Prefabricated reinforced concrete module for accommodation units, particularly in prisons; component of such a module and method for its construction

Abstract

The present invention relates to a prefabricated module element (2, 3) (1) comprising at least one reinforced concrete wall and / or slab, said wall or slab incorporating at least one lifting insert (41a, 41b, 41c, 41d) protruding from a surface of the wall and / or slab through at least one oblong attachment hole (42), said lifting insert (41a, 41b, 41c, 41d) comprising a metal box cast as a single piece of reinforced concrete with said wall or slab and configured to receive and cooperate with a hook (43) for lifting the element (2, 3) or the module (1). Figure for the abstract: Fig. 1

Description

Title of the invention: Prefabricated reinforced concrete module for accommodation units, particularly in prison settings, element of such a module and method for its production. Technical field

[0001] The present invention relates to the lifting and handling of reinforced concrete elements and modules for the construction of prefabricated accommodation units.

[0002] To this end, it proposes, in particular, reinforced concrete elements and modules for the construction of these accommodations, as well as a method for lifting and handling these elements and modules. It also proposes a method for manufacturing these modules.

[0003] The invention finds particularly advantageous - but not limited to - application for the construction of accommodation units in a prison environment. STATE OF THE ART

[0004] Modular construction has been known for many years. It consists of assembling individual modules prefabricated remotely on a site where a building is being constructed.

[0005] In the case of prefabricated reinforced concrete modules, the lifting and transport of the modules or the elements that compose them are generally done using slings and cranes.

[0006] It is known for this purpose to embed in the concrete metal inserts allowing the attachment of slings and allowing the modules or their elements to be maneuvered safely.

[0007] Typically, in the case of parallelepiped accommodation units, the modules can be lifted from the top, by means of inserts embedded in the veil closing the upper part of the modules. Description of the invention

[0008] It was found that this lifting technique was unsatisfactory and could cause damage to the concrete walls during the handling and transport of the modules or their components. Furthermore, there were safety and ergonomic issues at the workstations.

[0009] There is therefore a need for a lifting and handling solution for prefabricated modules or their elements which is simple to execute and allows for reliable and even safer handling for personnel, without risk of damage to these modules or their elements.

[0010] The invention proposes for this purpose a prefabricated module element comprising at least one wall and / or a reinforced concrete slab, said wall or said slab integrating at least one lifting insert emerging from a surface of the wall and / or the slab through at least one oblong hooking hole, said lifting insert comprising a metal box cast as a single piece of reinforced concrete with said wall or said slab and being configured to receive and cooperate with a hook for lifting the element or the module.

[0011] The prefabricated module element according to the invention is advantageously complemented by the following characteristics, taken alone or in any technically possible combination thereof: - a top slab from which extend at least four walls intended to form the sides of the module, and at least one lifting insert located on at least one of the walls in an intermediate position between the top slab and an end of the distal wall of the top slab; - two lifting inserts located on opposite sails; - the element includes concrete with a compressive strength greater than or equal to 5.5 MPa around the lifting insert(s); - two lifting inserts located on either side of one face of one of the walls intended to form the sides of the prefabricated module, in a position adjacent to one end of the distal wall of the upper slab; - a lower slab and two lifting inserts located on either side of the same slice of the lower slab, the slice being contiguous to a wall configured to be a front face of the prefabricated module; - the element includes concrete with a compressive strength greater than or equal to 40 MPa around the lifting inserts - a top slab from which extend at least four walls intended to form the sides of the module, and at least one lifting insert located on at least one of the walls in a position adjacent to one end of the distal wall of the top slab.

[0012] The invention also relates to a prefabricated module comprising a module element according to the invention, in particular a prefabricated module in which the two lifting inserts located on the same slice of the lower slab are on one side of the module opposite the two lifting inserts located on either side of one face of one of the walls intended to form the sides of the module, in a position adjacent to one end of the distal wall of the upper slab, the two sides of the module being intended to form faces of the prefabricated module.

[0013] The invention also relates to a method for manufacturing a prefabricated module, the method comprising the following steps: - pouring of the upper slab, the walls and the lower slab; - turning over the lower slab; - insertion of a lifting hook into a first lifting insert of one of the walls and into a second lifting insert of the face of the wall adjacent to the lower slab; - lifting the first element using the first lifting insert and the second lifting insert; - assembly of the upper wall and the walls on the lower slab.

[0014] This process is advantageously complemented by a heating step comprising maintaining the element at a temperature greater than or equal to 40°C for a period greater than or equal to 16 hours.

