INDUSTRIAL BUILDING CONSTRUCTION PROCESS

Abstract

The present disclosure relates to a construction process, the so-called Zaina process, which was designed to industrialize the construction of buildings. The Zaina construction process operates like an industry that receives raw materials and transforms them into a product; it establishes an analogous vertical production line, the end product of which is a building. It is an industrial process implemented at the delivery site of the product, that is to say, the building.

Claims

1: An industrial process for constructing buildings comprising the steps of: a) Execution of the staking; b) Concreting the foundation blocks and securing the formwork to the ground; c) Assembly of the operational platform; d) Assembly of the columns; e) Casting of chassis on the operational platform; f) Lifting of the chassis; g) Closing and finishing of floors; h) Replacement of the last module of the columns and installation of elevators and stairs; i) Interconnection of utility systems; j) Removal of operational platform and formwork.

2: The process according to claim 1, wherein in step b) the foundation block of the columns is formed in two phases: a first phase to ensure the positioning of the pulley inside the block for one or more cables depending on the building and allow the topographic location with planialtimetric control of the starter of the columns; a second phase to anchor the rag bolts.

3: The process according to claim 2, wherein in this area also the clamps and/or tie rods are placed to anchor the metal formwork, with the surface prepared to receive the casting of all the chassis of the building.

4: The process according to claim 1, wherein in step c) the operational platform is prepared at the site of the building immediately after the foundation blocks and the formwork in a compacted flat area and with paved accesses; over a formwork fixed on the floor, with a suitable space for mounting the metal ring, above the foundation block and, together with the starter of the columns, the steel armors of both the beams and the slabs are to be assembled for a two-level concreting; at a level above the Formwork mobile platforms are installed; a utility network is installed away from the chassis perimeter; and in the ground a drainage network is installed.

5: The process according to claim 4, wherein said devices are installed at the ground level and allowing access to the formwork having the conformation of the bottom of the slab to be used for molding the chassis, which is manufactured in: reinforced concrete with or without carbon fiber and/or prestressing steel; in metallic structure and/or a mixed structure of metallic profiles and concrete.

6: The process according to claim 4, wherein a command cabin is installed at a height above the operational platform with panoramic view, outside the perimeter of the building.

7: The process according to claim 1, wherein in step d) the columns are mounted, with the installation of the lifting cables and engagement of the first ring in the Formwork; the columns being made of rolled steel profiles, distributed in the vertices of geometric figures of four or more sides, being interconnected, contravened, stiffened with bars containing holes, protrusions, through- and threaded holes, racks, and being prepared to receive other engaging devices or hoisting equipment, also metallic, in the sequence of the chassis assembly.

8: The process according to claim 7, wherein the columns are manufactured in a boiler shop in four segments: the starter, the standard module, the top with pulleys and that of the water tank; the starter is smaller and has a base plate with a hole for the rag bolts and the other standard modules are constructed in accordance with the local transport legislation; and the last module is provided with hydraulic cylinders and pulleys and is removed after lifting all the chassis to allow installation of the water tanks.

9: The process according to claim 7, wherein the columns are provided with small removable elevators and in that the column starters are short and light segments and the other segments of the columns require a crane to assemble them, one after the other and, to enable the installation of the steel cable system for lifting the chassis.

10: The process according to claim 7, wherein the steel cables are as many as required and are housed and anchored in metal inserts in the inscribed space of the columns with free access for the vertical displacements of the accessories, both in the vertical shaft of the hook of the metal ring of the chassis and in the vertical shaft of the drag cable descending to the pulley of the foundation block; wherein the hoisting cable system is previously prepared in the ground and consists of two motorized steel cable winders.

11: The process according to claim 10, wherein one of the cable winders contains the steel cable in its entire length, suitably housed with the other incorporated accessories, and fixed to the column in the top segment next to the pulleys, and the other cable winder also contains housed steel cables and is fixed to the first segment of the column, close to starter.

12: The process according to claim 1, wherein in step e) the chassis are cast at the ground level on the operational platform and are provided with a metal ring with a device for connecting the lifting hooks and also of the eyebolts for engaging the locking and supporting bars of the chassis, circumscribed to the perimeter of the column and inserted into the structural concrete of the chassis or welded in the profiles if the chassis is of a metal structure, split and its assembly is in the surroundings of the column starters by the union of the two parts that should engage in the formwork of the platform.

