The invention relates to a method for manufacturing a module of a building, the module comprising:
Such a method is known from CN108312291A. In this known method, a foundation is first formed at the location of the cavity walls and after printing the leaves of the cavity walls, vertical reinforcement cages are placed locally between these leaves and the space within these cages and immediately around them is filled with concrete in order to form columns. Near the top of the cavity walls, floor slabs are arranged between the cavity walls, which will form the floor for a further building module of the building to be subsequently formed thereon. Reinforcement is applied to the floor slabs and then a layer is printed on the floor slabs. In this known method, said concrete slab is the ceiling of the building module or the floor of the module to be formed above it. The building modules manufactured according to this known method are not movable but form a direct part of the building under construction. The cavity walls and the top layer of the floor are printed one after the other.
An object of the invention is to provide a method according to the preamble of claim 1, with which movable building modules can be manufactured in an inexpensive manner, so that a building can be built with them in a cheaper and faster manner. To this end, the method for manufacturing a building module according to the invention is characterized in that it comprises the steps of:
In the method according to the invention, the floor of the building module forms said concrete slab. This is in contrast to the known method where the ceiling of the building module forms the said concrete slab. By printing the formwork for the floor and the cavity walls in a continuous process and eventually also pouring the floor during the printing of the cavity walls, more modules can be produced per unit of time than according to the known method, which means that the 3D concrete printer is used more efficiently and the costs of using the 3D concrete printer are lower.
Because both the floor and the cavity walls are made of the building module, the building module can be moved. This is not the case with the known building module, which consists of the cavity walls and the floor connected thereto for the module above it, or the ceiling of the formed building module. In the method according to the invention, the cavity walls are printed next to beams which form a whole with the floor, so that the floor, the beams and the cavity walls form one solid whole. Fast-hardening concrete is preferably used for the beams and the floor.
An embodiment of the method according to the invention is characterized in that after pouring concrete into the space between the formwork, the formwork becomes part of the concrete slab and/or of the beam.
A further embodiment of the method according to the invention is characterized in that the printing of the formwork for the concrete slab and the printing of the lower layers of the cavity wall is carried out in a continuous (uninterrupted) 3D concrete printing process.
Yet another embodiment of the method according to the invention is characterized in that the formwork for the concrete slab and the lower layers of the cavity wall is printed in such a way that the lower layers of one of the leaves of the cavity wall form part of the formwork of the concrete slab.
Preferably, the printing of the formwork for the concrete slab and the printing of the lower layers of the cavity wall followed by the printing of the remaining layers of the cavity wall is carried out in a continuous (continuous) 3D concrete printing process.
An embodiment of the method according to the invention is characterized in that, after the cavity walls have been printed, columns are arranged in or against the cavity walls, which columss are attached to the reinforcement of the beams. With the 3D concrete printing of the cavity walls, only the leaves of the cavity walls are printed, whereby empty spaces are formed between the leaves. By attaching the columns directly to the reinforcement in the beams, a strong construction is obtained.
In order to be able to securely fasten the columns to the reinforcement in a simple manner, coupling plates are preferably attached to the reinforcement for the beams and the columns are attached to these coupling plates. These coupling plates are preferably attached to the reinforcement before the beams and the floor are cast, preferably before the reinforcement for the beams is placed on the substrate. By arranging coupling plates, the columns can be attached to the beams in a simple manner, for instance by means of bolts.
Preferably, at the locations where the columns are attached to the reinforcement for the beams, from the outside of the cavity walls to the reinforcement of the beams, the cavity walls are removed or the cavity walls are formed in such a way that recesses are formed in the cavity walls at these locations. This allows the columns to be placed within the outer boundary side of the cavity walls, so that they do not protrude.
In order to integrate the columns even more into the construction and to allow them to protrude even less or not, when printing the cavity walls, leaves of the cavity walls are printed, whereby at the locations where the columns are attached to the reinforcement for the beams, the leaf or leaves is/are printed in such a way that coves are formed in the cavity wall in which the columns can be placed. This allows the cavity walls to still be formed up to the edges of the floor while the columns do not protrude due to the presence in the formed coves.
In a further method according to the invention, the module further comprises a concrete column which is attached to the concrete slab, which column has a circumferential wall and the space within the circumferential wall is filled with concrete, in which method also the circumferential wall of the column is manufactured by means of 3D concrete printing. The further method is characterized in that the method further comprises the steps of:
It is noted that the above method can also be applied in a method in which the formwork is not 3D printed but is manufactured in the usual way through walls of wood or plastic or by stone or concrete blocks.
An embodiment of the method according to the invention is characterized in that that before the supporting plate is arranged, angled reinforcing rebars provided with two legs standing at right angles to each other, each with a first of the legs are inserted into the reinforcement wire basket and the other, second leg is inserted through a hole in the support plate. In this way the beam and column to be formed can be firmly attached to each other in order to obtain a strong construction, so that the module can be moved relatively easily without additional support.
One way in which the supporting plate is properly supported is characterized in that before the supporting plate is arranged, angled reinforcing rebars, provided with two legs at right angles to each other, are each inserted into the reinforcing wire basket with a first of the legs and with the other second leg support the supporting plate. The second legs are herein held vertically and are preferably bent at right angles at the free end, wherein the bent parts carry the support plate.
In order to obtain a better attachment of the beam to be formed with the column to be formed, a further embodiment of the method according to the invention is characterized in that the support plate is U-shaped and the reinforcing wire cage is inserted through the opening within the U-shape and adjacent to the second legs of the reinforcing rebars. A firm attachment of the column to the beam can hereby be obtained. Preferably, the reinforcing wire cage is arranged along the second legs of the reinforcing rebars over a length of at least 40 cm. This eliminates the need to attach the reinforcing rebars to the reinforcing wire cage. The concrete to be poured afterwards ensures a sufficiently strong connection between the reinforcing rebars and the column. The same applies to the length over which the first legs of the reinforcing rebars are inserted into the reinforcing wire basket.
