Patent Application
20240410168
The present disclosure generally relates to construction technology. In particular, the present disclosure relates to construction of prefabricated wall(s) for use in construction technology.
Existing construction technologies involve one-off (e.g., customized) build-on site approaches in which construction material is brought to the construction site where the actual construction is performed. This has been the traditional methodology and approach for many years but has certain inherent challenges, including non-availability of skilled workforce (e.g., manual labor), heavy and expensive on-site machinery, incorrect estimate of completion time of construction projects, delays in delivery of projects, inclement weather, poor quality and wastage of materials, noise and air pollution, and cost involved in disposal of debris. This approach is also “one-off” as it provides no repeatability or scalability leverage. Each building is constructed and each project is performed differently, and results vary widely, which may be undesirable considering present day demand for symmetrical construction projects with enhanced look and feel. However, constructing each individual component of a building on site incurs significant expenditures in time and resources. It also increases a project's vulnerability to unforeseen factors, such as poor weather, worksite accidents, improper pour, etc.
In order to address the aforesaid shortfalls of these build-on site approaches, some construction projects use prefabricated building modules. For example, walls could be prefabricated at factories under factory scaling, repeatability, and in-factory conditions, and then delivered to a building site for expeditious on-site assembly. These walls are lightweight due to less material requirements, are faster to make, and have better performance.
Further, execution of construction projects needs an ensemble of technologies/domains such as structural integration, civil engineering, mechanical joints, materials science, etc. Although there have been significant advancements in construction technologies, due to the above factors, the average cost of construction and the effective cost of owning a house is still high for a majority of aspiring owners. Needless to say, housing still remains beyond the reach of many due to associated construction costs.
Accordingly, there remains a need in the art for constructing a modular housing system based on improved and robust prefabricated walls to withstand load, climate changes, and daily wear and tear as may be subjected to any house or establishment. Alternatively, there lies a need for improved and better-quality prefabricated walls.
Embodiments for constructing and interconnecting building blocks/modules in construction technology that address at least some of the above challenges and issues are disclosed.
In a first aspect, the present disclosure is directed to a wall assembly that includes a plurality of girders each including a first insulator and having a longitudinal axis, the plurality of first insulators spaced apart along a first direction transverse to the longitudinal axes. Further, the wall assembly includes one or more second insulators, and fastening elements coupled to the plurality of girders and supporting the one or more second insulators along the first direction between sequentially spaced ones of the plurality of girders. Furthermore, the wall assembly includes a first concrete layer coupled to surfaces of the plurality of first insulators and the one or more second insulators.
In some embodiments, the wall assembly further includes a second concrete layer. Further, in some embodiments, the first and second concrete layers sandwich the plurality of first insulators and the one or more second insulators.
Furthermore, in some embodiments, surfaces of the plurality of first insulators and the one or more second insulators are substantially co-planar. Additionally, in some embodiments, the first concrete layer, the second concrete layer, or both include fiber reinforced concrete (FRC).
In some embodiments, the fastening elements include one or more clips each having a vertex and a first leg with a first end, each first end supporting one of the one or more second insulators between sequentially spaced ones of the plurality of girders. Further, in some embodiments, the first ends urge the one or more second insulators towards the first concrete layer. Furthermore, in some embodiments, each of the one or more clips has a second leg with a second end, the first and second ends urge sequentially spaced ones of the one or more second insulators towards the first concrete layer. Additionally, in some embodiments, the wall assembly further includes, for each girder from the plurality of girders: a rod extending parallel to the longitudinal axis of the girder, the vertexes of the one or more clips coupled to the rod. In addition, in some embodiments, each girder from the plurality of girders includes one or more connectors coupling the girder to the rod. In addition, in some embodiments, for each rod from the plurality of rods, the one or more connectors alternate with the one or more clips along a longitudinal axis of the rod.
In some embodiments, each of the plurality of first insulators includes Extruded Polystyrene Insulation (XPS), and each of the one or more second insulators includes Expanded Polystyrene Insulation (EPS).
In some embodiments, the plurality of first insulators alternate with the one or more second insulators along the first direction.
In some embodiments, the plurality of girders are coupled to each other along the first direction through at least one of: a plurality of angle shaped connectors, a plurality of box connectors, and a plurality of iron bars.
