FIELD OF TECHNOLOGY

The present innovation generally relates to a modular construction for building's components, or modules, are constructed in a factory setting before being transported to site for assembly. In particular, a modular wall system having a stackable wall panel or pillar designed to facilitate assembly and dismantling for future changes.

BACKGROUND OF THE INNOVATION

Construction waste accounts for about 40% of landfill waste, and many companies are working hard to create waste reduction or repurposing strategies. According to the US Environmental Protection Agency (EPA), new commercial building generates around 3.9 lb of garbage per square foot. They US EPA also calculated that 88 million tons of construction and demolition waste are added to landfills annually, in spite of the progress towards sustainability.

For example, demolished a 50,000ft building generates 4,000 tonnes of garbage, much of which is polluted with other materials and cannot be repurposed. All of the recyclable components, such as glass, wood, steel, and other metals, are blended with non-renewable and non-recyclable elements. Therefore, all this material may go to landfill. Furthermore, high-energy procedures, higher transportation requirements, and the likelihood for material loss and deterioration can cause impact to the planet.

Modular construction ultimately helps the environment by conserving raw resources, reducing site interruption and waste contamination, and reducing pollution from vehicles and heavy equipment. Although modular building can be environmentally friendly when built using energy-efficient methods, a major commitment to the world's resources is still required. This includes reducing the amount of waste that ends up in landfills.

It is preferable to construct using a system that is produced of long-lasting but low- cost materials and that allows for easy modification, removal, and reuse without the waste of materials and manpower associated with traditional demolition methods. The development of a building system that allows for the wholesale recycling and reuse of entire buildings through the use of durable large-scale construction components is desirable.

Therefore, a modular construction systems that are designed for disassembly that are reconfigurable are desirable, thus ensuring the building can be recycled as efficiently as possible at the end of its lifespan is proposed by the present invention.

SUMMARY OF THE PRESENT INNOVATION

The present invention relates to a modular wall system, comprising: a floor base plate mount onto a floor slab; a plurality of stackable modular wall panels placed on the floor base plate for forming a wall; a plurality interlocking tubes; a tie rod base mount onto the floor slab; and at least one pillar module placed on the tie rod base for forming a column assembly , wherein each of the stackable modular wall panels has a plurality hollow core sections for receiving or slotting at least one of the interlocking tubes in vertical or horizontal plane, and the pillar module has a plurality apertures for receiving or slotting at least one of the interlocking tubes in vertical plane, characterized in that, the column assembly having a tie rod junction box having corresponding apertures of the pillar module, and at least one tie rod positioned on the tie rod base on one end within the interlocking tubes in upright position, wherein each end of the tie rod is made of interconnecting means for forming interconnection, such that the tie rod interlock with the tie rod junction box on another end of the column assembly, in which the tie rod junction box having at least one side aperture for forming an interlock with the modular wall panels through the hollow core sections in horizontal position by using the interlocking tubes position in horizontal plane, and another tie rod positioned the interlocking tubes in horizontal plane, such that the modular wall panels able to mount onto the column assembly for forming the modular wall system.

Further, the modular wall system comprising a top cover mounted on top of the column assembly to cover the column assembly or the tie rod junction box.

Further, the modular wall system comprising a tie rod bracer on each end of the pillar module or the modular wall panels for securing of the tie rod in vertically.

Preferably, top the modular wall system having at least one roofing component.

Further, the modular wall system comprising a window base, a lintel, and a window cap for forming a windows on the wall. Further, the modular wall system comprising at least one corner column for holding corner end caps of the wall.

Preferably, the modular wall panels having a corresponding shapes on at least one top surface, bottom surface, side surface, or any combination thereof for interlocking means.

Preferably, the pillar module having a plurality apertures for receiving or slotting the tie rod in vertical.

Preferably, the modular wall panels having a plurality hollow core section for receiving or slotting the tie rod in vertical or horizontal plane.

Preferably, the tie rod is in shape tubular corresponding the interlocking tubes to secure framework of the column assembly.

The present innovation consists of features and a combination of parts hereinafter fully described and illustrated in the accompanying drawings, it being understood that various changes in the details may be made without departing from the scope of the innovation or sacrificing any of the advantages of the present innovation.

