Method and system for construction of a building
09556632 ยท 2017-01-31
Assignee
Inventors
- Giedrius Malakauskas (Amsterdam, NL)
- Marius BALTRAMIEJUNAS (Amstelveen, NL)
- Harald Dieter Muller (Gdansk, PL)
- Erik Roger ANDERSSON (Konstancin Jeziorna, PL)
- Thomas HATTIG (Berlin, DE)
- Steen Torben SODEMANN (Leuven, BE)
- Philip Muller (Gdansk, PL)
Cpc classification
E04B1/34869
FIXED CONSTRUCTIONS
E04B1/35
FIXED CONSTRUCTIONS
E04B1/348
FIXED CONSTRUCTIONS
E04B1/74
FIXED CONSTRUCTIONS
International classification
E04H1/00
FIXED CONSTRUCTIONS
E04B1/74
FIXED CONSTRUCTIONS
E04B1/348
FIXED CONSTRUCTIONS
Abstract
A method for providing at least a part of a building includes the steps of prefabricating a module by assembling four walls extending between a floor and a roof to form a rectangular cuboid shape; providing at least one compartment within the cuboid shape; providing waterproof layers on the interior walls and floor of the compartment for creating a wet area within the module; arranging technical installations within the cuboid shape; and providing interior equipment within the cuboid shape. The method further includes the steps of prefabricating a plurality of panels and slabs; and connecting these panels and slabs to a lateral side of the module for providing a further rectangular cuboid shape forming a panel-built room.
Claims
1. A method for providing at least a part of a building, comprising the steps of: (a) prefabricating a module by; (i) assembling four module walls extending between a floor and a roof to form a rectangular cuboid shape, each of said four module walls comprises a frameless planar wooden core providing the four module walls with load-bearing properties, wherein the module comprises at least one compartment within the cuboid shape, the compartment being defined by the floor and the roof and interior wall surfaces; (ii) providing waterproof layers on the interior wall surfaces and the floor defining the compartment and forming a wet area within said module; (iii) arranging technical installations within said cuboid shape; (iv) providing interior equipment within said cuboid shape; (v) providing the module with engagement means for engagement with prefabricated panels or slabs or other prefabricated modules by means of connecting devices; and (vi) providing a service space on top of or at a bottom of the module by assembling said four walls extending between said floor and said roof such that upper edges of said four walls extend beyond an outer surface of the roof, or such that lower edges of said four walls extend beyond an outer surface of the floor, said service space providing access to a coupling means end of at least one of the technical installations; (b) prefabricating a plurality of panels and slabs, each being constructed as a load-bearing structure and provided with engagement means for engagement with the module or other panel or slab by means of the connecting devices; and (c) connecting said plurality of panels and slabs to a lateral side of said module, by the engagement means and the connecting devices, for providing said part of a building such that said lateral side of said module together with said plurality of prefabricated panels and slabs form a further rectangular cuboid shape, wherein said module and said plurality of panels are constructed to support at least one module and plurality of prefabricated panels located thereabove.
2. The method according to claim 1, wherein the step of prefabricating the module further comprises providing interior partition walls for forming at least two compartments within the cuboid shape.
3. The method according to claim 2, wherein the step of providing interior partition walls is performed such that two separated compartments are formed, and wherein each one of said compartments is ready to be occupied by its own resident.
4. The method according to claim 3, wherein the interiors of the two separated compartments are symmetrical along a centre line of said module.
5. The method according to claim 1, wherein the module is prefabricated with dimensions of approximately 6.5-7.0 m in length, about 2.5 m in depth, and about 3.0 m in height.
6. The method according to claim 1, further comprising the step of providing said four module walls, floor, roof, panels and/or slabs by arranging the planar wooden core adjacent to at least one insulating layer for each one of said module walls, roof, floor, panels and/or slabs.
7. The method according to claim 6, wherein the planar wooden core is formed by cross-laminated timber.
8. The method according to claim 6, further comprising the step of providing at least one of said insulating layers as a multi-layer structure comprising an inner layer of acoustic damping material and/or fire resistant material, and an outer layer.
9. The method according to claim 8, wherein the multi-layer structure further comprises a heat insulation material.
10. The method according to claim 8, wherein the outer layer comprises gypsum board.
11. The method according to claim 6, further comprising the step of providing hollow electrical cable guides within said panels and/or slabs.
