Construction system for prefabricated houses with perimeter structural metal frame

Abstract

The present utility model relates to a detailed construction system with its components, steps, and construction method for prefabricated houses with a perimeter structural metal frame.

Description

Construction system for a prefabricated house with a perimeter structural metal frame. Field of Application

[0001] This application is intended for the field of civil construction, but may also benefit architecture and design professionals as it is a detailed construction model with its components, stages, and construction model for a prefabricated house with a perimeter structural metal frame. State of the Art

[0002] The construction industry has undergone a significant process of evolution throughout history. From ancient structures, such as the pyramids of Egypt and Greek temples, to modern constructions, such as skyscrapers and large bridges, engineering and the materials used have improved over time.

[0003] For many centuries, the construction industry primarily used masonry techniques, employing stones, bricks, and mortar to erect structures. However, with the advent of the Industrial Revolution in the 18th century, new technologies and materials emerged that revolutionized the construction industry.

[0004] The use of iron and, later, steel as the main structural material in buildings made it possible to create taller and more robust structures. The development of machinery and equipment also streamlined the construction process, increasing productivity and efficiency.

[0005] In the 20th century, with the advancement of construction techniques and the search for faster and more economical processes, prefabricated houses began to gain popularity. The manufacturing of components in a factory, with rigorous quality control, allowed for quick and precise assembly. Construction site. This approach significantly reduced execution time, in addition to offering the possibility of project customization.

[0006] Along with the emergence of prefabricated houses, another important advancement in civil construction was the development of self-compacting concrete. This type of concrete, also known as SCC, has a fluid consistency and spreads uniformly in complex molds and forms without the need for external vibration.

[0007] Self-compacting concrete is composed of a precise combination of materials, such as cement, fine aggregates, and superplasticizing additives. Its use has brought significant advantages, such as greater strength, durability, and the possibility of constructing more slender structural elements with bolder architectural forms.

[0008] Precast construction is defined according to the NBR 9052 standard in two ways: (a) precast, being the element that is manufactured off-site, produced under less stringent quality control conditions, without the need for personnel, laboratory and similar facilities, and (b) prefabricated, being the element produced off-site, in a plant or similar facilities that have permanent personnel and laboratory facilities for quality control.

[0009] Both prefabricated houses and the use of self-compacting concrete represent important advances in civil construction, allowing for greater efficiency, speed, and quality in construction projects. These technologies continue to evolve and be applied in projects around the world, contributing to the modernization and development of the construction industry.

[0010] The agile construction processes currently available on the market can be categorized into two distinct modalities: dry construction and prefabricated construction. Drywall is an English expression meaning "dry wall," that is, one that does not require the use of mortar for its construction. As with masonry, drywall partitions are constructed using a rigid structure composed of steel profiles, to which special gypsum boards are screwed. These boards are used to form walls, ceilings, and partitions in buildings. It is a fast and flexible method of construction, allowing for efficient customization of spaces. It is widely used in residential, commercial, and industrial buildings, providing a smooth appearance and high-quality finishes. The main characteristic of this system is its lightness and strength, which facilitates the quick and economical assembly of buildings.

[0011] Steel frame construction is widely used in medium and large-scale projects, such as commercial, industrial, and even residential buildings, due to its ability to support high loads and provide a high degree of design flexibility.

[0012] Skeletal systems consist of linear elements such as beams and columns of different shapes and sizes combined to form the skeleton of the structure. These systems are suitable for buildings that require high architectural flexibility. This is due to the possibility of using large spans and achieving open spaces without the interference of walls. They are important for industrial buildings, shopping centers, parking lots, sports centers, and also for large office buildings.

[0013] Prefabricated panels are used for internal and external enclosures, elevator shafts, central cores, etc. Prefabricated panel systems are widely used in residential construction and small commercial buildings. This solution can be considered an industrialized form of cast-in-place walls, conventional bricks, or masonry walls. The surface of the elements is smooth on both sides and ready to receive paint or wallpaper, being widely used in... Prefabrication allows for faster and more precise construction, as well as offering design flexibility and high durability.

[0014] Following this line of reasoning, document CN115748325A reveals a self-compacting concrete construction method for a precast metro track slab, comprising the following steps: construction of a base; assembly of the precast track slab: After the installation of the installation adjustment component is completed, the precast track slab undergoes an edge sealing treatment, and then an anti-swell component is installed on the precast track slab; self-compacting concrete.