13: The process according to claim 10, wherein the chassis are concreted in the same way in two stages to allow the laying of all the embedded elements and the concrete is steam cured; the hydro-sanitary installations are executed at half height, the finishing and sealing material of the floor are deposited on its surface; and by the time the chassis are ready for hoisting, the hydraulic devices equipped with cameras are mounted and in strategic positions the nozzles are activated to inject compressed air into the removal of formwork.

14: The process according to claim 1, wherein in step f) the support columns receive the chassis that are ready and they are lifted having the columns as guides and fixed in a top-down sequence; in that the foundation block houses an inner pulley and the hoisting is made by steel cables which hang from the pulleys at the top of the columns and engage the hooks in the inserted part of the metal ring of the chassis and are driven by drag winches located outside the perimeter of the building.

15: The process according to claim 14, wherein the hoisting process is carried out by hydraulic winches installed at the top of the columns or by winches on the ground that must simultaneously synchronously work to tension the cables and perform the lifting of the chassis, installed in the ground in opposite positions along the longitudinal axis of the building, on suitable foundations remote from the perimeter of the chassis; the diameter of the cable winders loosely accommodates the whole extension of the cable, in a single turn; and the winches have brake, mechanical locking and operate with programmed shutdowns under remote control.

16: The process according to claim 14, wherein the chassis after the lifting, positioning and locking have a tray mounted on the lower part in each column, fixed by special screws, to receive a grouting; and after the fixing of the chassis in the columns, the assembly of the sealing panels is started.

17: The process according to claim 5, wherein a command cabin is installed at a height above the operational platform with panoramic view, outside the perimeter of the building.

18: The process according to claim 8, wherein the columns are provided with small removable elevators and in that the column starters are short and light segments and the other segments of the columns require a crane to assemble them, one after the other and, to enable the installation of the steel cable system for lifting the chassis.

19: The process according to claim 8, wherein the steel cables are as many as required and are housed and anchored in metal inserts in the inscribed space of the columns with free access for the vertical displacements of the accessories, both in the vertical shaft of the hook of the metal ring of the chassis and in the vertical shaft of the drag cable descending to the pulley of the foundation block; wherein the hoisting cable system is previously prepared in the ground and consists of two motorized steel cable winders.

20: The process according to claim 15, wherein the chassis after the lifting, positioning and locking have a tray mounted on the lower part in each column, fixed by special screws, to receive a grouting; and after the fixing of the chassis in the columns, the assembly of the sealing panels is started.

Description

BRIEF DESCRIPTION OF THE FIGURES

[0043] FIG. 1 shows stakes and foundation block with the rag bolt and insertions.

[0044] FIG. 2 shows A) a positioned formwork with the column starters; B) Engagement of the metal ring into the formwork; C) A metal ring.

[0045] FIG. 3 shows A) a segmented column with the chassis attachment inserts; B) Grating tray inserted under the chassis; C) Locking and support bars of the chassis/fixing inserts; D) Bottom view of the tray.

[0046] FIG. 4 shows A) embodiment of the penthouse chassis; B) Raising the penthouse frame; C) Fixing the penthouse frame.

[0047] FIG. 5 shows an industrialized building with 6 floors and slab of 325 m.sup.2.

[0048] FIG. 6 shows the starter winchpositioning and A) frame of trusses; B) Connection of the cable to the cable winder.

DETAILED DESCRIPTION OF THE INVENTION

[0049] The present invention describes the industrial process for building buildings comprising the steps of: [0050] a) Execution of the staking; [0051] b) Concreting the foundation blocks and securing the formwork to the ground; [0052] c) Assembly of the operational platform; [0053] d) Assembly of the columns; [0054] e) Casting of chassis on the operational platform; [0055] f) Lifting of the chassis; [0056] g) Closing and finishing of floors; [0057] h) Replacement of the last module of the columns and installation of elevators and stairs; [0058] i) Interconnection of utility systems; [0059] j) Removal of operational platform and formwork.

[0060] It is important to point out that, before beginning the construction process as described here, some steps inherent to any type of construction are necessary: [0061] Development of an Architectural Project defining the occupation of the standardized area for a type pavement, which will lead to the development of executive construction projects. [0062] Positioning of the openings in the chassis for the installation of elevators, stairs and shafts to lower cables and pipes. [0063] Knowledge of soil surveys at the building site. [0064] Development of the Structural Project of Infrastructure and Superstructure Building. [0065] Development of executive projects for hydro-sanitary installations and other utilities, including electric, telephone installations and etc. [0066] Preparation of the quotation documents and budgets necessary for the execution of the metallic structures of the columns and the chassis if the structural option is of metallic structures, metal rings, stairs and other metallic inserts and for execution of the stacking with scheduling of the delivery dates. [0067] Development of the building implementation project with definition of the points of entry and measurement of water, gas and electric energy, containing information for the preparation of the land such as: access, platform, surface treatment, areas for the installation of containers, drainage network, positioning of reference marks of coordinates and levels. [0068] Implantation of containers to house hydro-sanitary facilities, changing rooms, dining room, activities of command and administration, tooling, stock of material, electromechanical workshop and the equipment of production such as: compressor, generator, boiler and instruments for measurement and control.