12. The method according to claim 1, wherein the step of prefabricating the module by assembling four module walls extending between a floor and a roof is performed such that the upper edges of said four module walls extend beyond an outer surface of the roof when the module walls and the roof are in an assembled position.
13. The method according to claim 1, wherein the step of prefabricating the module by assembling four module walls extending between a floor and a roof is performed such that the lower edges of said four module walls extend beyond an outer surface of the floor when the module walls and the floor are in an assembled position.
14. The method according to claim 1, further comprising providing at least one opening on at least one of the four module walls forming a part of the further rectangular cuboid shape, and at least one opening on the opposite module wall of said module.
15. The method according to claim 14, wherein the openings being provided with doors.
16. The method according to claim 1, wherein the step of providing waterproof layers for creating said wet area within said module is performed by covering at least a part of the interior sides of said walls and slabs with said waterproof interior layers.
17. The method according to claim 1, wherein the step of providing waterproof interior layers for creating said wet area within said module is performed by covering the complete interior sides of said walls and slabs with said waterproof interior layers.
18. The method according to claim 1, wherein the step of providing waterproof interior layers is performed by applying solid layers.
19. The method according to claim 1, wherein the step of providing waterproof interior layers is performed by applying liquid layers.
20. The method according to claim 1, wherein the step of arranging technical installations within said cuboid shape comprises arranging at least one ventilation duct, at least one mains electricity cable, at least one low voltage electrical cable, at least one water supply pipe, and at least one water sewage pipe within said module.
21. The method according to claim 20, wherein the step of arranging technical installations further comprises arranging a water-based heating system, and/or a cooling system, and/or a sprinkler system.
22. The method according to claim 20, wherein when the module walls and the roof are in an assembled position, upper edges of the four module walls extend beyond an outer surface of the roof forming an area above the roof, or lower edges of the four module walls extend beyond an outer surface of the floor forming an area below the floor, and wherein one end of at least one technical installation is accessible in the area formed above the roof of said module or in the area formed below the floor of said module.
23. The method according to claim 20, wherein said at least one ventilation duct extends within a first shaft extending along a wall of the module.
24. The method according to claim 23, wherein the at least one mains electricity cable, the at least one low voltage electrical cable, the at least one water supply pipe, and the at least one water sewage pipe extend within a second shaft extending along a wall of the module.
25. The method according to claim 24, wherein said first and second shafts are formed as a common space.
26. The method according to claim 20, wherein the at least one low voltage electrical cable is connected to at least one distribution board.
27. The method according to claim 1, wherein the step of providing at least one compartment is performed such that two major compartments are formed, and at least one shaft is formed for said technical installations.
28. The method according to claim 1, wherein the step of providing interior equipment within said cuboid shape comprises installing a bathroom in the module.
29. The method according to claim 1, wherein the step of providing interior equipment within said cuboid shape comprises installing a kitchenette in the module.
30. The method according to claim 1, wherein the step of providing interior equipment within said cuboid shape comprises installing furniture and/or fixtures in the module.
31. The method according to claim 1, further comprising the step of providing said module with at least one engagement element capable of engagement with a prefabricated panel or slab or another prefabricated module by means of a connecting device.
32. The method according to claim 1, further comprising the step of providing said panels and slabs with at least one engagement element capable of engagement with a prefabricated module or another prefabricated panel or slab by means of a connecting device.
33. The method according to claim 1, wherein the step of connecting said plurality of panels and slabs to a lateral side of said module is performed by connecting a first wall to one lateral side edge of said module, a second wall to another lateral side edge of said module, a third wall to a center portion of the lateral side of said module, a first floor slab to the first and third wall, a second floor slab to the second and third wall, a fourth wall to free lateral edge portions of the first and third walls, respectively, a fifth wall to free lateral edge portions of the second and third walls, respectively, a first roof slab to free upper edge portions of the first and third walls, respectively, and a second roof slab to free upper edge portions of the second and third walls, respectively.
34. The method according to claim 33, wherein said fourth wall and said fifth wall are formed as one piece.
35. The method according to claim 33, wherein said fourth wall and/or said fifth wall is formed as one piece with another wall arranged vertically aligned in the same plane with said fourth and/or fifth wall.
