Prefabricated building structural member

Abstract

The present disclosure generally relates to a prefabricated building module (100), a building structure (50) comprising a prefabricated building module (100), and a method for constructing a building structure (50). A prefabricated building module (100) comprises a structural body (102) and a groove (106) formed longitudinally along a groove-shaped surface (108) of the structural body (102) and arranged to receive a connecting member (110) for joining to another prefabricated building module (100). A transverse cross-section of the groove (106) includes a first groove portion (112) and a second groove portion (114), the first groove portion (112) being formed between the groove-shaped surface (108) and the second groove portion (114), the first groove portion (112) being narrower than the second groove portion (114).

Description

[0001] This application is a divisional application of Chinese invention patent application filed on August 14, 2020, with national application number 2020801039572 (PCT / SG2020 / 050470) and invention title "Prefabricated Building Structural Components". Technical Field

[0002] This disclosure generally relates to prefabricated building structural components. More specifically, this disclosure describes various embodiments of prefabricated building modules, building structural components including prefabricated building modules, and methods for constructing building structural components. Background Technology

[0003] In the construction industry, on-site construction methods, such as pouring concrete on-site, are known and commonly used; however, these methods are often labor-intensive and time-consuming. Off-site precast or cast-in-place concrete structural components are increasingly used because they reduce on-site construction time. Cast-in-place components are connected on-site using connecting members anchored therein. Recently, precast prefabricated volumetric building components (PPVCs) have been adopted in the construction industry, and this is a new method that has been developed to significantly accelerate construction. In PPVCs, building modules with precast structural components, such as entire rooms, are prefabricated in off-site manufacturing facilities before being transported to the site. On the construction site, the precast building modules are connected and assembled to construct building structural components such as buildings. The precast building modules are formed with connecting members, allowing them to be connected and assembled.

[0004] Singapore Patent 10201703972W describes a prefabricated building module comprising a panel body and guides, such as wire loops, partially embedded within the panel body. The guides need to be precisely positioned within the prefabricated building module to ensure proper alignment and connection with other prefabricated building modules. Prefabrication of the building modules requires considerable time to ensure correct placement of the guides, thus slowing down manufacturing and overall build productivity. The steel guides protruding from the panel body can create obstacles during on-site assembly and may be harmful or dangerous to on-site workers, especially in the event of accidental falls or collisions with the steel guides.

[0005] Therefore, in order to solve or mitigate at least one of the above problems and / or disadvantages, there is a need to provide an improved prefabricated building module, a building structural member including the prefabricated building module, and a method for constructing the building structural member. Summary of the Invention

[0006] According to a first aspect of this disclosure, there exists a prefabricated building module comprising a structural body and a groove formed longitudinally along a grooved surface of the structural body, the groove being arranged to receive a connecting member for connection to another prefabricated building module. The transverse section of the groove includes a first groove portion and a second groove portion, the first groove portion being formed between the grooved surface and the second groove portion, the first groove portion being narrower than the second groove portion.

[0007] According to a second aspect of this disclosure, there exists a building structural member comprising a first prefabricated building module and a second prefabricated building module arranged adjacent to each other. Each prefabricated building module includes a structural body and a groove formed longitudinally along a groove-shaped surface of the respective structural body. The prefabricated building modules are arranged such that the respective grooves face each other, and a connecting gap including the groove is formed between the respective groove-shaped surfaces. The building structural member further includes: a connecting member inserted into the connecting gap; and a connecting filler material that fills the connecting gap and connects the prefabricated building modules together. For each prefabricated building module, the transverse section of the respective groove includes a first groove portion and a second groove portion, the first groove portion being formed between the respective groove-shaped surface and the second groove portion, the first groove portion being narrower than the second groove portion.

[0008] According to a third aspect of this disclosure, there is a method for constructing a building structural member. The method includes: providing a plurality of prefabricated building modules, each prefabricated building module including a structural body and a groove formed longitudinally along a groove-shaped surface of a respective structural body; arranging a first pair of prefabricated building modules adjacent to each other such that the corresponding grooves face each other and a first connecting gap including the grooves is formed between the corresponding groove-shaped surfaces; inserting a first connecting member into the first connecting gap; filling the first connecting gap with a connecting filler material to connect the first pair of prefabricated building modules together; and curing the connecting filler material to construct a building structural member including the connected prefabricated building modules. For each prefabricated building module, the transverse section of the corresponding groove includes a first groove portion and a second groove portion, the first groove portion being formed between the corresponding groove-shaped surface and the second groove portion, the first groove portion being narrower than the second groove portion.

[0009] Therefore, this document discloses prefabricated building modules according to the present disclosure, building structural members including prefabricated building modules, and methods for constructing building structural members. Various features, aspects, and advantages of the present disclosure will become more apparent from the following detailed description of embodiments of the present disclosure by way of non-limiting example only, in conjunction with the accompanying drawings. Attached Figure Description

[0010] Figure 1A and Figure 1B These are examples of building structural members comprising pairs of prefabricated building modules according to some embodiments of this disclosure.

[0011] Figure 2A and Figure 2B This is an example of another building structure comprising paired prefabricated building modules according to some embodiments of the present disclosure.

[0012] Figure 3A , Figure 4A , Figure 5A and Figure 6A These are various examples of the transverse cross-section of the groove of a prefabricated building module according to some embodiments of the present disclosure.

[0013] Figure 3B , Figure 4B , Figure 5B and Figure 6B These are various examples of the transverse cross-section of a groove in another prefabricated building module according to some embodiments of this disclosure.

[0014] Figures 7A to 7H These are various examples of connecting members for linking pairs of prefabricated building modules according to some embodiments of the present disclosure.

