HK1223664B - A structural module for construction of buildings - Google Patents

Description

Structural modules for building buildings

This application is a divisional application of the invention patent application with application date of July 22, 2010, application number 201080037279.0, and invention name “Structural module for constructing buildings”.

Technical Field

The present invention relates to structural modules for constructing buildings.

Existing technology

Published specification No. WO2007080561 describes a structural module, a method for manufacturing the same, and the construction of a multi-story building by placing the modules on top of each other.

The present invention aims to achieve improved technical characteristics of such modules, such as greater robustness, improved fire resistance, improved sound insulation, and improved stability, particularly with regard to the materials used. Another objective is to achieve a more efficient manufacturing method. Another objective is to improve resistance to hurricane forces and seismic activity.

Summary of the Invention

According to the present invention, there is provided a structural module comprising a structural base plate, a load-bearing wall and a structural top plate, the structural module being arranged to support a plurality of other structural modules in a multi-storey building, wherein at least one load-bearing wall comprises a structural frame and lightweight concrete located between frame members of the structural frame, the lightweight concrete having a density in the range of 300 kg/m ³ and 1200 kg/m ³ .

In one embodiment, the concrete is porous, including entrapped air.

In one embodiment, the density of the concrete is in the range of 400 to 600 kg/m ³ .

In one embodiment, the concrete is formed between the frame members, completely filling the spaces between the frame members along the plane of the wall.

In one embodiment, the wall is configured to form a combined wall when two modules are juxtaposed, the combined wall comprising a cavity between the modules.

In one embodiment, the wall is aligned on at least one side by panels, the lightweight concrete and panels providing a fire resistance of at least two hours.

In one embodiment, the wall sheet material contains MgO.

In one embodiment, the concrete is cast over a steel frame and slab.

In one embodiment, at least a portion of the top slab comprises lightweight foam concrete between structural members in the trusses.

In one embodiment, the base plate includes a peripheral structural steel frame and comprises lightweight concrete with steel reinforcement.

In one embodiment, the module includes vertical locating pins at a corner for engaging in receptacles at a corner of another module.

In one embodiment, the modules include generally vertical receptacles at the corners for engaging locating pins of an attached upper or lower module.

In one embodiment, the module includes a connecting plate configured to be secured to a plurality of other modules at corners.

In one embodiment, the plate comprises through holes for receiving locating pins of connected modules.

In one embodiment, the module comprises an inner wall connected to the structural wall by a releasable connection.

In one embodiment, the releasable connection comprises a connection of flexible padding extending in a vertical direction.

In another aspect, the present invention provides an assembly of a plurality of modules mounted one above the other, wherein the modules are structural modules as described in any one of the above embodiments.

In one embodiment, at least some of the modules connect reinforced concrete cores and abut in a vertical plane.

In one embodiment, at least one module has a connection piece with a head that engages behind a vertical slot in the core.

In one embodiment, the vertical slot is located in an insert embedded in the core block.

In one embodiment, the insert comprises a flange parallel to a plane facing the outer surface of the module, and side walls connecting the flange to the front wall of the introduction slot.

In one embodiment, a plurality of modules are connected together at the connecting corners by a connecting plate and at least one locating pin extending through the connecting plate and into a socket of an upper or lower module.

In another aspect, the present invention provides a method of manufacturing a structural module as described in any of the above embodiments, the method comprising manufacturing a structural base plate, structural walls and a structural top plate and connecting them together, the method comprising the steps of selecting a concrete composition and/or density for each structural wall according to its intended position and function in a building to be constructed using the module, and casting the selected lightweight concrete into the wall.

In one embodiment, the density of the concrete is in the range of 400 kg/m ³ to 600 kg/m ³ .

In one embodiment, the concrete is prepared by selecting the proportions of materials and foaming agents in the concrete mix before pouring the concrete into the wall structural frame.

In another aspect, the present invention provides a method of constructing a building, comprising the steps of manufacturing structural modules according to the method as described in any of the above embodiments, transporting the modules to a site with core blocks mounted upright, placing at least some of the modules adjacent to the core blocks, and connecting at least some of the modules to the core blocks.