BRIEF DESCRIPTION OF THE DRAWINGS

To further clarify various aspects of some embodiments of the present innovation, a more particular description of the innovation will be rendered by references to specific embodiments thereof, which are illustrated in the appended drawings. It is appreciated that these drawings depict only typical embodiments of the innovation and are therefore not to be considered limiting of its scope. The innovation will be described and explained with additional specificity and detail through the accompanying drawings in which:

Figure 1 illustrates one embodiment of cross-section of a column assembly connected to a tie rod base having a tie rod positioned on the tie rod base within the column in upright position.

Figure 2 illustrates one embodiment of cross-section of a modular wall system comprising of a plurality of Stackable modular wall panels and having a column assembly for forming a wall.

Figure 3 illustrates one embodiment of a stackable modular wall panels.

Figure 4 illustrates shapes of the stackable modular wall panels.

Figure 5 illustrate one embodiment of a horizontal bracing used in a modular wall assembly process.

Figure 6 illustrates one embodiment of parts permanent column forms.

Figure 7 illustrates one embodiment of cross-section of a modular wall system comprising of a plurality of Stackable modular wall panels and having a column assembly using a plurality interlocking tubes and a plurality tie rods. Figure 7 illustrate one embodiment of a permanent column forms used for the column assembly for receive the wall panel base plate and assembly of the wall panels.

Figure 8 illustrates a close up view of the tie rod junction box in Figure 7 using a plurality interlocking tubes and a plurality tie rods.

DETAILED DESCRIPTION OF THE INNOVATION

The present invention relates a pre-fabricated modular wall panels, permanent structural exhibits and it's bracing and tie rod elements allows for the standardization of all it's components to provide for structural integrity, and dimensional stability. The overall set up in aligning with this principles, and it's features and probabilities makes it possible that forms the criteria in transforming Engineering to Production (E2P) solution as a new revolution in sustainable integrated building system methods.

The Light weight prefabricated modular wall panel are manufactured according to Non autoclaved aerated concrete (NAAC) guidelines having a density ranging between 800kg/m3 to 1200kg/m3. Dimensions of the modular wall panels are standard with slight variations made on the tongue and groove sections. The Non autoclaved aerated concrete (NAAC) is a type of lightweight concrete which is used to produce blocks and replace bricks.

Each of the modular wall panels have at least two vertical hollow core section for tie rod assembly and one for mechanical and electrical systems use. Mechanical systems can include elements of infrastructure, plant and machinery, tool and components, heating and ventilation and so on. The dimensions of the modular wall panels are normalized at 1000mm length and 250mm height for ease of handling while the width is range between 100mm and 200mm in order to meet technical specifications. Meanwhile , top part, bottom part and window base of the prefabricated modular wall panels are design for 'high performance concrete' standards with the integration of at least 2-6nos. of horizontal cores for tie rod reinforcement functions as an alternative to the conventional structural reinforce concrete beam systems.

The top, window base and bottom of the prefabricated modular wall panels assembly functions as conventional reinforce concrete beam.

Post tension method is applied to suspended beam assembly to reduce column structures. Post-tensioning is a method of prestressing in which the tendons are tensioned after the concrete has hardened and the prestressing force is primarily transferred to the concrete through the end anchorages. The post tension method use on a suspended beam assembly.

Vertical tie rods assembly methods consist of control tubing’s or interlocking tube that functions to ease positioning during assembly process, lock plates to support loads from upper forces, and tie rod shaft are used for locking in the center position of each prefabricated modular wall panel to ease disassembly process, and also to accommodate repairs and modifications.

The control tubing or interlocking tube is used enhance precision in locking of the tie rod and to prevent mechanical damages to the lock position.

The length of this assembly units formed from the lower ground slab to the top of the last panel capping for single floor method and extend through the upper floor slab and continue likewise until the final level is concluded in multi-level assemblies. The distance between each tie rod is typically 500mm and tie rod shaft sizes are determined accordingly to technical requirement for structural integrity.

