Innovative geometric building unit elements made from recycled concrete and natural materials and innovative modular building systems comprising these unit elements

Abstract

The invention relates to modular building systems composed predominantly of concrete waste and natural materials, wherein the mixture ratios and component dimensions can be adjusted according to varying climatic conditions and intended building use. The system comprises lightweight, highly durable unit building elements featuring an innovative geometry, high energy efficiency, and sustainability. These unit elements incorporate a unique connection detail, enable the construction of high-strength structures, and provide an economical solution that can be disassembled and relocated when desired. The invention further encompasses the production processes of these modular, easily applicable, high-strength, low-carbon-emission building systems.

Description

[0001] DESCRIPTION

[0002] INNOVATIVE GEOMETRIC BUILDING UNIT ELEMENTS MADE FROM RECYCLED CONCRETE AND NATURAL MATERIALS AND INNOVATIVE MODULAR BUILDING SYSTEMS COMPRISING THESE UNIT ELEMENTS

[0003] TECHNICAL FIELD

[0004] The invention relates to modular building systems composed predominantly of concrete waste and natural materials, wherein the mixture ratios and component dimensions can be adjusted according to varying climatic conditions and intended building use. The system comprises lightweight, highly durable unit building elements featuring an innovative geometry, high energy efficiency, and sustainability. These unit elements incorporate a unique connection detail, enable the construction of high-strength structures, and provide an economical solution that can be disassembled and relocated when desired. The invention further encompasses the production processes of these modular, easily applicable, high-strength, low-carbon-emission building systems.

[0005] TECHNICAL FIELD

[0006] The invention possesses distinctive sector-specific characteristics comprising the novel material composition, the innovative geometry of the unit elements, the connection configuration of these unit elements, the superior properties of the building systems constructed therefrom, and the construction methodology. The invention further includes the production process of the unit elements and the capability of the structural systems to be updated in accordance with changing conditions and emerging technologies, as detailed in the technical field section.

[0007] Within this scope, the prior technical detailing has been conducted under the following headings:

[0008] • Cement-based and geopolymer composites in the literature and industry,

[0009] • Recycling of waste materials in the literature,

[0010] • Insulation-featured building materials in the literature and industry,

[0011] • Unit and panel building elements in prefabricated systems,

[0012] • Connection configurations of unit and panel elements in prefabricated systems, • Characteristics of prefabricated building systems.Concrete continues to be the most widely used construction material in the traditional building industry and maintains its characteristic of possessing high mechanical strength. Numerous studies have been conducted to enhance the physical and mechanical properties of concrete. Recent scientific research on concrete materials has predominantly focused on improving the mechanical performance and durability parameters of concrete. In this context, the concrete types developed are generally referred to as engineered cementitious composite concretes. These types of concretes exhibit superior properties compared to conventional concrete.

[0013] Fiber-free cement-based composites typically comprise mixtures containing approximately 70% aggregate, along with varying proportions of water and cement. As the strength level increases, the aggregate content decreases while the cement content increases, resulting in the cement paste / mortar becoming the primary load-carrying component of the composite. Under these conditions, the brittleness of the composite increases concurrently with its strength. However, increased strength does not always provide an advantage for the composite material. Consequently, the design and production of fiber-reinforced cementitious composites have become necessary in the literature. Through the incorporation of fibers, the increased brittleness can be mitigated, and the energy absorption capacity of the composite can be enhanced.

[0014] Composite materials are generally based on polymeric fibers that contain artificially produced, petroleum-derived polymer chains, such as polypropylene, polyethylene, nylon, polyester, and acrylic. These materials exhibit combustible characteristics. In cement-based composites, various chemical components (including lignin, naphthalene, melamine, and polycarboxylate ether) are incorporated into the mixture to enhance the performance of the composite. However, while such additives may improve the mechanical or durability properties of the composite, they may also increase potential concerns related to sustainability and human health.

[0015] A review of previous studies indicates that various types of fibers have been utilized in cement-based composites, including glass fibers, shape-memory fibers, polymeric fibers (such as polyethylene, nylon, polypropylene, and polyvinyl alcohol), cellulose fibers, carbon fibers, and steel fibers. As mineral additives, materials such as volcanic ash, silica fume, amorphous silica, volcanic scoria, diatomite, pulverized glass, rice husk ash, limestone powder, calcium carbonate, titanium dioxide, and quartz have been employed. As aggregates, lightweight materials selected from crumbrubber, pumice-andesite basalt mixtures, pumice, ignimbrite, expanded perlite, expanded clay, expanded glass, boron compounds, silicate salts, and shredded rubber particles have been incorporated. As binders and chemical admixtures, Portland cement, slag cement, various cement classes (CEM I, II, III, IV, and V), polycarboxylates, naphthalene-based admixtures, sugar-based plasticizers, cellulose, air-entraining polymers, plasticizers, lemon vinegar, aluminum sulfate, and corn syrup have been used.