In one embodiment, the modules are connected by engaging connectors in vertical slots in the core blocks and securing the connectors to the modules by welding or fasteners.

In one embodiment, a plurality of the modules are connected at connected corners by engaging generally vertical locating pins on a module with generally vertical sockets in an above or below module.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention will be more clearly understood from the following description of some embodiments thereof, given by way of example with reference to the accompanying drawings, in which:

Figure 1 is a perspective view of the structural elements of a structural module of the present invention, and Figure 2 is a perspective view showing a number of such modules arranged to form a building, again showing only the structural frame of the module;

FIG3 is a cross-sectional view through the connected structural wall when two modules are juxtaposed;

Figures 4 and 5 are perspective views of the corners of the modules, showing how they are connected together to enhance earthquake resistance;

FIG6 is a plan view showing the connection of the non-load-bearing inner wall to the load-bearing outer wall of the module; and

Figures 7 and 8 are perspective views of connectors used to connect modules to building cores;

9(a) to (c) are side views showing the use of connectors for connecting modules to the bottom plate level, and FIG. 10(a) to 10(c) are side views showing the use of connectors connected at the top plate level.

DETAILED DESCRIPTION

Referring to Figure 1 , a structural module 1 includes a base plate 2 having a peripheral structural steel frame and reinforced concrete. Structural walls 3 are supported on the base plate 2 and include box-section structural steel studs 4. A roof plate 5 includes structural steel trusses 6 spanning the walls 3. The walls 3 have sufficient structural strength to support numerous modules in a multi-story building, such as a hotel or apartment building, as shown in Figure 2 . The wall studs 4 are 60x60x3 SHS steel with 600mm center spacing and are supported on flanged edge frame members 7 of the structural base plate 2. The trusses 6 have support plates 8 supported on the walls 3, directly overlying the studs 4. The structure of the structural walls, base plate, and roof, in terms of their structural framework, is described in WO2007080561.

A brace 9 extends from a central position of the end wall 10 toward the longitudinal wall 3 .

FIG2 illustrates how a break may be present in module 1, in this example, at 2.25 times the height of module 1. This break in structural wall 3 could be caused by any of a number of accidental events, such as a vehicle impact or a gas explosion. The base plate 2, structural walls 3 and 10, and structural top plate 5 provide sufficient strength to prevent collapse in the event of a break in the structural wall, up to 2.25 times the module height.

Referring to Figure 3, the structural wall 3 includes steel studs 4 with varying design center spacing. The steel studs 4 are hollow, square or rectangular, typically 60x60x3 SHS steel. When two modules are placed adjacent to each other, there are two modular walls 3 and 16, with the two aligned studs 4 separated by a cavity 15. Each wall 3 and 16 has a molded-in lightweight foam concrete 20. The foam concrete 20 is made with foam to provide entrained air, resulting in a very low density. An example is commercially available Neopor ^™ , known as porous lightweight concrete. In this embodiment, the density is approximately 500 kg/ ^m³ , however, the density can vary from 300 kg/ ^m³ to 1200 kg/ ^m³ .

The structural strength of the module walls 3 and 16 is provided by steel studs 4, supplemented by concrete 20 cast inside. The foamed concrete 20 fills the spaces between the studs 4 and the inner surface MgO outer panels 21. Strips 23 of MgO panels are located between the studs 4 and the MgO panels 21.

This combination of materials and their physical structure provides the following properties:

Fire resistance. MgO plates 21 have excellent fire resistance. Foamed concrete 20 reduces heat transfer to the steel and has a much lower thermal conductivity than conventional concrete, contributing to its improved fire resistance. The delayed rise in steel temperature to the critical level of approximately 500°C is highly beneficial for fire safety in multi-story buildings. In the EN 1365-1 fire test for supporting components, a fire resistance of 120 minutes was achieved, despite the relatively thin walls, in this example 82 mm.

