Field of the invention

The present invention relates to a system for constructing a building by means of prefabricated elements.

Background art

In the construction sector, prefabricated concrete elements are often employed for the construction of several types of buildings, for example, residential buildings, schools, hospitals, offices and hotels.

One of the disadvantages of the background art is the difficulty in manipulating prefabricated elements. In fact, these elements are not sufficiently stable, and require to be suitably fastened during the steps of construction and transport from the production site thereof to the worksite.

Furthermore, disadvantageously, the assembly of the traditional prefabricated elements is particularly long and demanding, requiring costly shoring prior to the wet connections with cement mortars.

A high number of highly specialized personnel is also required for the assembly of such structures.

To date, the need to achieve a building construction system allowing to overcome the aforesaid drawbacks is felt.

Summary of the invention

The present invention provides a building construction system, the system comprising:

at least two monolithic elements adapted to be arranged along at least two mutually parallel vertical planes to form a first story of the building,

wherein each monolithic element is a reinforced concrete prefabricated component consisting of

- a horizontal base,

- two mutually parallel pillars, arranged perpendicular to the horizontal base, wherein the horizontal base is arranged below the two pillars,

wherein there is provided a plurality of first connecting metal bars, arranged inside each pillar, parallel to the longitudinal axis thereof, and each having an end segment which projects from the upper end of the respective pillar, preferably only from said upper end,

wherein there are provided anchoring elements, provided with through holes, fastened to a lower portion of the horizontal base at each pillar;

wherein each anchoring element is configured to be fastened to second connecting bars of a respective foundation plinth by inserting the second connecting bars into said through holes and clamping each anchoring element to the respective second connecting bars by means of clamping means,

whereby each monolithic element is adapted to be fastened to two foundation plinths.

According to an aspect, the invention also provides a method for constructing a building by means of the construction system of the invention, wherein there are provided foundation plinths provided with second connecting bars,

the method comprising the steps of:

a) arranging said foundation plinths in the ground;

b) fixing two foundation plinths to each of said monolithic elements, by inserting the second connecting bars into said through holes of the anchoring elements, and clamping each anchoring element to the respective second connecting bars by means of clamping means;

c) injecting an anti-shrinkage cement mortar between the foundation plinths and the horizontal base.

Advantageously, the invention provides monolithic elements which are intrinsically stable. In fact, the lower surface of the entire horizontal base is the only resting surface of each monolithic element.

In particular, the construction system provides that the monolithic elements are specifically designed to have the horizontal base, or beam, below the vertical pillars, and to be advantageously used in this manner. This specific orientation and geometry of the monolithic elements is maintained from the production thereof in the plant, and also during the transport and assembly steps.

It should be noted that each monolithic element is particularly heavy. Therefore, once produced with this specific orientation - with the base entirely below the pillars - it is very advantageous to be able to maintain them in this position in all subsequent steps, without the need to provide for any shoring.

Advantageously, the person skilled in the art may appreciate that the connection between two superimposed monolithic elements is of the pillar-beam type. In particular, the two pillars of a monolithic element are fastened to the horizontal base of the monolithic element above.

Advantageously, when constructing is required on a sloping ground, the monolithic elements may still be produced with pillars of the same height, only providing for plinths suitably sized in height to compensate the ground disparity and therefore guarantee the perfectly horizontal position of the base of the monolithic elements. The monolithic elements production process may therefore be optimized and standardized as much as possible.

Advantageously, the monolithic elements of the invention do not require shoring for the assembly thereof during the mounting step.

Furthermore, by virtue of the specific orientation of the monolithic elements, it is also possible to provide for a prefabricated wall inserted between the base and the vertical pillars.

Hydraulic pipes and/or electric cables can be inserted into such wall. The wall may also comprise ducts for pipes and/or electric cables. In this way, advantageously, the monolithic elements may be produced in the plant and be assembled with other monolithic elements in the worksite. The production in plant allow for lower production times and a greater precision.