[0016] Another aspect of cement-based composite materials is that, despite improvements in mechanical performance, they may contribute to high carbon emissions. This is primarily due to the significant energy demand associated with cement production and the reliance on fossil fuels to supply this energy, resulting in substantial carbon release into the atmosphere. Nevertheless, the literature also reports the development of cement-free composite materials, both fiber-reinforced and non-fiber-reinforced. The binder phase of these composites can be formulated using mineral-based materials such as fly ash, slag, metakaolin, red mud, industrial waste, and recycled materials. Activation of these mineral materials is achieved through the incorporation of alkali activators (e.g., sodium hydroxide, potassium hydroxide) and silicate compounds such as sodium silicate, enabling chemical reactions that harden the material into a structural composite. However, the global availability and resource stock of these materials are limited. Consequently, although cement contributes to high carbon emissions, its widespread production and global accessibility continue to support its use as a common construction material. Additionally, the high pH levels, extremely fine particle structure, and reactive nature of cement-free composite components pose health concerns and hinder their widespread practical application. Furthermore, upon reaching the end of their service life, these materials may generate substantial environmental waste due to their high content of artificial and potentially harmful constituents.

[0017] The literature includes various construction materials produced through the recycling of waste products. In recent years, the recycling of concrete waste has also become an area of interest within this scope. However, the majority of studies in this field focus not on producing an innovative material from recycled concrete, but rather on manufacturing new concrete. The final product obtained from the recycling of materials that have reached the end of their service life generally falls into a lower quality category compared to its conventional counterpart. This constitutes a significantlimitation on the use of recycled materials in the production of new construction products. In some cases, when the waste material is not adequately analyzed, the resulting recycled product may exhibit disadvantages contrary to the expected performance characteristics of the new material.

[0018] The unit weight of cement-based composites, geopolymers, and concrete produced from recycled waste varies depending on the constituents used, and generally ranges between 1.5 and 2.5 tons / m3. In addition to these types of concrete, the literature also includes studies on lightweight concrete. However, a reduction in unit weight typically leads to a decrease in the modulus of elasticity and, consequently, a reduction in flexural and axial stiffness parameters. This condition diminishes the structural system’s resistance under lateral loading. Accordingly, there is a need in the construction sector for a material that is both lightweight and exhibits high strength.

[0019] The strength parameters of cement-based composites and similar materials can be increased by adjusting the water-to-cement ratio. However, such adjustments reduce the workability of the mixture. Methods such as heat curing can also be used to enhance strength, but their application is highly limited in field conditions due to the significant energy demand. Polymer-based fibers, as detailed above, can improve flexural stiffness and tensile strength. Nevertheless, these polymers reduce workability and, due to their combustible nature, may cause sudden strength loss when exposed to high temperatures.

[0020] In cement-based composites and similar materials, compressive strength is generally higher than tensile strength. For structural elements expected to carry loads, an isotropic mechanical behavior where compressive and tensile strengths are relatively close to each other is a desirable characteristic.

[0021] In addition to the increasing consumption of concrete in the construction sector, various materials have also been developed for insulation purposes, and scientific research continues in this field. Among the most widely known materials used for this purpose are pumice-based lightweight concrete (bims) and autoclaved aerated concrete (AAC). In general, bims contains pumice, sand, gravel, water, and cement, while AAC contains quartzite, cement, lime, gypsum, aluminum powder, and water. However, the literature also includes various insulation products derived from these materials. A significant portion of the research and patents related to insulation materials focuses on mortar-based formulations. Therefore, rather than defining a standalone insulation product, studies typically describe the mixture compositions ofinsulation mortars. Examples include cement-based lightweight precast mortars; ready-mixed plasters containing pumice aggregate; lightweight plaster mixtures incorporating perlite, pumice stone, boron compounds, silicate powder, lemon vinegar, aluminum sulfate, and corn syrup; polystyrene-based insulation materials; and mixtures composed of cement, cellulose, volcanic scoria, diatomite, perlite, clay, and foam mortars. These mixtures can be applied as coatings on wall surfaces or placed between two panels to form composite sections. Composite sections placed between two panels can be manufactured entirely as precast sandwich panels. These systems are generally used in structural applications as partition walls for thermal and acoustic insulation. Consequently, due to their compressive strengths being lower than that of conventional concrete, they do not possess independent load-bearing capacity. In the Turkiye Building Earthquake Code, masonry structural systems and the masonry units permitted for use in such systems are defined. The regulation specifies that these units may consist of cut stone, brick, or autoclaved aerated concrete (AAC). Among these materials, AAC is the only one that possesses inherent insulation properties. Accordingly, under the provisions of the regulation, AAC is the only material that can be used both as an insulation product and as a load-bearing element.