- High strength-to-weight ratio. By using low-density foamed concrete, a similar structural deadweight can be achieved compared to the modules of WO2007080561, which is approximately 15% lighter than conventional buildings.

Excellent sound insulation. Due to the composition of the walls, the modules' sound insulation is significantly improved, as the walls are designed to handle a wider range of sound frequencies. A partition wall formed from two modules has been tested in the laboratory and achieved an Rw of 62dB and an Rw+Ctr of 57dB. This is approximately 9dB lower than current building regulations in Ireland and 12dB lower than current UK building regulations.

- Robustness.

Improved insulation compared to conventional concrete. Lightweight foamed concrete (CLC) with a density of approximately 500 kg/ ^m³ is, on average, 14 times more effective at insulating than conventional concrete. This reduces the insulation requirements for the exterior walls.

- Stability. No synthetic or artificial polymers are required. The foaming agent used in the mix is made from natural ingredients and is biodegradable and water-friendly. Eco-cement can also be used with this product, reducing the need for additional insulation layers.

It will be appreciated that the wall structure contributes significantly to providing the structural module with the required properties in its manufacture, in its use in constructing buildings and in other uses for residential and commercial purposes.

The properties of the wall may be different in the factory, depending on the intended use characteristics of the module 1. This is achieved by adjusting the density of the foamed concrete 20 during the off-site (factory) manufacturing process of the module 1. In one embodiment, the foamed concrete is prepared as follows:

In a mechanical drum mixer, first mix the correct grade of river quicksand with cement in the desired proportions. Optionally, polypropylene fibers can be mixed in to reduce shrinkage. Then, water is added to the required volume and mixed thoroughly. Once the desired volume is reached, foam is added to create a mixture with the desired wet density.

The foam is generated in a machine containing water, compressed air, and a bio-foaming agent, which produces a lightweight foam with encapsulated small bubbles. This allows the foam to be mixed into the sand-cement-water mortar without the bubbles collapsing, thus maintaining the mix at a stable density. After the foam is fully incorporated into the mix, it is transferred to a hopper and scraped off the level before being cast into the slab on a horizontal bed.

This has many advantages for the construction of the walls, for the construction of buildings from modules and for the method of manufacturing the modules. One of the most important advantages is that the present modules solve the characteristic sound insulation problems usually associated with modular structures.

Also should be understood that, owing to avoid manually filling insulation layer, lightweight concrete is cast by machine, so this manufacturing method is more efficient.In factory, casting machine automatically casts, leveling (level) and scrape (screed) the filled concrete.

Referring to Figures 4 and 5, the corner joints are formed by a connecting plate 30 with four corner holes 31, sockets 32, and dowel pins 33. These components interconnect eight modules 1 at the corners: four below and four above. The connecting plate 30 is welded to the corner members 32 of the lower module 1 at the butt joints 37. The chamfered top edges 34 of the connecting plate 30 facilitate the necessary welds to secure the plate 30 directly to the support plates 8 of the top trusses 6 of the connected modules 1. This secures the plate to the four lower modules 1, and these edges are accessible from above. These welds are indicated by the number 36 in the figures.

The adjacent upper module 1 is welded to a connecting plate 30 around the corners of the upper module's base plate 2 at weld seams 37. The connecting plate 30 has four holes 31, one at each corner. The two adjacent upper modules 1 are then placed and secured in a similar manner. The last upper module is secured in place by inserting dowel pins 33 through holes 31 in the plate 30. Dowel pins 33 extend through adjacent sockets 32 below and are filled with a non-shrinking, high-strength grout. The depth of the sockets and the length of the dowel pins are determined by the forces they need to provide. In some cases, this grout may also be required to be fast-hardening to achieve the desired strength in the connection as quickly as possible. This is particularly true for high-rise buildings, where the structure must withstand wind and other final loads before construction is completed. In one embodiment, the grout is, for example, Sikadur-42HE high-performance epoxy grout. This dowel pin connection has the same ability to withstand all relevant forces as the welds between the upper module and the connecting plate.

