels can be installed one at a time and remain in place while adjacent panels are installed until a desired size and shape of the building or interior space is completed. FIGS. 138-147 portray exemplary processes for connecting panels in the construction module consistent with some embodiments of the present disclosure and as discussed above.
[0217] Referring to FIG. 138, once wall panels, wall lintel, trusses/facades, slab panel and prefabricated elements arrive at a building site, wall panels are first installed on a casted in concrete level 56. Referring to FIG. 139, wall bottom panels 57 would then be installed at the top of the casted in concrete level. Rebar connections 81 are placed on top of the installed wall bottom panels 57. Referring to FIG. 140, trusses/facades core bottom 59, trusses/facades long bottom 60 and trusses/facade short bottom 61 panels for the structural facade would then be installed at the end of the installed wall panels. Rebar connections 81 are placed on top of the installed trusses/facade panels 59, 60, 61. Referring to FIG. 141, core prefabricated elements would then be installed. Such elements include Stair Type 1 element 63, Stair Type 2 element 64, Shaft Cabinet element 65, Elevators Doors Module element 69 and Technical Floor element 70. Referring to FIG. 142, bottom prefabricated elements would then be casted in concrete. The pouring of the bottom concrete 71 would connect wall panels, trusses/facades panels and prefabricated core elements into a whole. Connecting rebar 81 would be left on top of the casted in concrete elements to connect the top wall panels, top trusses/facades to the already installed bottom prefabricated elements.
[0218] Referring to FIG. 143, wall top panels 72 would then be installed at the top of the installed and casted in concrete wall bottom panels. Rebar connections 81 are placed on top of the installed wall top panels 72. Referring to FIG. 144, trusses/facades core top 74, trusses/facades long top 75 and trusses/facade short top 76 panels for the structural facade would then be installed at the end of the installed wall panels and on top of the bottom trusses/facades panels. Referring to FIG. 145, core prefabricated elements would then be installed. Such elements include Stair Type 1 element 63, Stair Type 2 element 64, Shaft Cabinet element 65, Wall Lintel element 78 and Technical Floor element 70. Referring to FIG. 146, prefabricated slab panels unit 79 would then be installed. Referring to FIG. 147, top prefabricated elements would then be casted in concrete. The pouring of the top concrete 80 would connect wall panels, trusses/facades panels, prefabricated elements and slab panels into a whole.
[0219] Referring now to FIGS. 148-157, in the construction module 100X34, wall panels, trusses/facades, slab panel and prefabricated elements are connected via rebars and other connections. In some embodiments, vertical rebars in all the element panels are connected to horizontal rebars from other element panels. In some embodiments, on-site concrete unifies the rebars on different panels and the entirety.
[0220] In some embodiments, the present disclosure is directed to a method of assembling modular panels to produce a building or interior space. In some embodiments, the modular panels are self-supporting, so individual panels can be installed one at a time and remain in place while adjacent panels are installed until a desired size and shape of the building or interior space is completed. FIGS. 148-157 portray exemplary processes for connecting panels in the construction module consistent with some embodiments of the present disclosure and as discussed above.
[0221] Referring to FIG. 148, once wall panels, wall lintel, trusses/facades, slab panel and prefabricated elements arrive at a building site, wall panels are first installed on a casted in concrete level 56. Referring to FIG. 149, wall bottom panels 57, end wall bottom panels 58 would then be installed at the top of the casted in concrete level. Rebar connections 81 are placed on top of the installed wall bottom panels 57 and end wall bottom panels 58. Referring to FIG. 150, trusses/facades 100X34 bottom 62 for the structural facade would then be installed at the end of the installed wall panels. Rebar connections 81 are placed on top of the installed trusses/facade panels 62. Referring to FIG. 151, core prefabricated elements would then be installed. Such elements include Stair Type 1 element 63, Stair Type 2 element 64, Shaft Cabinet element 65, Bath Module element 66, Bath Common Module element 67, Kitchen Module element 68, Elevators Doors Module element 69 and Technical Floor element 70. Referring to FIG. 152, bottom prefabricated elements would then be casted in concrete. The pouring of the bottom concrete 71 would connect wall panels, trusses/facades panels and prefabricated core elements into a whole. Connecting rebar 81 would be left on top of the casted in concrete elements to connect the top wall panels, top trusses/facades to the already installed bottom prefabricated elements.
[0222] Referring to FIG. 153, wall top panels 72 and wall top panels w/opening 73 would then be installed at the top of the installed and casted in concrete wall bottom panels. Rebar connections 81 are placed on top of the installed wall top panels 72 and wall top panels w/opening 73. Referring to FIG. 154, trusses/facades core 100X34 top 77 for the structural facade would then be installed on top of the bottom trusses/facades panels. Referring to FIG. 155, core prefabricated elements would then be installed. Such elements include Stair Type 1 element 63, Stair Type 2 element 64, Shaft Cabinet element 65 and Technical Floor element 70. Referring to FIG. 156, prefabricated slab panels unit 79 would then be installed. Referring to FIG. 157, top prefabricated elements would then be casted in concrete. The pouring of the top concrete 80 would connect wall panels, trusses/facades panels, prefabricated elements and slab panels into a whole.
[0223] In some embodiments, prefabricated groups of rebars connect wall, lintel, trusses/facades and slab panels. In some embodiments, the on-site casted concrete connects the panels into a whole. In some embodiments, any gaps at the joints between wall, lintel, truss/facade, slab panels and prefabricated elements are filled with polyurethane foam spray, which is fast-solidifying and has thermal insulation properties. In some embodiments, gaps between adjoining panels and/or truss/facade panels are stuck with adhesive. In some embodiments, construction of subsequent floors of a building begins after the underlying floor has settled. In some embodiments, the upper floor is formed by installing panels on the internal structures of the previous floor. In some embodiments, upper floors are subsequently constructed in a similar manner.
