Method for erecting a prefabricated building using modular element

Abstract

A method for erecting a prefabricated building, comprising: the assembly of premanufactured construction modules to form at least the floor (figure 4: 1) and walls (figure 3: 2), wherein each module i

Description

The invention pertains to the field of building construction, specifically to modular structures assembled from modules on-site. BACKGROUND OF THE INVENTION A known patent, FR2997977B1, published on November 14, 2012, describes a modular construction system using lightweight panels and boards to create walls, roofs, and other structural elements. The panels are cut and joined using mounting boards, enabling the creation of a stable structure with relatively simple assembly. The system provides a standardized connection framework for all structural elements, making the assembly process less flexible and highly dependent on precise manufacturing. Exact matching of all elements is required, which may necessitate adjustments and modifications during on-site assembly. Another known patent, US4852310A, published on December 30, 1982, discusses constructing a structure from insulated panels with inner and outer coverings separated by insulation material. The invention includes a thermal barrier system to prevent “thermal bridges’’ at panel joints and between other structural elements (e.g., walls and roofs). The panels feature standardized passages for routing electrical wiring, simplifying the installation of utilities. Additionally, solutions are provided for standard windows and doors by utilizing supplementary panels and inserts. However, this system has significant drawbacks: • Limited versatility of the connection system. The connecting elements and fastening systems for the panels lack adaptability, restricting their use in complex architectural designs or projects requiring structural modifications. • Limited capacity for modification and reconstruction. The system does not allow for disassembly and subsequent reassembly, thereby limiting the flexibility of the structure throughout its lifecycle. Additionally, no adjustments are possible during the installation phase. A method for erecting a prefabricated building is also known, involving the assembly of pre-manufactured individual modules to form floors, walls, and columns. Each module for floors, walls, and columns is designed as a box module with outer, side, and inner walls (see patent FR3086309A1, published March 27, 2020). The drawbacks of this method include limited flexibility in the connection system. The assembly elements are constrained to fixed dimensions, limiting configuration variability and necessitating meticulous planning during the design phase. The fixed dimensions of the elements restrict their use in non-standard architectural projects. These limitations create challenges for implementing more complex structures and require high precision throughout all stages of design and construction. Additionally, limited access to utilities complicates building maintenance and operation. SUMMARY OF THE INVENTION The invention aims to enhance the ease of assembly, reconstruction, and modernization of buildings by ensuring access to installed utilities and other internal components. Modularity is achieved through a scalable range of module sizes with a unified construction design. The invention facilitates access to engineering systems at all stages of building operation and allows for adjustable structural strength by varying the spacing of load-bearing modules, optimizing material usage and increasing structural reliability. The technical result is achieved by assembling pre-manufactured individual modules to form, at a minimum, floors and walls. Each module, whether for floors or walls, is designed as a Box Module with outer, side, and internal lift-off panels. According to the invention, Box Modules of various sizes are used during assembly, with the width and length of each module being multiples of a standard unit. Beam modules are installed between floor Box Modules to interconnect them, and vertical load-bearing modules are placed between wall Box Modules to interconnect the walls. The inner panel of each Box Module is designed as a lift-off panel, allowing it to be removed during building operation. Service openings for utilities are preformed in the side walls of the Box Modules, as well as in the beam and vertical load-bearing modules. These openings follow a consistent spacing to align with adjacent modules. The inner panels of the Box Modules are secured only after the modules are interconnected and the building’s utilities are installed. For the exterior surfaces of the modules, finishing materials such as ceramic granite tiles, veneer made from precious wood species, or fiber cement tiles are used. These finishes are preinstalled at the factory during module production. Insulation material, preferably made of basalt mineral wool, is pre-attached to the inner lift-off panel of the module. Upon installation in the Box Module, this insulation ensures a snug fit against the internal surfaces of the panel, eliminating thermal bridges and significantly improving the building's thermal insulation properties. Illustrations of the Invention The invention is explained with the help of drawings: • Fig-1 : A set of primary elements of the mod ular construction. • Fig. 2 : Main components of a Box Module, including