Brief description of the Figures

Further features and advantages of the invention will become more apparent in light of the detailed description of preferred, but not exclusive, embodiments of a construction system. The description is provided by way of explanation and not by way of limitation, with reference to the attached drawings, also provided by way of explanation and not by way of limitation, wherein:

Figure 1 shows a perspective view of part of a building constructed by the system in accordance with the invention;

Figure 2 shows a perspective view of a detail of Figure 1 ;

Figure 3 shows a perspective view of a component of the construction system of the invention;

Figure 4 shows a perspective view of a component of the construction system of the invention;

Figure 4a shows a perspective view of a variant of the component of Figure 4; Figure 5 shows a perspective view of a component of the construction system of the invention;

Figures 6 to 9 show in perspective an assembly sequence of some components of the system of the invention, partially drawn and in transparency;

Figures 10 to 13 show a component of the invention, frontally viewed from four different sides;

Figures 14 to 17 show a component of the invention, viewed frontally from four different sides;

Figure 18 shows a cross section of some elements of the system of the invention, viewed frontally and partially in transparency;

Figure 19 shows a cross section of the components of Figure 18 not in transparency; Figure 20 shows a front view of some elements of the system of the invention, viewed frontally and partially in transparency;

Figure 21 shows a front view of the components of Figure 20 not in transparency; Figure 22 shows a perspective view of a component of the system of the invention; Figure 22a shows a perspective view of a component of the system of the invention; Figure 23 shows a sectional view of an example of connection between monolithic elements and foundation elements;

Figure 24 shows a perspective and top plan view of a foundation element;

Figures 25a to 25c show a component of the invention, viewed frontally from three different sides;

Figures 26a to 26d show a component of the invention, viewed frontally from four different sides;

Figures 27a to 27d show a component of the invention, viewed frontally from four different sides;

Figures 28 to 29 show a component of the invention, viewed respectively in plan and frontally.

The same reference numerals in the Figures identify the same or analogous elements or components.

Detailed description of one preferred embodiment of the invention

With reference to the Figures, an embodiment of a construction system in accordance with the invention is shown. In this embodiment, the building is multistory.

The construction system provides for a plurality of monolithic elements 3. Each monolithic element 3 substantially consists of two mutually parallel vertical pillars 4, and of a horizontal base or beam 5, arranged perpendicularly and below the pillars 4. The pillars 4 are arranged on a same side, or face, of the horizontal base 5, which is the upper portion of the horizontal base 5. The horizontal base 5 is completely below the pillars 4.

The lower face or surface of the horizontal base 5 is flat or substantially flat, advantageously providing a support plane on the pillars 4 of another monolithic element or to the pillars of the foundation plinths. Preferably, the lower surface does not have projections. In particular, the lower surface defines a base plane, and does not have projections with respect to such base plane. Preferably, the width of each horizontal base 5 is equal to a value comprised in the range between 30 and 60 cm. The width of each horizontal base 5 is lower than the length thereof.

It should be noted that the construction system provides that the monolithic elements 3 are specifically designed to have the horizontal base 5 below the pillars 4, and to be advantageously used in this manner.

The monolithic elements 3 are reinforced concrete prefabricated components. In particular, the two pillars 4 and the horizontal base 5 of each monolithic element 3 are reinforced concrete prefabricated components. The monolithic elements 3 are produced in a production plant, different from the building worksite or construction site.

Each horizontal base 5 has two side ends 51 along the direction of the longitudinal axis thereof. Typically, there are provided monolithic elements wherein the pillars are separated from the side ends of the horizontal base (visible, for example, in Figures from 10 to 13), and monolithic elements wherein at least one pillar is at one side end of the horizontal base and the other pillar is separated from the other side end (visible, for example, in Figures from 14 to 17). Monolithic elements 3 may also be provided, wherein two pillars are at two respective side ends of the horizontal base (visible, for example, in Figures from 25a to 25c).

The pillars 4 of each monolithic element 3 have all the same height. However, it is also provided that the pillars of a same monolithic element have a different height from one another.

In accordance with the invention, the monolithic elements 3 may be arranged along at least two mutually parallel vertical planes, for example two or more monolithic elements 3 arranged parallel to one another at a same height. In particular, in this case, the monolithic elements 3 are arranged with the horizontal bases 5 thereof longitudinally parallel to one another.

The monolithic elements 3 may also be arranged so that the horizontal bases thereof are longitudinally aligned to one another at a same height.

