Method for manufacturing modular structure for construction

Abstract

A method for manufacturing a modular structure for construction according to an embodiment of the present invention comprises the steps of: manufacturing a ceiling assembly including a ceiling steel frame, in which a plurality of ceiling beams and nodes are connected, and a ceiling stud panel, which forms a ceiling surface (S11); manufacturing a floor assembly including a floor steel frame, in which a plurality of floor beams and nodes are connected, and a floor stud panel, which forms a floor surface (S12); manufacturing a wall assembly including a long-side wall assembly, which forms a long-side wall, and a short-side wall assembly, which forms a short-side wall (S13); manufacturing a pod that forms a bathroom (S14); assembling an assembly that includes the ceiling assembly, the floor assembly, the wall assembly, and the pod (S2); and performing finishing work by sealing joints outside the modular structure with sealant, installing a partition wall, and installing interior and exterior finishing materials (S3). Parts corresponding to the floor, walls, ceiling, and pod are each manufactured in parallel through separate processes into assemblies, after which the assemblies are assembled into a single complete body and finishing is performed, and thus productivity can be significantly improved. In addition, when assembling the assemblies manufactured separately through the respective processes, the assemblies are assembled by securely fixing each of the assemblies at the correct location and properly aligning same horizontally or vertically using a 3D jig, and thus it is possible to manufacture a modular structure of the correct size and shape without errors.

Description

Method of fabricating modular structures for construction

[0001] The present invention relates to a method for manufacturing a modular structure for construction using a manufacturing method in which each part is manufactured in advance in the form of an assembly, and then these are assembled and finished to complete the entire manufacturing process.

[0002] Unlike conventional construction methods, modular construction involves manufacturing the interior and exterior of a single modular structure in a factory. This is then transported to the construction site, where one or more modular structures are stacked and assembled to complete the building. These factory-built modular structures include not only the skeleton, including columns and beams, but also the interior walls, doors, windows, and various mechanical and electrical equipment that comprise bathrooms and kitchens.

[0003] Therefore, modular construction methods can dramatically shorten construction periods, ensure consistent quality, minimize construction defects, and, with mass production systems, even reduce costs. Furthermore, modular components require no cutting or other fabrication processes, minimizing losses. This facilitates expansion and renovation, and the materials can be easily reused and recycled after use, making them an environmentally friendly method.

[0004] Typically, modular structures for construction are constructed in a hexahedral shape, resembling a rectangular box. They include columns forming the framework at the four vertical corners, ceiling beams connecting the upper portions of the columns, and floor beams connecting the lower portions of the columns. The beams, including the columns, ceiling beams, and floor beams, are typically made of steel, such as steel, but can also be made of various materials, including non-ferrous metals like aluminum, wood, or plastic. Depending on the size and internal design of the modular structure, the number of columns and beams can be four or more.

[0005] The traditional method of manufacturing modular structures for construction involved sequentially completing a single modular structure at a single factory location, with workers assigned to each process. This meant that construction was conducted in a single location from start to finish, and because multiple processes could not be performed simultaneously, it took a long time to complete the final assembly. Furthermore, because productivity depended on the skills of workers assigned to each process, the existing method was inadequate compared to manufacturing methods geared toward mass production.

[0006] Meanwhile, conventional modular structures for construction are manufactured in factories using plumb lines and spirit levels to measure vertical and horizontal levels, then manually weld and secure columns, ceiling beams, and floor beams. Furthermore, temporary supports have been used without separate fixing devices to absorb deformation during skeletal welding. This method of modular structure manufacturing leads to significant deformation and construction errors during the welding of columns, ceiling beams, and floor beams. When multiple modular structures with errors are connected on-site and constructed, the entire building cannot be constructed according to design, which can lead to structural defects. Furthermore, significant defects in insulation, airtightness, soundproofing, and waterproofing can occur over time.

[0007] An embodiment of the present invention provides a method for manufacturing a modular structure for construction, which significantly improves productivity by manufacturing parts corresponding to a floor, a wall, a ceiling, and a pod in a separate process in parallel in the form of an assembly, and then assembling and finishing each assembly into a single completed body.

[0008] In addition, an embodiment of the present invention provides a method for manufacturing an architectural modular structure of an accurate size and shape without error by assembling assemblies produced for each process by using a 3D jig to firmly fix each assembly in an accurate position horizontally or vertically when manufacturing an architectural modular structure.

[0009] The problems to be solved by the present invention are not limited to the problem(s) mentioned above, and other problems not mentioned will be clearly understood by those skilled in the art from the description below.

[0010] A method for manufacturing a modular structure for construction according to an embodiment of the present invention may include a step (S11) of manufacturing a ceiling assembly including a plurality of ceiling beams and a ceiling steel frame that connects nodes and a ceiling stud panel that forms a ceiling surface; a step (S12) of manufacturing a floor assembly including a plurality of floor beams and a floor steel frame that connects nodes and a floor stud panel that forms a floor surface; a step (S13) of manufacturing a wall assembly including a long-side wall assembly that forms a long-side wall and a short-side wall assembly that forms a short-side wall; a step (S14) of manufacturing a pod that forms a bathroom; a step (S2) of assembling an assembly including the ceiling assembly, the floor assembly, the wall assembly, and the pod; and a finishing step (S3) of sealing a joint on the outside of the modular structure with a sealant, installing a partition wall, and installing interior and exterior finishing materials.

