EP1757750B1

EP1757750B1 - Construction system based on prefabricated plates

Info

Publication number: EP1757750B1
Application number: EP05750229A
Authority: EP
Inventors: Valentin Leiro Paz
Original assignee: Individual
Current assignee: Individual
Priority date: 2004-05-20
Filing date: 2005-05-18
Publication date: 2010-04-28
Anticipated expiration: 2025-05-18
Also published as: ATE466147T1; PT103271B; DE602005020932D1; ES2289844A1; EP1757750A1; PT103271A; WO2005113912A1; ES2289844B1

Abstract

The invention refers to a totally new system which has been specially designed based on some predetermined prefabricated boards with the addition of some components designed to be combined with the same to create a new construction system for all types of building. In order to do this and within the described technology system, boards will be manufactured which are reinforced boards, cover boards, non-structural or load-bearing boards and double sided boards with a middle heat installation layer.

Description

As indicated in its title, this Invention Patent application referrs to "A CONSTRUCTION SYSTEM BASED ON PREFABRICATED BOARDS" the new construction, layout and design features of which fulfil the purposes for which it has been specifically designed with maximum safety and efficiency.
More specifically, the invention refers to an especially designed, totally new system based on predetermined prefabricated boards with the addition of some components designed to be combined with the same to create a new construction system for all types of building. In order to do this and within the described technology system, boards will be manufactured which are reinforced boards, cover boards, non-structural or load-bearing boards and double sided boards with a middle heat installation layer. Due to this system the workload is basically transferred from the construction site to the factory where the boards and components are manufactured as shall be detailed below.
This is a very simplified system of structural boards, because it makes the boards act as large beams. In this way, load distribution is exact at foundation level so that the foundations may fit in with the features of the land. Where ground strength is superficial, the appropriate solution will be to have insulated housings. If ground strength is semi-deep, foundation trenches will be used and if ground strength is deep, piles shall be used.
The innovative aspect of the system, as defined in claim 1, is that it does not necessarily have to match standard board sizes; board sizes may be of any size using the same system. The system uses a combination of inner reinforcement which forms one or more right angles with its perimeter reinforcements according to the edge of the board which are joined by metal strips located inside the panel which may be attached together using arc welding.
Boards already exist on the market and therefore may be considered as technical construction systems such as those described in the Spanish patent invention for "PROCEDURE FOR BUILDING CONSTRUCTION" number 540.232 held by the same company in which smooth pieces are described and claimed. These are moulded onto the flooring onto which side walls are attached for subsequent building. This is achieved by attaching the appropriate reinforced wire framework and by pouring the relevant amount of cement into the space defined on the aforementioned flooring by the framework. This framework comprises a metal framework made from metal strips of appropriate sizes which are attached and permanently fixed onto it. These pieces are horizontally supported on the flooring until the cement has completely set.
Also, in the Spanish Patent number 990-2834 in addition to the above, improvements are claimed through which the movement and transfer of the smooth pieces is achieved by locating each piece on four anchoring points, two in the upper corner and two on the side frames of the base with the inclusion of some strips onto the ends of these frames onto which a hook has been welded. This hook may be welded to the plate itself or to the reinforcing structure of the board.
The pieces manufactured under the terms of the system use the above described system in any type of layout in inner thicknesses of 8m, 10 mm and other similar sizes. The single pieces have a structure formed by 15 x 30 mm diameter, double mesh and U-shaped connectors which join the aforementioned mesh at its side and horizontal ends with angled, structural frameworks and on its side and horizontal ends attached to which at regular distances are hooks for handling the boards. These frames are held on to the mesh with these connectors using a continuous planed bead weld.
In the event that the aforementioned boards have openings for doors, windows or other similar items, they are reinforced by bars around the outside of the openings forming a strong framework for them.
Pieces used for enclosing are formed by an inner structural board inside of which there is an insulating chamber and with an outer board which is thinner than the inner board on the outside to enclose the space. The inner structure of the inner board is the same as that for the openings defined for single boards. It is also the same for the enclosure board with only the thickness of the inner board varying from 80 mm as opposed to 60 mm for the enclosure board. The double board is attached in the same manner as single boards using the appropriate hooks. Other details and features shall be shown during the description given below which will refer to drawings attached to this report in which the preferred details are shown in diagrams.
Below is a list of the main parts in the invention which are shown in the drawings; (10) single board, (11) double enclosure board, (12) edge strip, (13) connector, (14) single mesh, (15) connector, (16) double mesh, (17) stone or cement coating, (18) reinforcing board, (19) strips, (20) enclosure formed by double boards (11), (21) cover boards, (22) support panels, (23) hook, (24) end strip, (25) openings, (26) UPN, (27) bars, (28) round wire, (29) drilled holes, (30) round wire, (31) drilled hole, (32) cover, (33, 34, 35 and 36) strip, (37) bead weld, (38) polyurethane filler, (39) mortar, (40) insulation, (41) plaster coating, (42) tiles, (43) slate pieces, (44) inner board, (45) hole, (46) floor, (47) ground, (48) plate, (49) plate, (50) connector, (51) reinforcing round wire, (52) outer face, (53) top piece, (54) foundation hole, (55) housings, (56) reinforcing wire, (57) outer board, (60) tarmac material, (61) clean cement, (62) filler mortar, (63) expanded polyurethane board, (64) concrete slab.