[0069] After the completion of these pre-steps, the industrial process of building construction will begin.

[0070] In step (b), the foundation block of the columns will be embodied, in accordance with FIG. 1, in two phases: [0071] The first phase is to ensure the correct and accurate positioning of the pulley inside the block for one or more cables depending on the building and allow the topographic location with planialtimetric control of the starter of the columns. [0072] The second phase is to anchor the rag bolts with the function of absorbing the static and dynamic loads.

[0073] After positioning and fixing the columns, the foundation block will have the finished concrete (both by steam curing) with the rag bolts grated and torqued to ensure the lifting of the chassis.

[0074] Clamps and/or tie rods to anchor the metallic formwork with the surface prepared to receive the casting of all the chassis of the building will also be executed in this area.

[0075] In step (c), the operational platform will be prepared at the site of the construction immediately after the execution of the foundation blocks and the Formwork in compacted flat area and with paved accesses, according to FIG. 2.

[0076] On the fixed formwork on the floor, with adequate space for the assembly of the metal ring, above the foundation block and next to the starter of the columns will be assembled the steel armors of both the beams and the slabs, for a concreting in two levels to allow utilities to be installed and accelerate concrete curing time.

[0077] At a level just above the Formwork, mobile platforms (expansive swivel arms) will be installed that will allow people and materials access to the assembly, checking, testing and sampling work of both hardware and concrete and of utility grids across the entire chassis surface. The accessibility of the responsible professionals and technicians is fundamental to the performance of the tests of quality of materials and services as well as of the operation of the utility grids that are embedded in the chassis. A little away from the perimeter of the chassis, there will be a grid of utilities to meet the productive activities (water, compressed air, energy, steam, communication, floodlights, etc.) and in the ground a drainage network to guarantee a circulation of machines and people in a dry, clean stable and safe area. These devices that we call the operational platform are installed at the ground floor and allow access to the formwork that has the conformation of the bottom of the slab to be used for molding the chassis, which can be manufactured in: reinforced concrete with or without carbon fiber and/or prestressing steel; in metallic structure and/or mixed structure of metallic and concrete profiles.

[0078] A command cabin shall be installed at an elevation just above the operational platform with a panoramic view, outside the perimeter of the building, to follow all construction activities up and proceed with remote control of all chassis lift operations.

[0079] In step (d) the columns will be assembled, with the installation of the lifting and fitting cables of the first ring on the Formwork. The columns are made of rolled steel profiles, distributed in the vertices of geometric figures of 4 or more sides, to accommodate the installation of the drag cables with their respective accessories (blocks, slings, shackles, shoes, hooks and etc.). They are interconnected, braced, stiffened with bars containing holes, protrusions, through- and threaded holes, racks, and prepared to receive other engagement devices or lifting equipment, that are also metallic, in the sequence of assembly of the chassis, as shown in FIG. 3.

[0080] The columns are manufactured in a boiler shop in four segments: the starter, the standard module, the top with pulleys and that of the water tank; are held in stock and transported and then assembled on site.

[0081] The first segment called starter is smaller and has a base plate with a hole for the rag bolts in order to facilitate handling during the placement. The other standard modules can be up to 15 meters long to meet the traffic conditions legislation in the streets and roads of So Paulo, Brazil. These measures may be altered in accordance with local transport legislation.

[0082] The last module is equipped with hydraulic cylinders and pulleys for tension adjustment in the cables and possible level correction for the support bar attachment and will be removed after lifting all the chassis to allow the installation of the water tanks.

[0083] The columns will be provided with small removable elevators that will externally surround the columns. In buildings with large pavement areas, the internal space between columns can be used by permanent elevators to carry people.

[0084] Column starters are short and relatively light segments to allow for easy handling and adjustment during the placement (positioning). However, the other segments of the columns require a crane to assemble them all, one after the other, and to enable the installation of the steel cable system for lifting the chassis. For a very tall building, upon the assembly, the columns will receive a locking at the top constituted by a frame of trussed metal beams. This crane should return at the end of the work to remove the last segment with the cables collected and the pulley at the top of the column, and assemble the metal reservoirs for fire water, drinking water and reuse water in the place thereof.

