Title of Invention

"INTEGRAL PREFABRICATION BUILDING SYSTEM"

Abstract The invention concerns an integral prefabrication building system with a frame structure having finished lightweight components comprising: internal partition walls (11) spaced to form apartment modules and incorporating portal structures for supporting the floors, filler panels (16) storey floors (20) and roof floors (25) spanning the partition walls to form a rigid surface, portal structures (26) and bracing elements (27) wherein horizontal joints of rigid surface, continuity of vertical reinforcement and seismic resistance of bracing elements are provided by injected shrink-resistant material in recesses (32) provided in the lightweight components and by connection devices (31), said filler panels (16) are provided with a top beam (17) for forming horizontal earthquake-proof joints, the filler panels (16), which features hollow tubular vertical ventilation elements and continuous insulation, incorporates the top beam (17) which rests at the level of said partition wall (11) on its end pillar (12).
Full Text The present invention concerns an integral prefabrication building system with frame structure incorporating finished lightweight components. As is known, various systems exist for the construction of prefabricated buildings, for residential use, which can be classified in two categories: frame systems and supporting panel systems. The frame systems create, by means of beams, pillars and floors, the structural skeleton of the building which must then be completed on site with the filler panels, partitions and floor consolidation castings.
The frame systems are therefore not "global" as the prefabrication has to be integrated with a completion work on site. In supporting panel structures, the outer and inner walls have the job of sustaining the floor and creating a box-shaped structure forming, the room module, the disadvantages being that it is not possible to alter the distribution from floor to floor, consequently it is not possible to design the ground floor as required, on piloty and underground garage.
Furthermore, although it is possible to obtain integral prefabrication, the concrete supporting elements make the structure heavy' and therefore anti-economic especially in countries where the cost of materials affects the final cost to a far greater extent than labour costs. The aim of the present invention is to produce an integral prefabrication system with frame structure featuring finished lightweight components
that overcome the above-mentioned disadvantages.
This and the other objects are achieved by integral prefabrication building system with a frame structure having finished lightweight components comprising: internal partition walls spaced to form apartment modules and incorporating portal structures for supporting the floors, filler panels storey floors and roof floors spanning the partition walls to form a rigid surface, portal structures and bracing elements wherein the horizontal joints of the rigid surface, the continuity of the vertical reinforcement and the seismic resistance of the bracing elements are provided by injected shrink-resistant material in the recesses provided in the lightweight components and by means of connection devices, said filler panels are provided with a top beam for forming horizontal earthquake-proof joints, and in that the filler panels, which features hollow tubular vertical ventilation elements and continuous insulation, incorporates the top beam which rests at the level of said partition wall on its end pillar.
Briefly, it should firstly be observed that the system of the invention uses walls that create an apartment module and not a room module; the walls are finished and incorporate a frame structure and a lightweight internal area to reduce the weight as far as possible with channels which can also be used. In addition to the floors being extremely lightweight, ducts for wiring and other installations can be made inside them and connected to the vertical wall channels. All the components
are finished and no on-site casting is required during assembly, except for mortar injections. The system is defined integral in the sense that the building is constructed 100% with finished lightweight prefabricated components, maintaining the static advantages of the frame structures and the finishes of the supporting panel structures, but eliminating the negative aspects of the two structures; the system is therefore lightweight, economic and versatile and is competitive both for single-family terraced buildings and for buildings with over 20 floors.
Further objects and advantages of this invention will become clear from the following description and the accompanying drawings, provided purely as a non—restrictive example, in which:
figure 1 shows an axonometric view, partially in section, of the integral prefabrication building system with finished lightweight components, according to the present invention;
figure 2 shows a wall supporting the floor, called partition wall, of the prefabrication system of the invention;
figure 3 shows a filler panel of the prefabrication system of the invention;
figure 4 shows a floor of the prefabrication system of the invention;
figure 5 shows a roofing floor of the prefabrication system of the invention;
figures 6-6A-7-7A show a variation of the roofing floor by means of a flat frontal panel that conceals the pitch of the roof of the prefabrication system of the invention;
figures 8-9 show beam aid pillar elements forming a portal frame, of the prefabrication system of the invention;
figure 10 shows a bracing element of the prefabrication system of the invention;
figure 11 shows a bathroom shell of the prefabrication system of the invention;