Figure 1(a) is a side view, (b) is a longitudinal cross-section, (c) transversal cross-section of the single board (10), manufactured in accordance with the system in this invention.
Figure 2 (a), is a side view, (b) a transversal cross-section of a double enclosure board (11), (C. and D.) a transversal cross-section is manufactured in accordance with the system in this invention.
Figure 3 is a view of edge strip (12) used for edging the double enclosure board (11).
Figure 4 (a) is a detail of a connector (15) for joining an angled piece (26) to a mesh (14) not shown in the drawing, (b) detail of a connector (15) joined to a double mesh (16) and an angled piece (26).
Figure 5 is a detail of a side view of an edge piece (12) for transferring and assembly of a double enclosure board (11), (a) longitudinal section, (b) transversal section, (c) top view.
Figure 6 is a detail of the join between two double board walls (11) forming an outer corner.
Figure 7 is a detail of the join between two double board walls (11) covered with stone or cement (17) forming an inner corner.
Figure 8 is another detail of the join between two double board walls (11) forming an inner corner.
Figure 9 is an alternative detail of the join between two double board walls (11) forming an inner corner with an outer cover of stone or cement.
Figure 10 is a detail of the join between two single cement board walls (10) a) with an inner coating of stone and cement (17), (b) with an outer covering (17) of stone or cement.
Figure 11 is a detail of the join between a reinforcing board (18) with a double exterior board (11), on the board (18) there is the ground or flooring (47).
Figure 12 is a reinforcing board (a) seen from above (b), in the longitudinal cross-section (c) in transversal section.
Figure 14 is a detail of the strips (19) for welding vertical joints between boards (10) and (11) with their connectors (50) welded to (19), (a) front view (b) top view, (c) side view, (d) in perspective.
Figure 15 is a perspective with a detail of the join between reinforced boards (18) with its flooring (47) and double vertical enclosure boards (11), joined by welding the angle pieces (26).
Figure 16 is a partial longitudinal cross-section of the detail of the join between reinforcing boards (18) with the assistance of some angled pieces (26).
Figure 17 is a transversal side view of the join between double vertical boards (11) with a reinforcing board (18) with its flooring (47).
Figure 18 is a perspective view of the construction of an enclosure (20) based on two double boards (11) of the same height with the assistance of strips (48).
Figure 19 is a perspective view of the construction of an enclosure (21) based on two double boards (11) of the same height using strips (49).
Figure 20 is a view (a) from above of a cover board (21), (b) a longitudinal cross-section, (c) a transversal section.
Figure 21 are some perspective views showing (a) the attachment of some covering boards with an end strip (24) forming a covered view and (b) resting on some enclosure boards (11) with the assistance of some support panels (22). Figure 22 are some perspective views showing the detail of the covering boards joining the end strip (24), (a) is a view of the join of the two covering boards with the end strip (24) with the assistance of angled pieces (26), (b) is a view of some support panels (22) for covering boards with end strips (24).
Figure 23 is a partial transversal cross-section of a covering board (21) with hook detail (23) to be safely transferred to a double mesh (16).
Figure 24 is the transversal cross-section of an end covering piece (24).
Figure 25 is a partial transversal cross-section of an Arab tile roof (42) based on covering boards (24) meeting double enclosure boards (11).
Figure 26 is a partial transversal cross-section of a slate roof (43) meeting double enclosure boards (11).
Figure 27 is a perspective view which shows (a) the method of joining single boards (10) or double boards (11), (b) between boards (10) and a reinforcing board (18) using plates (33, 34 and 35).
Figure 28 is a detail of the joint for panels of all types, single or double, forming a head (10, 11) at their ends by welding (37) angled pieces (26).
Figure 29 is a partial transversal cross-section of a detail of a joint between double boards (11) by welding (37) angled pieces (26).
Figure 30 is a partial transversal cross-section of a detail of the joint of single boards (10) by welding (37) angled pieces (26).
Figure 31 is the partial transversal cross-section with detail of a top piece (53) finished with tiles (42) based on covering boards (21) protected by an insulating layer (40). Figure 32 is a partial transversal cross-section of the detail of a top piece (53) finished in zinc using covering boards (21) protected by an insulating layer (40) and pieces of slate (43).
Figure 33 is a perspective view of a strip (49) designed to join double boards (10) as shown in the following drawing.
Figure 34 is a partial longitudinal cross-section of the joint between a single vertical board (10) with another horizontal single board (10) using a strip (49).
Figure 35 is a perspective view of a strip (50) designed to join two single panels (10).
Figure 36 is a longitudinal cross-section with a detail of a vertical single board (10) joining a horizontal single board (10) using a strip (50).
Figure 37 is a longitudinal cross-section of the joint between two boards (11) using a strip (50) and welding (37) the angle pieces (26).
Figure 38 is a longitudinal cross-section of the joint between two boards (10) using a strip (50) and welding (37) the angled pieces (26).
Figure 39 was a partial longitudinal cross-section of a foundation hole (54) constructed in accordance with the purposes of this invention.
Figure 40 is a partial longitudinal cross-section of insulated housings (55) constructed in accordance with the purposes of this invention into which the double boards are located (11).
Figure 41 is the longitudinal cross-section of a detail of the surface foundation using insulated housings (55) located in filled in land using reinforcing (56).
In one of the preferred implementations for this patent application, the recommended system is formed by combining the following elements:
- single boards (10)
- double enclosure boards (11) with an interior board (44) and an outer board (57)
- a reinforcing board (18)
- an enclosure board (21)
- end strips (24)
- strips (33, 34, 35, 36, 48 and 49).

