LAYERED PANEL AND METHOD OF CONSTRUCTION THEREOF

Abstract

Described herein is a layered panel for on-site modular construction of buildings. The layered panel includes a layer formed by a prefabricated cement-bonded particle board, a supporting structure and fastening elements attaching the pre-fabricated cement-bonded particle board to the supporting structure. Also described herein is a method for manufacturing the layered panel, an installation for manufacturing the layered panel and a method for the construction of buildings with a plurality of the layered panels.

Claims

1. A layered panel for on-site modular construction of buildings, the layered panel comprising: a layer formed by a prefabricated cement-bonded particle board, the prefabricated cement-bonded particle board being a composite board comprising wood particles or other natural fibers and a mineral bonding agent; a supporting structure comprising a metal grid and a perimeter frame, the perimeter frame being configured to receive and surround the prefabricated cement-bonded particle board, and the metal grid and the perimeter frame being attached to each other; and fastening elements attaching the prefabricated cement-bonded particle board to the supporting structure.

2. The layered panel according to claim 1, wherein the fastening elements attach the prefabricated cement-bonded particle board to the supporting structure by threading, and wherein the fastening elements comprise screws that are inserted through holes in the metal grid and threaded into the prefabricated cement-bonded particle board.

3. The layered panel according to claim 1, wherein the fastening elements attach the prefabricated cement-bonded particle board to the supporting structure by threading, and wherein the fastening elements comprise screws that are inserted through holes in the perimeter frame and threaded into the prefabricated cement-bonded particle board.

4. The layered panel according to claim 1, further comprising an outermost layer and an innermost layer on opposite sides of the supporting structure, and wherein the prefabricated cement-bonded particle board is the outermost layer.

5. The layered panel according to claim 4, wherein the innermost layer comprises at least one insulating layer and a finishing layer.

6. The layered panel according to claim 4, wherein the innermost layer overlaps only partially with the supporting structure and the outermost layer.

7. The layered panel according to claim 6, wherein the innermost layer has a smaller surface area than the outermost layer such that it overlaps a central portion of the supporting structure and the outermost layer, while at least two side strips of the supporting structure and the outermost layer remain exposed.

8. The layered panel according to claim 7, further comprising mounting brackets attached to the supporting structure in correspondence with the exposed side strips.

9. The layered panel according to claim 5, wherein the insulating layer is a thermal bridge break layer.

10. The layered panel according to claim 1, wherein the prefabricated cement-bonded particle board is a single piece with a shape and dimension to fit the perimeter frame.

11. The layered panel according to claim 1, wherein at least part of the metal grid comprises hollow tubular members filled with a vacuum-manufactured expanded polystyrene bar.

12. A method for manufacturing the layered panel according to claim 1, the method comprising: manufacturing the supporting structure comprising the metal grid and the perimeter frame; cutting the prefabricated cement-bonded particle board according to a predetermined layout; assembling the cut prefabricated cement-bonded particle board inside the perimeter frame of the manufactured supporting structure; and fastening the cut prefabricated cement-bonded particle board to the manufactured supporting structure.

13. A method for the construction of buildings with layered panels according to claim 1, the method comprising: erecting a building skeleton comprising load-bearing columns and beams; and forming at least outer walls of the building skeleton by attaching layered panels to columns and/or beams of the building skeleton, and to other layered panels, with screws and/or rivets.

14. The method according to claim 13, further comprising: arranging in shipping containers an installation for manufacturing the layered panel the installation comprising a first station to form the supporting structure comprising the metal grid and the perimeter frame, a second station for cutting the prefabricated cement-bonded particle board according to a predetermined layout, and a third station to receive the supporting structure and the prefabricated cement-bonded particle board from the first station and the second station, and for assembling the prefabricated cement-bonded particle board inside the perimeter frame of the supporting structure and fastening the prefabricated cement-bonded particle board to the supporting structure; transporting the shipping containers to a desired building site; deploying the first, second, and third stations of the installation from the shipping containers at the desired building site; operating the first, second, and third stations of the installation to manufacture the layered panels; and constructing the buildings with the layered panels at the desired building site.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0052] Non-limiting examples of the present disclosure will be described in the following, with reference to the appended drawings, in which:

[0053] FIG. 1 shows the supporting structure of an example of a panel according to the present disclosure.

[0054] FIG. 2 shows a perspective view, partly cut away, of an example of a partially assembled panel according to the present disclosure.