figure 12 shows a staircase of the prefabrication system of the invention;
figures 13 to 15 show a device used to produce bracing elements by connecting several partition walls and to produce the earthquake-proof joints of the prefabrication system of the invention;
figure 16 shows a sectional view of the staircase of the prefabrication system of the invention; and
figure 17 shows an exploded axonometric view of a structure
created with the prefabrication system of the invention.
With particular reference to the figures mentioned, the integral prefabrication system with frame structure featuring finished lightweight components of the invention comprises firstly a component 1 1 called partition wall.
The internal partition wall 11 fitted at intervals on the apartment module to sustain the floor, is "cast in vertical formworks to obtain the two finished outer surfaces and consists of a flat frame, made of two end pillars 12 and an upper beam 13, and a lightweight wall with vertical holes 14, obtained by means of special tubular formworks that contract elastically for extraction
The flat columns pillars 12 have dimensions that can be adjusted to static requirements, and contain a sheath (a sheet metal tube) 15 which is to be injected by mortar. The injection ensures distribution of the loads front floor to floor and vertical continuity of the reinforcing bars inserted one on top of the other.
The tubes that form the lightening holes 14 can be positioned as required and have fixed and modular dimensions.
They can also be used to obtain continuous vertical channels for wiring,
ventilation and fume expulsion, and to provide vertical structural
continuity with continuation of the reinforcement.
The partition walls permit the creation of walls with different total thickness for the variable loads due to the different number of floors (in general, purely as an example, 15, 20, 25 cm for holes of 10 cm to 55 cm).
Another component of the system of the invention is the filler panel 16 shown in figure 3.
It is made with continuous thermal insulation by means of one fixed and one moving support and with stainless steel connectors that disengage the outer wall supported by the inner supporting wall and with internal hollow ventilation tubes which during the winter prevent internal condensation of humidity and in the summer prevent internal temperature increases due to radiation.
The panel is characterised by a top beam 17 which rests at the level of the partition wall 11 on its end pillar 12.
The top beam 17 has the following functions:
earthquake-proof joint beam;
beam supporting the external facing, which can be blind, windowed or absent;
assembly template for the partition wall above; partition wall bracing right from the assembly stage;
stiffening of the filler panel which can cover spans up to 10 m, minimising concrete thickness.
The partition wall-filler panel node is provided by the insertion of a vertical bar 18 that enters the sheath 15 of the partition wall 11 and crosses a stainless steel loop 19, so that it is not necessary to make holes in the formworks, with ropes coming out of the top beam 17.
Further injection:
provides an earthquake-proof connection that transmits the action of the joint to the bracing element;
at the same time ensures vertical continuity of the reinforcement; ensures distribution of the vertical loads, providing a seal that allows the injected mortar to embed the resting surface.
Another component of the system of the invention is the floor component 20 of figure 4.
It is a floor covering a large span (up to 10 m) produced by pre-stressing, with adjustable width and length. It is completed on site by panels 21 which rest between two elements 22 thus providing a series of channels 23 which can be used for wiring and other installations also because the statics of the floor are independent of the panels 21 which can therefore be positioned once the structure is complete and also removed subsequently.
The horizontal hole of the floor can be made not only 10 by means of polystyrene blocks but also, like the wall holes, via special tubular formworks which contract elastically for extraction based on exactly the same concept as those of the partition walls.
The horizontal holes of the floors are connected to the vertical holes of the partition walls thus permitting distribution of the wiring and other installations both horizontally and vertically.
The floors are fixed to the partition wall not by means of the usual on-site casting but by means of a mechanical connection 40 (fig. 1) , while on the joining line of two elements one, two or three welded connections 24 can be performed so that the intradas of the floors creates a rigid horizontal surface.
In the floor, the panel 21, which is independent of the floor statics, can be positioned at the end of assembly and can be subsequently raised like a trapdoor to access the wiring and other installations or can be entirely eliminated to obtain, for example, an earth container flush with the floor.
The floor and the panels can have a finished surface which, once 'aid,
constitutes the finished floor of the house, or the floor can be used as a
base for laying a self-levelling material on which an impact noise
insulation layer and then tiles, carpet, linoleum etc. are glued to provide
dry flooring.
Figure 5 shows a roofing floor 25, belonging to the prefabrication system of the invention.
The element has a flat intrados constituting the ceiling of the last floor, while the extrados consists of a covering slab with transverse and longitudinal pitch of 15%, in order to create:
an air space between the intrados slab and the roofing slab providing thermal inertia;