The horizontal bracing assembly process is similar to the vertical tie rod assembly methods with exceptions to its final length that varies in construction lay out designs and are simultaneously lock in place using the horizontal bracer and tie rod junction box place internally in designated slots at the permanent column form units.

Column assembly consist of tie rod base component that connects the reinforcing ground floor slab starter bars, composite or concrete infill units with braces at both ends, tie rod junction box, and a top cover. The overall components are brace together to form a monolithic unit by using at least 4nos. of control rods and the main tie rod shaft place at the middle of the bracer for stability. The locking of all components are similarly to the method use in the wall ties assembly method. The permanent column forms are then inserted onto the column assembly to receive the wall panel base plate and assembly of the wall panels.

The monolithic structure formed based on a column assembly-all component assembled together to provide structural integrity.

Permanent column forms are preferably made of fiber reinforce polymer (FRP) material for its light weight advantage, durability, and mechanical properties. The variation on the shapes of this permanent forms are design to provide and facilitate columns, beam, cantilever beam and suspended beam assembly.

Vertical wall panel joints are seal together with liquid gasket copolymer and conceal with acrylic sealant to facilitate de-construction. Horizontal joint gaps may left unattended for aesthetic purpose. Final finishing on wall panels is completed at manufacturing center.

Roofing structures and parts of external wall framework is design such that it able to cater for installation of solar panels to support energy savings initiatives.

Floor panel hollow section support is based on 'strength to weight ratio' using at least two units smaller hollow section, put in place at one unit bigger hollow sections to enhance mechanical properties and to ease assembly/disassembly process. The Engineering to Production (E2P) modal application is not limited to Design for Disassembly (DFD) building concept. It's adaptability in various other construction works is possible without any alteration to its methods and components with exceptions only to its dimensions. With this innovation, construction waste generated is estimated to be lower than 10% base on mass volume throughout it's component life cycle. This will provide the ideal solution to sustainable development concept. Preferably, the wall assembly, pillar, column, stackable wall is made of Non-Autoclaved Aerated Concrete (NAAC) Blocks, in which it known for conserving energy, because the heating and cooling loads, annual heat loss, and amount of heat transfer of NACC were lower than those of fired brick and normal concrete.

Benefits

• reduce workforce, excessive work culture, and promotes productivity and safety.

• follows cradle to cradle model concept.

• reducing the embodied energy and carbon emissions of the construction industry.

• preserving natural resources and it's environment.

• stimulating and providing high skill work opportunities beyond existing facilities

• potential savings in time and cost.

• recreation of re-sales values.

• upgrading and bridging the gap of rural and urban architecture.

• superior performance in terms of sustainability.

One embodiment of the column assembly (100) is illustrated in Figure 1 , the column assembly (100) connected to a floor slab using a tie rod base (101 ), wherein the column assembly (100) is made of at least one pillar module (103,105) with at least one vertical bracer (102,104) on each end, and a tie rod junction box (106) affixed on top portion. The pillar module (103,105) has a plurality apertures or hollow core section for receiving or slotting at least one control tubing or interlocking tube in vertical plane. The first pillar module (103) slotted or mounted on the tie rod base (101 ), where the tie rod base (101 ) has a first interlocking tube affixed, in which the first interlocking tube protruding out from the tie rod base (101 ) to form a protrusion having corresponding shape of the hollow core section of the first pillar module (103).

Each of the pillar module (103,105) having a wall surrounding or sides the plurality apertures or hollow core section and a vertical bracer (102, 102’, 104, 104’) with corresponding apertures on each end to form the pillar module (103,105).The vertical bracer (102, 102’, 104, 104’) may use to position the hollow core section or the interlocking tube, or to enclose the side wall around the hollow core section, in particularly top and bottom portion. The main function of a pillar is to support part of a solid vertical structure such as a building or a monument. Each of the pillar module (103,105) or the vertical tie rod may further include a washer or fastener placed in between each of the pillar module (103,105) to avoid leakage in between the pillar module (103,105).