[0085] Once the foundation blocks have been completed, the specific modules of the columns will be mounted over the starters and in sequence those containing the pulleys.

[0086] The top pulleys are hydraulically supported to allow a millimetric vertical displacement with remote control in the cabin to allow the necessary adjustment of the lifting of the chassis for introduction of the locking bar through a hydraulic device into the holes of the chassis inserts and of the column to lock and support the floor in the final position.

[0087] The steel cables that will draw the chassis will also be as many as required and will be housed and anchored in metal inserts in the inscribed space of the columns with free access for the vertical displacements of the accessories, both in the vertical shaft of the metal ring hook of the chassis, as well as in the vertical shaft of the drag cable down to the pulley of the foundation block.

[0088] The hoisting cable system is previously prepared on the ground and consists of two motorized steel cable winders.

[0089] One of the cable winders contains the steel cable in its entire length, properly housed with the other accessories incorporated, and is attached to the column in the top segment near the pulleys.

[0090] The other winder also contains housed steel cables and is fixed to the first segment of the column, close to the starter.

[0091] In each column there will always be a pair of cable winders (one upper and one lower) for each steel cable, which will work together. The removable elevator allows the installation and removal of cables by a professional at the start and end of hoisting operations.

[0092] In step (e) the chassis will be casted into operational platform at the ground level. The chassis will be fitted with a sturdy metal ring, structurally integral and specially prepared to wrap and displace along the columns with a device to connect the lifting hooks and also the eyebolts for engaging the locking and supporting bars of the chassis.

[0093] This metal ring is circumscribed to the perimeter of the column and is inserted into the structural concrete of the chassis or welded in the profiles if the chassis is of a metallic structure, always ensuring the structural integration with the chassis, but totally isolated from the metallic formwork fixed to the ground to be hoisted together with the chassis.

[0094] The metallic ring, a key to the operation of the system, is split and its assembly takes place in the surroundings of the column starters by the union of the two parts that should engage in the formwork of the platform.

[0095] The chassis will be made in the same way in two phases to allow the placement of all embedded elements such as: electric wire conduits, telephone cables, computer cables and pipes for water pipes, sewage, gas, fire water, alarm systems, guides for fixing the sealing panels; of frames and for junction boxes, etc.

[0096] Finished the installing of the embedded elements, the chassis will be concreted and the concrete cured by steam, with strict quality control. The 3- to 4-day time required to reach the massive resistance will be used to correct an eventual deformation of the chassis and running of the hydro-sanitary installations at half height and also to deposit the finishing material and pavement seal on the surface of the chassis that will move up.

[0097] Thus, the chassis will be obtained after the second concreting phase when the concrete solidifies and becomes a rigid and resistant plate with all utility networks incorporated and tested. The slabs supported on the columns have a deformation in the center and free edges that grow proportionally with the increase in the distance between the columns. For each product, the sags in these points are evaluated and the correction to obtain the leveling of the chassis will be done with the application of propensity cables (Dywidag type) and/or carbon fiber in the manufacturing phase.

[0098] This time is what is needed to prepare winches, hoisting cables, locking rod drive devices for fixing the chassis to the columns, and small metal truss beams securing the personnel lift tower to the chassis.

[0099] On the scheduled day of hoisting, which should take from 2 to 6 hours, the productive activity on the operational platform will be temporarily halted until the chassis fixation is completed.

[0100] In the sequence, there will be made the inspections and tests to release the lifting of the chassis that will be fixed to the columns in the definitive position.

[0101] After the tests, when the chassis are ready for hoisting, the hydraulic devices will be mounted, which are responsible for actuating the displacement of the locking and lifting bars when the chassis reaches the designed level. These hydraulic devices are equipped with cameras to enable remote control in the command cabin.

[0102] As the chassis execution process is continuous as soon as it is executed, it must be transferred to the end of the production column, i.e., the highest pavement.

[0103] In strategic positions nozzles will be installed to inject compressed air in the formwork that is the removal of the chassis of the Formwork and to make the hoisting possible.

[0104] In step (f), the lifting columns will receive the chassis that are ready. The chassis will be erected with the columns as guides and fixed in a sequence from top to bottom, that is, first the penthouse, then the last floor, then the next to last floor and in this sequence to the lowest floor, i.e., the first as shown in FIG. 4. The concentration of loads in the columns due to static and dynamic loading requires foundation blocks with high load capacity stakes where the column starters are anchored.

