Construction System

Abstract

A building construction system utilizing prefabricated stacked modules creating tubular resistant modules forming spaced hollow columns interconnected by bridges and a plurality of elongate structural profiles made of bendable steel used as column and beam components in the modules.

Claims

1. A construction system for multi-level buildings comprising a plurality of modules stacked one on top of the other, each of said modules having vertical side walls such that said stacked modules create tubular resistant modules forming spaced hollow columns; a bridge flexibly connected with said hollow columns; and a plurality of elongate structural profiles used as column and beam components in said modules, each of said profiles having first and second opposing ends, each of said profiles being made of bendable steel bent to have uniform cross-sections along the length thereof between said first and second ends, said cross sections defining a web having first and second longitudinal side edges defining a width therebetween, first and second spaced, planar side flanges extending from said first and second side edges of said web, respectively, to be perpendicular to said web from said first end to said second end of said profile, an indentation in said web having a V shape, and first and second planar stiffening inner flanges extending toward said indentation from said first and second planar side flanges, respectively, said stiffening inner flanges being disposed in a plane parallel to and spaced from said web and terminating at inner edges spaced from each other.

2. A construction system as recited in claim 1 wherein said plurality of profiles are joined together to form rigid frames pre-assembled at a factory for transportation to a construction site for the buildings and said modules are formed using said profiles as columns and beams.

3. A construction system as recited in claim 2 wherein said modules are open boxes formed of panels coupled with said columns and beams forming said metal frames

4. A construction system as recited in claim 3 wherein said boxes are grouped to accommodate damp elements.

5. A construction system as recited in claim 3 wherein said modules are grouped to form building modules and staircase modules.

6. An elongate steel structural profile for use as a column or beam building element in construction of a building, said profile being made of bendable steel bent to have a uniform cross-section along the length thereof between said first and second ends, said cross section defining a web having first and second longitudinal side edges defining a width therebetween, first and second spaced, planar side flanges extending from said first and second side edges of said web, respectively, to be perpendicular to said web from said first end to said second end of said profile, an indentation in said web having a V shape, and first and second planar stiffening inner flanges extending toward said indentation from said first and second planar side flanges, respectively, said stiffening inner flanges being disposed in a plane parallel to said web and terminating at inner edges spaced from each other.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0030] FIG. 1 is a perspective view of a framework formed by a plurality of connected bent steel structural profiles for supporting an arrangement of modules for a building constructed according to the present invention.

[0031] FIG. 2 is a perspective view of a plurality of bent steel structural profiles for supporting staircase modules for a building constructed according to the present invention.

[0032] FIG. 3 is a perspective view of a partial house module arrangement constructed according to the present invention.

[0033] FIGS. 4a and 4b are exploded views of a building constructed in accordance with the present invention utilizing boxes, staircase modules and bridges.

[0034] FIG. 5 is a broken perspective view of an elongate structural bent steel profile according to the present invention.

[0035] FIG. 6 is an end view of the elongate structural bent steel profile shown in FIG. 5.

DETAILED DESCRIPTION OF THE INVENTION

[0036] The construction system according to the present invention can be considered to be a kit formed of a set of elements that, when assembled, produce the desired architectural result (the building), the elements including the metal structure and the composite panels with a hollow core. They are quantified depending on the function of the typology in which the construction system is used. Elements of the metal structure can include bolt plates, tie bolts, columns, long girders, short girders, connection nodes, connection bolts and reinforcement plates. Elements of composite panels with hollow core can include composite panels with hollow slab core (sheet), composite panels with hollow core for exterior vertical walls, and composite panels with hollow core for interior vertical walls.

[0037] The construction system of the present invention typically includes building modules and staircase modules, both made up of the aforementioned kit elements. The modules are stacked in a metal framework 40 to form resistant tubular modules as shown in FIG. 1, where the stacked modules are supported by a plurality of cold-shaped elongate profiles P creating the framework 40. The profiles are formed of steel coil, for example, A715-92 steel which covers high-resistance and low-alloy sheets and strips and cold-laminated sheets with improved shaping properties compared to A606 and A607. Profiles 42 act as horizontal girders and profiles 44 act as vertical columns. The profiles are supplied in cut lengths or in reels to form elongate structural elements available in four resistance levels, 50, 60, 70 and 80; and eight types (according to chemical composition). The steel is transformed into a fine, granular material and includes elements of microaeleation, such as columbium, vanadium, titanium and zirconium, etc.