[0015] Figure 8 This is a flowchart illustration of a method for constructing building structural components according to some embodiments of the present disclosure.

[0016] Figures 9A to 9E These are various examples of prefabricated structural members comprising pairs of prefabricated building modules connected in various arrangements, according to some embodiments of the present disclosure. Detailed Implementation

[0017] For the purposes of brevity and clarity, the description of embodiments of this disclosure, with reference to the accompanying drawings, pertains to prefabricated building modules, building structures including prefabricated building modules, and methods for constructing building structures. Although aspects of this disclosure will be described in conjunction with the embodiments provided herein, it should be understood that these embodiments are not intended to limit the disclosure to these embodiments. Rather, this disclosure is intended to cover alternatives, modifications, and equivalents to the embodiments described herein, which are included within the scope of this disclosure as defined by the appended claims. Furthermore, in the following detailed description, specific details are set forth to provide a thorough understanding of this disclosure. However, those skilled in the art will recognize that this disclosure can be practiced without specific details and / or can be practiced with a variety of details arising from combinations of aspects of particular embodiments. In many cases, known systems, methods, process steps, and components are not described in detail to avoid unnecessarily obscuring aspects of embodiments of this disclosure.

[0018] In embodiments of this disclosure, the description of a given element or consideration or use of a particular reference numeral in a particular drawing or reference to that element or reference numeral in the corresponding descriptive material may include the same, equivalent or similar element or reference numeral identified in another drawing or in descriptive material associated with that other drawing.

[0019] The terms "implementation / example," "another implementation / example," "some implementations / examples," "some other implementations / examples," etc., indicate that one or more implementations / examples described so as may include specific features, structures, characteristics, performance, elements, or limitations, but not every implementation / example must include that specific feature, structure, characteristic, performance, element, or limitation. Furthermore, repeated use of the phrases "in an implementation / example" or "in another implementation / example" does not necessarily refer to the same implementation / example.

[0020] The terms "comprising," "including," "having," etc., do not exclude the presence of other features / elements / steps besides those listed in the embodiments. Listing certain features / elements / steps in different embodiments does not imply that combinations of these features / elements / steps cannot be used in those embodiments.

[0021] As used herein, the terms “a” and “an” are defined as one or more. Unless otherwise stated, the “ / ” used in the accompanying figures or associated text is understood as “and / or”. The enumeration of specific numerical values ​​or ranges herein is understood to include or refer to an enumeration of approximate numerical values ​​or ranges. According to known mathematical definitions, the term “group” is defined as a non-empty finite group of elements that mathematically presents at least one cardinality (e.g., a group defined herein may correspond to a unit, a single element, a group of unit components, or a group of multiple elements). The terms “first,” “second,” “third,” etc., are used only as markings or identifiers and are not intended to impose numerical requirements on their respective terms. The term “each other” indicates a relationship between two or more elements.

[0022] This disclosure provides an illustrative or exemplary embodiment of a prefabricated building module 100 and a building structure 50, the building structure 50 comprising a plurality of prefabricated building modules 100. Figure 1A and Figure 2A Some embodiments of a building structure 50 are illustrated, which includes a first prefabricated building module 100a and a second prefabricated building module 100b arranged adjacent to each other.

[0023] In one embodiment, building structure 50 is a wall, floor, or ceiling structure (etc.) comprising a plurality of prefabricated building modules 100 connected together, including by stacking on top of each other. In another embodiment, building structure 50 forms the structural frame of a habitable unit or apartment (or part thereof), comprising a plurality of prefabricated building modules 100 connected together, wherein each prefabricated building module 100 forms a room or partition of the apartment, such as a living room, bedroom, or kitchen. For example, prefabricated building modules 100 may be connected to form four walls, a floor, and a ceiling of a room. In another embodiment, building structure 50 is a building comprising a plurality of connected prefabricated building modules 100, such as those connected to form rooms in an apartment and those connected to form floors / story units of the building. Building structure 50 may be a single-story or multi-story building having various prefabricated building modules 100. The above examples are non-limiting, and it is understood that various types of prefabricated building modules 100 and building structural components 50 may be used in the PPVC industry.

[0024] Each prefabricated building module 100 includes a structural body 102 formed from a suitable material for PPCV, such as precast concrete. The terms "prefabricated" and "precast" are used interchangeably in this disclosure. The structural body 102 may be manufactured in the form of a beam, column, wall, panel, support, or slab. In one embodiment, the structural body 102 is a corner structural column or support for connection to another prefabricated building module 100, such as another room. In another embodiment, the structural body 102 is a wall panel for connection to another prefabricated building module 100, such as a floor / ceiling building module or another wall. The structural body 102 includes a plurality of surfaces, including pairs of opposite end surfaces 104.

[0025] The prefabricated building module 100 includes a group of one or more recesses 106 formed longitudinally along one of the side surfaces of the structural body 102. In many embodiments, the prefabricated building module 100 includes a recess 106 formed longitudinally, i.e., along the z-axis, and the recess 106 extends along a recessed surface 108 of the structural body 102. The recessed surface 108 may refer to a connecting surface arranged to face a corresponding recessed surface 108 of another prefabricated building module 100 to be connected together. In some other embodiments, the prefabricated building module 100 may include two or more recesses 106, and various aspects of this disclosure relating to a prefabricated building module 100 including recesses 106 will apply in kind or similarly to prefabricated building modules 100 including two or more recesses 106.

