Method of construction of buildings or cellular fabrications from concrete by using automatic assembled and disassembled metallic cells

Abstract

Construction System for concrete buildings or concrete cellular fabrications by combining Metallic Cells that are assembled and disassembled automatically allowing the formation of the required openings for doors and windows as well as the fixing of electrical and plumbing installations. The system produces building fabrications of high quality, reduced time, low cost and low maintenance requirements. It is highly earthquake resistant, requires minimum personnel with minimum specialization and offers high protection against terroristic actions or war attacks. Minimizes the number of required construction materials. The system does not require fabrication installations and special equipment. Also, it does not requires specialized workers or technicians neither transportation and assembly of heavy pieces

Description

[0001] DESCRIPTION

[0002] Method of construction of buildings or cellular fabrications from concrete by using automatic assembled and disassembled Metallic Cells

[0003] The invention is a construction system that creates rooms that in combination make apartments, houses or other types of buildings. Also, it can be used for any cellular concrete construction.

[0004] The present invention offers a building construction method that is fast and results in excellent quality.

[0005] The present invention refers to a new construction methodology that is fast, with low cost, resistance in physical phenomena, high quality, and design flexibility.

[0006] The existing construction methods today are the following:

[0007] 1. The conventional construction method is on site with construction teams that perform miscellaneous works such as excavations, concreting, walls building, electrical installations, plumbing, plastering, door and window frames, floors, painting etc. This method is costly since it requires many manhours, and a lot of varied materials that sometimes do not much and which the need a lot of maintenance in the future.

[0008] 2, Method with precast units from reinforced concrete,

[0009] 2.1 Method of precast reinforced concrete panels from a factory without embedded facility networks.

[0010] 2.2 Method of precast in a factory modules / box from reinforced concrete.

[0011] The above 2.1 and 2,2 methods present the following technical and economical disadvantages.

[0012] 1. For the connection of the precast elements many different methods are used but all of them present cracks in the connection area since this area is weak and especially in the case of thermal deformatfens (expansion and contraction) and physical phenomena (earthquakes, high winds).

[0013] 2. The precast elements (PANELS or MODULES) are very heavy and dimension restrictions due to the need for transportation using the roads network.

[0014] 3. Due to the heavy weight of the elements they require, for handling and fixing on site and in the factory, cranes with remarkably high lifting capacity that are too costly,

[0015] 4. Because of the many and different pieces, a lot of coordination are required for the fabrication, transportation, and assembly of the elements;

[0016] 5. During the transportation and the assembly many damages happened. 6. The completion of the electrical and plumbing installations requires extra effort.

[0017] 7. They require a high-cost investment for the establishment and operation of the precast elements factory in a tolerable distance. Usually, the precast elements factories have low occupancy rate and high operation cost that results in high depreciation cost which increases the products cost disproportionally.

[0018] The proposed method also covers disadvantages of the conventional construction method that are:

[0019] 1. The need for a lot of personnel of many different specialties.

[0020] 2. Difficult control of the performed works.

[0021] 3. The existence of connection joints.

[0022] 4. The long construction time.

[0023] 5. The need for many and different construction materials.

[0024] 6. The requirement for important maintenance.

[0025] 7. The limited endurance to earthquakes.

[0026] 8. The limited endurance to terrorist actions.

[0027] 9. The limited endurance to War actions.

[0028] 10. The restricted capacity to sound insulation.

[0029] The proposed NEW method 2,3 brings the technoeconomic revolution to the building construction by replacing the existing precast methods, eliminating their basic weaknesses, lowering the cost, shortening the construction time, offering high quality, flexibility, and architectural standards for the industrial fabrication of certain building parts.

[0030] With the proposed invention the above-mentioned disadvantages are eliminated.

[0031] The construction is created using automatically assembled cell-formwork that form the individual rooms o r spaces of the building.

[0032] 1. The construction is done on the site in its final position.

[0033] 2. The concrete wails that are constructed with this system are also the structural elements of the building.

[0034] 3. The weight of the cell-formwork is small and so no big cranes are required,

[0035] 4. The required openings (doors, windows, arcs etc.) are created with high accuracy using frames that are bolted on the cell-formwork panels,

[0036] 5. Due to the high accuracy of creation of the openings it becomes possible the preordering and prefabrication of the doorframes and the window frames in the factory which means money and time economy.