[0038] As shown in FIGS. 2 and 3, respectively, the modules can be staircase modules and house or office modules with roof panels 52 formed at the top of the resulting building. Other types of steel of less resistance can be used with the structural calculations, and thus the dimensions of the profiles and the resistant tubular modules can be adapted to the desired requirements, (e.g. earthquakes, tornadoes and the like).

[0039] The construction system process includes the steps of laying out a foundation on slabs, with boards and tie bolts, positioning and securing of profile columns, assembling the framework of the slabs (the slabs can be put together on the ground before being hoisted up), hoisting the assembled slabs up and fixing with connecting bolts, securing connections, positioning subfloor panels, positioning roof slab panels, and positioning partition and wall panels.

[0040] Some of the advantages of the construction system of the present invention compared to prior art modular systems are that prior art modules have a disadvantage which has laid them open to criticism from architects and users, namely their extreme rigidity for the arrangement of the spaces. Indeed, the dimensions of the prior art modules are limited by the maximum weight that can be lifted by the respective equipment. Furthermore, there are maximum dimensions which must be complied with for handling and erecting prefabricated modules. For this reason, when it is necessary to obtain larger spaces allowing greater flexibility in architectural organization, existing module building systems cannot be used. This disadvantage has been overcome by the construction system of the present invention because the areas formed with the prefabricated modules are selected among those in which the rigidity imposed by the module presents no difficulty for the architectural design but which, on the contrary, improves this design from the construction point of view. Such is the case for the kitchen and bathroom areas, which can be put together on the ground in one assembly line, with all utilities, including fixtures and fittings. The spaces which require greater flexibility are put in the bridge, made up of the prefabricated floor which is supported by the resistant tubular modules. This space is limited in two directions by the walls of the modules and, in the other four directions, by modules and bridges, prefabricated panels, either walls or floors. The possibilities for combining modules and bridges are infinite and allow the architect to display all his/her imagination and creativity in order to achieve better shapes and spatial systems. Furthermore, the possibility of varying the separation between the resistant tubular module groupings within the same building or group of buildings breaks with the monotony of buildings using existing prefabricated module systems. The use of prefabricated panels on faades allows for variations in shapes and textures, giving a richer overall effect.

[0041] A fundamental element in the structure of a building being built with the construction system of the present invention is the resistant tubular module. This module is formed by the vertical stacking of the individual modules and the joining of the integrated structural elements within those modules using various connecting systems, the most important of which, in the case of high-rise buildings, is the use of post-tension cables or bars which, through compression on the columns, slabs or screens, forms a structural unit able to withstand the static or dynamic pressures of axial or horizontal forces. The use of post-tension elements allows for savings in the implementation of the system, because it eliminates weight in the components, which is an advantage as regards handling the prefabricated components, as well as regarding the reduction in seismic forces on the structure. In buildings of more than fifteen floors, horizontal forces can be resisted by way of the girders connecting the resistant tubular modules such that the building will react as a whole to seismic forces or wind. In the case of low-rise buildings, the vertical connection elements (columns) act as poles which, in combination with the connection nodes, can be used to hoist up the slabs that have been previously reinforced on the ground. The construction system combines metal structural elements with lightweight composite panels, which increases the rigidity and resistance of the resistant tubular modules and makes a continuous slab on the bridges.

[0042] The construction system has the following advantages: it reduces the number of heavy units which have to be erected in a building; it allows for the mounting of utilities and fittings to be concentrated in only one part of the group of prefabricated units (modules designed for utilities); the greater part of the constructed prefabricated area can be built with lightweight equipment, representing a saving on building costs; alternatives can be used as regards the type of interior partitions in the flexible areas, making use of the system feasible in buildings of greater quality and comfort; production of the majority of the building elements can be industrialized; and the use of lightweight composite panels means that the steel structure, subfloor slab and external and internal composite walls can be assembled in one single step.