[0026] The groove 106 is arranged to receive the connecting member 110, which is used for connection to another prefabricated building module 100. The connecting member 110 forms a connection between the prefabricated building modules 100 and distributes forces and loads on the prefabricated building modules 100. The connecting member 110 acts as a bridge for transmitting various types of forces, including direct tensile forces, interfacial shear friction forces, and pin forces on the prefabricated building modules 100. The groove-shaped surface 108, including the groove 106 itself, can be roughened, such as by a sandblasting process, to increase surface roughness and improve the transmission of interfacial shear forces or the transmission of shear forces by friction. The connected prefabricated building modules 100 form the building structure 50 into a monolithic structural unit, which has increased load-bearing capacity to resist the intended forces of the design, similar to monolithic building structures, comparable to similar structures constructed using conventional on-site construction methods.

[0027] In one embodiment, the groove 106 extends through both end surfaces 104 of the structural body 102. A connecting member 110 can be inserted into the groove 106 from either end surface 104. The longitudinal length of the connecting member 110 is at least the longitudinal length of the groove 106, such that the connecting member can extend beyond one or both end surfaces 104 of the structural body 102. The extension can be used to connect to another prefabricated building module 100 above or below.

[0028] In another embodiment, the groove 106 extends from one end surface 104 and partially through the structural body 102 to the desired length, terminating before the other end surface 104. For example, in the case where the prefabricated building module 100 is used for connection to a floor building module, the connecting member 110 can be inserted from the top end surface 104 into the groove 106, where the groove 106 terminates before the bottom end surface 104. Conversely, in the case where the prefabricated building module 100 is used for connection to a ceiling building module, the connecting member 110 can be inserted from the bottom end surface 104 into the groove 106, where the groove 106 terminates before the top end surface 104.

[0029] In many embodiments, the groove 106 has a consistent transverse cross-section (in the xy plane) along its length (along the z-axis). See also... Figure 1B and Figure 2B The transverse section of the groove 106 includes a first groove portion 112 and a second groove portion 114. The second groove portion 114 is preferably the innermost portion of the groove 106 formed inside the structural body 102. The first groove portion 112 is the outermost portion formed between the groove-shaped surface 108 and the second groove portion 114. The first groove portion 112 is preferably the outermost portion of the groove 106 recessed from the groove-shaped surface 108 into the structural body 102.

[0030] The first groove portion 112 has a first depth (along the x-axis) and a first width (along the y-axis), and similarly, the second groove portion 114 has a second depth (along the x-axis) and a second width (along the y-axis). Depending on the contour or geometry of the first groove portion 112 and the second groove portion 114, the first width and the second width may refer to the maximum width of the respective first groove portion 112 and the second groove portion 114.

[0031] The first groove portion 112 is narrower than the second groove portion 114. This can be defined as a first width being less than a second width, i.e., the maximum width of the first groove portion 112 is less than the maximum width of the second groove portion 114. The first groove portion 112 and the second groove portion 114 are connected to each other at a groove portion joint 116 along the y-axis. The first groove portion 112 is narrower than the second groove portion 114 such that the width of the first groove portion 112 immediately adjacent to the joint 116 is less than the width of the second groove portion 114 immediately adjacent to the joint 116. Therefore, the groove 106 has a transverse cross section that narrows from the second groove portion 114 to the first groove portion 112. This profile can gradually narrow at the joint 116 like a tapering ramp or it can abruptly narrow like a distinct step.

[0032] When manufacturing the prefabricated building module 100, the prefabricated building module 100 may include reinforcing elements or structural members embedded in the structural body 102, thereby providing structural strength, particularly tensile strength, to the prefabricated building module 100. A groove 106 can be formed in the structural body 102 using a mold structural member embedded in a recessed surface 108 of the structural body 102. The mold structural member is then removed after casting the structural body 102, thus forming the groove 106. The mold structural member may be formed from one or more thin-walled steel sections and / or corrugated pipes having the desired cross-section of the groove 106. For example, in forming such... Figure 1B When the groove 106 is shown, a smaller rectangular thin-walled steel section and a larger rectangular thin-walled steel section are used to form the first groove portion 112 and the second groove portion 114, respectively.

[0033] When constructing the building structure 50, pairs of prefabricated building modules 100 are arranged adjacent to each other such that corresponding recesses 106 face each other, and a connecting gap 118 is formed between the corresponding recessed surfaces 108. The connecting gap 118 includes the space between the opposing recesses 106 recessed into the corresponding recessed surfaces 108 and the unrecessed portions of the recessed surfaces 108. The connecting gap has a depth (along the x-axis) sized between the corresponding recessed surfaces 108.

[0034] Some exemplary dimensional relationships are described below. The depth of the connecting gap 118 may be approximately three times the thickness of the connecting member 110. The first width of the first groove portion 112 may be approximately 1.5 times the depth of the connecting gap 118. Therefore, the first width of the first groove portion 112 may be approximately 4.5 times the thickness of the connecting member 110.

[0035] In this arrangement of connecting the prefabricated building modules 100, the grooves 106 forming the connection gaps 118 are large enough and have suitable tolerances to accommodate the connecting members 110, thereby reducing potential errors during construction. The grooves 106 also serve as contractions in the modules 100, preventing the complete unfolding of the shear cone that would cause concrete cone failure. Concrete cone failure is a failure mode in concrete under tensile loads and is typically caused by crack propagation within the concrete. The grooves 106 prevent crack propagation completely through the structural body 102, thus preventing the complete unfolding of the shear cone.

[0036] Furthermore, the first groove portions 112 of the two grooves 106 form a narrowing or constricting path in the connecting gap 118 to insert the connecting member 110 into the connecting gap 118. The narrowing path reduces the tolerance between the connecting member 110 and the side of the first groove portion 112. This restricts the movement of the connecting member 110 within the connecting gap 118 and improves the structural stability of the connection between the prefabricated building modules 100.