the inner lift-off panel. • Fig. 3: The principle of wall assembly from wall modules. • Fig. 4: The principle of floor module assembly. • Fig. 5: An example of an assembled joint of the foundation, walls, and floors. • Figs. 6-8: The sequence of assembling a cross joint of walls. • Fig. 9: Assembly of a door opening. • Fig. 10: Assembly of a comer module. . Figs. 11-12: Installation of internal utilities. . Fig. 13: A fully assembled building. Description of the Construction Elements and Assembly Process The described method is implemented using the following structural elements. The building includes, at a minimum, floors (1) and walls (2), which are assembled from floor Box Modules (4), wall Box Modules (5), comer Box Modules (6), and end wall Box Modules (23). Additional components include beam modules (9), which serve as horizontal longitudinal loadbearing elements for assembling floors (1), and vertical load-bearing modules (10), which are used to construct walls (2). Beam modules (9) and vertical modules (10) feature sendee openings (11) spaced at standard intervals. The Box Modules (4, 5) and Box Corner Modules (6) have outer walls (12), side walls (13), and inner walls (14). The inner wall (14) is designed as a lift-off panel, which can be detached during building operation. The Box Modules (4 and 5) are constructed with a frame (15) made of timber, to which the side (13 ) and outer walls (12) are attached, forming an open box. The side walls (13) are equipped with through openings that enable precise alignment and connection of Modules (4 and 5) to Beam Modules (9) and Vertical Modules (10) by matching openings (16 and 11). Additionally, standard-diameter service openings (16) are provided for routing utilities, simplifying the installation of engineering systems. A sealing material (17) is attached to the inner surface of the lift-off panel (14), which, upon installation into the Box Module cavity, ensures a snug fit against the internal surfaces of the frame, eliminating gaps that could lead to thermal bridges. The lift-off panel (14) is secured to the mounting frame (18) of the Modules (4 and 5). The assembled modules are typically coated with a vapor- and waterproofing compound to protect the structure and interior components of the building from adverse environmental conditions, ensuring airtightness, vapor resistance, and windproofing. Building Assembly Process The assembly of the building is carried out as follows: Assembly begins with the placement of the first beam module (9), which serves as the foundation for subsequent installation of floor modules (4) without their inner lift-off panels (14). The beam module (9) is installed on a prepared foundation (foundation slab or screw piles). The beam modules (9) are placed with a spacing of 300 mm, which is optimal for precise placement of floor modules. Floor modules are placed into the grooves of the beam module (9) and fixed using bolt connections, ensuring the reliability and stability of the floor structure. These modules typically have a thickness ranging from 300 mm to 400 mm, the most optimal sizes for combining strength and thermal insulation properties. At the ends of the beam modules, end Box Modules (19) are attached to close off the floor’s edges, and corner end modules (19) are installed at the floor corners. The side (20) and inner (21) walls of the end modules (19) have through openings, while the outer wall (22) is solid and lift-off. During installation, the end modules (19) can be mounted either without the top side wall (20) or without the lift-off outer wall (22). The sizes of the end modules (19) may differ from those of the standard floor modules (4). Installation of end modules (19) follows the same process as for modules (4). After the installation of the first row of floor modules (4), the next beam module (9) is placed to enable further fastening of the modules (4) between the first and second beam modules (9). The subsequent beam module (9) secures the floor modules (4) between the two beam modules, providing additional rigidity to the structure. The spacing for installing beam modules (9) is also 300 mm, as this spacing ensures optimal support and ease of assembly. The process is repeated until all floor rows are assembled. Before installing the inner lift-off panels (14) of the floor modules (4), all necessary engineering systems are routed through the floor. This ensures easy access to utilities and simplifies future maintenance. Once all modules are installed, the inner lift-off panels (14) of the floor modules (4) and the top side walls (20) of the end modules (19) are mounted. The assembly of the floor is completed by attaching the outer walls (22) of the end modules (19). The assembly of wall modules begins with the installation of comer Box Modules (6), which are fixed with bolts onto the end floor modules (19). The most preferred dimensions for corner modules are 600x1200 mm or 600x600 mm, ensuring precise alignment and structural stability. After installing the comer modules (6), vertical load-bearing modules (10) are mounted between wall Box Modules (5). These vertical modules (10) are designed to bear vertical loads. The preferred dimensions for these modules range from 25x200 mm to 400x97 mm, ensuring strength and stability. The process of installing subsequent wall modules (5) continues with bolt and screw connections until all walls (2) are assembled. After