[0015] Document CN216615463U reveals that the steel-concrete composite beam structure suitable for the placement of self-compacting concrete belongs to the technical field of bridge engineering, including I-shaped steel, precast concrete slab and two spare cavity bar pieces, I-shaped steel forms the lower end section of the precast concrete slab, symmetry of two vertically symmetrical spare cavity bars forms the upper left and right end sections of I-shaped steel, the vertical mounting hole having a plurality of uniformly distributed upper end sections of I-shaped steel and the corresponding position section of two spare cavity bar pieces, the interior of a plurality of mounting holes is all provided with vertical screw rods, the upper and lower ends of a plurality of screw rods extend to the outside of the mounting hole,The upper end of a plurality of screw rods, all with the fixed connection of the lower end of the corresponding cavity spare bar. The application effectively improves the bonding strength between the precast connecting piece and the precast concrete slab, and reliability is increased.

[0016] Document CN103790083A discloses a technology for constructing a self-compacting concrete fill layer for a ballastless slab-type track of a high-speed railway. The construction technology for the self-compacting concrete fill layer of the ballastless slab-type track of the high-speed railway comprises the steps in which control is exercised over the transport of the self-compacting concrete, control over the pouring of the self-compacting concrete, control over the maintenance of the self-compacting concrete, and control over key points of the tools used for the self-compacting concrete.

[0017] Document CN212053238U describes a utility model that provides a structure for horizontally connecting a precast column to a precast column or a precast wall, comprising a precast component, vertical steel bars, and concrete; the precast components are precast columns and precast walls; trapezoidal grooves are formed on the horizontal connecting side faces of the precast columns and precast walls, and horizontal closed steel cables are embedded in the trapezoidal grooves in a vertical direction; the precast column and the horizontal closed steel cable of the precast wall are arranged in a staggered and parallel manner when connected to form a vertical hole, and the vertical steel bar is placed in the vertical hole and connected with the horizontal closed steel cable to form a node structure.This structural design is reasonable, reducing formwork, and during the horizontal connection of prefabricated posts and prefabricated walls, vertical reinforcing bars are placed directly in the vertical hole, and the assembled position is reliable, firm in the connection, and the overall structure is good. The joint is constructed simultaneously, and the shotcrete is placed directly on the wall, resulting in a fast construction speed. The advantage is that the degree of automation is high.

[0018] Document CN205712498U presents a utility model that refers to a type of precast wall body and prefabricated post or drywall fixing structure and construction method. The composition of the fixing structure of the precast wall body and prefabricated post or drywall includes the prefabricated structural element being embedded with the U-shaped reinforcing bar of closed horizontal reinforcement, vertical reinforcement, and concrete. After the installation of the prefabricated structural element is in place, the U-shaped reinforcing bar of the closed horizontal reinforcement is formed by interlacing the different components. The vertical reinforcement is placed in a vertical hole. The U-shaped reinforcing bar of closed horizontal and vertical reinforcement forms the steel reinforcement structure of the node structure, the entire node being filled with concrete.The fastening structure provided by the technology has a reasonable design, does not require molding, does not require construction by laying bricks or stones, has a high degree of automation, and offers a fast application speed.

[0019] This technology falls within the scope of prefabricated housing construction systems and aims to benefit the civil construction industry, seeking to make it substantially more efficient, economically advantageous, and ecologically sustainable. Primarily directed towards the construction of prefabricated residences, the advantages of this system are notable, encompassing significant savings in both time and financial resources, improved construction quality, reduced environmental impact, and broad versatility in architectural design. These characteristics give it an undeniably attractive appeal for both the real estate market and the construction industry as a whole. Technology Description

[0020] The search for faster solutions to address the housing deficit through the rapid construction of homes, using conventional materials such as concrete and iron, instead of alternatives like wood, plaster, and cardboard, was one of the motivators for the creation and evolution of this technology.

[0021] The invention begins with the production of self-compacting concrete walls and slabs, which go through sequential stages, including concrete preparation, wall pouring, slab pouring, drying, finishing, transportation, and finally, assembly.

[0022] After the concrete is prepared, it is pumped into the pre-assembled metal wall form, with the electrical and plumbing systems in a horizontal position. Once the form is filled, the self-compacting concrete must be leveled. The drying process takes 14 hours. After complete drying, the wall is placed in a vertical position for painting and finishing. The finished wall is then transported to the storage area along with the remaining walls of the construction model, which have been previously numbered and identified.

