Monolithic module structure to build constructions and method for its manufacture

Abstract

A new monolithic module structure for construction and its manufacture method to build monolithic constructions. The monolithic modules can be easily-transported and easily arranged on the conceived site for the construction of the edification. The method comprises the stages of: a) manufacture of the necessary number of harnesses for the fabrication of modules and panels; b) manufacture of modules, where the foundations are fabricated over which the module exterior walls will be manufactured; c) manufacture of panels and flat roofs and of interior panels, if required, simultaneously to the modules; d) integration of interior panels into the modules; e) assembly of the flat roof over the module walls; f) transport and storage of the already assembled module for its commercialization and distribution. The method permits to obtain construction modules at high volumes to be used for diverse constructions.

1 . A monolithic structure of construction of the type that is integrated from a plurality of harnesses, foundation and roof, characterized because it comprise:
 a) walls ( 23 ) that conform a single piece to each other,   b) a foundation slab ( 25 ),   c) a roof slab ( 32 ),   d) openings for doors ( 24 ) and windows ( 22 ),   e) mechanical, electrical, hydraulic and sanitary elements, and elements of connection of gas, and   f) elements of subjection and transport in the foundation and roof slabs ( 8 ,  27 ) that allow their transfer to the site of residence of the construction and which at the same time they allow the union and lateral joint of the monolithic structure of construction with another similar monolithic structure of construction,   wherein the walls are united structurally to the foundation and roof slabs.   
   
   
       2 . The monolithic structure of  claim 1 , characterized because it is a monolithic module ( 13 ). 
   
   
       3 . The monolithic structure of  claim 1 , characterized because additionally it comprise a plurality of interior panels ( 21 ) from who can vary the dimensions, capacities and uses of the interiors of the monolithic structure. 
   
   
       4 . The monolithic structure of  claim 1 , characterized because it provides a heat insulation of the living zone of at least the double on magnitude that the provided by hydraulic cement. 
   
   
       5 . The monolithic structure of  claim 1 , characterized because the foundation slab ( 25 ) and roof slab ( 32 ) contains hydraulic concrete of high resistance, and the walls ( 23 ) contain cellular concrete. 
   
   
       6 . The monolithic structure of  claim 5 , characterized because the cellular concrete develops compressive strengths values of at least 110 Kg/cm 2  and volumetric weights of at least 1,200 Kg/m 3 . 
   
   
       7 . The monolithic structure of  claim 1 , characterized because it has a dimension of 4 to 7 mts wide by 3 to 4 mts in length. 
   
   
       8 . The monolithic structure of  claim 1 , characterized because additionally it comprise:
 a) columns ( 61 ) located in the ends of the wall ( 23 ) where the monolithic structure of construction with another similar monolithic structure of construction is united and assembled laterally, and   b) a beam in the roof slab ( 66 ) located in the end of roof slab ( 32 ) where the monolithic structure of construction with another similar monolithic structure of construction is united and assembled laterally.   
   
   
       9 . The monolithic structure of  claim 8 , characterized because it has a dimension of 7 to 8 mts wide by 3 to 4 mts in length. 
   
   
       10 . A manufacture line method to obtain the monolithic structure of construction of  claim 1  by means of a plurality of stations that comprise the stages of:
 a) manufacturing of harnesses, in this stage the different types of harnesses which are integrated into each one of the parts that form the monolithic structure are manufactured, in this stage the harnesses for the flat roof, interior panel, foundations and exterior walls are manufactured;   b) manufacturing modules, where sub-stages along five working stations are carried out, called A, B, C, D and E;   c) manufacturing interior panels and flat roof, simultaneous to the fabrication of modules, the panel manufacturing unit produce the interior panel and flat roof, wherein the panel manufacturing unit consists of three workstations, identified as F, G and H, and in where specific operations are carried out.   d) Integrating of interior panels into the module, this stage of the manufacture method consists of two sub-stages only, carried out in the working station identified as I;   e) assembly of the flat roof over the walls of the module, this stage is also identified as the final stage or the operational conclusion of the module manufacture method, and   f) Transport and storage of the already assembled module for its commercialization and distribution.   
   
   
       11 . The method according to  claim 10 , characterized because in the stage of harness manufacture four types of harnesses are manufactured for the flat roof: a structural mesh harness, an electrical harness, a structural armor harness and a union plates harness. 
   
   
       12 . The method according to  claim 10 , characterized because in the stage of harness manufacture, several harnesses are manufactured for the interior panel: a structural mesh harness, an electrical harness and a union plates harness. 
   