[0022] The compressive strength values specified for AAC in the regulation vary depending on the compressive strength of the masonry unit. When the compressive strength of the masonry unit is 10 MPa, the compressive strength of the load-bearing wall is 5.7 MPa; when the unit strength is 15 MPa, the wall strength is 8 MPa; and when the unit strength is 20 MPa, the wall strength is 10 MPa. This demonstrates that, even in the case of AAC which is the only insulation material permitted for structural use the compressive strength of the wall can reach only up to approximately 50% of the compressive strength of the masonry unit. This effect varies depending on the strength of the mortar used between the units. Our research indicates that no insulation material with a compressive strength of 20 MPa has been identified. The strength of such materials remains significantly below the 25 MPa concrete strength permitted by the regulation. The existence of an insulation material with strength comparable to concrete would indicate the potential for such a material to replace concrete; however, no such insulation material has yet been encountered. For this reason, insulation materials are generally used for thermal and acoustic performance rather than for load-bearing purposes. Moreover, producing a high-strength material from a lightweight natural material with inherently low strength requires the use of a largeproportion of binder in the mixture. In patented insulation materials within the sector, this binder is often cement, but in some cases, mineral additives such as fly ash, silica fume, and metakaolin materials that are less economical and less readily available are used. Additionally, the literature includes insulation materials produced from various chemical components, plant-based substances such as corn syrup, and different types of fibers. However, their potential for commercialization is limited due to constraints in mass production and factory-scale manufacturing. Despite the wide range of insulation material formulations presented in the sector, only pumice-based lightweight concrete (bims) and AAC have achieved widespread commercialization and practical use, which confirms this limitation.

[0023] Prefabricated and lightweight prefabricated elements can be produced in the construction sector using the concrete-based materials, their derivatives, insulation components, or various combinations thereof, as detailed above. The prefabricated building sector can be classified into reinforced concrete systems, steel systems, container-type systems, light-gauge steel systems, timber systems, and plastic-based systems. In industrial structural applications, reinforced concrete and steel prefabricated systems are widely used. In reinforced concrete prefabricated systems, columns and beams are manufactured in factory conditions and assembled on-site using pin connections and cranes. In steel prefabricated systems, load-bearing elements are produced in the factory and assembled on-site through welding or bolted connections. Consequently, in both systems, once the structure is erected, disassembly or full modularity of the building is not feasible.

[0024] In wooden, plastic, and container-type prefabricated systems, some components are produced in a manner similar to reinforced concrete and steel systems, while others are manufactured entirely in factory conditions and subsequently transported to the installation site. These systems generally allow assembly without the use of cranes; however, except for container-type systems, full modularity is not achieved. Within this context, the systems that provide full modularity and allow the installation of load-bearing elements without cranes are predominantly container-type systems. Nevertheless, container-type systems are typically intended to meet temporary structural needs and are not suitable replacements for conventional permanent building systems. In addition to these systems, patent literature includes large-scale panel-type solutions composed of insulation materials placed between twostructural wall elements. However, such systems are generally used as partition walls rather than as primary load-bearing components. Most panel composite systems do not possess independent load-bearing capacity. This is because the Turkiye Building Earthquake Code classifies structural load-bearing systems as cast-in-place reinforced concrete, steel, precast reinforced concrete, light-gauge steel, masonry, and timber systems.

[0025] In the construction sector and in the literature, the assembly of panel systems is generally achieved through interlocking mechanisms or by connecting the panels to a common vertical load-bearing system. Reinforced concrete prefabricated systems and steel prefabricated systems utilize pinned, welded, or bolted connection details. In container-type and timber prefabricated systems, screwed or riveted interlocking mechanisms are commonly employed. In these systems, the strength of the connection detail is as critical as the strength of the load-bearing elements themselves, as the transfer of loads is primarily governed by the connection mechanism.

[0026] Following the COVID-19 pandemic and major earthquakes, “lego-type” construction systems have also emerged. These systems can be characterized more as masonry-type systems rather than conventional prefabricated systems. The unit elements used in such systems are typically composed of plastic or plastic-derived materials. Although these systems offer full modularity and crane-free installation, the use of plastic-based materials raises potential sustainability concerns. Furthermore, design specifications for lego-type systems are not yet included in current building regulations. However, the 2018 Turkiye Building Earthquake Code states: “In cases where adequate analytical models are not available, where a large number of similar components are used, or where assumptions made in the design require verification, experimental studies shall be conducted in accordance with the principles given in TS EN 1990 Annex D or equivalent international rules, and certification procedures shall be carried out in accordance with Section 1.2.3.” The referenced Section 1.2.3 further specifies that “Buildings designed under seismic effects according to this Regulation shall comply with Turkish Standards and the General Technical Specifications of the Ministry of Environment and Urbanization, the Construction Materials Regulation published in the Official Gazette dated 10.07.2013 and numbered 28703, and the Regulation on the Criteria Applicable to Construction Materials published in the Official Gazette dated 26.06.2009 and numbered 27270.” Within this framework, theearthquake code allows for experimental-based design approaches, provided that the construction materials comply with the applicable material regulations.