[0037] In such Figure 1A and Figure 1B In some embodiments shown, each prefabricated building module 100 has a transverse cross-section, wherein the total depth is at least 90 mm, and the first depth of the first recessed portion 112 may be at least half or approximately equal to the second depth of the second recessed portion 114. Additionally, the first depth may be greater than the depth of the connecting gap. As an example, each prefabricated building module 100 has a transverse cross-section with a total depth of 125 mm. Furthermore, the first depth is approximately 35 mm to 45 mm, the second depth is approximately 45 mm, and the connecting gap is approximately 20 mm.

[0038] In such Figure 2A and Figure 2B In some embodiments shown, each prefabricated building module 100 has a transverse cross-section, wherein the total depth is at least 90 mm, and the first depth of the first recess portion 112 may be less than half the second depth of the second recess portion 114. For example, the first depth of the first recess portion 112 may be the thickness of the structural material forming the recess 106. Additionally, the first depth may be less than the depth of the connecting gap. As an example, each prefabricated building module 100 has a transverse cross-section with a total depth of 100 mm. Furthermore, the first depth is approximately 5 mm to 8 mm, the second depth is approximately 45 mm, and the depth of the connecting gap is approximately 20 mm.

[0039] In such Figure 1A and Figure 2AIn the embodiment of the prefabricated building module 100 shown, each of the first recessed portion 112 and the second recessed portion 114 has a quadrilateral profile, such as a square or rectangular profile. The quadrilateral profile may have right-angled or acute-angled corners as shown, but optionally may have rounded / beveled / sloping corners. See also... Figure 3A The centroid of the second groove portion 114 roughly coincides with the geometric center of the structural body 102. Similarly, in... Figure 1B and Figure 2B In the embodiment of the prefabricated building module 100 shown, each of the first recessed portion 112 and the second recessed portion 114 has a quadrilateral profile, such as a square or rectangular profile. However, referring to... Figure 3B Although the groove 106 is centered along the y-axis of the structure body 102, the centroid of the second groove portion 114 may not coincide with the geometric center of the structure body 102.

[0040] Figure 3A and Figure 3B The recessed portions 112 and 114 with quadrilateral contours are shown. In some other embodiments, the recessed portions 112 and 114 may have other contours or geometries, such as, but not limited to, circles, trapezoids, and ellipses. Figure 4A , Figure 5A and Figure 6A Examples of various contours of the first recessed portion 112 and the second recessed portion 114 of the prefabricated building module 100 are shown. Figure 4B , Figure 5B and Figure 6B Examples of various profiles of the first recessed portion 112 and the second recessed portion 114 of the prefabricated building module 100 are shown. The first recessed portion 112 may have a thinner first depth, and due to this thinness, the first recessed portion 112 may be referred to as an inlet slot or hole leading to the second recessed portion 114. The above examples are non-limiting, and it should be understood that recessed portions 112, 114 of various profiles or geometries may exist.

[0041] After the prefabricated building modules 100 are arranged and the connecting gaps 118 are formed, the connecting members 110 are inserted into the connecting gaps 118. Therefore, the connecting members 110 can be easily inserted into the connecting gaps 118 from the end surface 104 of the structural body 102, especially when the access to the connecting gaps 118 is limited to the end surface 104.

[0042] In some embodiments, the building structure 50 includes a single connecting member 110 inserted into the connection gap 118. In some embodiments, the building structure 50 may include two or more connecting members 110 inserted into the connection gap 118. The structure of each connecting member 110 is described below. It should be understood that the two or more connecting members 110 inserted between the prefabricated building modules 100 may be the same as each other or different from each other.

[0043] like Figure 7A As shown, the connecting member 110 includes a plurality of longitudinal rods 120 and a group of one or more lateral connecting elements 122 connecting the longitudinal rods 120. For example, the connecting member 110 has pairs of longitudinal rods 120, and the lateral connecting elements 122 are connected to two rods 120. In some embodiments, the connecting member 110 may have three or more longitudinal rods 120, and the lateral connecting elements 122 are connected to all rods 120. When the connecting member 110 is inserted into the connecting gap 118, the longitudinal rods 120 are arranged such that the longitudinal rods 120 extend through a corresponding recess 106. More specifically, each longitudinal rod 120 extends through a corresponding second recess portion 114, and the lateral connecting element 122 extends across the connecting gap 118.

[0044] The longitudinal rod 120 is a reinforcing rod that bears axial loads along its longitudinal length. When the prefabricated building modules 100 are arranged vertically, the longitudinal rod 120 is similarly arranged vertically and bears vertical loads, such as those from other prefabricated building modules 100 stacked above. Lateral connecting elements 122 are connected to the two longitudinal rods 120 by various mechanical means, such as welding or joining, readily known to those skilled in the art, so that the connecting member 110 forms a monolithic structure. Alternatively, the connecting member 110 may be formed from a single structural material. The lateral connecting element 122 is the primary element for transmitting forces and loads across the longitudinal rods 120, causing the building structure 50 to behave like a monolithic building structure. The longitudinal rods 120 and the lateral connecting elements 122 are formed from structural steel materials, such as carbon steel or high-strength / low-alloy steel, but other building materials are also possible.

[0045] In some embodiments, groups of lateral connecting elements 122 are arranged at multiple discrete locations along the longitudinal length of the rod-shaped member 120. For example... Figure 7A As shown, there are three lateral connecting elements 122 disposed at discrete positions along the longitudinal direction of the rod-shaped member 120. Figure 7BAs shown, there are two pairs of lateral connecting elements 122 disposed at discrete positions along the longitudinal direction of the rod-shaped member 120. The lateral connecting elements 122 may include one or more of reinforcing rod-shaped members, ring-shaped members, mesh-shaped members, shear stud-shaped members, and strip-shaped members.