This configuration allows a fourth module 1 to be connected even if it is not possible to access the welds on the plate 30 after the top three modules are in place. Furthermore, it allows a combination of welding and doweling at each corner. By providing four holes 31 in the plate, it is possible to select on site which top module is lowered into position last.

This structure is designed to withstand the static and dynamic forces of an earthquake. Compressive loads are primarily borne by the vertical studs 4. Vertical tensile loads are resisted by corner connectors 40, specifically designed for this load. Horizontal forces are transferred to the reinforced concrete building core through the skin action, utilizing the floor panels and corner connections. These corner module connections are achieved using welds and/or grout-filled pins to meet the structural design requirements.

With reference to Figure 6, the non-load-bearing inner wall 50 of module 1 is connected to the structural base plate 2 and the top plate 5 by fastening structural elements. The inner wall 50 is connected to the structural wall 3 via guide rails 52 of grooved cross-section, which are fastened to the wall 3 by screws 53. A plasterboard strip 54 is fixed to the guide rails 52. The inner wall 50 is then moved into a position where its side edges abut the plasterboard 54. The plasterboard 54, fixed to the groove, rests on the first stud of the inner wall panel but is not mechanically fixed thereto. Connectors 55 of flexible material are provided between the plasterboard strip 54 and the plasterboard 56 of the inner wall 50.

In the event of severe seismic activity causing structural wall 3 to move, the nature of the connectors prevents inner wall 50 from being forced to move with structural wall 3. Connectors can break or become damaged, but any damage is superficial and easily repaired. The primary advantage is that inner wall 50 maintains its stability and integrity and does not generate forces that could further damage performance or cause serious harm to residents.

Figures 7 through 10 illustrate the connection of module 1 to a reinforced concrete core 61, which has previously been installed upright. Typically, core 61 contains the elevator and stairwells of a building. Slotted inserts 60 are inserted into core 61 in a precise vertical orientation and aligned with the module's floor and ceiling levels. The number of inserts is determined by the calculated forces. Slotted inserts 60 include side flanges 62 that merge into sloping sidewalls 67 of a front wall 63 with vertical slots 64.

Connector 65 comprises a flat plate with a notch at one end to provide a head 66 configured to fit within slotted insert 60. Connector 65 is engaged to slotted insert 60 in a vertical orientation and then rotated 90° until connector 65 is in a horizontal orientation. Connector 65 is then slid vertically until it engages the module's floor 2 (Figures 9(a) to 9(c)) or the top of module 1 (Figures 10(a) to 10(c)). Connector 65 is then welded to the module and is free to slide only vertically within slotted insert 60. This allows it to resist shear and tensile forces while accommodating any differential settlement between the module and the core, particularly in multi-story buildings. It also allows horizontal forces to be transferred from module 1 to the core structure 61. This detail is also crucial for accommodating static and dynamic forces in the event of an earthquake. Differential settlement in a 25 storey building may range in the region of 8mm to 15mm due to shrinkage of the concrete in the building core, but since the steel carries the load the shrinkage of module 1 is less noticeable.

As shown in Figures 9 and 10, the welding of the connector 65 may include first welding a buffer plate (Figures 10(a) to 10(c)) so that the top surface of the connector 65 is brought to the level of the top surface of the support plate 8. Optionally, the method may include removing a portion of the plate to create space for the connector plate (Figures 9(a) to 9(c)). The subsequent connection is provided between the transverse extensions of the bottom plate provided by the inverted U-shaped channel steel, as shown in the figure.

It will also be appreciated that the foamed concrete in the modular wall 3 significantly increases its overall stiffness. This in turn improves the wall 3's ability to resist transverse deflection forces. This is particularly advantageous in hurricane or earthquake zones, where braced frames and/or shear walls may also be required to resist these forces.

It will also be appreciated that the modules are adapted to avoid disproportionate collapse that could occur in the event of an unforeseen event. The modules are capable of withstanding the removal of up to 2.25 h (in meters) of the length of the module's long wall at one level without risk of collapse of the upper modules (h = module height). Similarly, the entire short wall of the module can be removed at one level without risk of collapse of the upper modules. This can be appreciated from FIG2 .