[0027] In contemporary construction practice, the general expectations from a building system include resistance to natural disasters, rapid on-site assembly, economic feasibility, energy efficiency, ergonomic design, high durability, and long service life. In recent years, additional criteria such as sustainability, compatibility with green building concepts, modularity, environmentally friendly solutions, energy-efficient building design, smart building integration, and low-rise architectural approaches have also gained prominence. Among prefabricated systems, reinforced concrete prefabricated structures do not offer modularity. Once constructed, disassembly and relocation to another site are extremely difficult. The same limitation applies to steel prefabricated systems. Timber prefabricated systems exhibit low fire resistance, while plastic-based prefabricated systems are limited in terms of sustainability and environmentally friendly performance. Reinforced concrete and steel systems require additional detailing to achieve adequate energy efficiency. Although light-gauge steel systems offer rapid on-site construction, they still do not fully satisfy all the performance parameters expected from modern structural systems. Consequently, while each of these systems provides advantages in certain aspects, they also present disadvantages in others. Within the broader framework of constructing carbon-neutral, sustainable, energy-efficient, economical, ergonomic, disaster-resistant, recyclable, and environmentally friendly urban environments, innovative building systems must incorporate environmentally friendly solutions, sustainable material compositions, modularity, high energy efficiency, rapid construction capability, long service life, and designs that ensure human and environmental health.

[0028] The structural unit elements and building systems detailed within the scope of the present invention incorporate the aforementioned characteristics. The unit elements and structural systems of the invention differ entirely from prior art in terms of material composition, unit element design, geometric configuration, connection detailing, production process, construction methodology, system functionality, and compatibility with emerging technologies. Furthermore, the production of the unit elements employs silicone molding and 3D-printing technologies, representing a conceptual departure from traditional manufacturing methods. Within this framework, the unit elements and structural systems produced under the present invention havesignificant potential to replace existing prefabricated, masonry, reinforced concrete, steel, and timber load-bearing systems. Additionally, unlike prior techniques, the structural systems described in the invention do not require plaster or paint, demand minimal labor, enable rapid construction following natural disasters, and provide modularity compatible with mechanical and electrical installation systems.

[0029] AIM OF THE INVENTION

[0030] The purpose of the present invention is to design modular building systems and to develop their components in order to construct buildings that are sustainable, energy-efficient, and cost-effective under normal conditions, while also enabling rapid construction following natural disasters. Within this scope, the invention introduces new construction materials, innovative modular building unit elements, and structural systems composed of these elements by utilizing concrete waste generated through urban transformation activities and natural disasters, as well as natural materials. These unit elements and structural systems are designed to be sustainable, thermally efficient, environmentally friendly, and resistant to earthquakes and other natural hazards. The problem definitions addressed by the invention include issues that cannot be resolved by prior art, such as the environmental impact of waste concrete, structural damage caused by natural disasters, non-modular building designs, thermal efficiency deficiencies, long construction durations, and lack of sustainability. The selection of these problem areas also considers the interaction between the construction sector and developments in environmental, energy, and climate fields.

[0031] The invention provides design details and assembly procedures for modular building unit elements capable of solving the identified problems. Within this framework, numerous existing methods in the sector have been examined and compared with the product and system proposed by the invention. As a result, the invention introduces a product and system capable of addressing seven distinct problems identified in the literature and unresolved by current industry practices.

[0032] The first problem addressed by the invention concerns the environmental impact of waste concrete and the increasing consumption of concrete. Urban transformation activities and natural disasters generate millions of tons of construction and demolition waste. The reuse of these materials, the development of environmentally friendly technologies, and the reintegration of waste into the economy are of significant importance. Reinforced concrete structural systems are the most widely usedconstruction method, which rapidly increases concrete production and consumption. Consequently, global demand for cement is expected to rise by approximately 200% in 2050 compared to 2010. Cement production releases substantial amounts of carbon dioxide into the atmosphere. The second problem to be addressed is the design of structures that are resistant to natural disasters. Building systems must possess adequate resilience against all nature-induced hazards. The third and fourth problem definitions relate to long construction durations and non-modular building designs. Construction time is a critical parameter in the cost analysis of a building. Additionally, following natural disasters, there is often an urgent need for rapid reconstruction in affected areas. In this context, minimizing construction time significantly increases the benefit-to-cost ratio.

[0033] Modularity in building systems is a contemporary research focus; however, the majority of structures constructed in the building sector do not incorporate this feature. The ability to disassemble a structure and relocate it to another site represents an innovative approach. Following natural disasters, modular structures are preferred due to their capacity to enable rapid construction. Accordingly, modularity has emerged as a desirable characteristic in modern construction practices. In the present invention, the assembly of unit elements is achieved through connection details fabricated from an innovative material possessing mechanical properties comparable to steel. Another problem addressed by the invention concerns the high thermal conductivity of concrete, which is widely used in the construction industry. As a result, reinforced concrete requires additional insulation applications to achieve adequate thermal performance. The final problem addressed by the invention relates to construction cost and sustainability. As in all fields, sustainability is an essential parameter in the construction sector. It is important that the materials used in building construction are sustainable and recyclable. Sustainable designs not only provide environmental benefits but also offer long-term economic advantages. Extended construction durations can negatively affect overall building costs. The invention develops design details and general assembly procedures for modular building unit elements and structural systems capable of solving the aforementioned problems. The developed unit elements are intended for use in the construction of residential, commercial, and industrial buildings, as well as for rapid reconstruction following natural disasters.One of the most significant environmental contributions of the present invention is the utilization of waste concrete generated through urban transformation activities and natural disasters, as well as the use of natural materials, to produce high-performance and sustainable construction materials for new building applications. The unit elements introduced as the product of the invention consist of sustainable, environmentally friendly materials with high thermal and energy efficiency. The incorporation of waste concrete and natural materials in the cross-sections of these unit elements, combined with practical application, minimal labor requirements, modularity, and high thermal efficiency without the need for additional insulation layers, provides substantial advantages in terms of construction costs. Furthermore, when considering the life-cycle analysis of structural systems, the parameters described above offer long-term economic benefits. The design proposed by the invention is capable of providing solutions for architectural applications with different functional requirements, thereby increasing the benefit-to-cost ratio. The innovative aspects and technological advantages introduced by the invention, addressing the existing problems identified in the literature, are listed below:

[0034] - Sustainable material and structural system

[0035] - Innovative material composition and unit-element geometry

[0036] - Modularity (compatible with mechanical and electrical systems)

[0037] - Practical application with minimal labor requirements

[0038] - High thermal efficiency

[0039] - Load-bearing system unaffected by temperature variations

[0040] - Resistance to natural hazards (earthquake, flood, fire, high wind)

[0041] - Compliance with green-building principles

[0042] - Reduction of carbon emissions

[0043] - High benefit-to-cost design ratio

[0044] - Adaptability to varying architectural configurations

[0045] - Reduction of construction costs

[0046] - Shortened construction duration

[0047] The distinctive aspect of the present invention is its ability to address all major problems identified in the sector through a single unit element and structural system. This integrated approach enables the invention to provide comprehensive solutions that previously required multiple independent systems or materials.Another significant distinctive feature of the present invention, differentiating it from prior art, is the ability to assemble the modular unit elements with a minimal number of technical personnel. From a labor-cost perspective, the system can be installed by only two to three technicians, and in terms of construction duration, both the load-bearing and insulation systems can be completed within approximately one month. This capability provides substantial advantages, particularly in post-disaster scenarios, where a structure may need to be relocated to another site after fulfilling its initial purpose. The connection details of the product consist of innovative systems reinforced with materials possessing mechanical properties comparable to steel. This provides users with confidence regarding structural performance under seismic effects and facilitates the inclusion of the system within relevant codes and technical specifications. Our sectoral and academic research indicates that no existing design combines all of these features within a single product.

[0048] Following the COVID-19 pandemic and the major earthquakes that have occurred in Turkiye, the demand for low-rise and rapidly constructible building systems has increased significantly, and this trend continues in anticipation of future large-scale seismic events. The structural unit elements and system introduced by the present invention offer an important innovative approach in this context.

[0049] The structural system proposed in the invention contributes substantially to the thematic areas outlined under the “Livable Cities and Sustainable Environment” section of the 12th Development Plan of the Presidency of the Republic of Turkiye, including “Urbanization,” “Housing,” “Urban Transformation,” “Environmental Protection,” and “Disaster Management.”

[0050] The unit element and structural system developed within the scope of the invention, composed of sustainable materials, stand out with their environmentally friendly, innovative, and modular characteristics. Accordingly, the invention contributes to several United Nations Sustainable Development Goals, including Goal 7 (Affordable and Clean Energy), Goal 11 (Sustainable Cities and Communities), Goal 12 (Responsible Consumption and Production), and Goal 17 (Partnerships for the Goals). Additionally, within the framework of the European Union’s 2030 objectives which include the construction of more than 100 carbon-neutral cities the invention supports the transition toward low-carbon building practices.Within the scope of these objectives, the unit elements and structural systems presented as the product of the invention do not constitute a temporary solution for the construction sector, which currently holds a substantial global market share. Instead, the invention provides the detailed framework of an innovative method that has the potential to replace many existing systems within the next few years. The proposed approach introduces a new generation of construction technology capable of addressing multiple sectoral challenges simultaneously through a unified structural system and modular unit element design.

[0051] LIST OF FIGURES

[0052] Figure 1. High-strength layer

[0053] Figure 2. High-energy-efficient layer

[0054] Figure 3. Modular unit element (high-strength + high-energy-efficient layers) Figure 4. Modular connection element (H)

[0055] Figure 5. Horizontal connection of two modular unit elements with H

[0056] Figure 6. High-strength corner connection detail

[0057] Figure 7. Structural system corner connection

[0058] Figure 8. Bottom surface of modular unit element

[0059] Figure 9. Modular building wall system

[0060] Figure 10. Modular system interlocking removable cap detail

[0061] Figure 11. Modular building wall system

[0062] Figure 12a-12b-12c. Building system composed of modular wall and modular slab elements and views from different perspectives