[0055] FIG. 3A shows a cross-section diagram of an example of a panel according to the present disclosure.

[0056] FIG. 3B shows a partial schematic diagram of the panel of FIG. 3A.

[0057] FIG. 4 shows in perspective a schematic installation for the manufacture of panels according to embodiments disclosed herein.

DETAILED DESCRIPTION

[0058] FIG. 1 shows a supporting structure 1, according to an example of the disclosed layered panel. More specifically, the panel includes a supporting structure 1 including a perimeter structure 13 and a plurality of ribs 14, both the perimeter structure and the ribs formed by hollow metal bars, and forming a metal grid according to a predesigned layout of the panel. As a result, the metal grid formed by the perimeter structure 13 and the ribs 14 also forms hollow spaces 30 in between them.

[0059] FIG. 2 shows in perspective a portion of the panel partly cut out, to show the supporting structure 1, layers and other elements found therein. More specifically, the outer portion of the panel, e.g., of a building wall, is illustrated. In this example, the supporting structure 1 further includes a perimeter frame 11 with an L-shaped profile configured to receive a plurality of layers of the panel.

[0060] According to this example, the following layers are assembled on and attached to the perimeter frame 11, in order to form the outer portion of the panel, e.g., of a building wall: an oriented strand board (OSB from now on) 21, a thermal bridge break layer 22, and a CBPB 23. An upper portion of each of layers 21, 22 and 23 is cut out in FIG. 2, so that all the layers are visible in the perspective view.

[0061] In any of the embodiments of the panel disclosed herein, the CBPB may be the outer structural layer of the panel: for example, the exposed structural layer on the outside of a building that is built using panels according to the present disclosure.

[0062] Furthermore, the hollow metal bars forming the perimeter structure 13 and the ribs 14 are filled by prefabricated vacuum-manufactured expanded polystyrene bars 131. In FIG. 2, only a cross section of a hollow metal bar forming the perimeter structure 13 is shown, filled by a polystyrene bar 131.

[0063] According to the present example, the layers may be attached to the supporting structure 1 being fastened to the ribs 14, by means of, for example, screws, in such a way that a portion of the outer layers of the panel is left exposed.

[0064] FIG. 3A shows a cross section perspective depiction of all the layers of the disclosed panel according to an example. More specifically, it shows a corner of the panel wherein the outer portion of the panel, e.g., of a building wall, is formed by the previously described perimeter frame 11, with OSB 21, thermal bridge break layer 22, and CBPB 23. On the opposite side of the perimeter structure 13 (and thus, of the supporting structure 1 shown in FIGS. 1 and 2), the following layers are attached, forming an inner portion of the panel: a second OSB 31, a vapor barrier layer 32, an omega-shaped profile 33, and a finishing plasterboard layer 34. Also, a rock wool layer may be placed filling up the space 30 defined between the OSBs 21 and 31 and the perimeter structure 13 and the ribs 14 of the supporting structure 1.

[0065] Furthermore, FIG. 3A also depicts the corner 35 of the panel. In this example, the perimeter structure 13 of the metal grid is longer along one of its dimensions than the layers of the inner portion of the panel, thus leaving an exposed side strip 36 on the inner layer of the panel. This is also depicted in FIG. 3B, wherein a central portion 3B1 of the panel is depicted to be narrower than the supporting structure 1, leaving two side strips 36 in the form of longitudinal sections. Also, the panel includes an anchor bracket 37 in each corner of the panel, which may be screwed to, for example, each corresponding rib of the supporting structure, which may be used to attach and fasten the panel to a pillar and/or beam of a building structure. Depending on the beams and pillars used on the building structure, more or less anchor brackets may be used in each panel. Furthermore, the strips 36 may be sized in order to match the size of the corresponding pillars or beams.

[0066] Also, according to this example, the outer layer of the panel is longer and wider than the metal grid, as it can be seen both in FIGS. 2 and FIG. 3A, thus leaving a portion of the outer layer of the panel exposed (which may be used, for example, to cover beams and pillars when the panel is attached to a building structure).

[0067] The manufacturing of panels according to examples of the present disclosure may be performed with a very high speed and efficiency in a manufacturing installation including several stations.

[0068] FIG. 4 shows the operational layout of an example of a manufacturing installation 400 for the manufacturing of layered panels according to embodiments of the present disclosure.