[0043] Based conceptually on a reasonable flexibility of spaces, concentration and differentiation of damp elements and/or areas with dry elements and/or invariant and variant spaces, the construction system permits easy and quick assembly with a construction process that does not require specializations. As a principle, the construction system poses the differentiation between type and typology. The concept of type refers to a sort of characteristic concentrated in the buildings, where the aim is to reproduce a standard model or archetype, attempting to reproduce a single characteristic of the variables presented. It supposes a reduction in the variation. This concept, by not considering other factors, for example environmental factors, results in the design of a dwelling which, by way of its homogenous characteristics leads to the establishment of models which repeat themselves according to cost savings. The scale of the buildings depends on the sum of requirements, with the human scale being lost. The concept of typology comes from the explanation of the formal and temporal variables which take into account not only the economic factor, but also include the alternatives which arise in a geographical context in a determined time, also considering the cultural aspect, which consists of a set of cultural, emotional and mnemonic assessments, for which the block of elements constituting the building appear as a unitary model, preferable to other, similar models (prototypes or derivatives), or including the specific effective and cultural attributes of a way of life. Approaching the architectural design process from this point of view allows for the variants and invariants, which are the product of the recognition of cultural and environmental determinants, to be considered. The construction system tends to establish typologies.

[0044] The basic elements of the construction system of the present invention include the metal framework 40 as shown in FIG. 1, the staircase modules shown in FIG. 2 and the home/office modules shown in FIG. 3 which are formed in the metal framework 40 and create structural modules as shown in FIGS. 4a and 4b. The structural modules feature an open (top and bottom) horizontal box 62, constructed of a system of panels 64 made of normal and/or hollow-core concrete, metals, resins, or combinations of any of these. Joints are fixed with bolts or welding and slabs 66 which form the bottom or top can be solid or ribbed and may have areas filled with lightweight material allowing for utilities to be embedded and limiting the weight to a minimum. The stacked arrangement of the modules creates resistant tubular modules, which bear the horizontal and vertical load requirements of the building. The use of elements such as brackets, bolts or other devices serving to support or join other horizontal structural elements, such as hollow-core girders and slabs, which connect the resistant tubular modules in the form of a bridge 70, creating a large frame that offers greater resistance to seismic pressures and can be used in conjunction with the system of panels, whether in normal or hollow-core reinforced concrete, metal, resins or a combination of any of these. Each module can form part of a specific unit of a dwelling. All elements for the final touches, finishing and utilities can be incorporated before the modules are erected on the same production line. With the construction system of the present invention, the resistant tubular modules can be laid out on the ground plan according to any model drawn up in the design (e.g. linear, bi-linear and radial). The construction system allows for the design of a module which, because of its laminar structure, can be moved from the vertical stack in the direction of its greatest dimension, thereby obtaining a building which is staggered on one side and flies on the other. Constructively, the modules can be prefabricated in a factory or elsewhere or be put together on an ongoing basis, and the lightweight composite panels allow the steel structure, subfloor slab and external and internal composite walls to be assembled in one single step.

[0045] As noted, the construction system is characterized by a metal framework, structure system which forms one or more resistant tubular modules, combining boxes and bridges, jointly using panels which can be made of normal or hollow-core concrete, metals or resins, or combinations of any of these types, to erect multiple-floor buildings which can serve as dwellings, offices, hotels or other services. The modules are positioned so that, when stacked one on top of another, the upper and lower spaces formed have a common element. The walls of the modules can be of uniform or variable thickness, depending on the structural resistance requirements corresponding to each building. The use of embedded elements such as brackets, steel bolts and other devices serve as supports or joints. The use of hollow-core slabs as top and bottom elements gives greater structural rigidity and enables sanitary and mechanical utilities to be embedded in them, limiting weight to a minimum. The lightened elements can be ribbed slabs with or without filling, hollow-core slabs or the like. The resistant tubular modules take all the horizontal and vertical load requirements of the building. The resistant tubular modules are formed by the vertical stacking of the modules fixed together with joints, which can have cement mortars, synthetic resins or Neoprene as interface materials and can be fixed with steel clamps and bolts. To achieve better structural unity and eliminate tensile stress, a system of post-tension cables or bars can be put in place from top to bottom, throughout the walls of the stacked prefabricated modules or of the columns embedded in rows. A building thus formed, is held together monolithically by the effects of post-tension. The structure is designed to take all the vertical and horizontal loads bearing on it and is, therefore, called a resistant tubular module. More complete structures can be formed with the use of girder structural elements which connect the resistant tubular modules, forming a large frame which gives greater resistance to seismic pressures on the building.

[0046] The absence of a limit in the separation between the resistant tubular modules permits separation from 2 m to 15 m or more, naturally depending on the thicknesses which are to be given to the slabs forming part of the bridge connecting them. This is achieved with the use of ribbed hollow-core slabs, with or without filling, as bridging elements between the resistant tubular modules by which they are supported. The ribbed slabs form a monolithic unit with the top or bottom of the individual module, with the use of mortar between the joints and longitudinal and transversal post-tension.

