Method for manufacturing dwellings with an incorporated roof

Abstract

The present invention relates to a method for manufacturing dwellings with an incorporated roof, said method comprising the construction of concrete parts in the factory, said parts being made up of an inner panel (11, 21, 31) of a floor (1), side walls (2) and a roof (3) of the dwelling (100); the fastening thereof by configuring a prismatic block; the application of a layer of insulating material (22) on the outer face of the side walls (2); the definition of pitches with a layer of insulating material (32) of varying thickness in the inner panel (31) of the roof (3); the pouring of a continuous outer layer (5) of concrete on the outer face of the floor (1), the side walls (2) and the roof (3), so that the roof (3) maintains the inclination of the pitches defined by the layer of insulating material (22); and the application of a layer of waterproofing product.

Description

[0001] DESCRIPTION

[0002] Manufacturing process for homes with built-in roofs

[0003] Technical sector

[0004] The present invention relates to a method for manufacturing homes with built-in roofs, applicable in the construction sector and which has characteristics aimed at incorporating the factory construction of a waterproof roof, which avoids the installation of auxiliary and waterproofing elements on said roof once the construction of the home has been completed.

[0005] State of the art

[0006] The state-of-the-art document closest to this application is the invention patent ES 2 350 336 B2, referring to a manufacturing process for compact modules for construction.

[0007] The patent aims to achieve prismatic modules with 100% monolithicity, which do not require rigid attachment to the ground and eliminate all vibration or expansion, preventing the appearance of cracks and moisture; all at surprisingly low costs and fully industrializable.

[0008] The manufacturing process for compact modules for construction, the subject of the aforementioned background, includes the following operational phases: factory manufacture of an interior permanent formwork based on at least six pieces, constituting a lower base, an upper base and four side walls; assembly of the constituent pieces of said permanent formwork, configuring a rectangular prismatic block, in which the various pieces are fixed together using high-strength mastics, resting said prismatic block directly on the ground or on a horizontal platform by means of spacer supports existing on the lower face of the lower base piece; placement on the external face of this interior permanent formwork of the necessary electricity, telephone, sanitation, hot water or other installations;Placement or projection of insulation material onto the exterior of the previous set, on those exterior walls that require it; placement of a properly calculated enclosing reinforcement on the exterior of the interior and lost formwork;

[0009] - arrangement of an exterior formwork structured by four pieces, each of which overlaps at one of its ends with the adjacent piece, such that its distance from the interior formwork is adjustable at will, resting these pieces of the exterior and recoverable formwork on the ground or on the horizontal platform established thereon, and substantially protruding from said interior formwork and lost by its upper edge;

[0010] - filling the defined perimeter space between both formworks with fluid concrete, which also fills the space defined between the inner formwork and the floor, as well as the area above said inner formwork, to form an upper slab; and

[0011] - after the concrete has set, the outer formwork has been removed and recovered.

[0012] This procedure involves the construction of a roof module that does not have the roof treatment, as it does not incorporate insulation, nor is it waterproofed or sloped for water drainage. Therefore, it does not include a solution for incorporating a roof into the construction process; a series of roofing components must be prefabricated separately and placed on top of the modules once they are installed.

[0013] These pieces must be positioned to form the roof's slopes and then waterproofed to ensure their tightness. This entails associated costs, both in the manufacturing of these pieces (labor and materials) and in their transportation and subsequent installation (auxiliary transport costs, assembly labor, and crane hours). Added to these costs is the risk associated with working on-site, with less controlled procedures than those found in an industrial setting, as well as the risks associated with rain and the possibility of the home being exposed to the elements without being completely waterproofed. Explanation of the invention

[0014] The present invention relates to a manufacturing process for homes with an incorporated roof, one of whose objectives is to improve the manufacturing process of the aforementioned precedent, incorporating features that entail substantial improvements in the quality of the final product, particularly with regard to the generation of a waterproof roof and its manufacturing process, to avoid having to manufacture said auxiliary parts or elements separately, arrange them on the roof and waterproof them on site once the modules that make up the home have been assembled.