The monolithic elements 3 may also be arranged, at a same height, perpendicularly to one another (Figure 1 ). In particular, to construct the building, some monolithic elements may also be provided for, arranged so that the horizontal bases thereof are arranged perpendicularly in a longitudinal direction, with respect to the horizontal bases of other monolithic elements. Preferably, but not exclusively, the height of each monolithic element corresponds to the height of a story of the building. When two monolithic elements 3 are arranged one on top of the other, the height of each pillar 4 is equal to the distance between the horizontal base 5 of a lower monolithic element and the horizontal beam 5 of an upper monolithic element.

In accordance with the present embodiment, the cross section of each pillar 4, along a plane perpendicular to the longitudinal axis thereof, is preferably quadrangular. For structural calculation needs, the dimensions of the pillars may easily be changed (for example, pillars 40x50 cm, 40x60 cm, etc.).

The horizontal bases 5 are provided, at each side and in the upper portion thereof, along all or part of the greater length thereof, with a corbel 21 which extends perpendicularly with respect to the longitudinal axis of the horizontal base 5, to allow the support of the floor without interfering with the pillar section (Figures from 18 to 20). It is further provided a variant of the monolithic elements positioned at the periphery of the building, which are provided with a single corbel 21 on one side, facing towards the inside of the building, of the upper portion thereof, and with a prefabricated casting holding wall 24 (Figure 20) extending upwardly.

It is provided that each horizontal base 5 has a rebar 23 (visible, for example, in Figure 3) which projects above the horizontal base 5 to realize the connection with the prefabricated floor.

Preferably, the side ends 51 of the horizontal bases are shaped so as to provide fitting areas, such as, for example, recesses or projections, for other elements of the construction system described below (in particular connecting beams). For example, the side ends 51 of the horizontal base 5 are shaped so as to have each a recess 14. Preferably, when a pillar 4 is at the side end 51 , the latter is not provided with the recess. Therefore, some monolithic elements have only one or no end 51 shaped to provide a fitting area. The recesses are opened above.

Preferably, it is provided that one or more monolithic elements are provided with a prefabricated wall (not shown), arranged for example between two pillars and the horizontal base. Such wall preferably comprises hydraulic pipes and/or electric cables. The wall may also comprise ducts for pipes and/or electric cables. In this way, advantageously, the monolithic elements comprising the prefabricated wall may be produced in the plant and be assembled with other monolithic elements in the worksite.

Irrespective of the employment of the prefabricated wall, it is preferable that one or more of the monolithic elements has one or more grooves, advantageously intended to accommodate the system elements of the building, such as hydraulic pipes and/or electric cables.

For example, the upper end of one or more pillars 4 is provided with a groove 43. Furthermore, also the horizontal base may be provided with one or more grooves 53, preferably obtained in the lower face of the horizontal base at the pillars, for example between the notches 28 which will be described below. Preferably, the grooves 43 of the pillars 4 extend perpendicularly with respect to the grooves 53 of the horizontal bases 5.

The connection between pillars 4 of a lower monolithic element and the horizontal base 5 of an upper monolithic element, superimposed to the lower monolithic element, is realized by means of anchoring elements 8. For example, the anchoring elements are metal plates or shoes 8, preferably of the "Halfen" type (Figures from 6 to 9) fastened to the lower part or face of the horizontal base 5, at each pillar 4. The anchoring elements are provided with through holes, into which metal bars 9, suitably threaded, or anchor bolts, are inserted, projecting from the head 41 , or upper end, of the pillars 4 of an underlying monolithic element. The segments of the metal bars 9 which project from the pillars 4 are indicated with reference numeral 9'. At least the segments 9' of the metal bars 9 are threaded. Preferably, each pillar 4 is provided with four bars 9.

Preferably, the metal bars 9 extend inside the respective pillar 4 for at least half of the height thereof, for example for about three fourths of the height of the relative pillar 4, preferably for the entire height of the respective pillar 4.

The clamping between the anchoring elements 8 and the segments 9' occurs by means of clamping means 13, preferably by means of bolting, for example, by means of nuts, realizing a connection of the mechanical type. The metal shoes 8 are fastened to the lower part of the horizontal base 5, for example, they are inserted into the lower part of the horizontal base 5.

To facilitate the connection with the bars 9, the lower part of the horizontal base 5 is provided with notches 28 at the pillars 4. These notches 28 preferably are the only exception to the flat shape of the lower face of the horizontal bases 5.