a well-insulated roof, with an insulating layer factory-laid on the ceiling panel and turned up over the tile ribbing in order to eliminate heat bridges;
a sloping roof made of highly waterproof concrete that does not require any further waterproofing layer;
a roof with the possibility of a false ceiling at the intrados between tiles which can be lifted up for access to and inspection of the air space;
a roof resistant to tornadoes and whirlwinds as it has no lightweight elements;
a ventilated roof, like the walls, obtained by exploiting the pitch of 15%.
Ventilation is obtained by means of two air inlet grills at the level of the flashing and two air outlet grills at the ridge.
lastly, a roof that is finished and can be assembled immediately, thus permitting maximum construction speed.
An end element 41 can also be provided featuring a flat front panel that conceals the pitched ventilatec roof behind, as shown in figure 7.
Figures 8-9 show particular views of a portal frame structure 26, belonging to the prefabrication system of the invention.
It consists of collar pillars 51 supporting an upturned T connection beam 50, which form a portal where the beam supports the floor and the pillars directly support the loads transmitted by the flat pillars in the partition walls of the upper floors.
The pillar with collar has one fixed and one variable dimension with the possibility, therefore, of also constituting "blade" pillars ranging, for example, from the minimum section of 25 cm x 40 cm to a section of 40 cm x 60 cm or 25 cm x 200 cm.
This is very useful when a ground floor on pillars is required or there is a garage below the building, or the ground floor has a height that would make the partition walls and filler panels impossible to transport.
Figure 10 shows a bracing element 27 consisting of partition walls that
form the stairwell or lift shaft.
Some of the partition wall holes can be through holes in order to contain
the vertical reinforcement cage 28 which continues from floor to floor.
The partition walls are interconnected by the insertion of bars 18 in the protruding steel wire rope loops 19 and by further injection as for the top beam of the panels.
Figure 11 shows a bathroom shell 29, belonging to the prefabrication system of the invention.
The bathroom shell 29 contains a fully accessoried bathroom, equipped and finished to provide integral prefabrication by components. The shell is made of a concrete element completely closed on the six sides, self-supporting, but able to perform also a bracing function for single-floor constructions during assembly. Its reduced height means that a storage compartment can be obtained in the upper part between the shell and the ceiling.
Figure 12 shows a staircase 30, to make the prefabrication system integral.
The staircase 30 consists of three overlapping finished elements consisting of a tubular structure fitted with the overhanging steps which
constitutes the stair supporting element inside which it is also possible to install a lift by removing the floor swam.
The three inter-floor elements are positioned one on top of the other and consolidated by injection of sheath reinforcement, as for the parting walls.
In this way, a stair unit 30 is produced, complete with landings, which can be fitted either inside or outside the building and is totally independent from the static point of view.
The steps can be made with finished risers and treads so that, once the component is fitted, there is no need for any further work.
In the earthquake-proof frame structure of the invention, the horizontal joints of the rigid floor, the continuity of the vertical reinforcement and the bracing elements are obtained without additional castings on site, but simply by injections at set points and with connection devices 31 consisting of stainless steel loops.
Said connection devices are made by inserting in the formwork retrievable magnetic elements which pull out of the wall, at the required intervals, a loop 19 made of stainless steel wire rope which does not require holes in the side and which, due to its flexibility, permits easy positioning of two adjacent walls during assembly.
During production the magnetic element that holds the loop is positioned in a semi-circular recess which permits, after on-site insertion of a reinforcing bar overhead injection of shrink-resistant mortar into a recess 32.
While the vertical reinforcement, continued, provides vertical continuity, the protruding loops provide both the insulated connection of the walls that constitute the earthquake-proof structure and the joints in the top beam of the filler panels.
To ensure quick assembly regardless of the climatic conditions, the frame with the earthquake-proof joints is produced by simple injections of mortar and therefore basically without on-site castings of cement mix, ensuring complete finishing of the building.
Finally, figure 17 shows an exploded axonometric view of a structure, indicated overall by reference number 100, made with the prefabrication system of the invention.
From the description provided, the characteristics of the integral prefabrication system featuring finished lightweight components, subject of the present invention, are clear as are the resulting advantages.
Finally, it is clear that numerous variations can be made to the integral
prefabrication system with frame structure featuring finished lightweight
components while remaining within the principles of novelty inherent in
the inventive idea.
In practical implementation of the invention, the materials, forms and dimensions of the details illustrated can be of any type according to requirements and the same may be replaced with other technical equivalents.
The scope of the invention is defined in the claims attached to the present application.