The present invention is not limited to the embodiments described herein, but rather can vary in structure and detail. For example, the same technique for constructing walls using cast lightweight foam concrete can also be used for the top, roof, and floor panels. Furthermore, in the described embodiment, a cavity is defined between the walls of two connected modules. However, it is contemplated that walls, such as the inner walls of a single module, could also incorporate a cavity. In this case, a structural frame could be provided on either side of the cavity. Furthermore, the connection structure used to connect the modules to the core blocks could be reversed, with the core blocks having connectors that engage slots in the modules.

Claims (14)

1. An assembly of multiple structural modules mounted vertically to each other, wherein each structural module comprises: a structural base plate (2), a load-bearing wall (3), and a top plate (5), configured to support multiple other structural modules (1) in a multi-story building, wherein at least one load-bearing wall (3) comprises a structural frame (4) and lightweight concrete (20) located between frame members of the structural frame, the lightweight concrete (20) having a density in the range of 300 kg/ ^m³ to 1200 kg/ ^m³ , and In this configuration, at least some of the structural modules are connected to the concrete core block (61) and are adjacent to the concrete core block in a vertical plane, and the at least some of the structural modules are free to slide relative to the concrete core block (61) only in the vertical direction. 2. The component according to claim 1, wherein the lightweight concrete (20) is porous, including air entrainment. 3. The component according to claim 1 or 2, wherein the lightweight concrete (20) is formed between the frame members, filling the gaps between the frame members along the plane of the load-bearing wall. 4. The component according to claim 1 or 2, wherein the load-bearing wall (3) is aligned on at least one side by plates, and the lightweight concrete and plates provide at least two hours of fire resistance. 5. The component according to claim 4, wherein the lightweight concrete (20) is cast onto the steel frame and the plate. 6. The component according to claim 1 or 2, wherein at least a portion of the top plate (5) comprises lightweight concrete (20) between structural members in the truss. 7. The component according to claim 1 or 2, wherein the structural base plate (2) comprises an outer structural steel frame and includes lightweight concrete (20) reinforced with steel bars. 8. The component according to claim 1 or 2, wherein the structural module (1) includes an inner wall (50) connected to the support wall (3) by releasable connectors (54, 55). 9. The component of claim 8, wherein the releasable connector includes a connector (55) with a flexible filler extending in the vertical direction. 10. The component according to claim 1 or 2, wherein at least one structural module has a connector (65) with a head (66) that engages behind a vertical slot (64) in the concrete core block. 11. The component of claim 10, wherein the vertical slot is located in an insert (60) embedded within a concrete core block. 12. The component of claim 11, wherein the plug (60) includes a flange (62) parallel to a plane facing the outer surface of the concrete core block of the structural module, and a sidewall (67) connecting the flange to a front wall (63) leading to the vertical slot (64). 13. A method for constructing a building using structural modules, the structural modules comprising: a structural base slab (2), load-bearing walls (3), and a top slab (5), configured to support a plurality of other structural modules (1) in the building, wherein at least one load-bearing wall (3) comprises a structural frame (4) and lightweight concrete (20) located between frame members of the structural frame, the lightweight concrete having a density in the range of 300 kg/ ^m³ to 1200 kg/ ^m³ , the method: The structural modules are manufactured by: manufacturing a structural base plate, load-bearing walls, and a top plate and connecting them together; and selecting the composition and/or density of lightweight concrete for each load-bearing wall according to its intended location and function in the building constructed using the structural modules, and casting the selected lightweight concrete into the load-bearing walls; and The structural modules are transported to the site with upright concrete core blocks, at least some of the structural modules are placed adjacent to the concrete core blocks (61), and at least some of the structural modules are connected to the concrete core blocks such that the at least some of the structural modules can slide freely relative to the concrete core blocks (61) only in the vertical direction. 14. The method of claim 13, wherein the structural module is connected by engaging the connector within a vertical slot (64) in the concrete core block and securing the connector to the structural module by welding or fasteners.