assembling the walls (2), engineering systems are installed. Channels and service openings with a 300 mm spacing are provided in modules (4 and 5), which is the optimal configuration for routing utilities (see Figs. 11 and 12 for utility installation within wall modules). The final stage of wall assembly involves mounting the inner lift-off panels (14) onto modules (4 and 5) for both floors (1) and walls (2). End wall modules (23) can also be used when assembling walls (2). The lift-off panels (14) typically have a thickness of 11 mm or more and serve the following functions: • Enhance thermal and sound insulation: Reducing heat loss and noise transmission. • Provide access to utilities: Allowing for easier maintenance. • Complete the building’s aesthetic appearance: Creating a finished look for the interior surfaces. The panels (14) are secured using bolts, which is the most reliable method for ensuring durability and protection against external influences. External finishes may include ceramic granite, veneer, or fiber cement tiles, providing strength and durability. After the wall modules (5) are installed, the floor (1) between the first and second floors of the building is assembled. This process is similar to the assembly of the main floor (1), using the same modules (4, 9, and 19). The construction of cross-walls also utilizes the modular system. This requires wall modules (24) specifically designed for cross-wall installation. These modules share the same design as the other Box Modules, with standardized service openings of consistent diameter and spacing for routing utilities. The process begins with constructing a column of wall modules (24). Vertical load-bearing modules (10) are then attached, serving as connecting elements between the cross-wall modules (24) and the adjacent wall modules (5). Each subsequent frame of a wall module (5) is installed such that the vertical module (10) fits into the groove between modules (5), ensuring additional structural rigidity. Modules are fastened together using bolts and screws, providing high strength to the entire wall structure. The inner lift-off panels (14) are then mounted on the previously installed wall modules (5), resulting in a sealed wall construction. To install windows and doors within the wall modules (5), structural openings are predesigned, as shown in Fig. 9 (example of a door opening). The structure consists of vertical loadbearing elements (10) fixed between wall modules (5), forming columns that create the desired width of the opening. A lintel module (25) is mounted above the opening to bear vertical loads from the upper wall structure. As shown in Fig. 10, the assembly of comer modules demonstrates the completion of the perimeter structure. Corner modules (6) are installed at the building’s comers, with lift-off covers (26) placed on the comer modules (6). This figure also illustrates the installation of engineering utilities within wall modules (5). After the walls are assembled, the installation of utilities follows, including: • Electrical wiring (27). • Water supply systems (28). • Drainage systems (29). Thanks to the modular wall design, utility installation is significantly simplified. Many modules already include predefined channels and service openings (11 and 16) for their installation. This allows all necessary engineering systems to be integrated during construction, minimizing the need for subsequent modifications to the completed structure. Once the utilities are installed, the lift-off panels are mounted on the Box Modules of the walls. This step represents the final phase of constructing the building's main structure. The liftoff panels not only complete the appearance of the surfaces but also provide additional protection for the structure against external influences, as well as improve the building’s thermal and sound insulation characteristics. The panels are secured using bolts or specialized fasteners, ensuring reliable attachment to the frame and resistance to external impacts. The complete building modules are transported to the construction site. These modules are delivered in a ready-to-assemble state, preserving the quality and precision achieved during factory production. Transportation is efficient due to the standardized sizes and designs of the modules. Example of Specific Dimensions of Key Modules (Fig. 1: Set of Primary Elements of the Modular Structure) • Wall Modules: Used to form the building's walls and available in several configurations: o Standard Wall Modules (preferred module dimensions): ■ Wall module: 600x1200 mm. ■ Wall module: 600x600 mm. ■ Wall module: 600x300 mm. ■ Wall module: 300x1200 mm. ■ Wall module: 300x600 mm. ■ Wall module: 300x300 mm. o Corner Modules (preferred module dimensions): ■ Corner wall module: 1200 mm height. ■ Comer wall module: 600 mm height. ■ Comer wall module: 300 mm height. o Cross-Wall Modules (preferred module dimensions): ■ T-shaped wall module: 1200 mm height. ■ T-shaped wall module: 600 mm height. o End Wall Modules (preferred module dimensions): ■ End wall module: 1200 mm height. ■ End wall module: 600 mm height. • Beam Modules (I-Joist): Beam modules are part of the structural system used to support floor modules. These modules are designed for assembly on a prepared foundation, preferably a concrete slab or screw piles. Beam modules are constructed from OSB panels and kiln-dried timber or LVL beams. They feature