The single boards (10) is one of the purposes of the invention as shown in Figure 1 and is formed by a double mesh structure (16) filled with cement with angled pieces on its side ends with the relevant UPN (26). All of this is shuttered within a mould. Where these single boards (10) have openings (25) they are reinforced around the edges by the corresponding bars (27) joining mesh (16) to UPN angled pieces (26) using connectors (15) as seeing in view (c) of Figure 1.
Double enclosure boards (11) as shown in Figure 2, have the same robust structure as that described for single boards (10) except, as can be seen in Figure 2b, that they are formed by two boards on the outer (57) 60 mm thick for the enclosure and another in a board (44) 80 mm thick with a structural function, with an insulating layer (40) in the middle.
In order to reinforce openings (25) as shown in Figure 20, the same procedure as that described for boards (10) is followed. Joining the double mesh (16) on the double enclosure boards (11) with the UPN (26) angled pieces may be seen in Figure 3 and 4. The UPN (26) receive connectors (15) on their horizontal section. These connectors (15) are perpendicular to the angled pieces (26) and are parallel to their wings. If a double board is used (11), they are perpendicular to their wings as shown in Figure 4b as the connectors are perpendicular to the base (26).
Given that the boards in the system (10), (11), (18), (21) and (22) are difficult to move because of their weight and in order to facilitate their handling, hooks formed by round wires (30) have been designed as shown in Figure 5. These are welded to the wings of the UPN (26) as shown in Figures 5(a) and (c). These wings have a drill hole (31) on their horizontal section (26) so that the operator with a crane passes the hook on the aforementioned equipment through the hole (31) around the round wire (30) and, remaining in his position, moves the double board (11).
Another alternative use of a hook is as shown in Figure 5(b) which shows the UPN (26) wings to which the round wire has been welded (30) and the connector (15) welded to a metal cover (32).
The reinforcing boards (18) which may be seen in Figure 12 comprised of a double mesh (16) and in view (p) and may be handled using hooks as shown in Figure 13. These are formed by a U-shaped round wire (28) which extends into horizontal arms which are welded to the double mesh (16) projecting from the surface of the boards (18) from drilled holes (29) as seen in Figure 12 (8) and (13). In this way the hock on a conventional crane is attached below the round wire (28) and in this way it is possible to transfer the aforementioned reinforced boards (18) to a suitable point. The enclosure boards (21) as seen in Figure 20(a) and (b) have a structure formed by a double mesh (16) to which has been added two rounded bars (58) as a means of a reinforcing for the board handling hooks (21) described as shown in Figure 13.
The construction system using the single (10), double (11) reinforcing (18) and enclosing (21) boards can be seen by combining the same as shown in Figure 27 joined by the UPN angled pieces (26), welded to a point has shown in detail one and three of view (b) of Figure 27 or by using single plates (19), (33), (34) and (35) welded to the UPN (26) at suitable points as shown in details 2, 4 and 5. Also in Figure 27 view (b) there is the same construction has in view (a) but which has been enlarged to show more detail of the plate and joining system (10) and (11) all of the head with continuous planed bead welding (37) all using the relevant plates (33), (34) and (35) resting on a reinforcing board (18) and held (10) to (18) using strips (33).
The double enclosure boards with end pieces (24) as seen in Figure 21 (b) are supported on support panels (22) which form the shape of the enclosure and slope of the enclosure boards (21) or end piece (24). As can be seen in view (a), two enclosure boards (21) are joined at their head by welding the UPN angled pieces (26) using strips (36) located at regular distances. These boards (21) rest on panels (22) and these panels of rest on the upper parts of the UPN angled pieces (26) located on the boards (11).
In the event that the roofing of a building is formed by several enclosure boards with end pieces (24), they are joined by 4 mm horizontal, continuous planed bead welding (37) on the angled pieces as shown in Figure 22(a).