WE CLAIM:
1. Integral prefabrication building system with a frame structure having finished lightweight components comprising: internal partition walls (11) spaced to form apartment modules and incorporating portal structures for supporting the floors, filler panels (16) storey floors (20) and roof floors (25) spanning the partition walls to form a rigid surface, portal structures (26) and bracing elements (27) wherein the horizontal joints of the rigid surface, the continuity of the vertical reinforcement and the seismic resistance of the bracing elements are provided by injected shrink-resistant material in the recesses (32) provided in the lightweight components and by means of connection devices (31), said filler panels (16) are provided with a top beam (17) for forming horizontal earthquake-proof joints, and in that the filler panels (16), which features hollow tubular vertical ventilation elements and continuous insulation, incorporates the top beam (17) which rests at the level of said partition wall (11) on its end pillar (12).
2. System as claimed in claim 1, wherein the said internal partition wall (11) consists of a flat frame, made of said two end pillars (12) and an upper beam (13), and a wall with vertical lightening holes (14) obtained by means of tubular formworks that contract elastically for insulation or ventilation.
3. System as claimed in claim 2, wherein the said pillars (12) and the walls provided with the lightening holes (14) have dimensions that are adjustable to static requirements wherein the said pillars are provided with a sheath (15) which, when injected, ensures distribution of the loads and vertical continuity of the reinforcement.
4. System as claimed in claim 1, wherein the said top beam (17) is an earthquake-proof joint beam, provides stiffening for said panel, supports panels for both the vertical loads and horizontal thrust, is an assembly template for the partition wall (11), and is a bracing for said partition wall.
5. System as claimed in claim 1,wherein between said partition wall and filler panels is a node provided by the insertion of a vertical bar (18) which enters the sheath (15) of the said partition wall (11) and connects the loops (19) protruding from the top beam (17).
6. System as claimed in claim 1, wherein the floor (20) is made of a pre-stressed element, of adjustable width, with intrados providing a rigid surface and extrados providing the walk surface with prefabricated panels (21) that rest between two elements (22) providing a series of channels (23) which is usable for wiring and other installations.
7. System as claimed in claim 7, wherein the said floors (20) are fixed
to the partition wall without additional casting but by means of
mechanical connections (40) and, on the joining line of two elements (22),
by means of welded connections (24)
8. System as claimed in claim 1, wherein said roof floor (25) is made of pre-waterproofed and pre-insulated elements with intrados providing a rigid surface constituting the top floor ceiling and extrados made of waterproof concrete with sloping longitudinal section in order to create an air space, with grill apertures for inlet of air at ambient temperature and outlet of the heated air on the ridge, thus providing roof ventilation, wherein the roof is made of adjacent single-block elements or alternating with roofing panels and is able to withstand tornadoes and whirlwinds.
9. System as claimed in claim 1, wherein the said portal (26) consists of varying dimension pillars, also constituting "blade" pillars, which directly receive the load of the upper floors and which, with an upper collar pillar (51), support an upturned T connection beam (50) bearing the floor (20).
10. System as claimed in claim 1, wherein said bracing element (27) consists of partition walls that form stairwells or lift shafts in which at least some of the partition wall holes are through holes in order to contain a vertical reinforcement cage (28) which continues from floor to floor and the partition walls are interconnected by the insertion of a bar (18) in the loops (19).
11. System as claimed in claim 1, wherein there is provided a bathroom shell (29) containing a fully accessoried bathroom, equipped and finished and made of a concrete element completely closed on six sides and self-supporting, with a storage compartment in the upper part between the shell and the ceiling.
12. System as claimed in claim 1, wherein there is provided a staircase (30) statically independent of the structure of the building, consisting of a tubular structure fitted with overhanging steps inside in which it is possible to install a lift, also at a later stage, three inter-floor elements being positioned one on top of the other and consolidated by injection of sheath reinforcement.
13. System as claimed in claim 1, wherein said horizontal joints are provided in panel folds and continuity of the vertical reinforcement are obtained by injection into the recesses (32) provided and by special connection devices (31) which are obtained without making holes in the formwork but by placing, in any position, retrievable magnetic elements that retain the loop folded inside them and, when retrieved, pull loops (19) out of the wall.
14. Integral prefabrication building system substantially as hereinbefore described with reference to and as illustrated in the accompanying drawings.