[0011] In the above embodiment, the ceiling assembly manufacturing step (S11) may include a step of manufacturing the ceiling steel frame by connecting the plurality of ceiling beams and nodes (S111); a step of installing the ceiling stud panel on one surface of the ceiling steel frame (S112); a step of installing ceiling insulation on the upper surface of the installed ceiling stud panel (S113); a step of installing a ceiling fireproof board on the upper surface of the installed ceiling insulation (S114); a step of installing MEP (Mechanical Electronic Plumbing) in the ceiling, including mechanical equipment, electrical equipment, or firefighting equipment, on the upper surface of the installed ceiling fireproof board (S115); a step of installing a computer bolt, a sling bolt, or a hanger on the wing portion of the ceiling stud panel (S116); and a step of installing a ceiling frame by combining a lightweight steel M-bar, a carrying channel, and a channel clip so as to be mounted on the computer bolt, sling bolt, or hanger (S117).

[0012] In the above embodiment, the floor assembly manufacturing step (S12) may include a step (S121) of manufacturing the floor steel frame by tightly connecting the plurality of floor beams and nodes; a step (S122) of installing the floor stud panel on one surface of the floor steel frame; a step (S123) of filling the interior of the installed floor stud panel with lightweight foamed concrete; and a step (S124) of installing a CRC board on the upper surface of the floor stud panel and the lightweight foamed concrete.

[0013] In the above embodiment, the wall assembly manufacturing step (S13) includes a step of manufacturing the long-side wall assembly (S131); and a step of manufacturing the short-side wall assembly (S132); and the long-side wall assembly and the short-side wall assembly may include a wall stud panel, insulation, a fireproof board, and a window.

[0014] In the above embodiment, the assembling step (S2) may include a step of installing the manufactured floor assembly (S21); a step of installing the pod on the installed floor assembly (S22); a step of installing a plurality of pillars on the floor assembly (S23); a step of installing the ceiling assembly on the upper portions of the pods and pillars (S24); and a step of installing the wall assembly on the side of the pillar (S25); and a step of sealing the joint exposed to the outside of the modular structure with sealant (S26).

[0015] In the above embodiment, the method may further include a step (S133) of welding a hollow window frame to the wall stud panel or connecting it with a direct screw or a direct screw, and installing the window by connecting it to the window frame; a step (S134) of installing a fire door including a pin hinge, a flush ring, a flush bolt, or a door closer; and a step (S135) of installing an entrance door including a butt hinge, a door lock, or a door stopper.

[0016] In the above embodiment, the finishing step (S3) may include a ceiling construction step (S31) of installing remaining MEP and ceiling gypsum board on the interior ceiling of the modular structure; an interior wall construction step (S32) of installing a partition wall inside the modular structure; a wall finishing step (S33) using a wall finishing material inside the modular structure; a ceiling finishing step (S34) using a ceiling finishing material inside the modular structure; a floor finishing step (S35) using a floor finishing material inside the modular structure; and an exterior finishing step (S36) of installing an exterior finishing material outside the modular structure.

[0017] In the above embodiment, in the assembly assembly step (S2) including the ceiling assembly, the floor assembly, the wall assembly, and the pod, the ceiling assembly, the floor assembly, the wall assembly, and the pod are firmly held using a 3D jig to be assembled in a target position, horizontality, and verticality, and the 3D jig may include a base including a first base rail and a second base rail aligned parallel to each other; and a post including one or more clamps for holding the ceiling assembly, the floor assembly, the wall assembly, and the pod, and being disposed on an upper portion of the first base rail or the second base rail, the post being positionable on the first base rail or the second base rail.

[0018] A method for manufacturing a modular structure for construction according to an embodiment of the present invention can significantly improve productivity by manufacturing parts corresponding to a floor, a wall, a ceiling, and a pod in a separate process in parallel in the form of an assembly, and then assembling and finishing each assembly into a single completed body.

[0019] Meanwhile, according to an embodiment of the present invention, a method for manufacturing a modular structure for construction uses a 3D jig to assemble floor assemblies, wall assemblies, ceiling assemblies, and pods, each manufactured through a separate process, by firmly fixing each assembly horizontally or vertically in an accurate position, thereby manufacturing a modular structure of an accurate size and shape without error.

[0020] FIG. 1 is a flowchart schematically illustrating each step of a method for manufacturing a modular structure for construction according to an embodiment of the present invention.

[0021] FIG. 2 is a drawing schematically illustrating the detailed configuration of a ceiling assembly manufacturing step (S11) according to an embodiment of the present invention.

[0022] FIG. 3 is a drawing schematically illustrating the detailed configuration of the floor assembly manufacturing step (S12) according to an embodiment of the present invention.

[0023] FIG. 4 is a drawing schematically illustrating the detailed configuration of a wall assembly manufacturing step (S13) according to an embodiment of the present invention.

[0024] FIG. 5 is a drawing schematically illustrating a detailed configuration of an assembly assembly step (S2) including a ceiling assembly, a floor assembly, a wall assembly, and a pod according to an embodiment of the present invention.

[0025] FIG. 6 is a drawing schematically illustrating a detailed configuration of a finishing step (S3) according to an embodiment of the present invention.