[0069] The installation 400 of FIG. 4 includes a first area 410 where metal bars are prepared and cut; a second area 420 where the supporting structure 1 of the panel is formed, by welding metal bars; a third area 430 where the layers of the outer portion of the panel are attached to one side of the supporting structure 1; and a fourth area 440 where the layers of the inner portion of the panel are attached to the other side of the supporting structure 1. The different areas may be aligned in a common line direction, as in FIG. 4, but they may also be arranged according to a different layout.

[0070] A non-limiting example of the stations or areas 410, 420, 430 and 440 and the operations performed in each of them to manufacture layered panels according to embodiments disclosed herein, will be described in more detail in the following.

Area 410

[0071] In a coating unit 411, hollow metal bars intended for the perimeter structure 13 and the ribs 14, as well as metal profiles intended to form the perimetral frame 11, may be coated with an anti-corrosive coat. This operation may be performed by a painting robot.

[0072] In a cutting unit 412 the hollow metal bars may be cut with a cutting laser tool, in order to obtain bars with the size and shape (such as diagonal cross-section cuts, etc. . . . ) to be assembled according to a predetermined layout, to form the perimeter structure 13 and the ribs 14 of the metal grid. This operation may be performed by a further robot with a cutting tool attached to its end effector.

[0073] The hollow metal bars may be filled with prefabricated vacuum-manufactured expanded polystyrene bars 131, the bars 131 having a square cross-section which assembles with the hollow bars, filling all the hollow space inside them, by a filling unit 413.

[0074] The metal bars may enter coating unit 411 and be transported on to subsequent unit on a conveyor 414.

Area 420

[0075] The welding area 420 includes in this example two inlets 421a, 421b, from which the metal tubes prepared in area 410 are fed into area 420, e.g., on pallets (not shown). In correspondence with each of the inlets 421a, 421b there is a supporting carriage 423a and 423b, displaceable along the line direction to reciprocate between a loading position 422a, 422b, in correspondence with the inlet 421a and 421b, and a working position 424 in a welding unit 425, which is common to both carriages 423a and 423b.

[0076] The welding unit 425 includes a number of welding robots 425a, 425b, etc., e.g., four welding robots, which may be arranged around the working position 424. The filled metal bars may be welded to each other by using, for example, a point-to-point welding, avoiding any type of welding involving the use of gas. Using a point-to-point welding may be a more sustainable option, avoiding the problems of gas-welding in an automated process. However, in the case that the robots may use a gas-based welding, each robot would normally carry its own gas tank, which would run out of gas at different times during the manufacturing process. Therefore, the overall manufacturing process may have to be stopped to fill the empty tank, which may force other robots to stop working, making the overall process slower and much more complicated. Hence, according to this example, the robots used in welding unit 425 may be robots using a point-to-point welding system in their end effectors.

[0077] Assembly operators (not shown) may manually load the metal tubes on each of the carriages 423a and 423b, which may be provided on their surface with a suitable template tool (not shown) to assist the operators in placing the tubes in the correct positions to form the metal grid including the perimeter structure 13 and ribs 14.

[0078] Each of carriages 423a, 423b, once metal tubes have been placed on it, is transferred to the working position 424, where the welding unit 425 welds together the tubes to form the metal grid, and then returned to their respective loading positions 422a, 422b, from where respective bridge cranes 424a, 424b empty the carriages 423a, 423b by picking the welded metal grid and transferring it to a conveyor 426.

[0079] The work on carriages 423a and 423b is done in an alternating mode: e.g., while carriage 423a is in the working position 424, carriage 423b is in the loading position 422b, and assembly operators are placing metal tubes on it. Once welding is completed on carriage 423a, this carriage returns to the loading position 422a and is emptied by the bridge crane 424a, while carriage 423b, with metal tubes prepared on it, travels from the loading position 422b to the working position 424, where the tubes are welded to form a new metal grid.

[0080] Conveyor 426 transfers downstream the line the completed metal grids for the panels, in the shape of a metal grid with a perimeter structure 13 and several ribs 14, formed by hollow metal tubes filled with a vacuum-manufactured expanded polystyrene bar.

[0081] More specifically, the metal grids are transported to the subsequent area 430 where the layers of the outer portion of the panel may be attached to one side of the supporting structure.