[0015] Finally, the invention also relates to a method of constructing a building comprising several prefabricated modules according to the invention and the building constructed according to this method, which includes a step of inserting lifting hooks into at least one lifting insert of a wall and at least one lifting insert of the bottom slab and in which at least one prefabricated module is lifted by these lifting hooks and lifting inserts and put in place on the site of the building. DESCRIPTION OF THE FIGURES

[0016] Other features, objectives and advantages of the invention will become apparent from the following description, which is purely illustrative and not limiting, and which should be read in conjunction with the accompanying drawings on which:

[0017] Fig. 1 is a schematic view of a prefabricated module according to one embodiment of the invention;

[0018] Fig. 2 is a schematic view, from a second angle, of a prefabricated module according to an embodiment of the invention;

[0019] Fig. 3 is a schematic view of an anchor box belonging to a prefabricated module shown in Figures 1 and 2 and of a hook configured to be inserted into the anchor box;

[0020] Fig. 4 is a flowchart illustrating steps of an example of a manufacturing process for a prefabricated module according to an embodiment of the invention;

[0021] Fig. 5 is a schematic view of a prefabricated module suspended by means of anchor boxes and hooks such as those shown in Fig. 3, according to one embodiment of the invention;

[0022] Fig. 6 is a schematic view along the second angle of two prefabricated modules according to one embodiment of the invention;

[0023] Throughout the figures, similar elements bear identical references. DETAILED DESCRIPTION OF THE INVENTION

[0024] The accommodation unit illustrated in figures 1 and 2 is a module 1 with a parallelepiped structure in reinforced concrete, closed by six walls.

[0025] The various prefabricated modules 1 are designed to be assembled together on site. They include recesses for vertical shafts and are delivered fully equipped: joinery elements (door, window), complete shower area, built-in wardrobe, and all furniture. They are assembled together on site to form the structure of the building being constructed. These modules 1 can be placed side by side or stacked on several levels. They are covered by a roof fixed to a wood or metal frame, and thermal insulation is added to the exterior, with a render applied to the facade.

[0026] The prefabricated module 1 is produced in a remote workshop. It comprises, in particular, two elements cast independently of each other and assembled in this workshop: - a low slab 3, forming a floor, - a five-sided element 2 which comprises a top slab 21 and four walls extending perpendicularly to define respectively a front face 22, a back face 24 and two side faces 23.

[0027] These two concrete elements 2 and 3 are each made with HA bar type reinforcements.

[0028] The lower slab 3 and the five-sided element 2 incorporate one or more lifting inserts 41a, 41b, 41c.

[0029] In particular, the two side faces 23 each incorporate a lifting insert 41a, located in an intermediate position (in this case, at mid-height) between the upper slab 21 and the lower slab 3. These two lifting inserts 41a are arranged on the two side faces 23, near the front face 22 where the cell door is located, on one side and on the other side of said face 22.

[0030] These lifting inserts 41a each have only one opening. The openings of the lifting inserts 41a are located on the lateral faces 23 into which they are integrated, being oriented outwards from the module.

[0031] The rear face 24, where the cell window is located, incorporates two lifting inserts 41b. These boxes 41b are similar to the boxes 41a. They are distributed on one side and the other of said rear face 24, being positioned near the lower slab 3 and in the vicinity of the edges of the module 1.

[0032] The lower slab 3 also includes one or more lifting inserts 41c similar to the lifting inserts 41a, 41b. These lifting inserts 41c open onto the edge of the lower slab 3, in this case at the level of its edges in line with the front face 22.

[0033] In the example of figures 1 and 2, the slab 3 has two lifting inserts 41c, distributed on the front edge of said slab 3 (edge ​​in line with the front face 22), near the lateral edges of said slab 3.

[0034] Thus, the lifting inserts 41b are located on the rear face 24, while the lifting inserts 41c are located on the front edge of the lower slab 3, which optimizes load distribution. Indeed, the lifting inserts 41a, 41b, and 41c are typically distributed in pairs on the walls and edges of the lower slab 3 according to the pairs 41a-41b and 41b-41c in order to distribute the load at points equidistant from a center of gravity during the respective lifting of the five-sided element 2 and the prefabricated module 1.

[0035] In addition, the upper slab 21 also includes one or more lifting inserts 41d, similar to the lifting inserts 41a, 41b, 41c. These lifting inserts 41c open onto the edge of the upper slab 21, preferably on the side of the lateral faces 23 and at an adjacent position to the upper slab 21. Indeed, the lifting inserts 41d are configured on the one hand for lifting and on the other hand for the horizontal connection of several prefabricated modules 1.

[0036] Numerous other configurations and distributions of the lifting inserts 41a, 41b, 41c, 41d are of course possible to achieve load balancing and distribution during lifting. In particular, the spacing of the lifting inserts 41a, 41b, 41c, 41d, located symmetrically in the same positions, is adapted according to the dimensions of the prefabricated module 1 so that the resultant of the lifting force is vertically aligned with the center of gravity of the prefabricated module 1.