[0023] After the assembly, concreting, and drying of the walls are complete, the slab assembly process begins. The slab assembly follows the same pattern as the wall assembly, fixing piece 1 together with piece 2 through piece 3. We then assemble the reinforcing mesh inside the formwork, and with the self-compacting concrete already prepared, we fill the formwork with it and level it. It then goes to the drying process, which lasts 14 hours. After complete drying, the slab can be stored, stacked in piles of a maximum of 4 slabs, previously numbered and identified.

[0024] With all the walls and slabs completed, they are transported to the construction site where assembly is carried out following a logical sequence pre-established by the architectural project, with the joining of the... walls and slabs are mechanically attached using a self-drilling screw, very similar to assembling wooden furniture.

[0025] The perimeter structural metal frame construction system represents a revolutionary approach in the civil construction industry, bringing a series of significant advantages compared to traditional construction methods. The main advantages we obtain by using our construction system are:

[0026] The walls and slabs are manufactured in a prepared factory, with equipment, materials, and personnel ready, eliminating the need for this on-site infrastructure. Cast-in-place construction depends on precise and appropriate concreting processes, which require experience and specialized skills to guarantee the adequate quality and strength of the structure.

[0027] The perimeter structural metal frame system offers several significant competitive advantages. One of the most notable is the ability to assemble precast structures in an impressively short period of 14 hours, compared to other traditional precast concrete-based systems. This represents a drastic reduction in wall fabrication time.

[0028] Another distinctive advantage lies in the ability of the perimeter structural metal frame to easily connect wall panels and slabs using self-drilling screws. This level of connection and flexibility is generally unattainable with conventional precast concrete, making the system more versatile and efficient in terms of assembly.

[0029] Furthermore, the solution provided by this perimeter structural metal frame system is known for its robustness and longevity. While dry systems often rely on panels to consolidate the structure, in this system, the panels are constructed with more durable materials, specifically self-compacting concrete. This results in a More solid and long-lasting construction, which is fundamental for the strength and quality of buildings.

[0030] Reducing material waste is one of the most notable benefits of manufacturing metal frame elements in a factory. This construction method allows for more precise planning and control of the materials used, thus minimizing resource waste. Controlled production in a factory environment ensures that the exact quantities of materials are used in the manufacture of each element, avoiding excesses and unnecessary waste, as well as in dry construction. This efficiency in materials management not only contributes to environmental sustainability by reducing the amount of waste, but also results in savings of financial resources, making the precast system an environmentally responsible and economically viable choice in civil construction.

[0031] The production of precast elements in factory facilities offers the construction industry a number of notable advantages, of which the reduction of material waste is just one facet. In addition to eliminating formwork, this manufacturing method allows for more efficient use of resources, with precise measurements and standardization, minimizing the need for adjustments and substantially reducing waste on the construction site. Rigorous quality control under controlled factory conditions also results in elements with fewer defects, avoiding costly disposal at the construction site. Additionally, planned production reduces excessive material inventories, contributes to operational efficiency and, consequently, saves time and resources. With less construction waste generated in the process, waste management is simplified, while simultaneously promoting more sustainable practices in the construction industry.

[0032] The reduction in dependence on skilled labor on the construction site, in contrast to dry construction and cast-in-place construction. Most of the complex tasks related to the fabrication of structural elements are carried out in factory environments, where the use of specialized machinery and equipment plays a fundamental role. This results in a considerably lower need for specific skills on the construction site, since the assembly and installation of precast components are more direct and simplified procedures. This reduction in the demand for highly specialized labor not only optimizes labor costs but also accelerates construction progress, making the precast perimeter structural metal frame system an efficient and economical choice for projects of various types and sizes.

[0033] The speed of assembly in the perimeter structural metal frame system is largely attributed to the prefabricated walls and slabs that arrive at the construction site ready and finished. These walls and slabs are manufactured under controlled factory conditions, allowing for precise and efficient execution of all construction details, including finishes. As a result, when these elements are transported and assembled on-site, there is a time saving compared to traditional construction, where each step, from molding to finishing, is carried out in situ.