[0026] FIG. 7 is a schematic drawing of a 3D jig for assembling assemblies to implement a method for manufacturing a modular structure for construction according to an embodiment of the present invention.

[0027] FIG. 8 is a schematic drawing of a post included in a 3D jig according to an embodiment of the present invention.

[0028] FIG. 9 is a schematic drawing of a locator included in a 3D jig according to an embodiment of the present invention.

[0029] FIG. 10 is a schematic drawing illustrating an example of a part of a modular structure being gripped by a 3D jig according to an embodiment of the present invention.

[0030] FIG. 11 is a schematic drawing illustrating an example of a safety bar mounted on a post of a 3D jig according to an embodiment of the present invention.

[0031] FIG. 12 is a schematic drawing of a worktable of a 3D jig according to an embodiment of the present invention.

[0032] The advantages and / or features of the present invention, and the methods for achieving them, will become clearer with reference to the embodiments described in detail below together with the accompanying drawings. However, the present invention is not limited to the embodiments disclosed below, but may be implemented in various different forms. These embodiments are provided only to ensure that the disclosure of the present invention is complete and to fully inform those skilled in the art of the scope of the invention, and the present invention is defined only by the scope of the claims. Like reference numerals refer to like elements throughout the specification.

[0033]

[0034] Hereinafter, embodiments of the present invention will be described in detail with reference to the attached drawings.

[0035]

[0036] FIG. 1 is a flowchart schematically illustrating each step of a method for manufacturing a modular structure for construction according to an embodiment of the present invention.

[0037] Referring to FIG. 1, a method for manufacturing a modular structure for construction according to an embodiment of the present invention may include a ceiling assembly manufacturing step (S11), a floor assembly manufacturing step (S12), a wall assembly manufacturing step (S13), a pod manufacturing step (S14), a step of assembling the manufactured assemblies (S2), and a finishing step (S3). Each step of manufacturing the ceiling assembly, floor assembly, wall assembly, and pod may be manufactured in a specific order according to the chronological relationship, but all steps may be manufactured simultaneously or some steps may be manufactured in parallel at different locations.

[0038]

[0039] FIG. 2 is a drawing schematically illustrating the detailed configuration of a ceiling assembly (a11) manufacturing step (S11) according to an embodiment of the present invention.

[0040] In the ceiling assembly manufacturing step (S11) according to an embodiment of the present invention, a ceiling assembly (a11) is manufactured by including a plurality of ceiling beams (a12) and nodes (a13) including a ceiling steel frame (a14) that is tightly connected and a ceiling stud panel (a15) that forms a ceiling surface.

[0041] Referring to Fig. 2a, the ceiling assembly manufacturing step (S11) first includes a step (S111) of manufacturing a ceiling steel frame (a14) using a ceiling beam (a12) and a node (a13). The ceiling beam (a12) forms long sides and short sides, respectively, and the ceiling steel frame (a14) is formed through a fastening operation such as bolting, riveting, joining, or welding using a node (a13) according to the size. The ceiling steel frame (a14) is generally rectangular, but may be square, have some sides circular, or be asymmetrical depending on the design of the modular structure.

[0042] Referring to Fig. 2b, after the ceiling steel frame manufacturing step (S111), a step (S112) of installing a ceiling stud panel (a15) on one surface of the ceiling steel frame (a14) is included. The ceiling stud panel (a15) can be installed by welding to the ceiling steel frame or another ceiling stud panel. The ceiling stud panel (a15) can be installed by pre-manufacturing and then joining, taking into account the gap between the ceiling beams (a12) of the ceiling steel frame (a14).

[0043] Referring to Fig. 2c, after step S112, a step (S113) of installing ceiling insulation (a16) in the empty spaces between the wing portions of the ceiling stud panel (a15) is included. For example, mineral wool or glass wool having a density of 40K to 80K can be used as the ceiling insulation (a16).

[0044] Referring to FIG. 2d, after step S113, a step (S114) of installing a ceiling fireproof board (a17) on the upper surface of the installed ceiling insulation (a16) is included. A material including gypsum can be used as the ceiling fireproof board (a17), and a fireproof board having characteristics that satisfy the 2-hour fire resistance standard with a thickness of 15T to 20T can be used.

[0045] Referring to FIG. 2e, after step S114, a step (S115) is included for installing MEP (Mechanical Electronic Plumbing, a18) within the ceiling, including mechanical equipment, electrical equipment, heating and cooling equipment, ventilation equipment, piping, or firefighting equipment, on the upper surface of the installed ceiling fireproof board (a17). The MEP (a18) may be installed to include all or part of the components according to the design, taking into account connections with other internal and external components.

[0046] Referring to FIG. 2f, a step (S116) of installing a computer bolt, a sling bolt, or a hanger (al9) on the wing portion of a ceiling stud panel (a15) for subsequent ceiling frame installation may be included. The computer bolt, sling bolt, or hanger (a19) may be installed on the wing portion of the ceiling stud panel (a15) other than the portion where the ceiling fireproof board (a17) is installed, taking into account the weight of the ceiling frame. The length of the computer bolt, sling bolt, or hanger (a19) may be appropriately applied according to the design, taking into account the height of the MEP, etc.