In a second aspect, a method of manufacturing a wall assembly includes arranging a plurality of girders spaced apart from each other along a first direction transverse to longitudinal axes of the plurality of girders, each of the plurality of girders including an associated first insulator; coupling a first concrete layer to the plurality of first insulators; securing one or more second insulators between adjacent ones of the plurality of girders along the first direction; and coupling a second concrete layer to the first concrete layer such that the first and second concrete layers sandwich the plurality of girders, the plurality of first insulators, and the one or more second insulators. In some embodiments, securing the one or more second insulators between the adjacent ones of the plurality of girders includes urging the one or more second insulators towards the first concrete layer. In some embodiments, the method further includes, for each of the plurality of girders, anchoring one or more clips along the longitudinal axis of the girder, each of the one or more clips having a vertex and a first leg extending therefrom, the first leg opposing a surface of one of the one or more second insulators. Preferably, each of the one or more clips further includes a second leg extending from a corresponding vertex in a direction opposite the first direction, the second leg opposing a surface of another of the one or more second insulators.
In some embodiments, for each of the plurality of girders, anchoring the one or more clips along the longitudinal axis of the girder includes coupling the vertexes of the one or more clips to a corresponding rod extending from a surface of the first insulator. Preferably, coupling the first concrete layer to the plurality of first insulators includes elevating surfaces of the plurality of first insulators above a floor of a mold, introducing a concrete mixture into the mold to a height substantially abutting the surfaces of the plurality of first insulators, and allowing the concrete mixture to harden, thereby forming the first concrete layer.
In some embodiments, each of the plurality of first insulators includes Extruded Polystyrene Insulation (XPS), and each of the one or more second insulators includes Expanded Polystyrene Insulation (EPS). In some embodiments, the first concrete layer and the second concrete layer include fiber reinforced concrete (FRC).
In a third aspect, a wall assembly includes a first wall panel disposed opposite a second wall panel, thereby defining a volume therebetween; a fastening assembly including a girder coupled to a first insulator and disposed within the volume, a longitudinal axis of the first insulator corresponds to a height of the volume and a second axis transverse to the longitudinal axis corresponds to a length of the volume; and one or more second insulators disposed within the volume and secured along a length of the volume by the fastening assembly. In some embodiments, the fastening assembly further includes one or more clips, each of the one or more clips having a first section and a first leg having a first end, and the first end and the first wall panel sandwiching the first insulator. In some embodiments, the one or more clips are spaced apart along the height of the girder.
In some embodiments, the fastening assembly further includes an upper chord engaging each of the one or more first sections. Preferably, each of the one or more first sections includes a bend for engaging the upper chord. In some embodiments, the girder includes a lattice girder including one or more lower chords, the upper chord, and one or more connectors coupling the one or more lower chords to the upper chord.
Preferably, the wall assembly further includes a third insulator, the first insulator and the third insulator being disposed on opposite sides of the girder along the second axis, where each of the one or more clips further includes a second leg extending from the first section opposite first leg along the second axis, the second leg having a second end, the second leg configured to support the third insulator within the volume. In some embodiments, the girder includes one or more connectors supporting the upper chord.
In some embodiments, the one or more connectors are spaced apart along the height of the girder. Preferably, each of the one or more first legs is configured to support the first insulator within the volume, and each of the one or more the first legs is configured to urge the first insulator against the first wall panel.
Preferably, the first insulator, the second insulator, or both include a modular insulator block.
Further advantages of the disclosure will become apparent by reference to the detailed description of preferred embodiments when considered in conjunction with the drawings. In the drawings, identical numbers refer to the same or a similar element.
The following detailed description is presented to enable any person skilled in the art to make and use the disclosure. For purposes of explanation, specific details are set forth to provide a thorough understanding of the present disclosure. However, it will be apparent to one skilled in the art that these specific details are not required to practice the disclosure. Descriptions of specific applications are provided only as representative examples. Various modifications to the one or more embodiments will be readily apparent to one skilled in the art, and the general principles defined herein may be applied to other embodiments and applications without departing from the scope of the disclosure. The present disclosure is not intended to be limited to the embodiments shown, but is to be accorded the widest possible scope consistent with the principles and features disclosed herein.
With modernization in construction-related technologies, there has been a rapid shift from normal customized build on-site construction methodologies to construction using modules or blocks (or artefacts) that can be built off-site. However, in such an approach, it may be of utmost concern that the modules are manufactured in such a manner that they are easy to transport, integrate, assemble, or mount on any construction site. Current manufacturing technologies fail to address this concern. The embodiments of the present disclosure address this concern by providing improved, multi-layered, and robust prefabricated components.