[0034] The perimeter structural metal frame system is notable for its ease of implementation, largely due to the mountable and dismountable nature of the metal frames used. Frame assembly is simplified, making them ready for use quickly and efficiently. Furthermore, transporting these elements is relatively simple, further speeding up the construction process. The ability to quickly start production of prefabricated walls is a valuable feature of this system, as it considerably reduces the time required to start and complete a construction project.

[0035] The inclusion of openings, such as windows and doors, during the concreting process is one of the advantageous features of the perimeter structural metal frame system. This prefabrication of openings within the wall structure itself significantly simplifies the assembly of the house. By creating precisely dimensioned openings during fabrication, the need for on-site cuts or adaptations is eliminated, saving time and reducing the complexity of the work on the construction site. This perimeter structural metal frame approach provides greater construction efficiency and contributes to the speed and precision in assembling the structures.

[0036] The use of self-compacting concrete in conjunction with metal frames gives the system greater lightness compared to in-situ precast construction approaches. This high-fluidity concrete allows for a reduction in the amount of material needed to achieve the desired structural strength, resulting in elements that are 50% lighter.

[0037] The assembly of precast structures is a strategically planned process. This assembly procedure is conducted carefully, considering factors such as alignment, leveling, and structural integrity, thus ensuring aligned walls and slabs that are easy to finish. This step is best placed during the construction of the walls and slabs, not during assembly.

[0038] The process begins with the creation of metal molds in the metalworking plant through the cutting and bending of galvanized metal sheets; the finished mold pieces then proceed to assembly.

[0039] To begin, separate the sides (1) and (2) to start the assembly, as shown in Figure 1. Two pieces (1) and two pieces (2) will be used, as can be seen in Figure 2. With the sides aligned (1) and (2), then fix the pieces (3) in all corners, thus joining the four parts. 4 parts (3) are needed for assembly, as shown in Figure 3.

[0040] For the internal metal structure, the internal structural reinforcement parts are assembled (Figure 5) and the possible internal electrical and hydraulic structures are assembled, according to the project, the parts that constitute the electrical and hydraulic systems of the walls following the project, as in this wall (Figure 6).

[0041] To assemble the slabs, it is necessary to separate the sides (1) and (2) to begin assembly, as shown in Figure 1, where two pieces (1) and two pieces (2) will be used, as can be seen in Figure 2. With the sides aligned (1) and (2), the pieces (3) are then fixed in all corners, thus joining the four parts, requiring 4 pieces (3) for assembly, as shown in Figure 3.

[0042] For the internal metal structure, the internal structural reinforcement parts are assembled (Figure 10); no electrical or hydraulic infrastructure is required in the slabs.

[0043] Concrete is a pre-mixed concrete blend containing a specific mixture of cement, aggregates (such as sand and crushed stone), water, and superplasticizing additives. The exact proportions and quality of the materials are crucial to ensure the desired strength. The aggregate sizes vary according to the final project objective; they can range from 280 kg / m³ to cement. 3at 400 kg / m 3 , water 280 Kg / m 3 at 360 kg / m 3 , sand between 400 kg / m³ 3 at 1200 kg / m 3 , polypropylene fiber and additives for self-compacting concrete, having a density of 700 to 1700 kg / m³ 3 always based on density varying between 800Kg / m³ 3 at 1600Kg / m 3 This concrete is supplied by equipment suitable for the preparation of self-compacting concrete.

[0044] The concrete is poured into the precast form in a controlled and uniform manner; the concrete must be protected from rapid and excessive drying. To allow for proper curing. After 14 hours of drying, the wall is ready to be erected using the metal frame that is incorporated into the self-compacting concrete.

[0045] After drying, it is essential to inspect the piece to ensure that it meets the quality and strength specifications of the project.

[0046] To finish, the wall is inspected for cracks, holes, or imperfections, and joint compound is used to level the damaged area. Then, the entire surface is sanded to remove residue and provide a uniform base.

[0047] Next, a short or medium nap paint roller is used to apply the paint to the wall, starting from top to bottom, in vertical movements, covering an area of ​​approximately 1 square meter at a time, applying the paint evenly and avoiding excess paint that could cause drips.

[0048] After waiting the drying time recommended by the paint manufacturer, the second coat is applied. This second coat will help to achieve a more consistent and uniform finish.

[0049] After the walls are ready, a container or support is used to position the walls vertically without them touching each other. Before assembling the prefabricated house, it is necessary to prepare the land where it will be built, which may include cleaning, leveling, and compacting the soil.