[0063] Reference Numbers Used in the Figures

[0064] 1. Load-bearing structural layer

[0065] 2. Energy-efficient layer

[0066] 3. Modular unit element

[0067] 3.1. Gasket channel

[0068] 3.2. Void

[0069] 4. Connection element

[0070] 5. Corner connection

[0071] 6. Cap systemDETAILED DESCRIPTION OF THE INVENTION

[0072] The present invention comprises a structurally innovative small unit element featuring a novel geometry and layered configuration, the material composition of these layers, the connection methodology of the unit elements, and the modular innovative building systems produced from these elements as detailed in the “Purpose of the Invention” section. Within this framework, the detailed description of the invention is presented under the following headings:

[0073] - Material composition of the innovative unit-element layers

[0074] - Geometry of the unit element

[0075] - Connection detail

[0076] - Technological mass-production process of the unit elements

[0077] - Modular building system produced from the unit elements and its superior characteristics

[0078] - Adaptation of the structural system within the invention to current technologies The present invention comprises a unit element formed by the complete integration through an innovative geometry of the high-strength load-bearing structural layer (1) shown in Figure 1 and the high-energy-efficient layer (2) shown in Figure 2 (Figure 3). Accordingly, the unit element of the invention has a monolithic structure.

[0079] The high-strength layer (1) differs from conventional concrete and cement-based composites commonly used in current construction practice. The material composition of the high-strength layer (1) contains 10-90% waste concrete. The term “waste concrete” refers to material derived from reinforced-concrete structural debris generated after natural disasters, from which steel reinforcement has been removed, and which has undergone aggregate recovery processes to separate mortar residues, resulting in a 0-4 mm recycled material safely usable in production. Thus, all components of recycled concrete are utilized to produce a new composite material distinct from conventional concrete. This is a significant aspect of the sustainability of the unit element.

[0080] Other components contributing to sustainability and used for thermal insulation and compressive strength in the high-strength layer (1) include natural pumice and waste marble. Pumice is incorporated in two different granulometries (0-0.063 mm and 0-2 mm), with a total content ranging from 5% to 50%. Waste marble is also used at 5% to 50%. High flexural strength in this layer is achieved through natural or syntheticfibers, used at 0.1% to 5.0% by volume. Up to this stage, all materials used in the mixture are natural or recycled.

[0081] Cement (CEM I, II, III, IV, V) is minimized in this load-bearing layer, with a content ranging from 10% to 40%. Additionally, various geopolymer and alkali-activated binders (pumice, ground granulated blast-furnace slag, fly ash, metakaolin, red mud, kaolin, palm oil fuel ash, dolomite, diatomite) may be used to reduce the cement content to 0%. Through optimization of mixture proportions, an isotropic structural material has been obtained. This is the most important characteristic of the high-strength layer (1), as the resulting material exhibits equal compressive and flexural stress performance.

[0082] The high-strength layer (1) also incorporates mineral admixtures (1%-75% silica fume, microsilica, ground granulated blast-furnace slag, fly ash, metakaolin, rice husk ash at least one) to enhance compressive strength and workability, and chemical admixtures (0.1%— 10% polycarboxylate, naphthalene, or sugar-based plasticizers at least one). Superabsorbent polymers are used at 0.1%-3.0% for internal curing.

[0083] Through optimization of all mixture components, a material with a unit weight / density of 1.00-1.90 g / cm3, compressive strength of 20-80 MPa, and flexural strength of 5-30 MPa has been produced. Thus, another distinctive feature of the invention is the development of a structural material that is lighter than conventional concrete yet exhibits high compressive and flexural strength.

[0084] Furthermore, tests have shown that this material possesses a deformation capacity of up to 2% under compressive loading, indicating a very high energy-absorption capability. In comparison, conventional concrete typically exhibits a deformation capacity of approximately 0.3% under compressive loading.

[0085] Another distinctive feature of the high-strength material developed within the invention is its ability to achieve a smooth and glossy exterior surface comparable to polished marble. When various pigment additives are incorporated into the mixture, a highly decorative appearance can be obtained without the need for plaster or paint. This unique aspect characteristic highlights the architectural and labor-saving advantages of the high-strength layer (1).

[0086] Another major advantage of the high-strength layer (1) of the unit element is that, due to its high flexural strength and toughness capacity, it does not require rebar. The high-strength layer (1) also exhibits excellent resistance to aggressive environmental conditions, including corrosion, carbonation, chloride exposure,seawater, freeze-thaw cycles, chemically aggressive environments, extreme weather conditions, abrasion, fire, and acidic environments. For this reason, the high-strength layer (1) forms the exterior surface of the modular structural unit.

[0087] Additionally, the high-strength layer (1) developed in the invention can be used independently of the modular unit element as a strengthening component in conventional construction and infrastructure systems. This expands the applicability of the material beyond modular systems and demonstrates its versatility as a high-performance structural solution.

[0088] The high-energy-efficient layer (2) of the invention consists of 50-95% natural materials (pumice, air lime, and hydraulic lime) and recycled concrete, excluding water. This layer (2) also contains natural or synthetic fibers at ratios between 0.1% and 5.0%. Additionally, superabsorbent polymers are incorporated at 0.1%-3.0% for internal curing. The cement content used as a binder is minimized, ranging only between 3% and 10%. Consequently, the unit element consists of 60-85% natural and recycled materials.