36. The method according to claim 1, wherein the step of connecting said plurality of panels and slabs to a lateral side of said module comprises providing at least one static connector and at least one dynamic connector for connecting at least one of said panels and/or slabs to said module.
37. The method according to claim 1, further comprising the step of connecting at least two prefabricated modules to each other in the direction of the length of the modules.
38. The method according to claim 1, further comprising the step of connecting at least two prefabricated modules to each other in the direction of the height of the modules.
39. The method according to claim 38, further comprising the step of aligning a first module with an adjacent module by means of alignment recesses provided on the upper edge portion of said first module and corresponding alignment protrusions on the bottom edge portion of said adjacent module.
40. A part of a building, comprising; (a) a prefabricated module having a rectangular cuboid shape formed by four module walls extending between a floor and a roof, each of the four module walls comprises a frameless wooden core providing the four module walls with load-bearing properties, and comprises: (i) at least one compartment within said cuboid shape, the compartment being defined by the floor and the roof and interior wall surfaces; (ii) waterproof interior layers on the interior wall surfaces and the floor defining the compartment having a wet area within said cuboid shape; (iii) technical installations within said cuboid shape; (iv) interior equipment within said cuboid shape; (v) the module having engagement means for engagement with prefabricated panels or slabs or other prefabricated modules by means of connecting devices; and (vi) a service space on top of or at a bottom of the module provided by said four walls extending between said floor and said roof such that upper edges of said four walls extend beyond an outer surface of the roof, or such that lower edges of said four walls extend beyond an outer surface of the floor, said service space providing access to a coupling means end of at least one of the technical installations; (b) a plurality of prefabricated panels and slabs, each being constructed as a load-bearing structure and provided with engagement means for engagement with the module or other panel or slab by means of the connecting devices, connected to a lateral side of said module, by the engagement means and the connecting devices, such that said lateral side of said module together with said plurality of prefabricated panels and slabs form a further rectangular cuboid shape, wherein said module and said plurality of panels are constructed to support at least one module and plurality of prefabricated panels located thereabove.
41. The part of the building according to claim 40, wherein a core material of said module walls, floor, roof, panels, and slabs provides a load bearing structure.
42. The part of the building according to claim 40, wherein the technical installations within said module comprise at least one ventilation duct, at least one mains electricity cable, at least one low voltage electrical cable optionally connected to a at least one distribution board, at least one water supply pipe, and at least one water sewage pipe.
43. The part of the building according to claim 40, wherein said interior equipment within said module comprises a bathroom and/or a kitchenette and/or a wardrobe or a coat hanger.
44. The part of the building according to claim 40, wherein said panels and slabs and/or said prefabricated module comprise at least one engagement element capable of engagement with a prefabricated panel or slab or another prefabricated module by means of a connecting device.
45. The part of the building according to claim 44, wherein said connecting device comprises at least one static connector and at least one dynamic connector.
46. The part of the building according to claim 44, wherein said static connector and said dynamic connector are integrated in a combined connecting unit.
47. A multi-room building comprising a corridor extending horizontally, and at least a first part of a building according to claim 40 arranged on a first side of said corridor, and a second part of a building according to claim 40 arranged on the opposite side of said corridor, wherein said second part of the building is aligned with the first part of the building.
48. The multi-room building according to claim 47, further comprising additional parts of a building arranged on top of the parts of the building already provided such that a part of a building of a specific floor is vertically aligned with the underlying part of the building.
49. The part of a building of claim 40, wherein the prefabricated module is constructed as a load-bearing structure, and wherein each of the plurality of prefabricated panels and slabs are constructed as load-bearing structures comprising a core element.