[0047] Referring to FIG. 2g, after step S116, a step (S117) is included in which a ceiling frame (a20) is installed so that the ceiling steel frame (a14) is turned upside down and hung on the hanger (a19). The ceiling frame (a20) can be installed by combining a lightweight steel M-bar, a carrying channel, and a channel clip. In addition, the material of the ceiling frame (a20) can be installed with various materials such as steel or aluminum, taking into consideration weight, cost, etc.

[0048] Figure 2h is a perspective view from above of the ceiling assembly (a11) completed through steps S111 to S117.

[0049]

[0050] FIG. 3 is a drawing schematically illustrating the detailed configuration of a floor assembly (a21) manufacturing step (S12) according to an embodiment of the present invention.

[0051] In the floor assembly manufacturing step (S12) according to an embodiment of the present invention, a floor assembly (a21) is manufactured by including a plurality of floor beams (a22) and nodes (a23) to form a tight floor steel frame (a24) and a floor stud panel (a25) that forms a floor surface.

[0052] Referring to Fig. 3a, the floor assembly manufacturing step (S12) first includes a step (S121) of manufacturing a floor steel frame (a24) using a floor beam (a22) and a node (a23). The floor beam (a22) forms long sides and short sides, respectively, and the floor steel frame (a24) is formed through a tightening operation such as bolting, riveting, joining, or welding using a node (a23) according to the size. The floor steel frame (a24) is generally rectangular, but may be square, have some sides circular, or be asymmetrical depending on the design of the modular structure. Referring to the left edge of Fig. 3a, the floor steel frame (a24) may be provided with a beam to firmly support a portion where a pod to be installed later is to be installed.

[0053] Referring to Fig. 3b, after the floor steel frame manufacturing step (S121), a step (S122) of installing a floor stud panel (a25) on one surface of the floor steel frame (a24) is included. The floor stud panel (a25) can be installed by welding to another floor stud panel or the floor steel frame. The floor stud panel (a25) can be installed by being manufactured in advance and then joined, taking into account the spacing between the beams of the floor steel frame (a24). Meanwhile, referring to the upper enlarged view of Fig. 3b, a frame for mounting a pod to a beam for a pod prepared in advance on the floor steel frame can be provided, and a connecting pin for fixing it to an accurate position can be provided.

[0054] Referring to Fig. 3c, after the floor stud panel installation step (S122), a step (S123) is included of filling the interior of the floor stud panel (a25), i.e., the empty spaces between the wing portions, with lightweight aerated concrete (a26). By filling the lightweight aerated concrete (a26), not only the insulation and soundproofing effects but also the structural support effect due to the weight can be maintained. After the lightweight aerated concrete (a26) has cured, a cushioning material can be installed.

[0055] Referring to FIG. 3d, a step (S124) of installing a CRC board (Cellulose fiber Reinforced Cement Board, a27) on the upper surface of a floor stud panel (a25) filled with lightweight aerated concrete (a26) is included. The CRC board (a27) is a high-strength, high-density building material produced by mixing Portland cement, silica sand, and cellulose fibers with water, pressurizing them at a high pressure of 10,000 tons, and then going through an autoclave curing process. By applying the CRC board (a27) as a flooring material, excellent weather resistance, water resistance, sound insulation, and non-combustibility as well as sufficient mechanical strength and environmental friendliness can be obtained.

[0056] Figure 3e is a perspective view from above of the floor assembly (a21) completed through steps S121 to S124.

[0057]

[0058] FIG. 4 is a drawing schematically illustrating the detailed configuration of a wall assembly manufacturing step (S13) according to an embodiment of the present invention.

[0059] A method for manufacturing a modular structure for construction according to an embodiment of the present invention may include a step (S13) of manufacturing a wall assembly (a31) including a long-side wall assembly forming a long-side wall and a short-side wall assembly forming a short-side wall. Specifically, the step (S13) of manufacturing the wall assembly (a31) may include a step (S131) ​​of manufacturing the long-side wall assembly and a step (S132) of manufacturing the short-side wall assembly. The step (S131) ​​of manufacturing the long-side wall assembly and the step (S132) of manufacturing the short-side wall assembly may be performed sequentially, but may also be performed simultaneously in parallel. The long-side wall assembly and the short-side wall assembly may be manufactured by including a wall stud panel (a35), an insulation material (a36), a fireproof board (a37), and a window (a33).

[0060] The wall assembly manufacturing step (S13) may further include a window installation step (S133), a fire door installation step (S134), and an entrance door installation step (S135).

[0061] Referring to FIGS. 4a to 4e, a window frame (a32) surrounding and supporting a window is manufactured by joining hollow metal square pipes. The joining can be accomplished by welding, direct screws, or direct screws. A wall stud panel (a35) is welded to the outside of the window frame (a32) to manufacture a long-side wall assembly or a short-side wall assembly. The window (a33) is installed into the manufactured window frame (a32) to complete the installation (S133).

[0062] After step S133, a fire door including a pin hinge, flush ring, flush bolt or door closer can be installed (S134), or an entrance door including a butt hinge, door lock or door stopper can be installed (S135).

[0063] Referring to FIG. 4f, after step S132, a step (S136) of installing insulation (a36) and a step (S137) of installing a fireproof board (a37) may be included. Mineral wool having a thickness of 100T may be used as the insulation (a36), and various materials may be used as the fireproof board (a37) having a thickness of 19T.