All types of enclosures are possible with this procedure as shown in Figures 25, 26, 31 and 32. These show a section of the enclosure by joining double boards (11), fitted with the corresponding heat insulation (40) in such a way that the enclosure board with end pieces (24) is supported on the double board (11) more specifically on the UPN angled pieces (26) interspersed with polyurethane filler (38) and mortar (39). An insulation board (40) is located on top of the enclosure board (24) and on this, a plaster board (41) and finally the relevant tiles (42) are placed on top.
Another similar use of the above as shown in Figure 26 is where the enclosure is constructed using the same system as described in Figure 25, the only change being three pieces of slate (43) instead of tiles (42).
Flooring in blocks of flats is formed by joining the reinforced boards (18) with double boards (11) as shown in Figures 15, 16 and 17. Figure 15 shows the joint between a double board (11) or a reinforced board (18) by cutting the inner face (44) of (11) to insert the head of the board (18). The enclosure wall is formed by boards (11) with the UPN angled pieces (26) welded to the head and the reinforcing strips (18) located in the hole (45) made by the two inner faces (44) of the aforementioned boards (11).
A floor (46) is formed by one or more reinforcing boards (18) for example as shown in Figure 16 joined by UPN (26) with a layer of plaster filling (62) on the upper surface of the reinforcing board (18) so equipment may move through if necessary. Flooring pieces (47) are placed on top of the layer (42).
In the event that double enclosure walls are to be made; rectangular plates (48) welded to the wings of the UPN angled pieces (26) on the plates (11) are located at regular distances of 150 cm as shown in Figure 18. These are welded four centimetres on each side of the plate. In the event that the enclosure wall is formed by two boards (10) or (11) at different heights, L-shaped plates (49) are used. These are welded at one end to the base of the angled piece (26) and to the wings of the UPN (26) at the other end as shown in Figure 19.
Board joints may be single (10) or double (11) ended as shown in Figures 28, 29 and 30. Here the angled metal pieces or UPN (26) are welded using a single planed bead welding (37) both for double mesh boards (16) as shown in Figure 37 and for single mesh boards (14) as shown in Figure 38.
Joining single or double boards (10, 11) at their ends may be carried out with plates (49) as shown in Figures 35 and 36. Figure 30 5(a) includes connectors (50) to the mesh (14 or 16) in Figures 34 and 36 with the addition of a reinforcing round wire (51) and welded to the plate (49) and to the angled piece (26).
Another aspect of the invention is joining single or double panels (10) and (11) at their ends by welding metal angled pieces (26) to a plate (50) and reinforcing (18) as seen in Figures 37 and 38.
Two double boards (11) meet to form an outer corner as shown in Figures 6, 7, 8, 9 and 10 (a) and (b) by joining the boards (11) to a point and sometimes injecting a polyurethane filler (38) by cutting the inner face (44) of the double boards (11), (see Figure (6). The joint between a double board (11) and a single board (10) see Figure 7 and the coating for the latter (10) using an outer stone coating (17) is made using an injected polyurethane filler (38) between (10) and (17), by cutting the inner face (44) and welding the outer face (52) using the UPN (26) and the UPN (26) on the board (10).
In order to finish off the preferred system and for the support and strengthening the boards (10, 11), foundation holes have been designed (54) in which the double boards (11) or similar objects rest on a concrete slab (64) formed by a concrete housing (55) which rests on the clean concrete (61) on firmer ground, see Figures 39 and 40. The ground is built with a layer of mortar (59) and with flooring (47) on top.
Where there is a filled land or similar in the foundation pieces, see Figure 41, a reinforced structure (56) is added as strengthening underneath the housing (55). This increases the strength of the foundations supporting the base construction for the aforementioned boards (10, 11). The floor is constructed from a layer of mortar (59) with flooring (47) on top.