[0105] FIG. 5 shows an example of an industrialized building with 6 floors and 325 m.sup.2 slab.

[0106] The foundation block houses an inner pulley that directs one or more steel cables that descend from the pulleys at the top of the column to the winch cable winder and allow adjustments in the location and elevation of the columns, since the process is industrial and accuracy is millimetric.

[0107] The hoist is made by steel cables that hang from the pulleys at the top of the columns engage the hooks in the insertion elements of the metal ring of the chassis and are driven by drag winches located outside the perimeter of the building, as shown in FIG. 6.

[0108] The hoisting process can be done by hydraulic winches installed at the top of the columns or by winches on the ground, which must work simultaneously synchronously to draw the cables and perform lifting of the chassis.

[0109] Winches installed in the ground in opposite positions along the longitudinal axis of the building, on suitable foundations a little further from the perimeter of the chassis must have high traction capacity for drag and low speed of the cable.

[0110] The diameter of the cable winders shall accommodate the entire length of the cable in a single turn, which requires lifting the chassis to the final position in the most unfavorable condition.

[0111] The winches must be braked, mechanically locked and operated with programmed halts under remote control.

[0112] After being connected to the metal ring hooks of the chassis, the cables will be subjected to an initial tension adjustment prior to lifting. This adjustment will be made by the vertical displacement of the pulley at the top of the columns promoted by hydraulic devices under remote control and will ensure that the robust winches with large load capacity will work simultaneously synchronized and with constant speed.

[0113] At the start of the hoisting operation, the fasteners of the steel cable conditioning system of the upper cable winder in the columns will be released; however, the two ends of the steel cable will be kept fixed, wherein the steel cable of the lower cable winder pulls the traction hook of the metal ring of the chassis throughout the column height.

[0114] Then the same lower winder cable pulls one of the now released ends of the steel cable that passes over the pulley and is housed in the upper winder to be connected to the tow winch. The other end will remain fixed on the upper cable winder. During the process, whenever a chassis rises, it is necessary to pull back the hook for connection to the next chassis. At the end of hoisting operations, the cables will be collected on both the lower and upper cable winder with all the incorporated accessories.

[0115] The upper winder, which houses the entire length of cable required for the hoisting procedure, is conditioned and fixed to the column in the top segment with the pulleys to be removed and to give rise to the installation of the water tank. The lower winder, which has thinner steel cable and smaller length, is simply removed for later use.

[0116] When the chassis reaches the programmed position, it will need to be mechanically automatically locked to allow the cable to be re-adjusted, if necessary, by means of small displacements of the pulleys at the top of the column until it reaches the correct elevation for allow the locking rods to be inserted into the holes of the insertion elements in the column.

[0117] Winches and other hoisting devices, operating under a unified command, need to work synchronously and harmonically integrated into the process.

[0118] The chassis after hoisting, positioning and locking will have a tray mounted on the lower part in each column, fixed by special screws, to receive a grouting that assures the perfect and solid support of the chassis in the column.

[0119] In parallel, in step (g) there will continuously be the closing and finishing activities of the floors in the top-down assembly sequence.

[0120] As soon as the chassis are fixed to the columns, the installation of the panels (in plasterboard, dry wall, cement board, etc.) will be started to divide, isolate and complete the half-height of the hydro-sanitary installations with their respective doors, windows and other constructive elements.

[0121] In step (h), the insertion of elevators and ladders that will preferably be metallic will be released for execution soon after the fixation of the chassis of the first floor and at the end of the fixation of the chassis the last module of the columns will be replaced by another module with reservoirs that meet the demand for drinking water, for fire and reuse water.

[0122] After that, in step (i) there will be the interconnection of utility systems with the feeding grids and the and effluent elements of the systems with the vertical shafts and/or down pipes to connect to the header networks for reuse or disposal, as well as the interconnection of other electrical systems, telephone systems, signal, etc.

[0123] Finally, in step (j) there will be the removal of the operational platform and the Formwork for concreting of the floor with execution of constructions foreseen in the architectural project.

[0124] The entire operation, not only of manufacturing, but also of lifting and fixing the chassis are controlled through monitors in a Command Cabin to ensure quality, time, cost and safety.

[0125] After the finished process, external treatments for vehicle parking and landscaping take place. In case of buildings in reinforced concrete, it is recommended that the ground floor subsoil be preserved. A possible excavation of the subsoil for car parking construction, according to conventional procedures, may occur outside the perimeter of the building. However, if the building is in metallic structure, there are no restrictions on the occupation of the subsoil.