Area 430

[0082] The layer forming area 430 includes two assembly lines 430a and 430b, which may run parallel to each other. The operations performed in each line may be the same ones but performed in an alternate mode, in order to maximize the output of the overall assembly line and manufacture more panels per unit of time. The two assembly lines are disposed in such way that the assembled metal grids arrive through line 430b to an assembly unit 431, which has an assembly robot 432 which lifts an incoming metal grid from the conveyor 426 into a assemble position 431a in assembly line 430a, wherein assemble operators may place the layers forming the outer portion of the panel, e.g., of a building wall, on top of the metal grid. The layers may be placed by the operators in such way to be subsequently fastened to the metal grid in the next fastening unit 432, and they may be assembled and fastened with the previously welded perimeter frame 11, although the assembly of the perimeter frame 11 may be performed further down the assembly line by, for example, assembly operators. More specifically the following layers may be placed by the assembly operators, the assembly being performed in the following order: [0083] an OSB 21, assembled with the perimeter frame 11; [0084] a thermal bridge break layer 22, to decrease the flow of heat through the panel, the layer being attached to the OSB 21 by a plurality of staples; [0085] a CBPB 23.

[0086] In this example, the prefabricated CBPBs 23 arrive from the manufacturer in single boards the size of the frames. The boards 23 may be cut according to a cutting layout beforehand, or, alternatively, a cutting station 434 may be used on-site, previous to assembly of the layers on to the supporting structure 1, wherein the CBPBs 23 are cut following a cutting layout which takes into account openings for doors and windows, cutting each board accordingly (or leaving it uncut, when no door or window opening is needed). According to the present example, the cutting station 434 may be operated by assembly operators, although, alternatively, a cutting robot (not shown) may also be used, the robot being in charge of cutting the CBPB and/or other layers of the panel, before the assembly of the layers. Furthermore, the cutting station may also be used by assembly operators to cut any other layer which may be subsequently assembled to the supporting structure 1.

[0087] Once the layers are assembled, the OSB 21 may be fastened with the perimeter frame 11 by screwing through the CBPB 23, thermal bridge break layer 22, OSB 21 and perimeter frame. Such operation may be performed by assembly operators working around the layer forming area 430.

[0088] After said assembly and fastening of the layers forming the outer portion of the panel, the supporting structure, with the perimeter frame and the three assembled layers, is moved along assembly line 430a. The same assembly of said elements to the supporting structure 1 may be made on assembly line 430b, while the already assembled supporting structure moves to the next unit, thus saving time performing in an alternating mode the same operations on both assembly lines 430a, 430b.

[0089] When a supporting structure 1 is assembled with said layers and the perimeter frame attached and fastened to the layers, it moves into a fastening unit 432, wherein a first fastening robot 432a attaches the assembled layers and the perimeter frame with the metal grid in the following way: the CBPB may be fastened to the metal grid, and consequently, also to the layers between the board and the supporting structure, by a plurality of screws. In this case, a plurality of screws may be threaded through the CBPB 23, the thermal bridge break layer 22, the OSB 21 and into the ribs 14 of the metal grid (to further fasten the layers to the metal grid). Furthermore, the CBPB may be leveled with the profile of the perimeter frame 11, in such a way that neither of them protrudes from the other. Also, the screws may be inserted in such a way that they do not protrude from the surface of the CBPB 23. This may be achieved, for example, by making a hole the size of the screw head partially into the CBPB 23. This way, when the screw is inserted, the head of the screw would not protrude, leaving the surface of the CBPB 23 with no protrusions. The gaps of the holes left between the hole and the screw may be plastered in order to leave a smooth surface of the CBPB 23.

[0090] Afterwards, a sealing of the layers may be performed by sealing robot 432b, sealing the joints found between the layers and the supporting structure 1 using a polyurethane-based filler.