[0064]

[0065] A method for manufacturing a modular building structure according to an embodiment of the present invention may include a step (S14) of manufacturing a pod (a41) forming a bathroom. The pod (a41) is a type of system structure that integrates bathroom and other amenities into a building. The pod (a41) may be manufactured to include electrical, mechanical, and plumbing equipment, excluding components such as a bathtub, toilet, or sink to be ultimately installed in the bathroom.

[0066]

[0067] FIG. 5 is a drawing schematically illustrating a detailed configuration of an assembly assembly step (S2) including a ceiling assembly (a11), a floor assembly (a21), a wall assembly (a31), and a pod (a41) according to an embodiment of the present invention.

[0068] The prefabricated ceiling assembly (a11), floor assembly (a21), wall assembly (a31), and pod (a41) are each lifted to a location within the factory and assembled. The assembly assembly step (S2) illustrated in Fig. 5 can be performed accurately and easily using a 3D jig for manufacturing modular structures, which will be described later.

[0069] Referring to Fig. 5a, the assembly assembly step (S2) first includes a step (S21) of installing the manufactured floor assembly (a21). Since the floor assembly (a21) serves as the overall support for the modular structure, it must be installed so as to achieve an accurate horizontal level.

[0070] Referring to Fig. 5b, a step (S22) is included for installing a pod (a41) on the floor assembly (a21) after step S21. Referring to Fig. 5c, the pod is installed by joining it to a previously prepared mounting location. Using a connecting pin allows for a more precise and secure installation of the pod.

[0071] Referring to FIG. 5d, a step (S23) of installing a plurality of columns (a42) on corners or edges of a floor assembly (a21) is included. Thereafter, a step (S24) of installing a ceiling assembly (a11) on top of the pod (a41) and the columns (a42) is included. The columns (a42) can be joined to the beams or nodes of the floor assembly (a21) and the ceiling assembly (a11) through welding. The joint between the top of the pod (a41) and the ceiling assembly (a11) can be sealed using a sealant to maintain airtightness.

[0072] Thereafter, as in Fig. 5e, a step (S25) of installing a wall assembly (a31) including a long-side wall assembly and a short-side wall assembly is included. Thereafter, referring to Fig. 5f, a step (S26) of sealing a joint exposed to the outside of the modular structure with a sealant is included. The joint exposed to the outside may exist between ceiling stud panels, between wall stud panels, and between ceiling stud panels and wall stud panels.

[0073]

[0074] FIG. 6 is a drawing schematically illustrating the detailed configuration of a finishing step (S3) according to an embodiment of the present invention.

[0075] Referring to FIGS. 6a and 6b, the finishing step (S3) includes a ceiling construction step (S31) of installing the remaining MEP and ceiling gypsum board (a51) on the interior ceiling of the modular structure. Referring to FIG. 6a, although the MEP was previously installed in the ceiling assembly manufacturing step (S11), the remaining MEP may be additionally installed for connection of related equipment while assembled with other assemblies. Thereafter, as shown in FIG. 6b, the ceiling gypsum board (a51) may be installed under the MEP equipment exposed on the ceiling.

[0076] After step S31, it may include an interior wall construction step (S32) of installing a partition wall (a52) inside the modular structure as in FIG. 6c, a wall finishing step (S33) using a wall finishing material (a53) inside the modular structure as in FIG. 6d, a ceiling finishing step (S34) using a ceiling finishing material (a54) inside the modular structure as in FIG. 6e, a floor finishing step (S35) using a floor finishing material (a55) inside the modular structure as in FIG. 6f, and an exterior finishing step (S36) of installing an exterior finishing material (a56) outside the modular structure as in FIG. 6g.

[0077] Figure 6h is a perspective view from above of a final completed unit modular structure through the finishing step (S3) including steps S31 to S36.

[0078]

[0079] FIG. 7 is a schematic drawing of a 3D jig for assembling assemblies (a11, a21, a31, a41) to implement a method for manufacturing a modular structure for construction according to an embodiment of the present invention. When assembling a floor assembly, a wall assembly, a ceiling assembly, and a pod, each manufactured through a separate process, a 3D jig is used to firmly fix each assembly in an accurate position, horizontally or vertically, thereby manufacturing a modular structure of an accurate size and shape without error.

[0080] Referring to FIG. 7, a 3D jig for manufacturing a modular structure for construction according to an embodiment of the present invention includes a base (1) arranged on a bottom surface, a post (3) arranged on an upper portion of the base (1) and including a clamp (35) for holding a member of the modular structure, and a locator (5) for stably fixing the lower portion of the modular structure to the base (1).