[0046] In such Figure 7A and Figure 7B In some embodiments shown, each connecting element 122 includes a steel rod or wire welded to the longitudinal rod 120, such that the connecting member 110 has a mesh structure. Figure 7C In one embodiment shown, each lateral connecting element 122 includes a bolt connected to the longitudinal rod-shaped member 120 via an end nut. An example of such a lateral connecting element 122 is a 4.6 grade hexagonal head steel bolt and nut. In... Figure 7D In one embodiment shown, each lateral connecting element 122 includes a high-strength wire loop connected to the longitudinal rod-shaped member 120. Each wire loop may include a connecting portion or a clamping portion at its central intersection. In such a manner... Figure 7E In one embodiment shown, each lateral connecting element 122 includes a pair of shear studs connected to each other and to the longitudinal rod 120. In such a way... Figure 7F In one embodiment shown, each lateral connecting element 122 includes an annular reinforcing rod connected to the longitudinal rod 120. In such... Figure 7G In one embodiment shown, each lateral connecting element 122 includes a strip element connected to the longitudinal rod 120 via an end anchor plate.

[0047] In some embodiments, groups of lateral connecting elements 122 extend continuously along the longitudinal length of the rod-shaped member 120. In such... Figure 7H In one embodiment shown, the group of lateral connecting elements 122 includes lattice beam elements or reinforcing rods connected to longitudinal rods 120. The lattice beam elements extend continuously along the longitudinal rods 120 in a meandering / sinusoidal arrangement, thereby connecting to the longitudinal rods 120 at corresponding vertices of the meandering / sinusoidal arrangement. In this embodiment, the connecting member 110 has a structure similar to that of the lattice beam.

[0048] After the connecting member 110 is inserted into the connecting gap 118, a connecting filler material is dispensed to fill the connecting gap 118 and connect the prefabricated building modules 100 together. The connecting filler material may include cement mixtures, epoxy resins, and combinations thereof. Cement mixtures are mixtures of water, cement, and sand. An example of a cement mixture is a grout, such as a high-strength or high-grade grout. The connecting gap 118 is filled with grout during processes such as pressure grouting, jet grouting, or by pouring grout under gravity. The grout is preferably a high-strength / non-shrinkage grout containing other compounds such as graded fillers and chemical additives. The connecting filler material may include epoxy resin, which may be combined with other fillers such as silica fillers, pigments, and hardeners. It should be understood that other components of the connecting filler material may be present. The curing / hardening of the bonding filler material bonds the prefabricated building modules 100 together and forms a sealant between the prefabricated building modules 100, thereby preventing external media or contaminants such as rainwater from seeping into the bonding gaps 118.

[0049] Prefabricated building modules 100 are connected together and supported by connecting members 110, while the connection gaps 118 are filled with connecting filler material. Therefore, the connecting members 110 stabilize the prefabricated building modules 100 and reduce errors during the filling of the connection gaps 118, such as inaccurate distribution of the connecting filler material. This reduces the required time and labor, allowing the building structure 50 to be constructed faster and more efficiently.

[0050] Therefore, structural component 50 is constructed from modules 100 manufactured in off-site facilities or factories and transported to the construction site. Productivity can be increased by expanding the manufacture of modules 100. Compared to on-site concrete pouring, which may be adversely affected by weather conditions, this facility also provides an environment where various factors can be controlled to improve the quality of the precast materials (e.g., concrete) of modules 100. Modules 100 can be manufactured in the facility while formwork engineering continues on the construction site, thereby reducing construction time and increasing productivity.

[0051] Another advantage of the building structural component 50 is that the connecting members 110 can be easily inserted into the connection gaps 118 formed between the prefabricated building modules 100 without the need for any guides embedded in the respective structural bodies 102. On the construction site, the formwork work required to form the connection is significantly reduced. Conversely, and as described in the background art, the presence of guides such as protruding steel rings / bars / rods would require proper alignment of these guides, thus reducing productivity. The absence of guides in the prefabricated building modules 100 makes the manufacture of the modules 100 easier, such as through the use of standardized molds. This increases the productivity of the modules 100 during the prefabrication phase and on-site construction of the building structural component 50. The absence of guides also eliminates safety risks and improves safety on the construction site.

[0052] Furthermore, due to the less complex design of the prefabricated building module 100 without guides, its production can be automated to further improve productivity. Without prominent guides, the module 100 is designed to be easy to manufacture and therefore suitable for construction using the Design for Manufacturing and Assembly (DfMA) approach. DfMA is a design methodology that emphasizes ease of manufacture and assembly efficiency to achieve advantages such as increased construction speed and productivity, reduced construction costs, and improved quality and reliability. DfMA is increasingly being adopted in the construction industry worldwide. For example, the Building and Construction Authority (BCA) of Singapore has identified DfMA as a key strategic driver for improving construction productivity. It should be understood that increased productivity will bring economic benefits beyond just reduced construction costs.

[0053] In such Figure 8 In the various embodiments of this disclosure shown, there is a method 200 for constructing a building structural member 50. The design and construction of the building structural member 50—including the manufacture and materials of its corresponding prefabricated building module 100, which includes its corresponding components such as the structural body 102 and connecting members 110—can be specified by various building, building component, and material codes / standards known to those skilled in the art. An example in Singapore is the European code EN 1992-1-1, which specifies the use of concrete structures. It should be understood that these codes / standards may vary in different regions of the world.

[0054] Method 200 includes step 202 of providing a plurality of prefabricated building modules 100. In many embodiments, step 202 provides a first pair of prefabricated building modules 100 including a first module 100 and a second module 100. Method 200 also includes step 204 of arranging the first pair of prefabricated building modules adjacent to each other such that corresponding recesses 106 face each other and forming a first connecting gap including the recesses 106 between corresponding recessed surfaces 108.