Claims

- "A CONSTRUCTION SYSTEM BASED ON PREFABRICATED BOARDS", using boards manufactured in a factory with moulds based on combining a very strong structure and cement, being characterised the aforementioned system by the combination of single boards (10), double boards (11), reinforced boards (18), cover boards (21) and eaves boards (24) held to each other using welded strips (37), applied to "UPN" frames (26) at their edges, assisted where necessary by plates (19, 33, 34, 35, 36, 48 and 49).
- "A CONSTRUCTION SYSTEM BASED ON PREFABRICATED BOARDS", according to the first claim characterised by the fact that the single boards (10) are formed by a double mesh structure (14) to which U-shaped connectors (15) have been welded at regular distances which in turn are welded at the ends to the "UPN" (26) all of which is filled with concrete in the corresponding mould.
- "A CONSTRUCTION SYSTEM BASED ON PREFABRICATED BOARDS", according to the first claim characterised by the fact that the double boards (11) are formed by two single boards, an internal board (44) 60 mm to 200 mm thick with a structural function and another 60 mm external board (57) acting as a seal with a 40 to 80 mm intermediate insulating layer (40) which includes a resistant structure formed by the double mesh system (16) to which are welded the corresponding U-shaped connectors (15)which in turn are welded to the "UPN" (26), all of which is filled with concrete in the corresponding mould.
- "A CONSTRUCTION SYSTEM BASED ON PREFABRICATED BOARDS" according to the aforementioned claims wherein the boards (10) and (11) have openings (25), boards (10) and (11) are reinforced by reinforcing rings (27) around the edge of the openings (25) welded to single or double mesh (14) and (16), all of which is filled with concrete in the corresponding mould.
- "A CONSTRUCTION SYSTEM BASED ON PREFABRICATED BOARDS" according to the first claim characterised by the fact that the reinforcing boards (18) are formed by a double mesh structure (16), welded at regular distances by U-shaped connectors (15) the ends of which are welded to the "UPN" (26), with the aforementioned mesh (16) including longitudinal, corrugated reinforcing rings (58), at regular distances for use as a connecting system formed by U-shaped hooks (28)the arms of which extend horizontally and are welded to the double mesh structure (16), with vertically drilled holes (28) (29) to accommodate the conventional hooks.
- "A CONSTRUCTION SYSTEM BASED ON PREFABRICATED BOARDS" according to the first claim characterised by the fact that the system uses plates (19) (33), (34), (35) welded to the "UPN" (26) to hold the single or double boards (10) and (11) to reinforcing boards (18).
- "A CONSTRUCTION SYSTEM BASED ON PREFABRICATED BOARDS" according to the first claim characterised by the fact that the eaves covering board (24) is supported on panels (22), which define the shape of the covering and support (22) on enclosing walls formed by double boards (11).
- "A CONSTRUCTION SYSTEM BASED ON PREFABRICATED BOARDS" according to the first and seventh claim characterised by the fact that covering is formed by eaves covering boards (24) welded to the head by plates (36) located at regular intervals on the UPN frames(26) of the boards (21).