The disclosed solutions/architectures provide at least an improved multi-layered wall assembly of prefabricated components such as wall panels to withstand load, climate changes, and daily wear and tear as may be subjected to any house or establishment. The wall assembly provides advantages in its simplicity of manufacture and system performance. By leveraging a controlled environment production, wall assemblies in accordance with the present disclosure ensure quality, cost reduction, and speedy installation.
Further, these wall assemblies exhibit energy efficiency. In some embodiments, wall assemblies in accordance with the disclosure have R-values of R-28 or more, far above R-values of conventional wall systems. Preferably, the wall assemblies include insulation layers that increase its thermal mass.
Further, wall assemblies in accordance with the present disclosure exhibit substantial fire resistance, with fire-resistance ratings of 1½ hrs or more. In some embodiments, these high ratings are achieved by using concrete or other fire-resistant materials. Among other things, these characteristics reduce insurance costs due to increased safety, security, reliability, and structural soundness.
Structurally, wall assemblies in accordance with the present disclosure include load bearing composite panels with very high loading capacity and further offer resistance to wind, hurricanes, floods, and other damaging environmental occurrences. Acoustically, these wall systems exhibit a Sound transmission class (STC) rating of over 49.
Further, in some embodiments, walls in accordance with the present disclosure are made of synthetic fiber reinforced concrete polypropylene (FRC PP), thereby requiring no or minimal reinforcement steel and ensuring better performance in service, less labor, faster manufacturing, and reduced cost.
Certain terms and phrases have been used throughout the disclosure and will have the following meanings in the context of the ongoing disclosure.
“LGS” refers to Light Gauge Steel framing, which is a construction technology that uses cold-formed steel as a construction material.
“R-value” refers to a measure of thermal resistance, where R stands for resistance to heat flow. An R-value is specified for every layer of material, and United States energy codes only refer to the R-values of insulation layers in the prescriptive R-value compliance path.
“IECC” refers to the International Energy Conservation Code. IECC provides three paths for compliance for a building envelope. The first path specifies the required minimum level of insulation in the wall, i.e., R-value; the second path specifies U-factors for the building envelope components; and the third path, in which an annual energy use analysis is required, is based on the total building energy cost budget for heating, cooling, and service water heating.
“SFH” refers to single-family home, which typically has one unit intended to house a single family.
“Wall panel” refers to a prefabricated multi-layered wall fabricated at an offsite location and installed on-site, wherein “on-site” denotes a construction site and “offsite” denotes away from the construction site.
“Modular” refers to individual and independent blocks or any mechanism or procedure for arranging them.
“Lattice girders” are three-dimensional, industrially prefabricated reinforcing elements. They consist of an upper chord, two lower chords, and continuous truss wires (e.g., diagonal chords). Typically, the continuous truss wires are connected to the chords by means of electric resistance welding.
“Cast-in-place concrete” or “Cast-in-situ concrete” is a building-construction technology where walls and slabs of the buildings are cast at the site in formwork.
In some embodiments, the wall assembly 100 also includes a plurality of clips 108 tied/secured from a first end to the plurality of girders 101 outside the first concrete layer 106. In some embodiments, the plurality of girders 101 are placed adjacent to the first concrete layer 106. In some embodiments, the plurality of clips 108 may include gull wing clips, tension spring clips, or similar functioning elements. The plurality of clips 108 are anchored to the plurality of girders 101 through an arrangement including a plurality of rods 114 supported substantially parallel to the longitudinal axis 114A of the plurality of girders 101, such that the plurality of clips 108 are anchored to the plurality of rods 114 substantially parallel to the longitudinal axis 114A of the plurality of girders 101. In some embodiments, the plurality of clips 108 are anchored at a plurality of positions between successive connectors of the plurality of connectors 102.
Further, one or more second insulators 110 are supported at a plurality of second ends of the plurality of clips 108 atop or parallel to the first concrete layer 106. In some embodiments, the second insulator 110 includes Expanded Polystyrene Insulation (EPS) that extends transversely with respect to the plurality of girders 101. Further, in some embodiments, the second insulator 110 includes modular insulation blocks. Preferably, the first insulator 104 and the second insulator 110 are disposed alternately along a width of the first concrete layer 106.