interfaces with a preferred spacing of 300 mm and service openings for utility routing. Beam modules are compatible with Stud modules. • Floor Modules: Floor modules are used to create horizontal structures between levels and to form the building's base: o Standard Floor Modules (preferred dimensions): ■ Floor module: 600x1200 mm. ■ Floor module: 300x1200 mm. ■ Floor module: 300x600 mm. ■ Floor module: 600x300 mm. ■ Floor module: 300x300 mm. o End Floor Modules (providing connections between wall and floor modules): ■ End floor module: 600 mm. ■ Comer end floor module. • Vertical Load-Bearing Modules (Stud): Studs are vertical elements placed between wall modules. They are preferably made from calibrated planed timber. The studs include positioning holes for assembly and service openings for utility routing. These modules are load-bearing, designed to handle vertical loads, and serve as alignment points for wall modules when assembling vertical structures. Assembly The building kit is packaged considering the sequence of assembly on-site. Similarly, unloading the building kit at the construction site is carried out in the order required for assembly. 1. Installation of the Building Kit: Assembly begins on a prepared site. The foundation is constructed in accordance with the house assembly recommendations. Water supply, sewage, electricity, and gas connections are pre-installed. 2. Inspection: Dimensions and tolerances of the foundation surface, as well as the positions of the utility connections, are checked to ensure compliance with the design specifications. 3. Assembly of the Main Floor (1): Beam modules (9) are installed on the foundation slab according to the assembly diagram. 4. Installation of Floor Modules (4): Floor modules (4), without the inner lift-off panels (14), are placed and secured between the beam modules. 5. Completion of the Main Floor: The floor structure of the future building is finalized, forming the main load-bearing platform. 6. Wail Module Installation: The first wall module frame is installed on the assembled floor. Vertical load-bearing modules (10) are placed between the wall modules (5). Additional wall modules are installed in sequence so that the vertical module (10) is positioned between adjacent wall modules (5). The wall structure is secured both internally and to the floor. 7. Sequential Wail Assembly: Using Box Modules (5), the walls of the first floor are constructed. Utilities are routed through the pre-installed service openings, and the inner lift-off panels of the wall modules (5) are attached. This completes the assembly of the finished walls (2) from the wall modules (5). 8. Roof Assembly: The roof structure above the first floor is assembled in the same way as the main floor (1), using the same modules (4, 9, and 19). 9. Installation of Remaining Building Elements: Remaining elements, such as rainwa ter drainage systems and roof waterproofing, are installed to finalize the exterior of the building. 10. Completion: The building is fully assembled! Post-Assembly Modernization The modular nature of the technology enables future upgrades and expansion. The disassemblable structure provides easy access to components and internal spaces for updates or modifications to accommodate changing needs and technologies. Breaking the construction process into these stages and utilizing standardized, prefabricated modules contributes to the efficiency, quality, and adaptability of the technology in modern construction projects. INDUSTRIAL APPLICABILITY The general principle of the invention involves the construction of buildings by assembling modules directly on-site. The structure comprises horizontal elements (such as floors and roofs) and vertical elements (such as walls and partitions), which are connected using studs, beams, and comer modules. These structures are designed for the rapid and efficient assembly of residential houses, public buildings, offices, and other facilities of various purposes, with particular emphasis on improving thermal insulation properties, unifying construction elements, and simplifying the assembly process. The scope of this invention includes the construction of low-rise buildings (such as individual residential houses and cottages) as well as public and commercial facilities (offices, schools, kindergartens, shops, etc.). The invention aims to address the challenge of creating energy-efficient structures by optimizing thermal insulation, waterproofing, material density, and inertia. It is particularly suitable for use in environments requiring low energy consumption for heating and cooling buildings. The construction system uses modular elements such as wall modules, beams, floor modules, and vertical load-bearing modules, which can be quickly assembled on-site, minimizing time and financial costs. A key aspect of the invention is the capability to produce buildings under factory conditions, which reduces construction time, lowers environmental impact, and ensures high assembly quality through pre-fabricated components. Thus, the proposed method increases the speed and precision of assembly. The use of standardized modules with preferred dimensions and a 300 mm installation step enables the construction of buildings with high efficiency and accuracy. The application of modules with preferred dimensions reduces production costs and simplifies the assembly process by unifying components and materials.

