Monolithic modular concrete system manufactured off-site for multifamily vertical buildings

Abstract

The invention relates to a monolithic modular concrete system manufactured off-site for multifamily vertical buildings constructed using concrete modules entirely manufactured in a factory environment. Forms are first produced (Figure 01) which then receive steel reinforcements (Figure 02) and self-compacting concrete (Figure 03), with the purpose of producing strong modules capable of withstanding stacking, thereby providing efficiency and speed in the construction of vertical building structures. The forms used as molds for manufacturing the modules are also produced in a factory. The complete modules include: walls, slabs, and an integrated plumbing and electrical system. The complete modules are assembled on the construction site. Each module corresponds to a part of the housing unit.

Description

[0001] DESCRIPTIVE REPORT MONOLITHIC MODULAR CONCRETE SYSTEM MANUFACTURED OFF-SITE FOR MULTI-FAMILY VERTICAL BUILDINGS

[0001] This descriptive report refers to the invention patent for the Monolithic Modular Concrete System Manufactured Off-Site, which uses a unique manufacturing system in a factory complex, resulting in vertical dwellings completely constructed off-site. The finished dwelling is the joining of several modules, which are positioned and coupled to each other, forming townhouses or apartments.

[0002] One of the main advantages of this invention lies in the fact that the modules, which will form the structure and enclosure of the vertical building, are produced in a factory and assembled on the construction site with speed and precision, eliminating the stages of formwork, reinforcement and concreting of the structure on site, as well as the erection of masonry for enclosure, serving the market in an agile manner with an industrialized construction system, without waste of raw materials and workers, obtaining a final product with high functional and finishing quality, at a controlled cost, according to plan, mainly due to the reduction of technical and administrative support that a conventional construction project requires.

[0003] Furthermore, the construction industry represents one of the largest expanding sectors of the national economy, accounting for 7% of Brazil's GDP. Given this, the agility and versatility of the Modular Monolithic Concrete System, manufactured off-site for multi-family vertical buildings, contribute to the exponential growth of the economy.

[0005] When comparing construction using conventional processes with the Modular Monolithic System, it becomes clear that the traditional masonry process is frequently characterized by high costs, low planning levels, low worker qualification, high waste rates, low quality, and incidences of pathological manifestations and poor environmental performance.

[0006] Regarding waste control and environmental performance, the Monolithic Modular System uses reusable forms that serve as the basis for the module's construction; that is, one form can be used to manufacture the same room multiple times, adding sustainability to the project.

[0007] Therefore, it is necessary to strengthen the use of industrialized construction systems, which inherently involve better planning and more precise technical-economic and logistical feasibility studies, as well as better results.

[0008] In the Traditional Masonry System, bricks are used, joined with mortar; in addition, it is necessary to construct foundations that are resistant and can support the weight of the structure to be built.

[0009] The Off-Site Fabricated Monolithic Modular Concrete System has the unique feature of using self-manufactured metal forms, generating an innovative construction system.The manufacturing process of the modules will be explained below.

[0010] First, the reinforcements are molded and transferred to the forms. At this stage, after the installation of the hydraulic system, the form is closed, making it ready to receive the high-performance self-compacting concrete.

[0011] In the concreting phase, the self-compacting concrete is poured into the form, filling it completely.

[0012] After the curing period, which varies according to the module produced, the module is removed from the form.

[0013] After the wet curing of the modules, they are transported in adapted trailers to the assembly site.

[0014] At the assembly site, the modules are stored in a specific location designated for this purpose.

[0015] Subsequently, according to the assembly project, the modules will be assembled on a raft foundation.

[0016] After the assembly of the modules that form the first floor, the topping slab is executed on top of them, followed by the installation of plumbing, electrical, and gas lines.The capping slab acts as a unifier of the modules and a leveler for receiving and fitting the modules of the second floor, repeating this process successively for as many floors as the project has.

[0017] After the assembly of the last floor is completed, the execution of the building's roof begins.

[0018] Internal services such as screed, porcelain tile installation, framing, joint treatment between modules, electrical wiring, installation of electrical and plumbing finishes, construction of elevator shaft and staircase, are carried out in parallel with the progress of the floor assembly.

[0019] In order to better understand the innovation in question, perspective drawings are presented (figures 1 to 20), illustrating the summarized stages and main components of the exemplary construction of a residential building, showing everything from site preparation to the assembly of multiple floors, so that references will be made to these illustrations in conjunction with the description that follows.

Claims

1 / 1 CLAIMS 1) MONOLITHIC MODULAR CONCRETE SYSTEM MANUFACTURED OFF-SITE FOR MULTI-FAMILY VERTICAL BUILDINGS characterized by: comprising an innovative Monolithic Building System manufactured entirely in a factory environment, with the modules being executed using prefabricated forms also in a factory environment, forming different modules, each forming a part of the building, which, when coupled horizontally and stacked, form an entire vertical structure. 2) MONOLITHIC MODULAR CONCRETE SYSTEM MANUFACTURED OFF-SITE, characterized by comprising the following stages: 1) formwork manufacturing; 2) release agent application; 3) reinforcement fabrication for support; 4) transfer of reinforcement to formwork; 5) Installation of electrical wiring in the reinforcement bars; 6) Installation of plumbing piping in the reinforcement bars; 7) External closure of the formwork;8) Pouring self-compacting concrete into closed and braced forms; 9) Opening the form; 10) Removing the module; 11) Transporting the module to the transport station; 12) Loading the module onto the transport vehicle; 13) Unloading the module at the construction site; 14) Assembling the ground floor on the foundation slab; 15) Completing the assembly of the ground floor; 16) Execution of the topping slab on the ground floor; 17) Beginning of the assembly of the 1st floor; 18) Completion of the assembly of the 1st floor; 19) Completion of the assembly of the 2nd floor; and, 20) Completion of the assembly of the 3rd floor;

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