[0015] The manufacturing process of homes with built-in roofs of the invention is of the type described in the preamble to the main claim and comprises: the factory construction of concrete pieces, forming an interior floor slab, side walls provided with openings for enclosures and a roof for the home; the fixing of said interior slabs using high-strength putty, forming a prismatic block; and the application of a layer of insulating material to the external face of the interior slab of the side walls and the installation of various services, such as electricity, telephone, sanitation, hot water or others.

[0016] According to the invention, this method comprises defining, in the factory, on the upper face of the inner concrete slab of the roof, slopes oriented towards a central area of ​​the roof, by applying on said upper face a layer of insulating material, of variable thickness and decreasing towards said central area; the incorporation into said layer of insulating material of the roof of a drain pipe provided with openings in the central area of ​​the roof and extending towards the lower area through the interior of the insulating material of the side walls.

[0017] This eliminates gutters and exterior downspouts, and, above all, by moving toward the center, prevents water from accumulating or seeping through any gaps in the roof and spoiling the home's exterior appearance.

[0018] An exterior formwork is then placed, and a layer of concrete of substantially uniform thickness is poured onto the outer face of the interior floor slab, over the insulating material layer of the roof and side walls. The interior floor slab is raised on support elements so that the outer layer of concrete encloses the floor, side walls, and roof, forming a monolithic module. The roof maintains the inclination of the slopes defined by the layer of insulating material.

[0019] Finally, a layer of waterproofing product is applied to the outer layer of concrete. In this case, this layer of waterproofing product will be applied within the factory itself, ensuring that the module is completely prepared and watertight for installation on site.

[0020] If the roof of the module or dwelling is walkable, the materials chosen by the client in each case will be installed in the factory.

[0021] To withstand the overload, the reinforcement and the thickness of the concrete layers will be sized according to calculations, creating a roof that rests on the components of the home's walls and does not require pillars, beams, or other similar support elements. All this is achieved in the manufacturing process itself, with the insulation slopes and the pouring of the outer layer of concrete over the entire exterior surface of the home, which is concreted at the same time, thus avoiding joints with different setting times.

[0022] The necessary roof reinforcements are embedded in the module wall, anchoring and overlapping the reinforcements accordingly, as indicated in the calculations, thus achieving a powerful, factory-finished roof.

[0023] Brief description of the content of the drawings

[0024] To complement the description being made and in order to facilitate the understanding of the characteristics of the invention, a set of drawings is attached to this specification in which, for illustrative and non-limiting purposes, the following has been represented:

[0025] - Figure 1 shows a plan view of a dwelling with an integrated roof manufactured using the method of the invention. - Figures 2, 3 and 4 show longitudinal sections along a vertical plane of the dwelling with an integrated roof of Figure 1 in successive stages of manufacture.

[0026] Figure 5 shows a partial view of an upper area of ​​the house in Figure 1, sectioned crosswise by a vertical plane, in which two of the inclined planes of the roof can be seen.

[0027] - Figure 6 shows a sectioned detail of a vahante embodiment of the side walls of the invention, incorporating an air chamber between the layer of insulating material and the outer layer of concrete.

[0028] Detailed exposition of embodiments of the invention

[0029] Figure 1 shows a top plan view of a house (100) manufactured according to the method of the present invention, incorporating a roof (3) with slopes towards the central area of ​​the same.

[0030] As shown schematically in figures 2, 3 and 4, this procedure initially comprises the construction in the factory of some concrete pieces forming respectively an interior plate (11, 21, 31) of a floor (1), of some side walls (2) provided with some openings (20) for enclosures, and of a roof (3) of the house.

[0031] As shown in Figure 2, the procedure comprises fixing said interior plates (11, 21, 31) using high-strength putty, forming a prismatic block.

[0032] Subsequently, as shown in figure 3, a layer of insulating material (22) is applied to the outer face of the inner plate (21) of the side walls (2) and the installation of various services, such as electricity, telephone, sanitation, sanitary water or others; and the definition on the upper face of the inner plate (31) of the cover (3) of slopes oriented towards a central area of ​​said cover.