[0089] The high-energy-efficient layer (2) forms the interior surface of the modular unit element. In this context, a healthy interior surface that does not pose risks to human health has been achieved for the living spaces of the modular building systems. Since 60-90% of the structural unit element’s cross-section consists of the high-energy-efficient layer (2), this beneficial effect (non-hazardous to human health) is also reflected at the scale of the modular unit element.

[0090] Furthermore, this high proportion of natural and recycled materials ensures that, once the modular unit element reaches the end of its service life, approximately 90% of its material composition will not cause environmental harm. This characteristic significantly enhances the sustainability profile of the invention.

[0091] Test results obtained for the high-energy-efficient layer (2) demonstrate that the unit weight / density ranges between 0.5-1.5 g / cm3, the compressive strength ranges between 1-15 MPa, and the flexural strength ranges between 0.3-2.0 MPa. Accordingly, even within the energy-efficient layer (2) which is designed primarily for thermal performance significant mechanical strength values have been achieved. In room-temperature tests conducted at 22 °C, one surface of the energy-efficient layer (2) was exposed to 300 °C for 30 minutes, while the opposite surface measured 25 °Cusing a thermal camera. This result demonstrates the fire-resistance capability of the energy-efficient layer (2).

[0092] Within the scope of the invention, a lightweight yet high-strength insulation material has been developed, representing a novel contribution beyond prior art. Independently of the modular unit element, the dry mixture of the energy-efficient layer (2) can also be used in conventional construction as a high-strength thermal insulation layer beneath floor systems.

[0093] Both the high-strength layer (1) and the energy-efficient layer (2) exhibit excellent workability and consistency. Furthermore, the high proportion of natural materials in the mixture provides a significant advantage in terms of sustainable and circular-economy principles.

[0094] The modular unit element of the invention is formed by the integration of the high-strength layer (1) and the high-energy-efficient layer (2) through an innovative geometry. In the modular unit element (Figure 3), full adhesion is achieved between the two layers (1, 2). Accordingly, adhesion tests between the layers have been conducted. The dimensions of the unit element vary depending on the intended use of the structure and the climatic conditions of the construction site. The high-strength layer (1) has a thickness ranging from 20 mm to 100 mm, while the high-energy-efficient layer (2) ranges from 50 mm to 180 mm. However, both the high-strength layer (1) and the high-energy-efficient layer (2) may also be used independently. In such cases, the modular unit element may have a thickness and height between 150 mm and 500 mm, and a width between 200 mm and 1000 mm.

[0095] In the invention, two modular unit elements (3) are connected using an H-shaped connector (4) made of solid or hollow steel or a material with mechanical properties similar to steel (Figure 4). The modular unit elements (3) can be assembled in a mortar-free manner using these small H-shaped steel or equivalent connectors (4) (Figure 5). To prevent the passage of air, water, and similar external effects between modular unit elements (3), a gasket channel (3.1) is provided on the modular unit element (3) as shown in Figure 3.

[0096] At the corner junctions of the modular unit element (3), a corner connection (5) made entirely of the high-strength layer is designed (Figure 6). The corner connection (5) is particularly important for dissipating concentrated energy at the junctions of the modular building system under horizontal loads. Two modular unit elements (3),combined with the H-shaped connector (4) and the high-strength corner connection (5), form the corner wall system (Figure 7).

[0097] The interior surface of the modular unit elements (3) features a ribbed geometry to allow mechanical and electrical installations to be integrated into the structural system. In the vertical direction, modular unit elements (3) are assembled by inserting the protruding vertical parts of the H-shaped connectors (4) into the voids (3.2) located on the underside of the modular unit element (3) (Figure 8). When all these details are combined, a modular wall system with both load-bearing and insulation properties is obtained in the horizontal and vertical directions (Figure 9).

[0098] To cover the ribbed interior surface of the modular wall system and to achieve a flat architectural finish, a removable / interlocking / replaceable cap system (6) made of natural material and installable with a simple hand tool is designed, as shown in Figure 10. This cap system (6) can be produced in any desired color or pattern, providing a unique architectural advantage within modular systems. The completed modular wall detail with the cap system (6) is shown in Figure 11. As a result, no additional plaster or paint is required for the modular wall system, and the detail is highly suitable for decorative applications. Advanced molding technologies supported by 3D printing are used in the mass production of the modular unit element, the corner connection detail, and the cap system.

[0099] The entire system described above is assembled horizontally and vertically (including the floor system) using the modular unit elements (3). On the surface of the modular unit element (3), the ribbed geometry is formed on profiles made of steel or materials with mechanical properties similar to steel (Figures 12a and 12b). The cap system (6) shown in Figure 10 can also be applied to the ceiling.

[0100] The modular building system, composed of the high-strength unit element (1) and the steel or steel-equivalent connection components, demonstrates its applicability to multi-story building systems. Furthermore, the high-energy-dissipation capacity of the node shown in Figure 12c confirms the system’s high resistance to both horizontal and vertical loads.