According to an example, two notches or four notches 28 are provided at each of the two pillars. Each bar 9 is arranged at a distance from the longitudinal axis of the pillar 4 so as to be at a respective notch 28 of the horizontal base 5 of the monolithic element above. In this way, it is possible to easily operate on clamping means 13, such as, for example, nuts, in the empty space provided by the notches 28. Typically, as previously said, each bar 9 crosses a respective hole of the metal shoe 8. Such empty space may also be occupied, at least partially, by the metal shoe 8. Following the bolting, there is provided the injection of a layer of anti-shrinkage and high-resistance cement mortar, preferably of the "Exocem G1 " type, between the head 41 of the pillar 4 and the horizontal base 5.

The employment of this type of connection ensures greater safety and speed of installation of prefabricated elements on site. Furthermore, it also gives the structural designer the opportunity to choose the type and quantity of rebars required for the construction of the node.

Also the connection between the horizontal base 5 and the foundation, in particular to the foundation plinths 30 (Figures 23 and 24) is realized by means of the anchoring elements 8 previously described, fastened to the lower part of the horizontal base 5, at each pillar 4. The metal shoes 8 allow the connection with the metal bars 39 projecting from the foundation 30, by means of clamping means, for example by means of bolting (realizing a connection of the mechanical type) and the subsequent injection, between the head of the foundation 30 and the horizontal base 5, of a layer of anti-shrinkage and high-resistance cement mortar, preferably of the "Exocem G1 " type. Preferably, the metal shoes 8 are inserted into the lower part of the horizontal base 5.

To construct the first story, or ground story, of the building it is envisaged that holes are excavated in the ground. In particular, the holes are localized and are excavated so as to be axially at the pillars 4 of each monolithic element 3 used for the first story. For example, two manholes are excavated for each monolithic element. A foundation plinth 30 is placed in each hole. Once the pillars are positioned at the respective foundation plinths 30, the foundation plinths may be covered with a suitable construction material (Figures 23 and 24).

A further advantage of the construction system of the invention is the possibility to easily build on sloping ground, i.e. on a slope. In this case, a dugout is preferably constructed to realize the first story. In particular, one or more foundation plinths may have a pillar of a suitable height, so as to compensate the ground inclination to adequately construct the building without slopes. Advantageously, when constructing is required on a sloping ground, the monolithic elements 3 may still be produced with pillars 4 of the same height, so as to optimize the production process thereof.

The system of the invention further comprises a plurality of connecting beams 15 (Figure 4) between a monolithic element 3 and the following one arranged along a same vertical plane, at the same height. Each connecting beam 15 is provided, at the two side ends thereof, with portions shaped so as to provide fitting areas, such as, for example, recesses or projections. For example, each connecting beam 15 is provided, at the two side ends thereof, with projections 16 adapted to be fitted, in particular by means of a top insertion, into the recesses 14 of the monolithic elements 3. Such connection ensures the structural continuity of the frame system. The connecting beams 15 are further provided with a corbel 22 at each side of the upper portion thereof, along the entire greater length thereof, for the support of the floor, with the exception of the projections 16. There is also provided a variant of the connecting beams 15' (Figure 4a), positioned at the periphery of the building, which are provided with a corbel 22 only on one side, in the upper portion thereof, facing towards the inside of the building, and with a casting holding wall which extends upwardly, arranged above the upper portion of the connecting beam 15' facing towards the periphery of the building, having a casting holding function.

The connecting beams 15, 15' are made of reinforced concrete, and are provided with the rebar 23'. The invention provides that the rebar 23' projects from above the connecting beams 15 to allow the connection with the prefabricated floor.

The system of the invention further comprises a plurality of floor panels 17, preferably of the prestressed alveolar type, adapted to transversely connect two monolithic elements 3 (Figure 2). The floor panels 17 are also adapted to transversely connect two connecting beams 15, 15' arranged along two different mutually parallel vertical planes, and arranged at the same height.