[0050] Next, the foundations are laid (Figure 7), which may vary depending on the type of prefabricated house, and can be made of concrete or another material, serving to support the house's structure. With the parts in place, the assembly of the prefabricated house begins. The parts are screwed together according to the house's design (Figure 8).

[0051] With the walls assembled (Figure 7), the slabs are transported from the stock to the construction site; this transport must be done with a The slabs are stacked horizontally on a platform using a Munck truck, in a maximum of 4 layers. They are hoisted using the internal reinforcement (Figure 9) and placed on the walls and fixed with self-drilling screws (Figure 11).

[0052] After the parts are assembled, the interior and exterior of the house are finished. This finishing may include wall coverings, electrical installation, plumbing, painting, and more. Designs

[0053] Figure 1 shows the sides (1) and (2).

[0054] Figure 2 shows the assembly of the two parts (1) and two parts (2).

[0055] Figure 3 shows the result of assembling part (3) with sides (1) and (2).

[0056] Figure 4 shows the side fastening piece (3).

[0057] Figure 5 shows the internal structural reinforcement parts (4).

[0058] Figure 6 shows the internal structural reinforcement parts (4) and assembly of possible internal electrical and hydraulic structures, assembled according to the project.

[0059] Figure 7 shows walls on the slab, where (7) slab, (1) piece applied to the self-compacting concrete wall, (2) piece applied to the concrete wall, (8) self-drilling screw in the metal frame.

[0060] Figure 8 shows the fitting fixed by means of self-drilling screws (8), part (1) applied to the self-compacting concrete wall and self-drilling screw (8).

[0061] Figure 9 shows the finished slab, assembled with two pieces (1) and two pieces (2) and two lifting handles (9).

[0062] Figure 10 shows the perimeter structure of the assembled slab (with two pieces (1) and two pieces (2)) together with the reinforcement (4), with the two lifting handles (9).

[0063] Figure 11 shows the walls assembled under the slab (7) and the closure with the top slab, fixed with self-drilling screws (8).

Claims

MODIFIED CLAIMS Received by the International Secretariat on September 17, 2025 (17.09.2025) 1- CONSTRUCTION SYSTEM FOR PREFABRICATED HOUSE WITH PERIMETER STRUCTURAL METAL FRAME, said perimeter structural metal frame consisting of two horizontal side pieces (1) and two vertical side pieces (2) fixed together, and provided with an internal metal structure, characterized by the fact that the horizontal side pieces (1) and the vertical side pieces (2) are fixed together by a piece (3) at all internal corners of the perimeter structural metal frame, the fixing of walls and slabs to the perimeter structural metal frame being done by means of self-drilling screws (8), and it has two lifting handles (9), said perimeter structural metal frame using self-compacting concrete containing the following composition: cement between 280 Kg / m³ 3 at 400 kg / m 3 ; water between 280 kg / m³ 3at 360 kg / m 3 , sand between 400 kg / m³ 3 at 1200 kg / m 3 , and polypropylene fiber and additives to self-compact concrete, having a density of 700 to 1700 kg / m². 2- CONSTRUCTION SYSTEM FOR A PREFABRICATED HOUSE WITH A PERIMETER STRUCTURAL METAL FRAME, according to claim 1, characterized by the internal metal structure being able to contain the electrical and hydraulic structures in the walls. 3- CONSTRUCTION SYSTEM FOR A PREFABRICATED HOUSE WITH A PERIMETER STRUCTURAL METAL FRAME, according to claim 1, characterized by the self-compacting concrete containing gravel at a density of 200 kg / m³. 3 and 400 kg / m 3 . 4- CONSTRUCTION SYSTEM FOR A PREFABRICATED HOUSE WITH A PERIMETER STRUCTURAL METAL FRAME, according to claim 1, characterized by the self-compacting concrete containing superplasticizer, accelerators, water reducers and air-entraining agents. 5- CONSTRUCTION SYSTEM FOR A PREFABRICATED HOUSE WITH A PERIMETER STRUCTURAL METAL FRAME, according to any one of claims 1 to 4, characterized by the self-compacting concrete being poured into the structural metal frame with complete filling in a single step and uniformly, and after compaction, the concrete must be protected from rapid and excessive drying in a closed, dry and moisture-free environment, requiring between 10 and 14 hours of drying.

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