[0037] 6. The surface of the wails that is produced with the steel panels does not requires any additional work, it is ready for painting, and it will not present problems in the future the way plaster is (swelling etc.)

[0038] 7. The construction is without joints (monobloc).

[0039] 8. It is extremely resistant to earthquakes. 9. it is exceptionally strong against terrorist actions as well as war situations.

[0040] 10. It reduces the number of materials that are required for the construction.

[0041] 11. It has increased sound insulation,

[0042] 12. The network for electrical installations, the boxes for the electrical switches and outlets and the junction boxes are all embedded in the concrete walls and their installation is done by the workers that manage the cell-formwork reducing in this way the manhours required by specialized workers (electricians).

[0043] 13. The building plan changes by changing the combination of placing of the cefl- formwork in the plan,

[0044] 14. In the case of multi-story buildings, the extension upwards is achieved by leaving reinforcement starter bars in the previous level.

[0045] 15. The reinforcement steel cages are prefabricated already and are positioned by the workers that handle the cell-formwork.

[0046] 16. With the cell-formwork we avoid in situ measuring and marking eliminating the possibility of mistakes,

[0047] Below we describe in detail the Invention based on an example of a house construction and referring to drawings.

[0048] The basic element of the method is the automatically assembled and disassembled cell- formwork.

[0049] The cell-formwork is of orthogonal shape, and it corresponds to a room or to a building space.

[0050] In drawing 1 the whole celi-formwork is shown while in drawing 2 the cell-formwork is shown with only two panels so that the internal details are shown.

[0051] The cell-formwork consists of the following parts:

[0052] 1. Rigid support frame (1.1, 3.1) that has special points (pad eyes) for the connection to the panels through the double articulation blades (3.2), The rigid support frame is shown in drawing 3.

[0053] The rigid support frame is designed in such a way so that undertakes: all the forces that are created during the use of the cell-formwork.

[0054] Also guaranties that the panels will be placed in the correct position creating in this way a space with exact dimentions and eliminating the posiibility of measuring or marking mistakes.

[0055] The top part of the rigid support frame (3.3) can also be used as a working platform for the concrete pouring after placing the proper working floor (wooden boards) .

[0056] 2. Panels for the formation of the surfaces of the walls (4.1). The Panels are shown in drawing 4.

[0057] The Panels have special points (pad eyes) (4.2) for their connection to the the rigid support frame through the double articulation blades. These points correspond to those of the rigid support frame . The Panell ends are shaped in a special way so that they permit the movement towards the inside of the Cell-formwork, without hitting each other, during the contraction of the cell in order to be stripped from the concrete (43) This Special shaping is shown in drawing 5 (cell-formwork ready for concreting) and in drawing 6 (cell-formwork contracted for stripping).

[0058] 3. Double articulation system (7,1)through which the panels are connected to the rigid support frame. The double articulations; are shown in drawing 7 (Cell- formwork in position for concreting) and in drawing 8 (Cell-formwork contracted during stripping). Also in drawing 9 it is shown more in detail the gap (9.1) that is created during the contraction of the cell-formwork making so possible the stripping from the concrete.

[0059] The cell-formwork operates as described below:

[0060] During the procedure for placing of the cell-formwork to the concreting position the cell- formwork is hanging from the rigid support frame is lowered to the floor of the construction. The panels are hanging from the rigid support frame through the double articulation blades. When the panels touch the floor of the construction then the rigid support frame is still in the air and tend to move downwards so that it will touch the construction floor too. The weight of the cell-formwork W creates the force F in the direction of the double articulation blades. This force F can be analysed to two components, the vertical that it is equal to the weight and a horizontal H that pushes the panels outwards to their final position, making the double articulation blades horizontal and allowing the rigid support frame to touch the construction floor too. These forces are shown in drawing 10.

[0061] In this final position due to the fact that the double articulation blades and the rigid support frame have the proper dimentions, the panels are guided to the correct position and so the correct dimentlons of the room or space is quarantied (Drawings 11 and 14).

[0062] During the stripping procedure the lifting force W is apptied.This Force creates a moment around the the horizontal that passes through point A (drawing 12).

[0063] Due to this moment the double articulation blades rotate and the force F, in the blade's direction, is created.

[0064] The force F has two components , the W that it is equal to the weight and the horizontal H which is pulling the panels inwards, it detach them from the concrete and creates the necessary gap for the removal of the cell-formwork.

[0065] The specia l formation of the panel ends permit the inwards movement and the cell- formwork contraction.