50. A method for providing a building, comprising the steps of: (a) prefabricating a plurality of modules, each of which by: (i) assembling four module walls extending between a floor and a roof to form a rectangular cuboid shape, each of the four module walls comprises a frameless wooden core providing the four module walls with load-bearing properties, wherein the module is constructed as a load-bearing structure and comprises at least one compartment within the cuboid shape, the compartment being defined by the floor and the roof and interior wall surfaces; (ii) providing waterproof layers on the interior wall surfaces and the floor defining the compartment and forming a wet area within said module; (iii) arranging technical installations within said cuboid shape; (iv) providing interior equipment within said cuboid shape; (v) providing the module with engagement means for engagement with prefabricated panels or slabs or other prefabricated modules by means of connecting devices; and (vi) providing a service space on top of or at a bottom of the module by assembling said four walls extending between said floor and said roof such that upper edges of said four walls extend beyond an outer surface of the roof, or such that lower edges of said four walls extend beyond an outer surface of the floor, said service space providing access to a coupling means end of at least one of the technical installations; (b) prefabricating a plurality of panels and slabs, each being constructed as a load-bearing structure and provided with engagement means for engagement with the module or other panel or slab by means of the connecting devices; (c) positioning at least a part of said plurality of modules in a horizontal array such that at least one module wall of a module is arranged in close proximity to one module wall of an adjacent module; and (d) for each module connecting at least a part of said plurality of panels and slabs to a lateral side of said module, by the engagement means and the connecting devices, for providing a part of a building such that one module wall of each module together with said connected prefabricated panels and slabs form a further rectangular cuboid shape, wherein said module and said plurality of panels are constructed to support at least one module and plurality of prefabricated panels located thereabove.
51. The method according to claim 50, wherein the step of distributing said modules is performed by arranging a first module at a central position, and subsequently extending the horizontal array in at least one direction from said first module.
52. The method according to claim 51, further comprising arranging a second module in parallel with said first module at a predetermined distance, and extending a horizontal array in at least one direction from said second module such that said horizontal arrays are aligned to each other.
53. The method according to claim 52, further comprising the step of aligning a further module relative the first or second module by aligning protrusions and corresponding recesses provided on the further module and the first or second module, respectively.
54. The method according to claim 51, wherein the step of extending the horizontal array of modules is performed in at least two directions.
55. The method according to claim 54, wherein the step of connecting at least a part of said plurality of panels and slabs to a lateral side of each module is performed in said at least two directions of the horizontal array.
56. The method according to claim 51, further comprising the step of providing faade cladding on the outer surface of said module and/or panels.
57. The method according to claim 51, wherein the step of extending the horizontal array of modules is performed in at least two directions.
58. The method according to claim 50, further comprising the step of positioning additional modules in a vertical array from said first and/or second module such that said vertical array corresponds to several floors of a multi-resident building.
59. The method according to claim 58, wherein the step of positioning at least a part of said plurality of modules in a horizontal array is performed for several floors simultaneously.
60. The method according to claim 58, wherein the step of connecting at least a part of said plurality of panels and slabs to a lateral side of each module is performed simultaneously for at least two modules of the vertical array.
61. The method according to claim 50, wherein the step of connecting at least a part of said plurality of panels and slabs to a lateral side of each module is performed for at least two modules simultaneously.
62. A kit of building components, comprising at least one prefabricated module having a rectangular cuboid shape formed by four module walls extending between a floor and a roof, each of the four module walls comprises a frameless wooden core providing the four module walls with load-bearing properties, and comprises: (i) at least one compartment within said cuboid shape defined by the floor and the roof and interior wall surfaces; (ii) waterproof interior layers on the interior wall surfaces and the floor defining the compartment and providing a wet area within said cuboid shape, wherein optionally one or more of the walls comprises a module wall; (iii) technical installations within said cuboid shape; (iv) interior equipment within said cuboid shape; and (v) a service space on top of or at a bottom of the module provided by said four walls extending between said floor and said roof such that upper edges of said four walls extend beyond an outer surface of the roof, or such that lower edges of said four walls extend beyond an outer surface of the floor, said service space providing access to a coupling means end of at least one of the technical installations; a plurality of prefabricated panels and slabs connectable to a lateral side of said module, the panels and slabs comprising at least one engagement element capable of engagement with another prefabricated panel or slab or another prefabricated module by means of one or more connecting devices, wherein said module and said plurality of prefabricated panels are constructed to support at least one module and plurality of panels located thereabove.
63. The kit of claim 62, wherein the one or more connecting devices comprise one or more static connectors and/or one or more dynamic connectors.
64. The kit of claim 62, wherein the module is constructed as a load-bearing structure, and wherein each of the plurality of prefabricated panels and slabs are constructed as load-bearing structures comprising a core element.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
(1) Embodiments of the present invention will be described in the following with reference to the accompanying, schematic drawings which illustrate non-limiting examples of the inventive concept.