   
       13 . The method according to  claim 10 , characterized because in the stage of harness manufacture, seven different types of harnesses are manufactured for the foundations: a structural inferior mesh harness, a structural superior mesh harness, an electrical harness, a structural bean harness, a sanitary harness, a union plates harness and a hydraulic harness. 
   
   
       14 . The method according to  claim 10 , characterized because in the stage of harness manufacture, several harnesses are manufactured for the exterior walls: a structural mesh harness, an electrical harness, a sanitary harness, a hydraulic harness, a gas harness, a union plates harness and a door harness. 
   
   
       15 . The method according to  claim 10 , characterized because in the stage of module manufacture, the following sub-stages are carried out in working station A: Sub-stage 1) a interior wall mold is submitted to a cleaning process, basic maintenance and application of demoulding oil on the surfaces that have contact with the concrete; and Sub-stage 2) the structural steal mesh harness, the electrical, sanitary, hydraulic and gas harness are assembled over the interior wall mold. 
   
   
       16 . The method according to  claim 10 , characterized as well because in working station A, the molds of windows, wall holes (vanos), doorframes and union plates to the interior panel and to the flat roof are placed over the mold of the interior wall. 
   
   
       17 . The method according to  claim 10 , characterized because in the stage of module manufacture in working station B, the following sub-stages are carried out: Sub-stage 3) the mold of the platform and the foundations are submitted to a cleaning process, basic maintenance and application of demoulding oil on the surfaces that have contact with the concrete; Sub-stage 4) The foundations mold is placed over the platform; Sub-stage 5) The beams of steal rod, which have been prefabricated in the harness unit, are assembled over the metallic mold; Sub-stage 6) At the concrete factory the normal concrete is prepared, which is distributed in a hopper to the station in order perform the adding of the concrete over the foundations mold. Sub-stage 7) Once the adding has been completed the vibration of the mixture is carried out to ensure the proper consistency and distribution of the concrete and subsequently a finish and a superficial polish is given in accordance with the given specifications; Sub-stage 8) Once the finish has been given to the foundations, the preliminary vapor curing is carried out under temperature, humidity and time specifications to ensure the adequate setting of the concrete. 
   
   
       18 . The method according to  claim 17 , characterized as well because in working station B, in between the sub-stages 5) and 6) the structural steal mesh harness that has also been prefabricated in the harness unit is assembled, this structural harness has the corresponding electrical harness integrated, next the hydraulic and sanitary harnesses are integrated into the structural harness, to finally install the plates and rods of union into the walls. 
   
   
       19 . The method according to  claim 10 , characterized because in the stage of module manufacture in working station C, the following sub-stages are carried out: Sub-stage 9) After the curing process, the platform is moved to station C; Sub-stage 10) the foundations is demoulded and the mold is returned to station B; Sub-stage 11) The interior wall mold (coming from station A) is placed over the foundations; Sub-stage 12) The exterior wall mold is submitted to a cleaning process, basic maintenance and application of desmoulding oil on the surfaces that have contact with the concrete; Sub-stage 13) The molding of the walls is completed using a exterior wall mold that is closed over the interior wall mold; Sub-stage 14) At the concrete factory the cellular concrete is prepared, which is distributed in a hopper to the station in order perform the adding of the concrete over the walls mold; Sub-stage 15) Once the adding has been completed the surface is leveled to ensure the specified slope for the walls; Sub-stage 16) The preliminary curing of the walls is carried out, staying there until the concrete has settled enough; Sub-stage 17) After the setting of the concrete for a determined time, the demoulding of the interior wall mold is carried out and the mold is returned to station A; and Sub-stage 18) The exterior wall mold is opened and it stays in station C waiting for the next molding and adding of walls cycle. 
   
   
       20 . The method according to  claim 10 , characterized because in the stage of module manufacture in working station D, the following sub-stages are carried out: Sub-stage 19) the platform is moved to station D; and Sub-stage 20) once the walls have been demoulded, the final vapor curing of the module is carried out under temperature, humidity and time specifications. 
   