In some embodiments, a second concrete layer 112 is disposed atop or parallel to the first concrete layer 106 and the second insulators 110, such that the first 106 and second 112 concrete layers sandwich the first insulators 104 and the second insulators 110. In some embodiments, one or both of the first concrete layer 106 and the second concrete layer 112 include fiber reinforced concrete (FRC). In some embodiments, the arrangement of the first insulators 104 and the second insulators 110 provide a substantially seamless wall of insulation adjacent the first concrete layer 106. Further, in some embodiments, the second concrete layer 112 is displaced from, and substantially parallel to, the first concrete layer 106, forming a cavity therebetween. In some other embodiments, the first 106 and second 112 layers of concrete are not substantially parallel.
In accordance with some embodiments described by
In some embodiments, the XPS 104 and Expanded Polystyrene Insulation (EPS) 110 (shown in
Wall assemblies in accordance with the present disclosure impart durability and adaptability, since they enjoy a long life due to their durable and low-maintenance surfaces. Insulated sandwich panels paired with precast concrete construction in accordance with the disclosure also provide moveable and reusable panels when refurbishing buildings rather than requiring prior art components, which require dismantling the panels altogether.
The wall assembly 100 in accordance with the present disclosure offers negligible air infiltration, lower energy costs, and improved moisture resistance.
The wall assembly 100 in accordance with the present disclosure is easy and economical to manufacture since concrete is cheap and readily available, used in almost every country of the world as a basic building material. Indeed, the largest ingredients of concrete, about 85% of its content, are generally low-energy, local, naturally occurring sand and stone. Moreover, on average, precast concrete plants are found within 200 miles (300 km) of many building sites. Appropriating local materials reduces the transportation required to ship heavy building materials, and the associated energy and emissions.
The wall assembly 100 in accordance with the present disclosure improves indoor environmental quality as concrete contains low to negligible volatile organic compounds (VOCs). The exposed concrete walls in accordance with present disclosure do not require finishing materials, eliminating particulates generated from sanding drywall and taping seams. Further, wall assemblies in accordance with the disclosure mitigate the urban heat-island effect, since they provide reflective surfaces that minimize the urban heat-island effect.
As a part of factory setting or preliminary steps, the lattice grid girder may be constructed by means known in the art. In accordance with some embodiments, for example, the lattice grid girder is produced by providing stainless steel for diagonal bars and reinforcement steel for the upper chord and the lower chord, cutting the bars and chords to specified lengths, welding them in place, and cutting the joined elements according to one or more specifications.
Thereafter, XPS 104 and EPS 110 may be prepared based on specifications. Based on the required length of the lattice grid girder, the XPS 104 is attached into the lattice grid girder. In some other embodiments, other cast-in-place items, such as a headed anchor, are connected to the girder for lifting purposes.
In some embodiments, the method 200 includes processes in accordance with the present disclosure which can be controlled or managed by a processor(s) and electrical components under the control of a computer or computing device including computer-readable media containing computer-executable instructions or code. The readable and executable instructions (or code) may reside, for example, in data storage such as volatile memory, non-volatile memory, and/or mass data storage, as only some examples. As explained later, in some embodiments, automation of the method 200 through a computer employs various peripherals such as sensors, robotic arms etc. to operate upon the wall assembly 100 during installation.
To generalize the explanation that follows, it is presumed that the level and flatness of a base mold used for preparation of the wall assembly is checked before assembling the mold for panel casting. Next, in accordance with some embodiments, the following steps are performed: The dimensions of the mold are checked to ensure that they are within the specified tolerances. In an example, the squareness of the mold forms is checked. Next, the mold is checked to ensure that it is clean and free from debris and old mortar. In some embodiments, the form oil or mold release agent is applied evenly over the mold surface. Finally, the joints and edges of the mold, stopper, side props and rubber seal are checked to ensure that they are intact and properly secured.
At step 202, a plurality of girders 101 (spaced apart from each other) are arranged in a mold along a first direction transverse to longitudinal axes of the plurality of girders 101. In some embodiments, each of the plurality of girders 101 includes an associated first insulator 104. In some embodiments, the first insulators 104 extend longitudinally along the plurality of girders 101. In some embodiments, the plurality of first insulators 104 includes XPS. In some embodiments, a plurality of girders 101 are joined with each other through at least one of: a plurality of angle shaped connectors, a plurality of box connectors, and a plurality of iron bars. In some embodiments, each of the plurality of girders 101 includes a lattice grid girder that is fixed with a precast angle plate and box plate connector, lifted, and cast in-place. In some embodiments, an optimum number of spacers with the correct sizes are properly placed and secured to achieve the required concrete cover during casting.