[0091] After the sealing is performed, a plurality of exterior finishing layers may be applied to the CBPB 23 by assembly operators, although alternatively a further robot (not shown) may be used to apply the finishing. More specifically, said finishing layers may include, in this order: [0092] a primer or undercoat layer, which is a preparatory coating put on the surface before painting. This layer seals the pores of the CBPB 23 (there are not many in an untouched part, but in the holes corresponding to the screws to attach the board 23 to the structure 1, pores may need to be sealed), ensures better adhesion of paint to the surface of the CBPB 23, increases paint durability, and provides additional protection against corrosion while covering the color of the CBPB 23. It also has a quick drying time. [0093] a pigmented elastic coating for exterior surfaces, used as an intermediate coat in the smooth elastomeric cycle, to protect wall surfaces, and especially those subject to cracking or fissures. In a wall formed by several panels, the panels would have an elastic joint in between each other, in order to prevent cracks or fissures on the wall. However, such joints compensate small movements such as terrain movements, expansions or contractions of materials due to temperature changes, or other similar movements in a wall. In case of a bigger movement (such as, for example, an earthquake), the joints may not resist and keep the panels together, but the elastic coating would still prevent the appearance of micro fissures (of a size in between 1 mm and 3 mm) on the cement board, which affect the internal structure of the panel. Thus, the wall would have to be repaired, but the panels may be reused, fixing only the joints in between them. The product for such elastic coating may be, for example, the commercially available ELASTRONG GUM from the manufacturer Oikos. Such product contains acrylic elastomeric resins in water dispersion, organic and inorganic pigments and titanium dioxide. The special elastomeric resins make the product highly elastic, water repellent, resistant to light, to weather conditions and to pollution: it also prevents the formation of mold and algae. The product remains elastic over time, even when subject to frost and thaw cycles and U.V. rays. It is inflammable and is friendly to both humans and the environment. [0094] a mate and elastic coating for exterior surfaces, such as the commercially available ELASTRONG PAINT GUM from the manufacturer Oikos, coming in a variety of colors, making it suitable as a final exterior layer. The product contains acrylic elastomeric resins in water dispersion, giving to the product outstanding elasticity, weather-ability, water repellence, light stability and resistance to pollution. Furthermore, the product prevents the formation of mold and algae. When treating the surface with said coating, the vapor permeability is maintained, and it becomes easily washable. The product remains elastic over time, even when subject to frost thaw cycles and U.V. rays.

[0095] When the assembly and fastening of the layers of the outer portion of the panel has been performed, the panel may be flipped, either manually by assembly operators or by a turning robot (not shown) in such a way that the surface of the panel opposite to the outer portion (e.g., what will become the inner portion of the panel) face upwards, thus allowing the subsequent units of the assembly lines to assemble other layers and work on that surface. The place where the flipping takes place may be in the conveyor space 435 between robot 432b and robot 432c. Once flipped, both assembly lines 430a and 430b may alternatively move the assembled supporting structures (with the outer portion of the panel in place, inner portion facing upwards) to the part of unit 432 wherein fastening robot 432c is found. Then, the inner portion of the panel, e.g., of a building wall, may be formed by assembly operators assembling the following layers in the following order: [0096] rock wool layer 30: filling up the space defined by the OSB 21 and the height of the supporting structure 1. It is used to thermally insulate; [0097] a second OSB 31; [0098] a vapor barrier layer 32. Such layer is of any material used for damp proofing, typically a plastic or foil sheet, that resists diffusion of moisture through the wall, floor, ceiling, or roof assemblies of buildings to prevent interstitial condensation and of packaging. Technically, many of these materials are only vapor retarders as they have varying degrees of permeability. The layer may be attached as a self-glued layer to the OSB 31. An omega-shaped profile 33. The omega profile 33 defines an intermediate hollow space 331 in between the previous layer and the subsequent layer. Such hollow space 331 is filled with an insulating material such as, for example, rock wool or fiberglass. The quantity of filling material is calculated in such a way that the resulting wall maintains a linear temperature on the inside of a building. This calculation takes into account an average high and low exterior temperature and fixates a desired temperature on the inside of the building. For example, a quantity of fiberglass may be calculated in order to maintain a temperature on the inside of the building of between 22 and 24, in an environment wherein the exterior temperature in the summer is an average of 40 C. and in the winter is an average of 40 C.

[0099] After the operators may have assembled the layers, the fastening robot 432c may fasten the layers accordingly, by nailing or screwing the profile 33, through the vapor barrier 32 and the OSB 31 and into the metal grid.

[0100] Furthermore, sealing robot 432d may also seal the joints found between the layers and the supporting structure 1 using a polyurethane-based filler, in a similar way as in the case of sealing robot 432b.