Each floor panel 17 has a rectangular shape, and is provided, at each of the two opposite ends, with slots 18. Each floor panel 17 is provided with four slots 18. The floor panels 17 are simply supported by the corbels 21 or 22, in a first mounting step, and subsequently bound to the beams 5 and to the connecting beams 15 and 15', by means of the connection rebars 23 and 23' and integrative concrete casting (Figure 18, Figure 20). Preferably, the building construction system comprises further prefabricated elements, such as, for example, staircases 60, ramps and landings provided for in suitable stairwells (Figure 22a), bracing panels, fixtures, etc. Furthermore, the system of the invention comprises transverse beams 29 (Figure 22) to transversely connect the monolithic elements 3 of the perimeter sides of each story of the building. According to one aspect, the invention comprises a method for constructing a building by means of the construction system of the invention, in which foundation plinths 30 are provided for, provided with second connecting bars 39,

the method comprising the steps of:

a) arranging said foundation plinths 30 in the ground;

b) fastening two foundation plinths 30 to each of said monolithic elements, by inserting the second connecting bars 39 into said through holes of the anchoring elements 8, and clamping each anchoring element 8 to the respective second connecting bars 39 by means of clamping means 13;

c) injecting an anti-shrinkage cement mortar between the foundation plinths 30 and the horizontal base 5.

The method may also further comprise the steps of:

d) arranging said monolithic elements of the second story on the monolithic elements of the first story by inserting the end segments 9' of the monolithic elements of the first story into a respective through hole of the anchoring elements 8 of the monolithic elements of the second story;

e) clamping, by means of clamping means 13, each anchoring element 8 of the monolithic elements of the second story to the respective end segments 9' of the monolithic elements of the first story.

During the construction step, it is possible to construct a story comprising monolithic elements 3, connecting beams 15 and floor panels 17, without requiring shoring. In accordance with a predetermined assembly scheme, in a first construction step, the monolithic elements 3, the connecting beams 15 and the floor panels 17 are initially fastened to one another in a mechanical manner or simply supported. The connections of the mechanical type of the monolithic elements 3 are realized according to the methods previously described, in particular with reference to the pillar-horizontal base connection of two superimposed monolithic elements, and with reference to the horizontal base-foundation connection. The structure being constructed is advantageously stable even without realizing wet connections. Subsequently, at the connections of the mechanical type, it is also possible to realize wet connections, between the elements such as the monolithic elements 3, the connecting beams 15 and the floor panels 17. Wet connections are connections made with mortars and/or concrete castings. The wet connections between the upper and lower monolithic elements are realized by means of anti-shrinkage mortars, preferably of the "Exocem G1 " type, with which the spaces between the shoes 8, including, for example, the spaces created by the notches 28, and the spaces between the pillars 4 and the horizontal bases 5 are filled.

In a particularly advantageous way, once the connections for a story of the building have been completed, it is possible to carry out the mechanical assembly of the elements of the upper story and simultaneously realize the wet connections of the lower floor, drastically reducing the building construction times.

The wet connections between the horizontal bases 5, the connecting beams 15 and the floor panels 17 are realized by means of concrete casting, upon positioning connecting irons 26 (Figure 5). Such connecting elements are U-shaped rebars 26 or clamps. The shaped bars 26 are preferably used in pairs; each pair of shaped bars 26 is used to provide a constraint between a floor panel 17, placed on a first side of a monolithic element 3, and another floor panel 17, placed on the second side of the monolithic element 3 (Figure 18). In the case of perimeter monolithic elements 3, each pair of shaped bars 26 is bound to the rebar 23 or 23' and to a floor panel 17 (Figure 20).

The invention also comprises a building comprising at least one module, or volumetric unit.

Each module comprises only two monolithic elements 3 arranged parallel to one another. In particular, the two monolithic elements 3 of each module are arranged so that the longitudinal axes of the respective horizontal bases 5 are mutually parallel and preferably the horizontal bases 5 are arranged at a same height.

In other words, the two monolithic elements 3 of each module are arranged along two respective mutually parallel vertical planes.

Optionally, two or more modules arranged one on top of the other are provided for. In a first variant of a multistory building, each story comprises at least one module provided with only two monolithic elements 3 arranged along two mutually parallel vertical planes, said vertical planes being always the same for each story of the building. In a second variant of a multistory building, a first story comprises at least one first module provided with only two monolithic elements 3 arranged along two first mutually parallel vertical planes, while a second story comprises at least one second module provided with only two monolithic elements 3 arranged along two second mutually parallel vertical planes and perpendicular to said first vertical planes.

In other words, an upper module has the monolithic elements arranged perpendicularly with respect to the monolithic elements of the lower module. The upper module is consecutively arranged above the lower module.

Preferably, each column of the building is formed only by a single pillar 4. The pillars 4 are in fact separated and not in contact with one another.