[0037] As illustrated [Fig. 3], each lifting insert 41a, 41b, 41c, 41d is integrated into the structure of the prefabricated module 1 and includes a through oblong hole 42. The dimensions of the walls of the lifting insert 41a, 41b, 41c, 41d and of the oblong hole 42 are determined to allow the lifting insert 41a, 41b, 41c, 41d to cooperate with a complementary lifting hook 43.

[0038] In particular, the internal reinforcement of the reinforced concrete constituting element 2 is arranged to define an internal parallelepiped volume formed in the mass of concrete of the lifting insert 41a, 41b, 41c, 41d. This reinforcement and the concrete are further dimensioned to withstand the stresses during the lifting of a module 1.

[0039] The hole 42 and the internal hollow shape of a lifting insert 41a, 41b, 41c, 41d are made by a metal box comprising 6 faces welded together, on which are fixed by welding reinforcements HA intended to ensure the distribution of forces in the reinforced concrete of module 1. The oblong shape of the hole 42 of each lifting insert 41a, 41b, 41c, 41d is oriented so that its greatest length X is perpendicular to it.

[0040] With reference to [Fig. 6], the horizontal connection of two prefabricated modules 1 placed opposite each other is achieved by attaching a connecting member to two lifting inserts 41d. The lifting inserts 41d are positioned so that their respective oblong holes 42 are aligned. The connecting member is, for example, a bolted assembly comprising perforated plates positioned respectively in each lifting insert 41d and between the two lifting inserts 41d, the plates being traversed by a threaded rod bolted through the perforations in the plates and the oblong holes 42.

[0041] The lifting and handling of the five-sided element 2, the lower slab 3 or the module 1 is done using lifting hooks 43.

[0042] Such a lifting hook 43 is, for example, a hook of the type commonly used for lifting shipping containers equipped with standard ISO corner fittings. It is made of high-strength steel and comprises a hooking portion with a hooking flat 43a and a portion equipped with an eye 43b for receiving slings intended for lifting. This lifting can be carried out by diagonal pulling or by vertical pulling (depending on the shape of the hook cooperating with the anchor box).

[0043] The lifting inserts 41a, 41b are advantageously used for lifting the five-sided element 2.

[0044] The lifting of the entire prefabricated module 1, i.e. including the five-sided element 2 and the lower slab 3, is carried out using hooks 43 cooperating with lifting insert 41b, 41c.

[0045] Thus, the reinforced concrete constituting element 2 in the vicinity of the first lifting inserts 41a preferably has a characteristic compressive strength of at least 5.5 MPa.

[0046] Similarly, the concrete of module 1 must have, for the use of the lifting inserts 41b, 41c, a characteristic compressive strength of at least 40 MPa for lifting on the construction site, lifting on the manufacturing site requiring only a compressive strength of at least 15 MPa.

[0047] The manufacture of a prefabricated module 1, illustrated [Fig.4], includes the following different steps. - Pouring of the five-sided element 2 and the lower slab 3 (step SI). This step is carried out in the remote manufacturing workshop. The concrete is preferably of consistency “S4” for the five-sided element 2 and of consistency “SF1” (self-compacting concrete) for the lower slab 3; - Heating (step S2) of the prefabricated module 1 to a temperature greater than or equal to 40°C for a period greater than or equal to 16 hours, in order to guarantee the characteristic compressive strength around the lifting inserts 41b, 41c, 41d for lifting operations for transport to the construction site and handling on the construction site itself; Turning over and then removing the formwork from the lower slab 3 (step S3); - Moving the lower slab 3 onto a transport support; - Insertion of lifting hooks 43 into lifting inserts 41a, 41b (step S4) and lifting by slings of the five-sided element 2 (step S5); - Placement of the five-sided element 2 on the lower slab 3 and assembly using a bonding mortar (step S6);

[0048] The handling of the modules 1 and their placement to construct a housing unit comprising several prefabricated modules 1 assembled is done using the lifting inserts 41b and 41c and / or 41d and inserting hooks from a first prefabricated module 1 during a step S7.

[0049] A prefabricated module 1 is lifted during a step S8 so that the forces are distributed both on the lower slab 3 via the lifting insert(s) 41c and on the rear face 24 via the lifting insert(s) 41b.

[0050] The prefabricated module 1 is then positioned at a desired location in the accommodation unit, and can be easily juxtaposed or stacked with a second prefabricated module 1 thanks to the position of the second and third lifting inserts 41b, 41c, which leaves the side faces 23 and the lower face of the lower slab 30 free of any obstacles.

[0051] In the case where prefabricated module 1 is juxtaposed with a second prefabricated module 1, a linking step of the two prefabricated modules 1 can be carried out to increase the overall strength of the accommodation assembly. This additional fastening beyond the mortar allows, in particular, for better resistance to seismic disturbances. The linking step S9 comprises bolting the respective lifting inserts 41d of the elements 2.