[0101] Afterwards, the corresponding conveyor (430a or 430b) may move the panel onwards towards fastening robot 432e. In such part of the conveyor 436, assembly operators assemble a finishing plasterboard layer on top of the omega-shaped profile. In this example, a commercially available plasterboard may be used known as superplaca from the manufacturer Knauf. Such board has the same composition as a regular plasterboard, but its manufacturing process makes it much denser than the usual commercially available plasterboard, thus rendering it harder, more resistant to cracks and fissures, and fireproof. After being assembled on top of the omega profile by the operators, the superplaca may be screwed to the omega profile 33 by the fastening robot 432e.

[0102] In order to finish it and further apply a finishing paint coat 34, the screws (which do not protrude from the surface of the plasterboard) may be filled with standard plasterboard filling material and painted with any suitable interior paint by the assembly operators after the plasterboard layer has been fastened to the omega profile.

[0103] Each of the robots in the manufacturing line of FIG. 4 or other manufacturing facility for a layered panel as disclosed in the examples of the present disclosure (e.g., welding robots, fastening robots such as screwing or riveting robots, sealing robots, etc. . . . ) may be an industrial robot, including at least three independently programmable axes. More specifically, for example, robots with four axes or six axes each, i.e., with six independently programmable degrees of freedom. Furthermore, the robots may include programmable rotation axes, linear axes, or other similar serial robots. When designing a panel, the thickness or density of any of the insulating layers (for example, the rock wool layer 30, the thermal bridge break layer 22, etc. . . . ), both in the inner and/or the outer portion of the panel, may be varied, in order to adapt the construction panel to different environments or weather conditions (depending on latitude, longitude, specific climates, etc. . . . ).

[0104] In addition to this, all the previous assembling can be performed with almost no drying waiting time involved, since all the layers may be prefabricated and ready to install or may be quick drying finishing layers.

[0105] Also, the combination of the supporting structure 1 and the threaded CBPB 23 renders a more solid and robust panel, i.e., earthquake resistant. Thus, the panels may be suitable to be used in emergency situations wherein a relatively fast construction of solid and cost-effective buildings is needed, such as post-natural disasters scenarios (i.e., earthquakes, tornadoes, tsunamis, etc. . . . ).

[0106] Once the panels are manufactured, they can be assembled to perform the construction of a building. In this case, according to the present example, when manufacturing the structure of the panels, a plurality of holes is drilled in the perimeter structure, following a predetermined layout. In this example, three pairs of holes may be drilled, each pair in the central part of three sides of the perimeter structure. This way, when the panel is erected in order to form a wall, the pairs of holes may be found in the lateral sides of the perimeter structure, and the upper perimeter side of the structure, corresponding to the ceiling of the floor of the building.

[0107] On the other hand, a building skeleton may be erected formed by beams and columns. The beams and columns are attached to each other by means of an intersection piece which bears holes, which correspond to holes found on the ends of the columns and beams. This way, the structure can be formed by screwing the columns and beams with each other by means of the intersection pieces. Furthermore, the beams and columns corresponding to lateral columns and ceiling beams may also have carved areas for receiving connecting plates, the carved areas having corresponding pairs of holes as in the holes found in the perimeter structure of the panels. Thus, the panels may be attached to the building skeleton by means of connecting plates screwed both into the panel and to the corresponding columns and beams.

[0108] A screwed attaching of the panels to the building skeleton assures that no welding or rigid attachment is needed to form walls within a building, thus making the overall building more resistant to movements related to, for example, the settlement of the building, or natural disasters such as earthquakes or tornados. It also assures a simple and fast on-site construction process of the building, needing only screwing tools and plates to form the walls of the building.

[0109] As a finishing insulation, the gaps found in between panels and the building skeleton or other panels may be covered by placing a rubber band or layer in between the panels and the columns, beams or other perimeter structures of adjacent panels. Such rubber bands may come from pre-manufactured rolls of, for example, polyurethane-based auto-adhesive bands, thus facilitating an easy and fast attachment in the gaps, in order to fully insulate the inside areas of the building.

[0110] Furthermore, the present disclosure includes examples according to the following clauses:

[0111] Clause 1. A layered panel for on-site modular construction of buildings, the panel including: [0112] a layer formed by a prefabricated cement-bonded particle board; [0113] a supporting structure including a metal grid and a perimeter frame, the perimeter frame being configured to receive and surround the cement-bonded particle board; and [0114] fastening elements attaching the cement-bonded particle board to the supporting structure.

[0115] Clause 2. The panel according to clause 1, wherein the fastening elements attach the cement-bonded particle board to the supporting structure by threading, and may include screws that are inserted through holes in the metal grid and threaded into the cement-bonded particle board.