[0047] The use of special prefabricated modules for areas with complex finishes, such as bathrooms and kitchens, are manufactured on the assembly line on the ground so that, before they are erected on the level that they occupy in the building, they already contain all the utilities, fixtures, windows, doors and fittings. The use of lightweight composite panels allows the steel structure, the subfloor slab and the external and internal composite walls to be assembled in one single step.

[0048] Some of the advantages of the panel elements used in the construction system include thermal insulation due to the panels responding perfectly to both load-bearing and insulating functions. The thickness and density of the panels are designed according to a specific thermal insulation that has been selected. The EPS base spreads without breaks across all the surfaces constituting the envelope of the building, without any thermal bridges, (e.g., a panel element with a finished thickness of almost 15 cm has a thermal insulation similar to that of an insulated masonry wall of some 40 cm, which leads to obvious advantages of larger usable spaces). Combination with sound-absorbing materials, such as plasterboard, cork, coco fiber, mineral wool and the like, optimizes the insulation of walls to comply with the most restrictive acoustic regulations. Resistance to weight in many laboratory tests carried out in different parts of the world have highlighted the panel elements' high resistance to weight. For example, compression tests, with a weight in the center, carried out on a standard finished panel 270 cm in height, obtained a maximum ultimate load equal to 1530 kN/m. Resistance to fire results from the quality of the expanded polystyrene used in the panel elements which is self-extinguishing and two concrete layers covering the sides of the panel prevent combustion. A wall built with the panel elements has demonstrated resistance to fire of above RE1120. Resistance to explosions in the panel elements covered with different types of high-resistance concrete produces an even shockwave on the front of the panels. The panels are lightweight and, at the same time, sufficiently rigid even before finishing with shotcrete, making them easy to handle and mount, including in difficult working conditions. A consistent reduction in construction times for building in comparison to those built with traditional systems. Walls built with the panels can be finished by applying a thick covering directly to the rough plaster or, alternatively, traditional paints on smoothed plaster allowing the use of any type of covering. Accordingly, the panels are advantageous both for the end user and for companies, because they provide better performance compared to traditional products at much lower costs.

[0049] Composite panel elements with hollow cores can be used on one or more floors. The composite panels can form hollow slab cores (sheets), exterior vertical walls or interior vertical walls.

[0050] The elongate structural profile P according to the present invention, is shown in FIGS. 5 and 6. The profile P is made of bendable steel as described above having a length L with opposing ends 82 and 84 with a uniform shape in cross-section along the length L between the opposing ends. The shape defines a central web 86 having a first longitudinal edge 88 and a second longitudinal edge 90 defining a width W therebetween, a planar side flange 92 extending from longitudinal edge 88 to be perpendicular to web 86, a planar side flange 94 extending from longitudinal edge 90 to be perpendicular to web 88 and in spaced parallel relation to side flange 92, a V shaped indentation 96 in the web 86 running centrally the length of the profile, a stiffening planar inner flange 98 extending from side flange 92 toward indentation 96 and a stiffening planar inner flange 100 extending from side flange 94 toward indentation 96 such that the stiffening inner flanges 98 and 100 are disposed in a plane parallel to and spaced from web 86. The stiffening inner flanges 98 and 100 terminate at inner edges 102 and 104, respectively, that are spaced from each other. The stiffening inner flanges strengthen the side flanges to prevent local buckling in that the stiffening reinforces the profile to allow the profile to be calculated as a closed element while reducing weight. The length S.sub.1+S.sub.2 of the stiffening created by the inner flanges is at least one-third of the width W of the web 86. The indentation 96 forms a reinforcing rib, and similar reinforcing indentations (ribs) can be disposed at various positions and in various numbers on the flanges.

[0051] As shown in FIG. 6, the shape of the profile P allows, in addition to resistance, for inserting walls in the concavity between edges 102 and 104, whether blocks or panels, creating a mechanical seal and thus avoiding the cracks that are produced when different kinds of materials are joined.

[0052] Inasmuch as the present invention is subject to many variations, modifications and changes in detail, it is intended that all subject matter discussed above or shown in the accompanying drawings be interpreted as illustrative only and not be taken in a limiting sense.