[0081] The base (1) is arranged on the floor of a factory where modular structures are manufactured so as to be level with the ground plane. The base (1) may be formed of a single plate or may be formed of a plurality of plates of different thicknesses. In this case, each plate must be connected to each other to integrally support the upper working load and must be arranged so as to be level with the ground plane. The upper portion of the base (1) includes a first base rail (13a) and a second base rail (13b) which are arranged in a first direction (a) and aligned parallel to each other. The side surfaces of the box-shaped modular structure each have two long sides and two short sides. The first direction (a) may be aligned with the direction of the short sides, but it is preferable to be set so as to be aligned with the direction of the long sides for the purpose of arranging the post (3) and facilitating stable gripping and fixing of the modular structure. The first base rail (13a) and the second base rail (13b) may each be composed of one rail, but may also be composed of two or more rails for stable fixation and smooth movement of the post (3), and when composed of multiple rails, each rail may be arranged side by side in the first direction (a). The first base rail (13a) and the second base rail (13b) may be formed of a rail made of a high-strength material such as steel, and may be formed so as to support a rolling means such as a roller that may be included in the lower surface of the post (3). The first base rail (13a) and the second base rail (13b) may be formed so that a portion of the upper surface of the base (1) is formed as a groove formed in the first direction (a), and a rolling means such as a roller that may be included in the lower surface of the post (3) may be formed so as to be movable within the groove. In addition, the first base rail (13a) and the second base rail (13b) can be formed in the form of a linear motion guide, and can be formed so that the post (3) can slide in the first direction (a) over the first base rail (13a) and the second base rail (13b) by slipping with a lubricant without a separate rotation means such as a roller.

[0082] The post (3) can be placed on the first base rail (13a) or the second base rail (13b) on the upper part of the base (1). One post (3) can be placed on each of the first base rail (13a) or the second base rail (13b), but two or more posts (3) can be placed to stably fix the modular structure. The number of posts (3) to be placed on each rail can be appropriately set according to the length of the long side, the number of columns, the type of work, etc. The post (3) can be moved on the first base rail (13a) or the second base rail (13b) by means of a motor that directly applies rotational force to wheels that can be included at the bottom. In addition, the post (3) can be moved on the first base rail (13a) or the second base rail (13b) by means of a pushing or pulling force caused by the rotation of a hydraulic or compressed air operating means or an external motor. The post (3) can be fixed to the base (1) using a separate fixing means to ensure stable operation after movement. The separate fixing means can be a fastening bolt or a fixing pin.

[0083] The locator (5) may be formed to stably fix the lower part of the modular structure, i.e., the floor assembly, to the base (1). The locator (5) may be formed to be detachable from the base (1) in order to change its position to stably fix modular structures of various sizes, or in cases where the support part of the modular structure needs to be changed or reinforced during work. The locator (5) may be fastened to the base (1) with bolts or pins, or fixed with clamps. In this case, the base (1) may have a plurality of holes formed therein, and the locator (5) may be attached to the base (1) with bolts or the like through the formed holes. In addition, since the horizontal slip of the locator (5) may be restricted by the weight of the modular structure, the locator (5) may be placed on the base (1) in the form of a pedestal without a separate fixing member, and the modular structure may be mounted thereon. In this case, a part of the pedestal may also be fixed to a hole of the base (1) using pins or the like.

[0084]

[0085] FIG. 8 is a schematic drawing of a post included in a 3D jig according to an embodiment of the present invention.

[0086] Referring to Fig. 8, the post (3) can be divided into a post upper portion (31) and a post lower portion (33). The upper surface of the post lower portion (33) may include a post LM guide (37) that enables the position of the post upper portion (31) provided thereon to be changed. The post LM guide (37) may be arranged in a direction unrelated to the first direction (a) mentioned above. However, considering that the first base rail (13a) or the second base rail (13b) is arranged parallel to the long side and the modular structure, i.e., the columns or assemblies, must be more firmly held, the post LM guide (37) may be arranged in a second direction (b) that is parallel to the cross-section of the modular structure, i.e., orthogonal to the first direction (a). Through the post LM guide (37), the post upper portion (31) can be positioned in response to the two-way size of the modular structure, i.e., the length of the short side, so that the assemblies or columns can be more firmly held.

[0087] The post (3) may include one or more post LM guides (37) for stable position change of the post upper portion (31). The post LM guide (37) may be formed of a rail made of a high-strength material such as steel, and may be formed to support a rolling means such as a roller that may be included in the lower surface of the post upper portion (31). The post LM guide (37) may be formed in a groove shape in the second direction (b) on the upper surface of the post lower portion (33), and may be formed so that a rolling means such as a roller that may be included in the lower surface of the post upper portion (31) can move within the groove. In addition, the post LM guide (37) may be formed in the form of a linear movement guide, and may be formed so that the lower surface of the post upper portion (31) can slide against the upper surface of the post lower portion (33) in the second direction (b) by slipping due to a lubricant without a separate rotation means such as a roller.

[0088] The upper post (31) can change its position on the upper surface of the lower post (33) by means of a motor or the like that directly applies rotational force to wheels or the like that may be included on the lower surface. In addition, the upper post (31) can change its position on the upper surface of the lower post (33) by means of a pushing or pulling force caused by the rotation of a hydraulic or compressed air operating means or an external motor. The upper post (31) can be fixed to the lower post by means of a separate fixing means for stable operation after the position change. The separate fixing means can be a fastening bolt or pin.