[0066] The abovementioned forces are shown in drawing 13.

[0067] An example of construction of using the automatic assembled and disassembled cell- formwork is described below. The example refers to the construction of a house with 2 bedrooms, hall, bathroom, sitting room and kitchen.

[0068] The plan of the house is shown in drawing 15. in the beginning the foundation slab is constructed. In this we embed whatever network is required. (Drawing 15).

[0069] After that we place the first cell-formwork on which we fix the frame for the window opening (drawing 16, detail A).

[0070] We fix the reiforcement cages (detail C) and the frame for the creation of the door opening (detail B) (drawing 17) .

[0071] We fix also the junction boxes for the electrical installations (detail D) and the ducts for the cables (detail E) (drawing 18),

[0072] After the cell-formwork is in position we fix the junction boxes in the pre-defined positions) these junction boxes have already attached the necessary ducts for the passing of the cables later

[0073] Also, we fex all the frames for the creation of the miscellaneous openings (doors, windows, light openings, holes for air conditioning etc.) On the frames we can also preposition embedded parts of the doors or windows such as their metallic frames that are in this way filled with concrete.

[0074] The placing of the prefabricated steel reinforcement cages follows with attached the necessary spacers for the concrete protection cover of them.

[0075] Next we place the second cell-formwork and the corresponding works of steel reinforcement, frames for openings, electrical network junction boxes and ducts are carried out (drawings 19 and 20).

[0076] Follows the placing of the third cell-formwork (drawing 21), the fourth cell-formwork (drawing 22), the fifth cell-formwork (drawing 23) and the sixth cell-formwork (drawings 24 and 25).

[0077] After that we place the external panels (drawings 26 and 27) and we pour the concrete.

[0078] The panels are tied with special ties to withstand the concrete pressure.

[0079] The next day we remove the cell-formworks and the external panels and we have the construction as shown in drawings 28 and 29.

[0080] To do this we remove the concrete ties that hold the panels, and we unbolt the opening frames, and the supports of the junction boxes from the panels. The roof slab formwork is very easy since there not beams and the support is already prepared in dimentions from the first use. Prefabricated slabs can be also used instead.

[0081] If we want to construct more levels we follow the same procedure using the roof slab of the lower level as floor slab of the upper.

[0082] If it Is require to have the room corners at right angle and not samfered then we can use with the cell-formwork the special pieces (drawing 30).

Claims

CLAIMS1, Metallic Cell that it is automatically assembled and disassembled creating a completespace and which accepts onframes for the formation or openings tor doors, windows etc. as well as permit the fixing of the electrical installation boxes for plugs, switches, junction boxes etc.The Metallic Cell consists of a Metallic Frame (1.1), which is used also as a working platform for the pouring of the concrete, and Panels (1.2) which act as formwork for the walls.The Metallic Ceil combined with the adjacent Cell or External Panels creates the space for the casing (formwork) for the concrete to be poured.The panels of the cell are connected to the Metallic Frame with double articulations (1.4). The panel ends have a special formation (1.3) such as not to create problems during the inward movement of the panels happening during the retraction of the cell. The Metallic Frame (1.1), when lifted, creates fortes that detach the panels from the concrete while during lowering creates forces that move the panels to the final position for concreting. If it is not desirable to have the corners chamfered, then we use the special pieces (1.5).

2. Metallic Cell, according Claim 1 , characterized by the forming of the panel ends with slope and overlapping (1.3) such as it is possible the inward movement of the panels during retraction and they are not hit on each other.

3. Metallic Cell, according to Claim 1, characterized by the operation of the double articulations (1,4) , that moving upwards or downwards create the forces for stripping or assembly of the formwork.

4. Metallic Ceil, according to Claim 1, characterized by the connection of the Metallic panels (1.2) through the double articulations (1.4) to the Metallic Frame (1.1) that undertakes the loads created during the procedure of stripping and assembly, guarantees the correct geometry of the space formed by the cell and it is used as a working platform during concreting,5. Metallic Cell, according to Claim 1, that can be disassembled for transportation reasons or for using its parts to assemble other ceils. The disassembly is done by removing the bolts that connect, through the double articulation blades, the pad eyes of the panels with those of the Metallic Frame.

6. Metallic Cell, according to Claim 1, that it is combined with the special pieces (1.5) for the shaping of the corners at right angles, in case it is not preferred these corners to be chamfered.

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