Documents:

950-delnp-2003-abstract.pdf

950-delnp-2003-claims.pdf

950-delnp-2003-complete specification (as files).pdf

950-delnp-2003-complete specification (granted).pdf

950-delnp-2003-correspondence-others.pdf

950-delnp-2003-correspondence-po.pdf

950-delnp-2003-description (complete).pdf

950-delnp-2003-drawings.pdf

950-delnp-2003-form-1.pdf

950-delnp-2003-form-13.pdf

950-delnp-2003-form-19.pdf

950-delnp-2003-form-2.pdf

950-delnp-2003-form-3.pdf

950-delnp-2003-form-5.pdf

950-delnp-2003-gpa.pdf

950-delnp-2003-pct-101.pdf

950-delnp-2003-pct-105.pdf

950-delnp-2003-pct-210.pdf

950-delnp-2003-pct-220.pdf

950-delnp-2003-pct-304.pdf

950-delnp-2003-pct-308.pdf

950-delnp-2003-pct-401.pdf

950-delnp-2003-pct-402.pdf

950-delnp-2003-pct-409.pdf

950-delnp-2003-pct-416.pdf

950-delnp-2003-petition-137.pdf

950-delnp-2003-petition-138.pdf


Patent Number 242941
Indian Patent Application Number 950/DELNP/2003
PG Journal Number 39/2010
Publication Date 24-Sep-2010
Grant Date 21-Sep-2010
Date of Filing 20-Jun-2003
Name of Patentee D.L.C.S.R.L
Applicant Address VIA TIZIANO, 19, I-20145 MILAN, ITALY.
Inventors:
# Inventor's Name Inventor's Address
1 ALBERTO DAL LAGO CORSO PLEBISCITI, 9, I-20129 MILAN, ITALY.
PCT International Classification Number E04B 1/04
PCT International Application Number PCT/EP01/14738
PCT International Filing date 2001-12-13
PCT Conventions:
# PCT Application Number Date of Convention Priority Country
1 MI2000A002758 2000-12-20 Italy