[0089] The post (3) may include a clamp (35) for holding a member such as an assembly or a column of a modular structure on the upper part of the post (31). The post (3) may include one clamp, but may also include multiple clamps for holding multiple parts of the members, such as holding the upper and lower parts of the column simultaneously, or holding a column and a ceiling assembly or a wall assembly simultaneously. The clamp (35) may hold the member individually, but different clamps included in different posts (3) may push or pull the member located between them to stably fix it. In addition, the clamp (35) may support or support the member from below. The clamp (35) may hold or release the member or push or pull the member by a hydraulic or compressed air driven means. The clamp (35) can be positioned in a third direction (c) that is perpendicular to the vertical direction, i.e., the first direction (a) and the second direction (b) on the upper part of the post (31). That is, the clamp (35) may include a clamp LM guide (39), through which the height in the third direction (c) can be adjusted. Accordingly, by adjusting the height of the clamp (35) in response to the size of the modular structure in the third direction (c), i.e., various heights, the column, ceiling assembly, or wall assembly can be more stably held, pushed, or pulled. The clamp LM guide (39) can be operated by a hydraulic or compressed air driving means. In addition, the clamp (35) is formed to be detachable so that it can be directly fastened to various heights on the post (3) with a bolt or pin. Since the members of the modular structure can be supported more firmly through the free horizontal movement of the post (3) and the free vertical movement of the clamp (35), it absorbs deformation that may occur during the frame welding, enabling accurate manufacturing with the planned dimensions.

[0090]

[0091] FIG. 9 is a schematic drawing of a locator included in a 3D jig according to an embodiment of the present invention.

[0092] Referring to Fig. 9, the locator (5) may include a fixing pin (51) and a pin fixing block (53). As described above, the locator (5) may include a pedestal-shaped configuration that is placed on the base (1) without a separate fixing means instead of the pin fixing block (53). The locator (5) may be positioned and fixed on the upper part of the base (1) through the pin fixing block (53) or the pedestal. The fixing pin (51) is arranged on the upper part of the locator (5). A circular joining hole may be formed in the bottom part of the modular structure, that is, the bottom part of the floor assembly or the pillar, and when the modular structure is mounted on the upper part of the locator (5), the fixing pin (51) is settled into the joining hole, so that the bottom of the modular structure can be finally firmly fixed to the base (1). Since the size of the long or short sides of the modular structure varies and may be asymmetrical or missing, the locator (5) can be freely changed to any position on the base (1) so that the modular structure can be fixed on the base (1) in an optimal state.

[0093]

[0094] FIG. 10 is a schematic drawing illustrating an example of a part of a modular structure being gripped by a 3D jig according to an embodiment of the present invention.

[0095] Referring to Fig. 10, the modular structure in the shape of a rectangular parallelepiped as an example is configured as assemblies including six columns, seven floor beams, and seven ceiling beams. The joints of the floor beams and columns constituting the floor assemblies are supported by a locator (5) and firmly fixed to the base (1), and each column is gripped by a clamp (35) of a post (3) and firmly fixed. As a result of manufacturing the modular structure as an example using an actual 3D jig, it was confirmed that the manufacturing error was within 0.5 mm.

[0096]

[0097] FIG. 11 is a schematic drawing illustrating an example of a safety bar mounted on a post of a 3D jig according to an embodiment of the present invention.

[0098] Referring to Fig. 11, the safety bar (7a) may be configured to prevent access to the upper part of the working post (31) or to ensure the safety of a worker riding on the upper part of the post (31) during a change in position of the upper part of the post (31). The safety bar (7a) is illustrated as a fence-shaped safety bar, but may also be implemented as a safety bar in the form of a screen or net.

[0099]

[0100] FIG. 12 is a schematic drawing of a worktable of a 3D jig according to an embodiment of the present invention.

[0101] Referring to Fig. 12, the worktable (7) can be configured for the safety and convenience of the worker when performing work such as welding or joining of assemblies or members such as columns that are held or supported by the clamp (35). In particular, when performing work at heights such as welding or joining of ceiling assemblies and columns, the worker can safely and conveniently perform the work by boarding the worktable (7). For the easy and safe boarding of the worker, the worktable (7) can include stairs or a safety bar (7b). The position of the worktable (7) can be changed in response to the position of the post (3). That is, when the position of the post (3) is changed in the first direction (a), the position can be changed to perform work on the members held on the post (3). In addition, regardless of the change in the position of the post (3), when work needs to be performed on various parts of the members, the position of the worktable can also be changed to a position that facilitates work on the relevant parts. The position change of the worktable (7) can be applied by applying the method of changing the position of the post (3) on the base (1) through the first base rail (13a) or the second base rail (13b). In addition, the worktable (7) can be positioned independently of the base by leaving the upper surface of the base, and in this case, the position change of the worktable (7) can be made possible by using a moving means such as a wheel, roller, or rail on the bottom.

[0102]

[0103] As described above, according to embodiments of the present invention, a method for manufacturing a modular structure for construction is provided, which significantly improves productivity by manufacturing parts corresponding to a floor, a wall, a ceiling, and a pod in parallel in separate processes in the form of assemblies, and then assembling and finishing each assembly into a single completed body.

[0104] Embodiments of the present invention enable the production of modular structures of various specifications. Furthermore, by applying manufacturing methods to the 3D assembly process, which has been the greatest challenge in manufacturing modular structures in factories, production lines can be easily established. This allows for the production of modular structures with high precision while dramatically improving productivity.

[0105]

[0106] While specific embodiments of the present invention have been described so far, it is clear that various modifications are possible without departing from the scope of the present invention. Therefore, the scope of the present invention should not be limited to the described embodiments, but should be defined not only by the scope of the claims set forth below, but also by equivalents thereof.