At step 204, a first concrete layer 106 is coupled to the plurality of first insulators 104. In some embodiments, the first concrete layer 106 is coupled to the plurality of girders 101 at the first insulators 104 by elevating surfaces of the plurality of first insulators 104 above a floor of the mold 505, introducing a concrete mixture into the mold 505 to a height substantially abutting the surfaces of the plurality of first insulators 104, and allowing the concrete mixture to harden, thereby forming the first concrete layer 106.
At step 206, second insulators 110 are inserted between successive ones of the plurality of girders 101. In some embodiments, the plurality of second insulators 110 includes EPS.
At step 208, additional second insulators 110 may be coupled to end/edge ones of the plurality of girders 101. In some embodiments, step 208 is an optional step performed, for example, when a clip secures a single second insulator to the first concrete layer, such as the single-leg clips 108′ adjacent to the inner perimeter of the mold 505 shown in
At step 210, the one or more second insulators 110 are secured or otherwise maintained between adjacent ones (and, optionally at the edges) of the plurality of girders 101 along the first direction, such as by using fastening assemblies, such as rod and clip arrangements, described above. In some embodiments, the one or more second insulators 110 are secured between the adjacent ones of the plurality of girders 101 by urging the one or more second insulators 110 towards the first concrete layer 106.
At step 212, a second concrete layer 112 is coupled to the first concrete layer 106 such that the first 106 and second 112 concrete layers sandwich the plurality of girders 101, the plurality of first insulators 104, and the one or more second insulators 110. In some embodiments, the second concrete layer 112 abuts, contacts, or is adjacent to surfaces of the first insulators 104 and the one or more second insulators 110. In some embodiments, the first concrete layer 106 and the second concrete layer 112 include FRC.
At step 214, the wall assembly including all the above discussed elements is erected on a foundation. In some embodiments, the foundation is a precast foundation.
In one aspect, a system (in an example, a computer) for performing the steps of method 200 is automated. Preferably, the computer includes a memory storing computer-executable instructions that when executed by a processor perform the steps of method 200. In different embodiments, a single robot arm or a pair of robot arms may be used to hoist/lower components, align them, and secure them in place.
In accordance with some embodiments, the wall assembly 100, as explained in the preceding figures may be used to achieve a rapid construct cross-section, such as an LGS modular construction. A plurality of blocks, such as the rapid construct cross-section, may be combined to allow rapid on-site assembly and completion of the house. In some embodiments, the rapid construct cross-section may be used for SFHs.
In some embodiments, the rapid construct cross-section includes a bottom portion attached to the foundation, a middle portion similar to the wall panel discussed previously in
It will be appreciated that the resulting rapid construct blocks obtained due to their construction technology are high quality, forming repeatable and scalable SFHs. They form an IECC energy compliant high-performance envelope.
With reference to the building blocks disclosed in
The terms “comprising,” “including,” and “having,” as used in the specification herein, shall be considered as indicating an open group that may include other elements not specified. The terms “a,” “an,” and the singular forms of words shall be taken to include the plural form of the same words, such that the terms mean that one or more of something is provided. The term “one” or “single” may be used to indicate that one and only one of something is intended. Similarly, other specific integer values, such as “two,” may be used when a specific number of things is intended. The terms “preferably,” “preferred,” “prefer,” “optionally,” “may,” and similar terms are used to indicate that an item, condition, or step being referred to is an optional (not required) feature of the invention. The term “connecting” includes connecting, either directly or indirectly, and “coupling,” including through intermediate elements.
The invention has been described with reference to various specific and preferred embodiments and techniques. However, it should be understood that many variations and modifications may be made while remaining within the spirit and scope of the invention. It will be apparent to one of ordinary skill in the art that methods, devices, device elements, materials, procedures, and techniques other than those specifically described herein can be applied to the practice of the invention as broadly disclosed herein without resort to undue experimentation. All art-known functional equivalents of methods, devices, device elements, materials, procedures, and techniques described herein are intended to be encompassed by this invention. Whenever a range is disclosed, all subranges and individual values are intended to be encompassed. This invention is not to be limited by the embodiments disclosed, including any shown in the drawings or exemplified in the specification, which are given by way of example and not of limitation. Additionally, it should be understood that the various embodiments of the building blocks described herein contain optional features that can be individually or together applied to any other embodiment shown or contemplated here to be mixed and matched with the features of that building block.
While the disclosure has been described with respect to a limited number of embodiments, those skilled in the art, having benefit of this disclosure, will appreciate that other embodiments can be devised which do not depart from the spirit and scope of the disclosure as disclosed herein.