The first interlocking tube penetrates into the first pillar module (103) of less than or more than half of the size of the first pillar module (103) to form an interlocking. Thereafter, the second interlocking tube is slotted, affixed or inserted into the first pillar module (103) above the first interlocking tube, to form a protrusion having corresponding shape of the hollow core section of the second pillar module (105), in which the second interlocking tube penetrates into the second pillar module (103) of less than or more than half of the size of the second pillar module (103) to form an interlocking.

Another embodiment of the invention is, where a first tie rod with first interlocking tube penetrates into the first pillar module (103) of less than or more than half of the size of the first pillar module (103) to form an interlocking. Thereafter, second tie rod and second interlocking tube is slotted, affixed or inserted into the first pillar module (103) above the first interlocking tube, such that the second tie rod form a protrusion having corresponding shape of the hollow core section of the second pillar module (105), in which the third interlocking tube slotted onto another end second tie rod, in which the third interlocking tube or the second tie rod penetrates into the second pillar module (103) of less than or more than half of the size of the second pillar module (103) to form an interlocking.

Further, at least one tie rod slotted into the interlocking tube in vertical plane for securing the first pillar module (103) up to the second pillar module (105) in vertical plane.

Thereafter, another interlocking tube with another pillar module can be placed above it to form a higher column assembly. Preferably, a tie rod junction box (106) having corresponding apertures of the pillar module (103,105), is be placed on the top of any pillar module or column assembly such that a protrusion from the interlocking tube is slotted, affixed or inserted into the tie rod junction box (106), to form a interlock for the column assembly or the pillar module in vertical or in upright position.

Further, a second tie rod could be slotted into the second interlocking tube in vertical plane for securing the wall vertically, in which one end of the second tie rod secured to another end the first tie rod for securing another end of the pillar module (103,105) vertically.

Another end of second tie rod protrude out to the tie rod junction box (106), such that the second tie rod secured the tie rod junction box (106) onto the pillar module (105) to form an enclosure for the column assembly (100).

The tie rod junction box (106) further comprising at least one side aperture to form an interlock with another column assembly, pillar module or to an adjacent modular wall system in horizontal position by using an interlocking tube position in horizontal plane. Preferably, the column assembly (100) has a top cover, where the top cover is used to cover the top portion of the column assembly (100).

The assembly process of the vertical bracer (102, 102’, 104, 104’) used for bracing is similar to the vertical tie rod assembly methods with exceptions to its final length that varies in construction lay out designs and are simultaneously lock in place using the horizontal bracer (103,105) with the tie rod junction box (106) place internally in designated slots at the permanent column units.

Preferably, the column assembly (100) has a top cover, where the top cover is used to cover the top portion of the column assembly (100). Preferably, the column assembly (100) having at least one tie rod secured onto the tie rod base (101 ) on one end within the column in upright position, and each end of the tie rod is made of interconnecting means for forming interconnection, wherein the tie rod interlock with the tie rod junction box (106) (102, 102’, 104, 104’) to secure the column assembly (100), and preferably the top cover mounted on top to brace the column assembly (100), such that the column assembly (100) can be enclosed on the top portion. The tie rod base (101 ) has at least one tie rod locked on the tie rod base (101 ) such that it can receive another tie rod in vertical position and interlocking tube position in position plane. Each of the modular wall panel (202, 203, 203’) or the horizontal tie rod may further include a washer or fastener placed in between each of the modular wall panel (202, 203, 203’) to avoid leakage in between modular wall panel (202, 203, 203’).

One embodiment of the modular wall system as illustrated in Figure 2 comprising of a plurality of Stackable modular wall panels for forming a wall, where a floor base plate (201 ) is placed at base for receiving or positioning a first modular wall panel (202) having a flat surface or corresponding surface to the floor base plate (201 ), and other modular wall panels (203, 203’) are stacked on each other. Preferably, each of the modular wall panels (202,203, 203’) having a corresponding shapes or interlocking means on at least one top surface, bottom surface, side surface, or any combination thereof for interlocking with the other modular wall panel. Preferably, each of the stackable modular wall panels (202, 203, 203’) has a plurality apertures or hollow core section for receiving or slotting at least one control tubing or interlocking tube (204) in vertical or horizontal plane. The first modular wall panel (202) slotted or mounted on the floor base plate (201 ), where the floor base plate (201 ) has a base plate interlocking tube affixed, in which the base plate interlocking tube protruding out from the floor base plate (201 ) to form a protrusion having corresponding shape of the hollow core section of the first modular wall panel (202).