[0055] Method 200 further includes step 206 of inserting a first connecting member 110 into a first connecting gap 118. For example, the first connecting member 110 is inserted into the first connecting gap 118 via a pair of end surfaces 104. Method 200 further includes step 208 of filling the first connecting gap 118 with a connecting filler material to connect the first pair of prefabricated building modules 100 together. Method 200 further includes step 210 of curing (e.g., hardening) the connecting filler material to construct a building structure 50 including the connected prefabricated building modules 100.

[0056] In such Figure 2A In the illustrated embodiment, the first prefabricated building module 100a and the second prefabricated building module 100b are arranged vertically and parallel to each other. Recessed surfaces 108 are located on the longer sides of the respective structural bodies 102, and corresponding recesses 106 face each other. In some other embodiments, the prefabricated building modules 100 may be arranged in different ways, such as horizontally, vertically, and / or parallelly.

[0057] In such Figure 9A In one embodiment shown, a first prefabricated building module 100a and a second prefabricated building module 100b are arranged vertically and perpendicular to each other. A recessed surface 108 of the first prefabricated building module 100a is located on the longer side of the corresponding structural body 102, and a recessed surface 108 of the second prefabricated building module 100b is located on the shorter side of the corresponding structural body 102. Corresponding recesses 106 face each other to form a first connecting gap 118, and a first connecting member 110 is inserted into the first connecting gap 118. The first connecting gap 118 is filled with a connecting filler material, and after curing, the second prefabricated building module 100b is connected to the first prefabricated building module 100a to construct the internal walls of the building structure 50.

[0058] In such Figure 9B In one embodiment shown, the first prefabricated building module 100a and the second prefabricated building module 100b are arranged vertically and perpendicular to each other. This embodiment is similar to... Figure 9AThe embodiments shown are similar, and the above aspects apply similarly. In this embodiment, the second prefabricated building module 100b is connected to the first prefabricated building module 100a to construct the edge walls of the building structure 50.

[0059] In such Figure 9C In one embodiment shown, a first prefabricated building module 100a and a second prefabricated building module 100b are arranged horizontally and parallel to each other on the same horizontal plane. A recessed surface 108 is located on the shorter side of the respective structural body 102, and corresponding recesses 106 face each other to form a first connection gap 118. A first connecting member 110 is inserted into the first connection gap 118, subsequently filled with a connecting filler material and cured. The prefabricated building modules 100 are connected to form a precast slab, such as the floor or ceiling of a building structural member 50.

[0060] In such Figure 9D In one embodiment shown, a first prefabricated building module 100a and a second prefabricated building module 100b are arranged horizontally and parallel to each other on the same horizontal plane. A recessed surface 108 is located on the shorter side of the respective structural body 102. Each prefabricated building module 100 includes two recesses 106 formed adjacent to each other. Specifically, the first prefabricated building module 100a has a first recess 106a and a second recess 106a' adjacent to each other. Similarly, the second prefabricated building module 100b has a first recess 106b and a second recess 106b' adjacent to each other. The paired first recesses 106a, 106b face each other relative to each other, and the paired second recesses 106a', 106b' face each other relative to each other, thereby collectively forming a first connecting gap 118.

[0061] The first connecting member 110a and the second connecting member 110b are inserted into the first connecting gap 118 and through the groove 106. Specifically, the first connecting member 110a is inserted through a pair of first grooves 106a and 106b, and the second connecting member 110b is inserted through a pair of second grooves 106a' and 106b'. The first connecting gap 118 is filled with a connecting filler material, and after curing, the prefabricated building modules 100 are connected to form a precast slab, such as the floor or ceiling of the building structure 50.

[0062] In such Figure 9EIn one embodiment shown, a first prefabricated building module 100a and a second prefabricated building module 100b are arranged vertically and parallel to each other. A recessed surface 108 is located on the longer side of the respective structural body 102. Each prefabricated building module 100 includes three recesses 106 formed adjacent to each other. Specifically, the first prefabricated building module 100a has a first recess 106a, a second recess 106a', and a third recess 106a'' adjacent to each other. Similarly, the second prefabricated building module 100b has a first recess 106b, a second recess 106b', and a third recess 106b'' adjacent to each other. Pairs of first recesses 106a and 106b face each other, pairs of second recesses 106a' and 106b' face each other, and pairs of third recesses 106a'' and 106b'' face each other, thereby collectively forming a first connecting gap 118.

[0063] The first connecting member 110a, the second connecting member 110b, and the third connecting member 110c are inserted into the first connecting gap 118 and through the groove 106. Specifically, the first connecting member 110a is inserted through the pair of first grooves 106a and 106b, the second connecting member 110b is inserted through the pair of second grooves 106a' and 106b', and the third connecting member 110c is inserted through the pair of third grooves 106a' and 106b'. The first connecting gap 118 is filled with a connecting filler material, and after curing, the prefabricated building modules 100 are connected to form a precast slab, such as the wall of the building structure 50.

[0064] Despite Figure 9D and Figure 9E The embodiments shown depict prefabricated building modules 100 with two and three recesses 106, respectively. However, it should be understood that prefabricated building modules 100 may have a plurality (e.g., two, three, four or more) of recesses 106 formed adjacent to each other, and a corresponding number of connecting members 110 (e.g., one, two or more connecting members 110 for each connecting gap 118). It should also be understood that the prefabricated building modules 100 need not be identical, i.e., the prefabricated building modules 100 need not have the same shape and size.