[0101] The modular building system can be constructed on any sufficiently load-bearing, flat ground surface (preferably a concrete base). Within the scope of the invention, designs addressing all current challenges in the construction sector have been presented under the categories of building materials, modular unit elements, and modular building systems, offering a broad future vision for the industry.The structural systems developed through the designs detailed in the invention are not only modular but also sustainable, environmentally friendly, economical, practical, demountable, and easily adaptable to modern technologies such as seismic isolation.

Claims

CLAIMS1. An innovative geometrically designed structural unit element produced from recycled concrete and natural materials, characterized in that it comprises: - A load bearing structural layer (1) manufactured from waste concrete, pumice, waste marble, natural or synthetic fibers, cement, mineral additives, chemical admixtures, and superabsorbent polymer; the layer comprising protrusions on its inner surface that align with the outer surface of the energy efficient layer (2), and recesses located at each corner to allow passage of a connection element (4);- An energy efficient layer (2) produced from natural and recycled concrete, natural and synthetic fibers, superabsorbent polymer for internal curing, and cement; the layer comprising multiple polygonal protrusions on its inner surface and recesses on its outer surface corresponding to the protrusions of the load bearing structural layer (1);- A modular unit element (3) formed as a monolithic structure by the integration of the load bearing structural layer (1) and the energy efficient layer (2); - A connection element (4) having an H shaped geometry, configured to fit into the recesses located at the upper and lower corners of the modular unit element (3);- Corner connection components (5) and a cap system (6).

2. The innovative geometrically designed structural unit element produced from recycled concrete and natural materials according to Claim 1 characterized in that it comprises a load-bearing structural layer (1) produced from waste concrete originating from nature-induced disasters, the concrete having been separated from its reinforcing steel and further processed by a recycled aggregate improvement method in which the aggregate and residual mortar are separated.

3. The innovative geometric structural unit element made of recycled concrete and natural materials according to Claim 2, and its feature is that it contains a loadbearing structural layer (1) made of waste concrete separated in the range of 0 - 4 mm.

4. The innovative geometric structural unit element made of recycled concrete and natural materials according to Claim 1, and its feature is that it contains a loadbearing structural layer (1) with 5%-50% pumice.

5. The innovative geometric structural unit element made of recycled concrete and natural materials according to Claim 1, and its feature is that it contains a loadbearing structural layer (1) with 5%-50% waste marble.

6. The innovative geometric structural unit element made of recycled concrete and natural materials according to Claim 1, and its feature is that it contains a loadbearing structural layer (1) with 0.1%-5.0% fiber.

7. The innovative geometric structural unit element made of recycled concrete and natural materials according to Claim 1, and its feature is that it contains a loadbearing structural layer (1) with 10%-40% cement.

8. The innovative geometric structural unit element made of recycled concrete and natural materials according to Claim 1, and its feature is that it contains a loadbearing structural layer (1) with at least one mineral additive, such as silica fume, microsilica, ground granulated blastfurnace slag, fly ash, metakaolin, rice husk ash.

9. The innovative geometric structural unit element made of recycled concrete and natural materials according to Claim 1 , and its feature is that it contains a carrier structural layer (1) which includes at least one of the following as a chemical additive plasticizer: polycarboxylate, naphthalene, sugar-based additive.

10. The innovative structural element with innovative geometry, made from recycled concrete and natural materials according to Claim 8 characterized by a mineral additive ratio ranging from 1% to 75%.11.The structural unit element with innovative geometry made of recycled concrete and natural materials according to Claim 9, characterized by having a chemical additive ratio between 0.1% and 10%.

12. The structural unit element with innovative geometry made of recycled concrete and natural materials according to Claim 1, characterized by containing a loadbearing structural layer (1) with a superabsorbent polymer ratio between 0.1% and 3.0%.

13. The structural unit element with innovative geometry made of recycled concrete and natural materials according to Claim 1, characterized by containing anenergy-efficient layer (2) made of natural and recycled concrete consisting of pumice, lime and hydraulic lime.

14. The structural unit element with innovative geometry made of recycled concrete and natural materials according to Claim 13, characterized by having a ratio of 50%-95% of natural and recycled concrete.

15. The structural unit element with innovative geometry made of recycled concrete and natural materials according to Claim 1, characterized by containing an energy-efficient layer (2) with 0.1%-5.0% of natural and artificial fibers.

16. The structural unit element with an innovative geometry made of recycled concrete and natural materials according to Claim 1, characterized by containing an energy-efficient layer (2) with a superabsorbent polymer for internal curing in the range of 0.1%-3.0%.

17. The structural unit element with an innovative geometry made of recycled concrete and natural materials according to Claim 1, characterized by containing an energy-efficient layer (2) with a cement content in the range of 3%-10%.

18. The structural unit element with an innovative geometry made of recycled concrete and natural materials according to Claim 1, characterized by containing a modular unit element (3) with a gasket channel (3.1).

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