[0116] Clause 3. The panel according to any of clauses 1 or 2, wherein the fastening elements attach the cement-bonded particle board to the supporting structure by threading, and may include screws that are inserted through holes in the perimeter frame and threaded into the cement-bonded particle board.

[0117] Clause 4. The panel according to any of clauses 1 to 3, further including an outermost layer and an innermost layer on opposite sides of the supporting structure, and wherein the cement-bonded particle board is placed on the outermost layer.

[0118] Clause 5. The panel according to clause 4, wherein the innermost layer includes at least one insulating layer and a finishing layer.

[0119] Clause 6. The panel according to any of clauses 4 or 5, wherein the innermost layer overlaps only partially with the supporting structure and the outermost layer.

[0120] Clause 7. The panel according to clause 6, wherein the innermost layer has a smaller surface area than the outermost layer such that it overlaps a central portion of the supporting structure and the outermost layer, while at least two side strips of the supporting structure and the outermost layer remain exposed.

[0121] Clause 8. The panel according to clause 7, further including mounting brackets attached to the supporting structure in correspondence with the exposed side strips.

[0122] Clause 9. The panel according to clause 5, wherein the insulating layer is a thermal bridge break layer.

[0123] Clause 10. The panel according to any of clauses 1 to 9, wherein the cement-bonded particle board is a single piece with a shape and dimension to fit the perimeter frame.

[0124] Clause 11. The panel according to any of clauses 1 to 10, wherein at least 5 part of the metal grid includes hollow tubular members filled with a vacuum-manufactured expanded polystyrene bar.

[0125] Clause 12. The panel according to any of clauses 4 to 11, wherein the innermost layer of the panel further includes tubing and tubing connectors for water installations and/or electrical installations and/or heating installations.

[0126] Clause 13. A method for manufacturing a layered panel according to any of clauses 1 to 12, the method including: [0127] manufacturing a supporting structure including a metal grid and a perimeter frame; [0128] cutting a prefabricated cement-bonded particle board according to a predetermined layout; [0129] assembling the cut cement-bonded particle board inside the perimeter frame of the manufactured supporting structure and fastening the cement-bonded particle board to the manufactured supporting structure.

[0130] Clause 14. An installation for manufacturing a layered panel according to any of clauses 1 to 12, the installation including: [0131] a station to form a supporting structure including a metal grid and a perimeter frame; [0132] a station for cutting a prefabricated cement-bonded particle board according to a predetermined layout; [0133] a station to receive a supporting structure and a prefabricated cement-bonded particle board from the previous stations, and for assembling the cement-bonded particle board inside the perimeter frame of the supporting structure and fastening the board to the supporting structure.

[0134] Clause 15. The installation according to clause 14 wherein the metal grid includes hollow tubular members and the station to form a supporting structure includes a unit for inserting a vacuum-manufactured expanded polystyrene bar inside a hollow tubular member of the metal grid.

[0135] Clause 16. A method for the construction of buildings with layered panels according to any of clauses 1 to 12, including: [0136] erecting a building skeleton including load-bearing columns and beams; and [0137] forming at least outer walls of the building by attaching layered panels according to any of clauses 1 to 12 to columns and/or beams of the skeleton, and optionally to other panels, with screws and/or rivets.

[0138] Clause 17. A method for the construction of buildings according to clause 16, further including: [0139] arranging an installation according to any of clauses 14 or 15 in shipping containers; [0140] transporting the shipping containers to a desired building site; [0141] deploying the stations of the installation from the shipping containers at the desired building site; [0142] operating the stations of the installation to manufacture layered panels; and [0143] constructing buildings with the layered panels at the desired building site.

[0144] Clause 18. The method according to clause 17, wherein at least one station of the installation is arranged inside one container according to an operational layout, whereby the station may be substantially deployed by removing at least part of the container walls.

[0145] Although only a number of examples have been disclosed herein, other alternatives, modifications, uses and/or equivalents thereof are possible. Furthermore, all possible combinations of the described examples are also covered. Thus, the scope of the present disclosure should not be limited by particular examples but should be determined only by a fair reading of the claims that follow. If reference signs related to drawings are placed in parentheses in a claim, they are solely for attempting to increase the intelligibility of the claim and shall not be construed as limiting the scope of the claim.