   
       21 . The method according to  claim 10 , characterized because in the stage of module manufacture in working station E, the following sub-stages are carried out: Sub-stage 21) The platform is moved to station E; Sub-station 22) once the foundations-walls combination has its nominal resistance, the integration process of the module is carried out starting with the preparation of the surface and the assembly of the interior panel; Sub-stage 23) The preparation of the surface and the assembly of the flat roof is carried out; Sub-stage 24) The last stage of the module integration process is carried out, which consist on the retouching, detailing and sealing of the already integrated module; Sub-stage 25) Once the module integration process has been completed, the platform is moved to the exterior of the factory; Sub-stage 26) The module over the platform is dried out at ambient temperature for a determined time; Sub-stage 27) the module is moved away from the platform at it is transported to the module warehouse using a portico-type crane; Sub-stage 28) The platform is returned to station B to reinitiate the cycle. 
   
   
       22 . The method according to  claim 21 , characterized as well because in the stage of module manufacture in working station E, the interior panel-walls union is carried out through a welding process of the union plates previously placed on the foundations as on the exterior walls and the interior panel. 
   
   
       23 . The method according to  claim 21 , characterized as well because in the stage of module manufacture, in working station E, the flat roof-walls union is carried out through a welding process of the union plates previously placed on the walls as on the flat roof. 
   
   
       24 . The method according to  claim 10 , characterized because in stage of panel and flat roof manufacture, in working station F, the following sub-stages are carried out: Sub-stage 29) the mold of the platform and the flat roof are submitted to basic maintenance and application of demoulding oil on the surfaces that have contact with the concrete; Sub-stage 30) The flat roof mold is placed over the platform; Sub-stage 31) The polystyrene ‘bovedilla’ is placed over the platform of the mold; Sub-stage 32) At the concrete factory the normal concrete is prepared, which is distributed in a hopper to the station in order to perform the adding of the concrete over the flat roof mold; Sub-stage 33) When the adding has been completed, the vibration of the mixture is carried out to ensure the appropriate consistency and distribution of the concrete, subsequently a superficial finish is given, which includes the configuration of the flat roof fence in accordance with the given specifications; and Sub-stage 34) Once the finish has been given to the flat roof, a preliminary vapor curing is carried out under temperature, humidity and time specifications to ensure the required setting for the flat roof. 
   
   
       25 . The method according to  claim 10 , characterized because in stage of panel and flat roof manufacture, in working station G, the following sub-stages are carried out: Once the curing process is finished, the platform is moved to station G; Sub-stage 36) After the setting of the concrete, the flat roof is demoulded and the mold is returned to station F; Sub-stage 37) the platform and the interior panel mold are submitted to a cleaning process, basic maintenance and application of demoulding oil on the surfaces that have contact with the concrete; Sub-stage 38) The interior panel mold is placed over the platform; Sub-stage 39) The structural steal mesh harness that has been prefabricated in the harness unit is assembled; Sub-stage 40) At the concrete factory the cellular concrete is prepared, which is distributed in a hopper to the station in order to perform the adding of the concrete over the interior panel mold; Sub-stage 41) When the adding has been completed, a leveling to the surface and a superficial finish is given in accordance with the given specifications; Sub-stage 42) Once the finish has been given to the interior panel, the preliminary vapor curing is carried out under temperature, humidity and time specifications to ensure the appropriate setting of the concrete; and Sub-stage 43) After the setting of the concrete, the demoulding of the interior panel mold is carried out, the mold stays in station G waiting for the next molding and adding of the interior panel cycle. 
   
   
       26 . The method according to  claim 10 , characterized because in the stage of panel and flat roof manufacture, in working station H, the following sub-stages are carried out: Sub-stage 44) the platform is moved to station H; and Sub-stage 45) the final vapor curing of the flat roof as to the interior panel is carried out under temperature, humidity and time specifications. 
   
   
       27 . The method according to  claim 10 , characterized because in the stage of interior panel integration, in working station i, the following sub-stages are carried out: Sub-stage 46) The platform is moved to station I; and Sub-stage 47) using a crane system, the interior panel is transported to station E where the module is assembled. 
   
   
       28 . The method according to  claim 10 , characterized because in the stage of panel and flat roof assembly over the module walls, the following sub-stage is carried out: Sub-stage 48) using a crane system, the flat roof is transported to station E where it is assembled over the module walls, and once integrated into the module, it is retouched and detailed. 
   
   
       29 . The method according to  claim 10 , characterized because in the stage of transportation and storage of the already assembled module for its commercialization and distribution, the following Sub-stages are carried out: Sub-stage 49) once the flat roof and the interior panel have been integrated into the module, the platform is moved to the exterior of the factory; and Sub-stage 50) the platform is returned to station F to reinitiate the panel manufacture process.