Another way of obtaining a strong attachment of the column to be formed to the beam to be formed is characterized in that the support plate has a rectangular shape, and when arranging the reinforcement wire cage free ends of reinforcement wires which extend in the longitudinal direction of the reinforcement wire cage, are inserted through further holes in the support plate. In this case, these free ends preferably extended over a distance of at least 40 cm along the second legs of the reinforcing rebars.
Yet another way of obtaining a strong attachment of the column to be formed to the beam to be formed is characterized in that the supporting plate has a rectangular shape and the reinforcing wire cage is arranged on the support plate and rests on the support plate. Preferably, the second legs of the reinforcing rebars are arranged along the reinforcing wire cage over a distance of at least 40 cm.
Yet another embodiment of the method according to the invention is characterized in that the support has a foot arranged on the substrate and being provided with a hole, and a vertical tube arranged around the hole and attached to the foot on which the supporting plate is located or around which the supporting plate provided with a center hole, is arranged. This tube can later be used to connect two modules on top of each other in vertical direction.
Preferably, the second legs of the reinforcing rebars or the vertical tube being provided with external screw threads on which a nut is arranged, the height of the support plate being adjusted after the mounting plate has been fitted by turning the nut or the nuts.
The invention also relates to a module manufactured according to the method described above, comprising:
An embodiment of the module according to the invention is characterized in that it furthermore comprises a support on which the supporting plate is present and which is located next to the concrete beam, with angled reinforcing rebars extending with one leg into the reinforcing wire basket and with the other, second leg extending longitudinally of the column in the reinforcing wire cage or below the supporting plate, the support further comprising a holed foot and a tube attached to the foot around the hole. Due to this support, the circumferential wall of the column to be printed can be supported better.
A favorable construction in which it is not necessary to attach the reinforcing rebars to the reinforcing wire basket and to the reinforcing wire cage is characterized in that the reinforcing rebars extend with the first leg over a distance of at least 40 cm in the reinforcing wire basket and with the other, second leg extend over a distance of at least 40 cm in the longitudinal direction of the column in the reinforcement wire cage or under the support plate.
A further embodiment of the module according to the invention is characterized in that the tube extends through a hole in the support plate and partly protrudes above the support plate and is provided with a number of holes in the side wall, the holes connecting with through-holed elements are mounted on the side wall of the tube, into which bolts are turned, which, upon further rotation, enter the tube in order to remove a rod possibly present in the tube clamp in the tube. This creates a provision with which two modules stacked on top of each other can be connected to each other in vertical direction.
Preferably, the part of the tube protruding above the support plate extends over a distance of at least 40 cm in the longitudinal direction of the column in the column so that the tube does not have to be fixed to the reinforcement wire cage in order to obtain a sufficiently strong connection.
In order to have good access to the bolts, an opening through which the bolts are accessible is preferably present in the circumferential wall of the column at the location of the bolts.
Furthermore, the invention relates to a building composed of a number of modules as described above, of which several modules are present on other modules, wherein in at least one column of a lower module a rod is present which partly protrudes from the column and extends into the tube of the support of the module present on this module and is clamped by the bolts.
The invention will be further elucidated below on the basis of an exemplary embodiment of the method for manufacturing the building module according to the invention shown in the drawings. Wherein:
In an efficient construction method for a building, prefab construction modules are manufactured in a factory, which are placed on the construction site in the building under construction, where the construction module only needs to be coupled with the already present construction modules of the building under construction. For manufacturing the building module, a suitable substrate is first formed on which the building module can be manufactured. This can for instance be a plastic platform in which slots are present at the location where the beams are formed in the floor. These beams are thicker than the floor and protrude from the floor at the bottom of the floor to be formed.
A formwork 107 of concrete for the floor around the reinforcement baskets and the lower layers of the cavity walls 108 (shown schematically with broken lines) are printed with the 3D concrete printer. This 3D concrete printer uses fast curing concrete so that at the end of printing one layer, the next layer can be printed directly on top of the printed layer. Reinforcement wire meshes 109 (indicated by broken lines) for the floor to be formed have been placed on the ground between the reinforcement baskets 111 for the beams.
After the printing of the formwork 107 and the lower layers 108 of the cavity walls, the 3D printing process continues continuously for printing the remaining layers of the cavity walls and at the same time the floor is poured. The latter also happens with fast-setting concrete.
When printing the cavity walls 105, only the leaves of the cavity walls are printed.
Before the building modules are transported to the building under construction, they are further finished, for example by tiling the walls where desired and installing kitchen or bathroom equipment and, if necessary, placing doors and windows. Preferably, two building modules are also coupled to each other in advance and provided with a (temporary) ceiling 117 that offers protection during transport.
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Instead of being supported by reinforcing rebars, the supporting plate can also be part of a support that is placed on the substrate.
Instead of being attached to the tube 31, the support plate 22 can also be present loosely around the tube 31, see
The angled ends of the second legs 23B of the reinforcing rebars 23 can also support the support plate 22 in the same way as they also support the support plate 21 in
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For clarification,
Although the present invention is elucidated above on the basis of the given drawings, it should be noted that this invention is not limited whatsoever to the embodiments shown in the drawings. The invention also extends to all embodiments deviating from the embodiments shown in the drawings within the scope of the invention defined by the appended claims.
Number | Date | Country | Kind |
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2028922 | Aug 2021 | NL | national |
Filing Document | Filing Date | Country | Kind |
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PCT/NL2022/050454 | 7/31/2022 | WO |