Claims

1. A method for erecting a prefabricated building, involving the assembly of premanufactured individual construction modules to form at least floors and walls, wherein each module, at least for the floors and walls, is designed as a Box Module with outer, side, and inner lift-off panels, characterized in that Box Modules of various sizes are used during assembly, with the width and length of each Box Module being multiples of a standard unit. Beam modules are installed between floor Box Modules to interconnect them, and vertical load-bearing modules are placed between wall Box Modules to interconnect the walls, the inner panel of each Box Module is designed as a lift-off panel, allowing it to be removed during building operation, service openings for utility routing are pre-formed in the side walls of the Box Modules, as well as in the beam and vertical load-bearing modules, these openings follow a consistent spacing to align with adjacent modules and the inner panels of the Box Modules are secured only after the modules are interconnected and the building’s utilities are installed.

2. The method of claim 1, characterized in that the outer surfaces of the modules are finished with materials such as ceramic granite tiles, veneer made from precious wood species, or fiber cement tiles, which are pre-installed during module manufacturing.

3. The method of claim 1, characterized in that the lift-off panel of the module is secured to the frame using fastening elements, preferably screws.

4. The method of claim 1, characterized in that insulation, preferably made of basalt mineral wool, is pre-installed within the module frame, ensuring a snug fit against the inner surfaces of the panel to eliminate gaps and thermal bridges.22 10 25Amendments to claims have been filed as follows:CLAIMS1. A method for erecting a prefabricated building, involving the assembly of premanufactured individual construction modules to form at least floors and walls, wherein each module, at least for the floors and walls, is designed as a Box Module with outer, side, and5 inner lift-off panels, characterized in that:Box Modules of various sizes are used during assembly, with the width and length of each Box Module being multiples of a standard unit;Beam modules are installed between floor Box Modules to interconnect them, and vertical load-bearing modules are placed between wall Box Modules to interconnect the 10 walls,the inner panel of each Box Module is designed as a lift-off panel, allowing it to be removed during building operation, service openings for uti lity routing are pre-formed in the side walls of the Box Modules, as well as in the beam and vertical load-bearing modules, these openings follow a consistent spacing to align with adjacent modules and the inner15 panels of the Box Modules are secured only after the modules are interconnected and the building’s utilities are installed.

2. The method of claim 1, characterized in that the outer surfaces of the modules are finished with materials such as ceramic granite tiles, veneer made from precious wood species, or fiber cement tiles, which are pre-installed during module manufacturing.20 3. The method of claim 1, characterized in that the lift-off panel of the module i s securedto the frame using fastening elements, preferably screws.

4. The method of claim 1, characterized in that insulation, preferably made of basalt mineral wool, is pre-installed within the module frame, ensuring a snug fit against the inner surfaces of the panel to eliminate gaps and thermal bridges.

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