[0065] In some embodiments, a second pair of prefabricated building modules 100 includes a third module 100 and a fourth module 100. The second pair of prefabricated building modules 100 are arranged to form a second connecting gap 118 including corresponding grooves 106, wherein a second connecting member 110 is inserted into the second connecting gap 118. It should be understood that the various steps of method 200 for connecting the first pair of prefabricated building modules 100 are similarly or analogously applied to the second pair of prefabricated building modules 100, and will not be further elaborated for the sake of brevity. Method 200 includes connecting the second pair of prefabricated building modules 100 arranged relative to the first pair of prefabricated building modules 100, wherein the arrangement can be horizontal, vertical, and / or parallel.

[0066] In one embodiment, the first pair of prefabricated building modules 100 and the second pair of prefabricated building modules 100 are arranged vertically by stacking the second pair of prefabricated building modules 100 on top of the first pair of prefabricated building modules 100 to form a building structure 50 with high walls. In another embodiment, the first pair of prefabricated building modules 100 and the second pair of prefabricated building modules 100 are arranged horizontally and parallel to each other on the same horizontal plane to form a building structure 50 with a large floor or ceiling. In yet another embodiment, the first pair of prefabricated building modules 100 and the second pair of prefabricated building modules 100 are arranged perpendicular to each other. For example, the first pair may form a central wall, and the second pair may form the floor or ceiling of the building structure.

[0067] In some embodiments, method 200 includes arranging a second pair of prefabricated building modules 100 relative to the first pair of prefabricated building modules 100 such that the first connecting member 110 or the second connecting member 110 extends at least partially into the second connecting gap 118 or the first connecting gap 118, respectively. This extension or overlap may be a portion or the entire longitudinal length of the respective connecting gap 118. A longitudinal rod-like member 120 of one connecting member 110 may be a steel rod or bar, and a longitudinal rod-like member 120 of the other connecting member 110 may be a bellows, such that a steel rod-like member can be inserted into the bellows to extend into the respective connecting gap 118.

[0068] Method 200 may further include inserting stacked connectors into the first connection gap 118 and the second connection gap 118. Stacked connectors are structural elements, such as steel rods or bars, that reinforce the connection between pairs of prefabricated building modules 100.

[0069] The corresponding connecting member 110 or stacked connector extends at least partially into the corresponding connection gap 118 and may extend to the entire longitudinal length of the connection gap 118. Depending on the arrangement of the prefabricated building modules 100, this extension allows vertical or horizontal loads to be transferred to the connecting member 110.

[0070] In one embodiment, a second pair of prefabricated building modules 100 is vertically stacked on top of a first pair of prefabricated building modules 100. A second connecting member 110 extends along the extension into a first connecting gap 118. The second connecting member 110 may be inserted into the first connecting gap 118 before or after the connecting filler material has fully cured. Alternatively, the first connecting gap 118 may be partially filled with connecting filler material to the level below the extension. The second connecting member 110 may then be inserted into the first connecting gap 118 after the partially filled connecting filler material has cured. Partially filling the first connecting gap 118 with connecting filler material stabilizes the first pair of prefabricated building modules 100 for stacking the second pair of prefabricated building modules 100.

[0071] After stacking two pairs of prefabricated building modules 100 and inserting the second connecting member 110 into the first connecting gap 118, a connecting filler material is dispensed to fill the first and second connecting gaps 118. The connecting filler material also fills the horizontal connecting gaps formed between the two pairs of prefabricated building modules 100. The connecting filler material is cured to construct a building structure 50 comprising the connected pairs of prefabricated building modules 100. Spacer elements may be disposed between the two pairs of prefabricated building modules 100. The spacer elements form enclosed horizontal spaces between the two pairs of prefabricated building modules 100 for filling the connecting filler material and reducing the risk of leakage during curing.

[0072] Additional pairs of prefabricated building modules 100 can be vertically stacked on top of the second pair of prefabricated building modules 100 and connected in a manner similar to that described above for connecting the second pair to the first pair. Specifically, a third pair is connected to the second pair, a fourth pair is connected to the third pair, and so on. Multiple pairs of prefabricated building modules 100 can be stacked to increase the total height of the building structure 50. Similarly, additional pairs can be arranged adjacently / horizontally to widen the building structure 50.

[0073] It should be understood that the aforementioned aspects of the second connecting member 110 and its corresponding extension are equally or similarly applicable to the first connecting member 110 and the stacked connectors where applicable, and will not be further elaborated for the sake of brevity. It should also be understood that the aforementioned aspects of vertically stacking and connecting pairs of prefabricated building modules 100 are equally or similarly applicable to other arrangements, and will not be further elaborated for the sake of brevity.

[0074] After the structural member 50 is completed, various inspections and tests can be performed to assess the condition of the structural member 50 and its components—including the prefabricated building modules 100 and the connections formed in the connection gaps 118 by the connecting members 110—particularly to assess structural integrity. These inspections and tests can be specified by various specifications / standards known to those skilled in the art, but it should be understood that these specifications / standards may vary globally. One example is a sampling test to check the material strength of the connecting members 110. Another test is a grout strength test to check whether the joint filler material (e.g., grout or epoxy resin) has been properly cured and that the structure is intact.

[0075] In the foregoing detailed description, embodiments of the present disclosure relating to prefabricated building modules, building structural members including prefabricated building modules, and methods for constructing building structural members have been described with reference to the accompanying drawings. The description of various embodiments herein is not intended to represent or limit the specific or particular representation of the present disclosure, but is merely illustrative of non-limiting examples of the present disclosure.

[0076] This disclosure addresses at least one of the problems and issues associated with the prior art. Although only some embodiments of this disclosure are disclosed herein, it will be apparent to those skilled in the art, in view of this disclosure, that various changes and / or modifications can be made to the disclosed embodiments without departing from the scope of this disclosure. Therefore, the scope of this disclosure and the scope of the claims are not limited to the embodiments described herein.