The base plate interlocking tube penetrates into the first modular wall panel (202) less than or more than half of the size of the first modular wall panel (202) to form an interlocking. Thereafter, the another interlocking tube (204) is slotted, affixed or inserted into the first modular wall panel (202) above the base plate interlocking tube, to form a protrusion having corresponding shape of the hollow core section of the other modular wall panels (203, 203’), in which said interlocking tube (204) penetrates into the modular wall panels (203, 203’), of less than or more than half of the size of the modular wall panels (203, 203’), to form an interlocking.

Further, at least one tie rod slotted into the base plate interlocking tube in vertical plane for securing the first modular wall panel (202) vertically. Thereafter, another tie rod (204) slotted into the interlocking tube (204) for each of the modular wall panels (203, 203’) to form a wall system or assembly.

The tie rod (204) protrude out to form a protrusion having corresponding shape of the hollow core section of the other modular wall panels (203, 203’), in which said interlocking tube (204) penetrates into the modular wall panels (203, 203’) around half of the size of the modular wall panels (203, 203’), to form an interlocking.

Further, the wall system or assembly having horizontal interlocking tube slotted, affixed or inserted into any one of the modular wall panel (202, 203, 203’) to form an interlock with at least one column assembly, pillar module or to an adjacent modular wall system in horizontal position, where at least one horizontal tie rod slotted into the horizontal interlocking tube in horizontal plane for securing the wall horizontal, in which at least one end of the horizontal tie rod secured to the tie rod junction box (207) to form interlock in horizontal plane with the column assembly or pillar module having the tie rod junction box (207).

Each of the modular wall panel (202, 203, 203’) or the horizontal tie rod may further include a washer or fastener placed in between each of the modular wall panel (202, 203, 203’) to avoid leakage in between modular wall panel (202, 203, 203’).

The tie rod junction box (207) comprising at least one side aperture to form an interlock with another column assembly or the wall system or assembly in horizontal position by using the interlocking tube and horizontal tie rod position in horizontal plane.

Preferably, the modular wall panel (203, 203’) is be placed in line with the tie rod junction box (207) of the pillar module or column assembly such that a protrusion from the interlocking tube or the horizontal tie rod is slotted, affixed or inserted into the tie rod junction box (207) to form interlock for t the modular wall panel (202, 203, 203’) in vertical and horizontal position.

The modular wall panel (202, 203, 203’) or the wall system connected to the Column assembly (205), wherein the Column assembly (205) consist of tie rod base component that connects to a reinforcing ground floor slab starter bars or the tie rod base (206), where there are composite/concrete infill units with braces at both ends, tie rod junction box (207), and a top cover. The overall components are brace together to form a monolithic unit by using at least four units of interlocking tube with the tire rods in each of the interlocking tube, and at least one main tie rod shaft place at center of the of the Column assembly (205) for additional strength. The locking of all components are similarly to the method use in the wall ties assembly method. Further, a permanent column (208) are mounted or inserted onto the Column assembly (205) for mounting, receiving or positioning the wall panels (202,203), and the base plate (201 ) of the wall panel. The permanent column (208) are made of fiber reinforce polymer (frp) material for its light weight advantage, durability, and mechanical properties. The variation on the shapes of the permanent column (208) are design to provide and facilitate columns, beam, cantilever beam and suspended beam assembly. Preferably, at least one side of the permanent column (208) has a c-shaped slot to receive or position the wall system within the slot.

One embodiment of a stackable modular wall panels as illustrated in Figure 3. The stackable modular wall panel (400) has at least one apertures (401 ,402) or hollow core section for receiving or slotting a plurality interlocking tube (403,404,405) in vertical or horizontal plane manner. The interlocking tube (403,404,405) is slotted into the apertures (401 ,402) or hollow core in vertical or horizontal plane, for securing the stackable modular wall panel (400) onto another stackable modular wall panels.