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DETAILED DESCRIPTION OF EMBODIMENTS
(50) An illustrative example how the invention can be carried out is shown in the diagrammatical
(51) A building B according to an embodiment of the present invention is formed of a number of standardized elements (see
(52) In construction of a building B according to this concept, one starts with a first module 2 such that one lateral side of the first module 2 is in close proximity with a lateral side of an adjacent module 2. The two aligned modules must not necessarily be attached to each other by rigid fixtures, but may simply be put in close proximity to each other and secured in the correct position by means of alignment means provided on the lower side of the module facing the ground or foundation F, which optionally may have supporting structures, for instance of steel or concrete (not shown). In the shown example the modules 2 are placed in two spaced-apart rows, forming a corridor C between the two rows of modules 2. In order to make benefit of the corridor C the modules are provided with at least one door opening facing the corridor C (see
(53) In a next step slabs 8 are attached to the modules 2 to form floors in the corridor C and in the rooms R to be formed. Thereafter panels 4 are attached to the modules 2 to form the inner walls of the rooms R. The panels 4 are attached to the side of each module 2 opposite to the corridor C. In the next step panels 6 to form the outer walls are attached to the free edge portions of the panels 4 forming the inner walls, opposite the modules 2. Faade cladding 7 is then attached to the outer panels 6 forming the outer walls (see
(54) The step of attaching the slabs 8 and panels 4, 6 may be performed for different modules 2 in parallel. Hence, the first module may be connected to the panels and slabs at the same time as adjacent modules are arranged in a row, or array. As the modules being arranged adjacent to the first (or central) module are fixated at their respective position, further modules are arranged at these modules at the same time as panels and slabs are attached to the already provided modules. The first and second row may be constructed according to the manner described, i.e. a parallel extension of the rows or arrays.
(55) If the building B is to have further stories, the above steps are repeated, whereby the modules 2 of an upper storey are attached to the modules 2 of the storey below. As indicated in
(56) This on-site concept of erecting a building saves time and thereby reduces costs. Sometimes it may be preferred to gradually construct the building in only one direction, but also then the work is efficient since stacking of modules 2 can be performed upwards at the starting point meanwhile the panel-build rooms R are formed in sequence in horizontal direction.
(57) In
(58) To finalize the building B further parts are added, such as a main entrance, elevators and staircases, but these parts are optional and will not be described in detail here. In
(59) In
(60) As shown in
(61) Preferably, the external dimensions of the modules 2 are adapted to standard sizes of trucks. For instance, a module 2 of the type shown in
(62) In
(63) In each module 2 there is at least one vertical through ventilation duct 16, (see
(64) The modules 2 may be completed in the factory with all fittings required for the intended use of the module 2 in the finalized building B. The term fittings also include complete finishing, fixtures, set-ups, etc. Thus, a complete bathroom 10, including a bathroom door 24, an optional complete kitchen part 12, possible complete wardrobes 214 and all additional doors 20, 21, 22 are installed in the modules 2 already in the production site PS. All cables are pre-installed, such as main electrical and low voltages supplies, switch board meters, internet connections, etc. Furthermore, all types of water conduitssuch as tubings for heated and tap water as well as cooling and sprinkler systemsare installed in the factory of the production site PS. The same goes for all ventilation ducts and the sewage conduit system. These assemblies are also installed in the modules 2 at the production site PS. In summary, all so-called shaft assemblies and technical installations are pre-installed in the module 2.
(65) Due to the standardization and pre-installation of fittings and supplies, the modules 2 are basically ready-to-use when arriving by truck at the erection site ES. Furthermore, the well-planned arrangement of cables and conduits makes it easy to connect all supplies when the modules 2 are aligned and stacked on the erection site ES. Erection of the building B can be performed by staff mainly trained in construction work, whereas the requirement of highly skilled staff such as electricians and plumbers can be kept on a very low level which reduces construction time significantly.
