Monolithic module structure to build constructions and method for its manufacture

The present invention refers to methods and systems to build constructions, particularly to methods for the manufacture of construction modules that are integrated from a plurality of harnesses, and in conjunction with a flat roof, it is possible to build a great variety of constructions of the monolithic type, the dimensions, capacities and uses of these constructions are allowed to vary implementing in each module a plurality of panels. The field of application of the present invention is in regard to any construction, particularly constructions of prefabricated houses, classrooms and constructions with ample interior spaces, among others.

The traditional construction systems have distinguished themselves by creating edifications at the same place were they will reside through the gradual construction of diverse structural elements; however, these types of methodologies consume too much time, labor and their costs are too high. In this sense, the use of constriction processes for edifications using prefabricated elements, such as panels and diverse support structures that are subsequently assembled, represent superior alternatives, since they significantly reduce the existent inconvenients of the traditional construction systems.

Traditionally, the construction systems for buildings of the prefabricated type, have agreed to manufacture modules coated with concrete, which supported on metallic structures or concrete pillars are used to replace the traditional walls built with thin wall and concrete or any other material of this type to cover empty spaces between flanks of the structural elements of the building.

At the moment diverse solutions of construction systems from prefabricated elements and methods to obtain such are known.

Corredera¹ describes a building construction system that combines traditional or non-structural construction with structural construction, whereby concrete is used in both walls and slabs. According to this system, a concrete slab serves as a foundation means and reinforced concrete structural pillars are arranged thereon. On the other hand, cover plates are used to produce the walls, based on a light concrete which is reinforced using electrically welded mesh. In addition, gypsum panels or similar ones are connected to the inner faces of the walls, thus defining the final finish of the interior walls. Furthermore, other panels of expanded gypsum are placed on the interior of the gypsum panels that are connected to the inner faces of the walls in order to provide thermal and acoustic insulation. Finally it is described that the gypsum panels or similar are also provided on the cover plates corresponding to the slabs and in this case, the panels are humidity proof and are used to form the apparent face of the ceilings.

Another system that shows the limitations of the inventions in this field is described by Grace², in which convertible buildings and the methods for their production are divulged. Particularly this system refers to a building construction method that comprises the stages of the construction of a floor, the construction of the walls over the floor and above them the construction of the ceiling, where at least one of the walls contains at least one opening to pass though it. Likewise mechanic and electric internal connections are fixed at least alongside the floor, the walls, the openings and the roof on a predetermined route and are connected to the corresponding external connections. Another step is to cover the mechanic and electric internal connections with detachable adornments that assume the appearance of aesthetic or functional counterparts that are found in non-convertible apartments, in such a way that the mechanical and electrical routes are not perceived, but are always accessible to be transformed without having to demolish the floor, the ceiling or the walls.

However the described systems above do not eliminate the necessity to produce the majority of construction elements, such as walls or structural elements, on the site where the building will reside.

Another alternative to create edifications in less time is represented by the construction systems that create inhabitable modules prefabricated outside the site where buildings will reside, and which will be later transported from the factory to the construction site where they will be mounted and assembled.

In this sense, Olesch³ describes modular transportable edifications created from diverse elements previously constructed within a factory, and which are assembled in the site where the building will reside. The edification is created by the assembly of one factory module that is joined to a reinforced foundations previously placed on the terrain, placing horizontal and vertical segments that are assembled on the module to create habitable spaces attached to the main module. In this case, all the construction elements are made with light material panels (for example wood) and are reinforced with fillings of dense materials to provide them with resistance.

De Quesada⁴ describes multi-floor edifications made by the assembly of diverse modules composed of floor and roof segments connected among each other through a plurality of vertically extended columns that are placed on the corners of the module, in such a way that the columns, as well as the floor and the roof have assembly means which permits to connect them with other modules of similar dimensions. Once the structure of the module has been made, the walls are manufactured placing panels of diverse materials, generally light, that permit to produce the complete module.

Vicino⁵ describes modular monolithic construction structures made from demouldable molds made with rigid external matrices and internal inflatable and collapsible molds, allowing the molding of the module form. The modules are integrated with the application of a gypsum layer covered by a reinforcement steal fiber layer, which is formed over the exterior walls of the internal collapsible mold where the molding segments for doors and windows are temporarily placed. Subsequently, over the settled layers of material the external mold is placed creating a space between this and the layers, the empty space is filled with cementing material that is submitted to a curing and drying process. Over the cured and dried surface obtained, panels of diverse materials (wood, for example) are placed in order to form the walls, which contain a layer of gypsum that permits the joining of the surfaces. Finally the obtained structure, fit with a roof, walls, doors and windows, is joined with a foundations slab previously formed to create the complete module.

Hopkins⁶ describes modular prefabricated structures that can be assembled between each other to create edifications of various floors and stories. The non monolithic modules are designed to vertically align themselves one above the other and are fit with assembly means to generate the building; in addition they are composed of a plurality of panels, which configure the habitable space of the edification\'s interior. The walls formed by semi-light materials, are assembled over a monolithic concrete slab to create the first edification level over which similar modules are placed later on.

Coday⁷ describes monolithic construction modules prefabricated with concrete composed of a vertical wall, a horizontal roof and a pair of support structures in the way of columns fixed to the roof and localized on the opposite side of the wall. Panels of diverse materials can be placed over the monolithic structure, as well as diverse systems to provide residence services. Such modules can be placed one above the other or else adjacent to each other to create diverse constructions.

The former systems allow the transport and assembly of the module at the edification residence site, with which the inconvenients of the traditional systems and of assembly of prefabricated structural elements are eliminated, despite that such systems have the inconvenient of using light materials for the walls, thus the residences formed by such modules have a reduced stability, are less durable and don\'t have a convenient structure for environments with extreme ambient temperatures.

It is thus desirable to rely on efficient construction systems that allow the creation of stable and trusted edifications from prefabricated elements such as modules, to build durable, flexible and easily transportable monolithic constructions, which at the same time represent structural and economic advantages.

One of the objectives of the present invention is to provide prefabricated construction modules whose functional and structural resistance characteristics allow the edification of monolithic constructions of long durability that fulfill the quality and security standards established for such constructions.

Another objective of the present invention is to provide easily transportable prefabricated construction modules that can be used as structural elements for the generation of durable monolithic edifications, of great stability and that efficiently insulate the residences from the environment.

Another objective of the present invention is to provide prefabricated construction modules for versatile constructions that may be combined among each other to generate multiple construction types according to the particular construction necessities.

Another objective of the present invention is to provide with a module fabrication method for monolithic constructions, from which modules are obtained whose functional and structural resistance characteristics allow the construction of long durable buildings that fulfill the quality and security standards established for such constructions.

Another objective of the present invention is to provide with a module fabrication method for monolithic constructions that allows the fabrication of such modules at high volumes and competitive costs.