Further, at least one tie rod slotted into the interlocking tube (403,404,405) in vertical or horizontal plane for securing the stackable modular wall panel (400) vertically. Thereafter, another tie rod (204) slotted into another modular wall panels having interlocking tube (204) stacked above the stackable modular wall panel (400) to form a wall system or assembly.

Another embodiment of a stackable modular wall panels as illustrated in Figure 4. The stackable modular wall panel (500) can be stacked on each other to form a wall, where each of the modular wall panels having a corresponding shapes or interlocking means on at least one top surface, bottom surface, side surface, or any combination thereof for interlocking with the other modular wall panel. Each of the stackable modular wall panels has at least one apertures (501 ,502) or hollow core section for receiving or slotting a plurality interlocking tubes and tie rods in vertical or horizontal plane manner for securing the wall horizontally and vertically. The stackable modular wall panel (500) may further use at least one horizontal bracing. Figure 5 illustrate horizontal bracing. The horizontal bracing assembly (701 ) process is similar to the vertical tie rod assembly methods where the horizontal bracing used for simultaneously lock in place tie rod junction box place internally in designated slots at the permanent column form units.

Figure 6 illustrate permanent column forms are then inserted onto the column assembly to receive the wall panel base plate and assembly of the wall panels. The Permanent column forms (similar to permanent structural exhibits) are made of fiber reinforce polymer (frp) material for its light weight advantage, durability, and mechanical properties. The variation on the shapes of this permanent forms are design to provide and facilitate columns, beam, cantilever beam and suspended beam (means the beam is not sitting on top of wall) assembly.

One embodiment of the column assembly (900) is illustrated in Figure 7 & 8, the column assembly connected to a floor slab using a tie rod base (901 ), wherein the column assembly (900) having at least one pillar module with at least one vertical bracer (902,902’, 902”) on each end of the pillar module, and a tie rod junction box (903) affixed on top portion of the column assembly (900). The pillar module has a plurality apertures or hollow core section for receiving or slotting at least one control tubing or interlocking tube in vertical plane. The first pillar module slotted or mounted on the tie rod base (901 ), where the tie rod base (901 ) has a first interlocking tube affixed, in which the first interlocking tube protruding out from the tie rod base (901 ) to form a protrusion having corresponding shape of the hollow core section of the first pillar module. Each of the pillar module has a wall surrounding or sides the plurality apertures or hollow core section and a vertical bracer (902, 902’, 902”) with corresponding apertures on each end to form the pillar module. The vertical bracer (902, 902’, 902”) may use to position the hollow core section or the interlocking tube, or to enclose the side wall around the hollow core section, in particularly top and bottom portion for securing the pillar module or the column assembly (900) vertically. The main function of a pillar is to support part of a solid vertical structure such as a building or a monument. Further, at least one tie rod slotted into the interlocking tube in vertical plane of the column assembly to form an interlock for the column assembly or the pillar module in vertical or in upright position.

Further, at least one horizontal interlocking tube (906) used for horizontal bracing for wall system (907) or assembly, the horizontal interlocking tube (906) used for bracing is similar to the vertical tie rod assembly methods.

Further, the process is similar to the vertical tie rod (905) assembly methods with exceptions to its final length that varies in construction lay out designs and are simultaneously lock in place using the tie rod junction box (903) with the vertical bracer (902, 902’, 902”) place internally in designated slots at the permanent column units.

Preferably, the column assembly (900) has a top cover, where the top cover is used to cover the top portion of the column assembly (900). Preferably, the column assembly (900) has at least one tie rod (905) positioned on the tie rod base (901 ) within the column in upright position, and each end of the tie rod is made of interconnecting means for forming interconnection, wherein each of the tie rod interlocks with the vertical bracer (902, 902’, 902”) and the top cover (904) mounted on top to brace the column assembly (900), such that the column assembly (900) able to mount or position the wall for forming the modular wall system (907).

The present innovation may be embodied in other specific forms without departing from its essential characteristics. The described embodiments are to be considered in all respects only as illustrative and not restrictive. The scope of the innovation is, therefore indicated by the appended claims rather than by the foregoing description. All changes, which come within the meaning and range of equivalency of the claims, are to be embraced within their scope.