(66) The vertical section of
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(68) As best shown in
(69) As seen in
(70) Hence, when stacking modules 2 on top of each other the rods 26, 28 are inserted in the matching openings 30, 32 respectively, as is shown in detail in
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(72) As illustrated in
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(75) A facade panel 6 with two windows is shown in
(76) This type of facade panel 6 may have the length of two rooms which then will include two windows, one for each room. Normally, a large facade panel 6 of this type is not provided with any electrical and low voltage cabling or installed sockets and switches but may in another embodiment be. The panel 6 may be fixed to the panels 4 and to the slab 8 according to the above mentioned fixing procedure.
(77) Preferably, the wooden cores 41 and 46 described above are made of cross-laminated timber (CLT), but other wooden structures are of course feasible. However, CLT cores have proven very good results for prefabricated panels and slabs of this kind. The strength is excellent and it is easy to handle. In particular embodiments, the module 2 is constructed as a load-bearing structure carrying the weight of the building. Further, the walls and panels may also be constructed as load-bearing structures thus reducing the need for further structural components necessary for securing the robustness of the building.
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(79) In
(80) The first connector member 60 comprises a base plate 62 and a flange 64 projecting therefrom (
(81) The second connector member 70 comprises a base plate 72 and a flange 74 projecting therefrom (
(82) The bores 68, 78 of the respective connecting devices 60, 70 as well as the recess or cut-away 61 may form engagement means integrated in the wall panel 4 or module 2, respectively. The engagement means contribute to the attachment and use of the static connecting device 60, 70.
(83) When mounting the wall panel 4 to the module 2, the panel 4 is moved towards the module 2, which is installed on ground or on a foundation F or stacked on another module, in the direction of arrow A in
(84) The underlying idea with the static connectors 60, 70 is that they should fit integrated engagement means (cut-aways, anchoring means, etc) of the elements to be connected.
(85) In addition to the static connecting devices 60, 70 other types of connectors may be used, namely so called dynamic connectors. This type of dynamic connecting device 80 is provided for decreasing or eliminating the small gaps between building elements that may be left after connecting the static connectors 60, 70.
(86) The bore of the module wall, as well as the recess or cut-away 89, may form engagement means integrated in the wall of the module 2 and the panel, respectively. The engagement means contribute to the attachment and use of the dynamic connecting device 80. Tightening of the connector 80 is accomplished by a standard wrench (not shown) engaging the nut of the nut-washer assembly 88.
(87) A similar type of dynamic connector 80 can be used for module-slab connection as is shown in
(88) The idea behind the dynamic connecting operation is that the elements to be connected shall have prefabricated means so that the tightening can be performed swiftly on the erection site. The recessed cut-aways 89, 89 and the pre-installed fastening bars 82, 82 and connecting sleeves 86, 86 make it possible to achieve quick tightening by use of tools which are easy to handle.
(89) In a preferred embodiment, a single connector may be utilized which acts as both a static and a dynamic connector. Hence, the connectors 60, 80 or 70, 80 may be replaced by a single connector forming a combined connecting unit
(90) Preferably, sealing strips with rubber strings (not shown) are inserted in the joints between wooden elements of the building.
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(92) The hanger arrangement shown in
(93) As shown in
(94) A similar technique is used for connecting two drain pipes 100, 102 between two modules 2, as is shown in
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(96) The supply arrangements shown in
(97) The building B may be constructed in many different ways, and two alternatives are shown in
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(99) As well as there are different layouts of the overall building B there are also different layouts of the rooms R, especially the modules 2.
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(101) The panel-built part of the student home may be fully furnished with furniture after construction, for instance a table 162, chairs 164, a bed 166, etc. In order to keep costs low, the furniture may be standardized.
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(103) In
(104) A fourth example of a room 411 is shown in
(105) The bathroom 410 of this type of room 411 is adapted for a disabled person and it comprises special equipment 490, 492 for this purpose. In the same manner, the kitchen area 412 may include certain special equipment not described in detail here. Further modifications have been made in order to facilitate for a disabled person to move a wheelchair within the room. Hence, door hinges have been switched and in an embodiment not shown here it is also feasible that the door openings are made somewhat wider in order to give room for wheelchair movements.
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(107) It is to be appreciated that the inventive concept is by no means limited to the embodiments described herein, and many modifications are feasible within the scope of the invention set forth in the appended claims. For instance, other materials can be used for the elements included in the building constructions. Furthermore, other connection means can be used as long as reliable joining of the elements is achieved.