Claims

1. A prefabricated building module, the prefabricated building module comprising; Connecting components; Structural body; as well as A groove, integrally formed in the structural body, is provided for receiving a connecting member for linking the prefabricated building module to another prefabricated building module. The groove is arranged longitudinally along a groove-shaped surface of the structural body and extends at least partially through the structural body. The groove has a transverse cross-section comprising a first groove portion and a second groove portion, wherein the first groove portion is formed between the groove-shaped surface and the second groove portion; Wherein, the outer end of the first groove portion is aligned with the groove-shaped surface, and the inner end of the first groove portion is aligned with the groove portion joint portion, the groove portion joint portion being adjacent to the first groove portion and the second groove portion; Wherein, the first groove portion has an equal width between the inner end portion and the outer end portion; Wherein, the width of the first groove portion adjacent to the joint portion of the groove portion is smaller than the width of the second groove portion adjacent to the joint portion of the groove portion; and The total width of the connecting member is less than the width of the first groove portion.

2. The prefabricated building module according to claim 1, wherein, The width of the first groove portion is 4.5 times the total width of the connecting member.

3. The prefabricated building module according to claim 1, wherein, The centroid of the second groove portion roughly coincides with the geometric center of the main body of the structure.

4. The prefabricated building module according to claim 1, wherein, Each groove has a quadrilateral profile.

5. The prefabricated building module according to claim 1, wherein the prefabricated building module comprises a plurality of grooves formed adjacent to each other.

6. A building structural member, the building structural member comprising: A first prefabricated building module and a second prefabricated building module are arranged adjacent to each other. Each prefabricated building module includes a structural body and a groove, the groove being integrally formed in the structural body. The groove is arranged longitudinally along the groove-shaped surface of the corresponding structural body and extends at least partially through the structural body. The prefabricated building modules are arranged such that the corresponding grooves face each other and a connecting gap including the grooves is formed between the corresponding groove-shaped surfaces; A connecting member, which is inserted into the connecting gap; as well as A connecting filler material is used to fill the connection gaps and connect the prefabricated building modules together. For each prefabricated building module, the transverse cross-section of the corresponding groove includes a first groove portion and a second groove portion, wherein the first groove portion is formed between the corresponding groove-shaped surface and the second groove portion; Wherein, the outer end of the first groove portion is aligned with the groove-shaped surface, and the inner end of the first groove portion is aligned with the groove portion joint portion, the groove portion joint portion being adjacent to the first groove portion and the second groove portion; Wherein, the first groove portion has an equal width between the inner end portion and the outer end portion; Wherein, the width of the first groove portion adjacent to the joint portion of the groove portion is smaller than the width of the second groove portion adjacent to the joint portion of the groove portion; and The total width of the connecting member is less than the width of the first groove portion.

7. The building structural member according to claim 6, wherein, The width of the first groove portion is 4.5 times the total width of the connecting member.

8. The building structural member according to claim 6, wherein, The connecting component includes: Multiple longitudinal rods, each extending through a corresponding second groove portion; and A group of lateral connecting elements that connect the longitudinal rod-shaped members, the lateral connecting elements extending across the connecting gap.

9. A method for constructing a building structural member, the method comprising: Multiple prefabricated building modules are provided, each prefabricated building module including a structural body and a groove, the groove being integrally formed in the corresponding structural body, the groove being arranged longitudinally along the groove-shaped surface of the corresponding structural body and extending at least partially through the corresponding structural body; The first pair of prefabricated building modules are arranged adjacent to each other such that the corresponding grooves face each other and a first connecting gap including the grooves is formed between the corresponding groove-shaped surfaces; Insert the first connecting member into the first connecting gap; The first connection gap is filled with a connecting filler material to connect the first pair of prefabricated building modules together; and The connecting filler material is cured to construct the building structure comprising the connected prefabricated building modules. For each prefabricated building module, the transverse cross-section of the corresponding groove includes a first groove portion and a second groove portion, wherein the first groove portion is formed between the corresponding groove-shaped surface and the second groove portion; Wherein, the outer end of the first groove portion is aligned with the groove-shaped surface, and the inner end of the first groove portion is aligned with the groove portion joint portion, the groove portion joint portion being adjacent to the first groove portion and the second groove portion; Wherein, the first groove portion has an equal width between the inner end portion and the outer end portion; Wherein, the width of the first groove portion adjacent to the joint portion of the groove portion is smaller than the width of the second groove portion adjacent to the joint portion of the groove portion; and The total width of the connecting member is less than the width of the first groove portion.

10. The method of claim 9, further comprising connecting a second pair of prefabricated building modules arranged relative to the first pair of prefabricated building modules.

11. The method of claim 10, further comprising arranging the second pair of prefabricated building modules relative to the first pair of prefabricated building modules such that the first connecting member extends at least partially into a second connecting gap formed between the second pair of prefabricated building modules.

12. The method of claim 10, further comprising arranging the second pair of prefabricated building modules relative to the first pair of prefabricated building modules such that the second connecting member of the second pair of prefabricated building modules extends at least partially into the first connecting gap.

13. A prefabricated building module, the prefabricated building module comprising; Connecting components; Structural body; as well as A groove, integrally formed in the structural body, is provided for receiving a connecting member for linking the prefabricated building module to another prefabricated building module. The groove is arranged longitudinally along a groove-shaped surface of the structural body and extends at least partially through the structural body. The connecting component includes: Multiple longitudinal rods, each extending through a corresponding groove; and A group of lateral connecting elements that connect the longitudinal rod-shaped members. Each lateral connecting element includes a pair of shear studs that are connected to each other and to the longitudinal rod.

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