[0052] The proposed prefabricated module 1 elements 2 thus allow for easier handling and a reduced risk of damage both during lifting in the workshop, for the manufacturing and loading phases for transport and during construction on site, which results in a reduction in handling time, an increase in quality and safety.

[0053] Such elements find application in all types of construction. They are perfectly suited to the construction of prison buildings with prefabricated cells.

Claims

Demands

1. Element (2, 3) of a prefabricated module (1) comprising at least one reinforced concrete wall and / or slab, said wall or slab incorporating at least one lifting insert (41a, 41b, 41c, 41d) emerging from a surface of the wall and / or slab through at least one oblong hooking hole (42), said lifting insert (41a, 41b, 41c, 41d) comprising a metal box cast as a single piece of reinforced concrete with said wall or slab and configured to receive and cooperate with a hook (43) for lifting the element (2, 3) or the module (1).

2. Element (2) of prefabricated module (1) according to claim 1, comprising a top slab (21) from which extend at least four walls (22, 23, 24) intended to form the sides of the module (1), and at least one lifting insert (41a) located on at least one of the walls (23) in an intermediate position between the top slab (21) and an end of the wall (23) distal to the top slab (21).

3. Element (2) of prefabricated module (1) according to claim 2, comprising two lifting inserts (41a) located on opposite walls (23).

4. Element (2) of a prefabricated module (1) according to any one of claims 2 and 3, wherein the element (2) around the lifting insert(s) (41a) comprises a concrete having a compressive strength greater than or equal to 5.5 MPa.

5. Element (2) of prefabricated module (1) one of claims 2 to 4, comprising two lifting inserts (41b) located on either side of one face of one (24) of the walls intended to form the sides of the prefabricated module (1), in a position adjacent to one end of the wall (24) distal to the upper slab (21).

6. Element (3) of prefabricated module (1) according to claim 1, comprising a lower slab (3) and two lifting inserts (41c) located on either side of the same slice of the lower slab (3), the slice being contiguous to a wall configured to be a front face (22) of the prefabricated module (1).

7. Element (2,3) of a prefabricated module (1) according to any one of claims 5 and 6, wherein the element (2) around the lifting inserts (41b, 41c) comprises a concrete having a compressive strength greater than or equal to 40 MPa.

8. Element (2) of prefabricated module (1) according to claim 1, comprising a top slab (21) from which extend at least four walls (22, 23, 24) intended to form the sides of the module (1), and at least one lifting insert (41d) located on at least one of the walls (23) in a position adjacent to an end of the wall (23) distal to the top slab (21).

9. Prefabricated module (1) comprising a module element (2) according to any one of the preceding claims.

10. Prefabricated module (1) comprising an element (2) according to claim 5, assembled on a base slab of an element (3) according to claim 6.

11. Prefabricated module (1) according to claim 10, wherein the two lifting inserts located on the same slice of the lower slab (3) are on one side of the module opposite the two lifting inserts (41b) located on either side of one face of one (24) of the walls intended to form the sides of the module (1), in a position adjacent to one end of the wall (24) distal to the upper slab (21), the two sides of the module being intended to form faces of the prefabricated module (1).

12. A method for manufacturing a prefabricated module (1) according to claim 11, the method comprising the following steps: - casting (step S1) of the top slab (21), the walls (22, 23, 24) and the bottom slab (3); - turning over (step S3) the bottom slab (3); - inserting (step S4) a lifting hook (43) into a first lifting insert (41a) of one of the walls (23) and into a second lifting insert (41b) of the face of the wall (24) adjacent to the bottom slab (3); - lifting (step S5) of the first element (2) by means of the first lifting insert (41a) and the second lifting insert (41b); - assembling (step S6) the top wall (21) and the walls (22, 23, 24) onto the bottom slab (3).

13. A manufacturing process according to claim 12, comprising a heating step (step S2) including maintaining the element (2) at a temperature greater than or equal to 40°C for a period greater than or equal to 16 hours.

14. Method of constructing a building comprising several prefabricated modules (1) according to claim 11, comprising a step of inserting lifting hooks (43) into at least one lifting insert (41b) of a wall (24) and at least one lifting insert (41c) of the bottom slab (3) and wherein at least one prefabricated module (1) is lifted by these lifting hooks (43) and lifting inserts (41b, 41c) and placed on the building site (step S8).

15. Construction method according to claim 14, further comprising a step of joining two prefabricated modules (1) according to claim 11, the two prefabricated modules (1) comprising elements (2) of prefabricated module (1) according to claim 8, the joining step (S9) comprising bolting the respective lifting inserts (41d) of the elements (2).

16. Building constructed according to the method of one of claims 14 and 15.

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