- "A CONSTRUCTION SYSTEM BASED ON PREFABRICATED BOARDS" according to the first claim characterised by the fact that the enclosing walls may be formed by double boards (11) joined at regular distance by angular plates (49) welded at one end to the frame (26) and at the base, and at the other end to one of the wings of the other frame (26).
- "A CONSTRUCTION SYSTEM BASED ON PREFABRICATED BOARDS" according to the first claim characterised by the fact that the enclosure walls may be formed by double boards (11) joined at their "UPN" (26) by rectangular plates (48) welded to their shorter ends to the wings of the aforementioned frames (26) on each side of (48).
- "A CONSTRUCTION SYSTEM BASED ON PREFABRICATED BOARDS" according to the first, second and third claims characterised by the fact that, during the construction of flats, reinforcing boards are used (18) with double boards (11), cutting the inner face (44) of (11) to allow the face of board (18) to enter, housing it on the edge of (18) in the opening (45) delineated by the inner faces (44).
- "A CONSTRUCTION SYSTEM BASED ON PREFABRICATED BOARDS" according to the first claim characterised by the fact that the floors are formed by the union of two "UPN" (26) reinforcing boards (18) using discontinuous welding of the frames (26) and applying a layer of mortar on them (62) and on the wall of the covering (46).
- "A CONSTRUCTION SYSTEM BASED ON PREFABRICATED BOARDS" according to the first and seventh claim characterised by the fact that covering is formed by eaves covering boards (24) supported on double boards (11) with the insertion in the contact area between (24) and (11) of an injected polyurethane filler (38) and mortar (39) with, on top of board (24) heat insulation (40), mortar (41) and an Arab tile finish (42) or pieces of slate (43).
- "A CONSTRUCTION SYSTEM BASED ON PREFABRICATED BOARDS" according to the first claim characterised by the fact that a covering may be formed by covering boards (21) joined at regular distances by plates (36) welded to the "UPN" (26) a regular distances, covered (21) by heat insulation material (40), a layer of mortar (41) and tiles (42) and ridges (53).
- "A CONSTRUCTION SYSTEM BASED ON PREFABRICATED BOARDS" according to the first, second, third and twelfth claims characterised by the fact that in the construction of flats, floors are formed by placing reinforced boards (18) with double boards (11), cut on their inner face (44) by (11) to locate a board head (18), housing the edge of (18) in the opening (45) delineated by the inner faces (44) and welded to the respective "UPN" (26) on the edge of the inner boards (44) of (11) with the edge "UPN" (26) of the reinforcing board (18).
- "A CONSTRUCTION SYSTEM BASED ON PREFABRICATED BOARDS" according to claim 1, 2, 3, 12 and 15 characterised by the fact that the joint between a vertical single board (10) and another horizontal board (10) uses a plate (49) welded to a "UPN" (26) on the edge of the horizontal board (10) and its connectors (15) welded to single mesh (14) and connectors (50) of a single board (10) welded to its mesh (14) using a reinforcing ring (51).