[0033] The definition of said slopes is carried out by applying on said upper face of the inner layer (31) of the cover a layer of insulating material (32) of variable thickness that decreases towards said central area of ​​the cover (3); also incorporating into said layer of insulating material (32) a drain pipe (4), provided with access openings arranged in the central area of ​​the cover (3), which extends towards the lower area through the interior of the insulating material (22) of the side walls (3).

[0034] Then, as shown in figure 4, an external formwork (not shown) is placed and a continuous outer layer (5) of concrete of substantially uniform thickness is poured onto the layers of insulating material (22, 32) of the roof (3) and the side walls (2) and onto the outer face of the inner plate (11) of the floor (1), keeping the inner plate (11) of the floor (1) elevated on support elements, so that said outer layer (5) of concrete externally envelops the floor (1), the side walls (2) and the roof (3) forming a monolithic module; and that the roof (3) maintains the inclination of the slopes defined therein by the layer of insulating material (22).

[0035] Finally, a layer of waterproofing product (not shown) is applied to the outer layer (5) of concrete.

[0036] In the cross section of figure 5, two of the slopes defined by the cover (3) towards its central area can be seen.

[0037] This invention comprises an embodiment variant, shown in Figure 6, of the construction of the side walls and, if necessary, of the roof, consisting of the incorporation of an air chamber (23) between the layer of insulating material (22) and the outer layer (5) of concrete. In this embodiment, said air chamber (23) is defined by a cellular polycarbonate panel arranged on the outer face of the layer of insulating material (22) before pouring the concrete forming the outer layer (5) of concrete of the dwelling.

[0038] This polycarbonate panel for defining the air chamber (23) provides the necessary resistance to prevent the collapse of the air chamber due to the pressure applied to it by the pouring of concrete, forming the outer layer of concrete (5) of the house, between said panel and the outer formwork.

[0039] Once the nature of the invention has been sufficiently described, as well as a preferred embodiment example, it is stated for the appropriate purposes that the materials, shape, size and arrangement of the elements described may be modified, provided that this does not imply an alteration of the essential characteristics of the invention claimed below.

Claims

CLAIMS 1. Method for manufacturing homes with built-in roofs; comprising: the factory construction of concrete pieces, respectively forming an interior slab (11, 21, 31) of a floor (1), side walls (2) provided with openings (20) for enclosures, and a roof (3) of the home (100); the fixing of said interior slabs (11, 21, 31) by means of high-strength putty, forming a prismatic block; and the application on the external face of the interior slab (21) of the side walls (2) of a layer of insulating material (22) and the installation of various services, such as electricity, telephone, sanitation, hot water, or others; characterized in that it comprises: - the definition in the factory, on the inner plate (31) of the cover (3), of slopes oriented towards a central area of ​​said cover (3), by applying on said inner plate (31) a layer of insulating material (32) of variable thickness and decreasing towards said central area; - the incorporation into said layer of insulating material (32) of the cover (3) of a drain pipe (4) provided with openings in the central area of ​​the cover and which extends towards the lower area of ​​the house through the interior of the insulating material (22) of the side walls (2); - the placement of an external formwork and the pouring onto the layers of insulating material (22, 32) of the side walls (2) and the roof (3), and onto the external face of the inner slab (11 ) of the floor (1 ) of a continuous outer layer (5) of concrete; keeping the inner slab (11 ) of the floor (1 ) elevated on support elements, so that said outer layer (5) of concrete externally envelops the floor (1 ), the side walls (2) and the roof (3) forming a monolithic module; and that the roof (3) maintains the inclination of the slopes defined therein by the layer of insulating material (22); and - the application of a layer of waterproofing product on the outer layer (5) of concrete.

2. Manufacturing method according to claim 1, wherein the manufacturing of at least the side walls (2) comprises the incorporation of an air chamber (23) between the layer of insulating material (22) and the outer layer (5) of concrete.

3. Manufacturing method according to claim 2, wherein the air chamber (23) is defined by a cellular polycarbonate panel arranged on the outer face of the layer of insulating material (22), before pouring the outer layer (5) of concrete.

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