[0107] Although the present invention has been described with reference to limited embodiments and drawings, it is not limited to the above-described embodiments. Those skilled in the art will appreciate that various modifications and variations are possible based on this disclosure. Therefore, the scope of the present invention should be understood solely by the scope of the claims set forth below, and all equivalent or equivalent modifications thereof are deemed to fall within the scope of the present invention.

Claims

1. In the method of manufacturing a modular structure for construction, A ceiling assembly manufacturing step (S11) including a plurality of ceiling beams and nodes, a ceiling steel frame and a ceiling stud panel forming a ceiling surface; A floor assembly manufacturing step (S12) including a plurality of floor beams and nodes, a floor steel frame and a floor stud panel forming a floor surface; A wall assembly manufacturing step (S13) including a long-side wall assembly forming a long-side wall and a short-side wall assembly forming a short-side wall; Step of making a pod that forms a bathroom (S14); An assembly assembly step (S2) including the ceiling assembly, floor assembly, wall assembly and pod; and A method for manufacturing a modular structure for construction, characterized by including a finishing step (S3) of sealing the joints on the outside of the modular structure with sealant, installing a partition wall, and installing interior and exterior finishing materials.

2. In paragraph 1, The above ceiling assembly manufacturing step (S11) is: A step (S111) of manufacturing the ceiling steel frame by connecting the plurality of ceiling beams and nodes; A step of installing the ceiling stud panel on one side of the ceiling steel frame (S112); Step (S113) of installing ceiling insulation on the upper surface of the installed ceiling stud panel; Step (S114) of installing a ceiling fireproof board on the upper surface of the installed ceiling insulation material; A step (S115) of installing MEP (Mechanical Electronic Plumbing) in the ceiling including mechanical equipment, electrical equipment or fire-fighting equipment on the upper surface of the installed ceiling fire-resistant board; Step (S116) of installing a computer bolt, a sill bolt or a hanger on the wing portion of the ceiling stud panel; and A method for manufacturing a modular structure for construction, characterized by comprising a step (S117) of installing a ceiling frame by combining lightweight steel M-bars, carrying channels, and channel clips to be mounted on the above-mentioned computer bolts, sill bolts, or hangers.

3. In paragraph 1, The above floor assembly manufacturing step (S12) is A step (S121) of manufacturing the floor steel frame by connecting the plurality of floor beams and nodes; A step of installing the floor stud panel on one side of the above floor steel frame (S122); Step (S123) of filling the interior of the installed floor stud panel with lightweight aerated concrete; and A method for manufacturing a modular structure for construction, characterized by including a step (S124) of installing a CRC board on the upper surface of the floor stud panel and the lightweight aerated concrete.

4. In paragraph 1, The above wall assembly manufacturing step (S13) is Step (S131) ​​of manufacturing the above-mentioned long wall assembly; and Including a step (S132) of manufacturing the above single-sided wall assembly; A method for manufacturing a modular structure for construction, characterized in that the long-side wall assembly and the short-side wall assembly include a wall stud panel, insulation, fire-resistant board, and window.

5. In paragraph 1, The above assembling step (S2) is: Step (S21) of installing the manufactured floor assembly; Step (S22) of installing the pod on the installed floor assembly; Step (S23) of installing a plurality of pillars on the above floor assembly; Step (S24) of installing the ceiling assembly on the top of the pod and pillar; Step (S25) of installing the wall assembly on the side of the pillar; and A method for manufacturing a modular structure for construction, characterized in that it includes a step (S26) of sealing a joint exposed to the outside of the modular structure with a sealant.

6. In paragraph 4, A step (S133) of welding a hollow window frame to the wall stud panel or connecting it with a direct screw or a direct screw, and installing the window by connecting it to the window frame; Step (S134) of installing a fire door including a pin hinge, flush ring, flush bolt or door closer; and A method for manufacturing a modular structure for construction, characterized in that it further comprises a step (S135) of installing an entrance door including a butt hinge, a door lock or a door stopper.

7. In paragraph 2, The above closing step (S3) is Ceiling construction step (S31) of installing remaining MEP and ceiling gypsum board on the inner ceiling of the above modular structure; An internal wall construction step (S32) of installing a partition wall inside the above modular structure; A wall finishing step (S33) using a wall finishing material inside the above modular structure; Ceiling finishing step (S34) using ceiling finishing material inside the above modular structure; A floor finishing step (S35) using a floor finishing material inside the above modular structure; and A method for manufacturing a modular structure for construction, characterized in that it includes an exterior finishing step (S36) of installing an exterior finishing material on the outside of the modular structure.

8. In paragraph 1, In the assembly assembly step (S2) including the ceiling assembly, floor assembly, wall assembly and pod, Using a 3D jig, the ceiling assembly, floor assembly, wall assembly and pod are firmly held and assembled to the target position, horizontality and verticality. The above 3D jig, A base including a first base rail and a second base rail aligned parallel to each other; and A method for manufacturing a modular structure for construction, characterized in that it comprises a post, which comprises one or more clamps for holding the ceiling assembly, the floor assembly, the wall assembly and the pod, and is positioned on the first base rail or the second base rail and is capable of changing its position on the first base rail or the second base rail.

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