DESCRIPTION:

Technical field of the invention

The invention relates to a method for manufacturing a module for a building, said module comprising: a concrete supporting beam, as well a concrete column attached to the supporting beam, which column has a circumferential wall and the space inside the circumferential wall is filled with concrete, in which method the circumferential wall of the column is manufactured by means of 3D concrete printing.

Background of the invention

Such a method is known from CN108312291A. With this known method, a foundation is first formed at the location of the walls and, after printing of the outer leaves of the walls, vertical reinforcing wire cages are placed locally between these leaves, and then the space within these cages and immediately around them is filled with concrete in order to form vertical construction columns. Near the top of the walls, floor plates are placed between the walls, which will constitute the floor of a further building module of the building to be made thereon. Reinforcement is applied to the floor plates and then a layer is printed on the floor plates. In this known method, said horizontal plate is the ceiling of the building module or the floor of the storey to be formed above it. The building modules manufactured according to this known method are not movable but are directly a part of the building to be made. The walls and the top layer of the floor are printed one after the other. Summary of the invention

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 cheaply, so that a building can be realized with them in a cheaper and faster manner. To this end, the method according to the invention for manufacturing a module is characterized in that the method comprises the following steps: installing on the surface a formwork for the concrete supporting beam and an elongated reinforcing wire cage for the supporting beam, installing of a supporting plate on the reinforcing wire basket or installing a support provided with a supporting plate next to the reinforcing wire basket,

3D concrete printing of the layers of the circumferential wall of the column on the supporting plate, installing an elongated reinforcing wire cage inside the circumferential wall of the column, such that there is an intertwined structure of wires of the elongated reinforcing wire cage and/or of wires of the reinforcing wire basket and/or of reinforcing bars that are installed before the reinforcing wire cage is installed, in such a way that after pouring concrete into the formwork and inside the peripheral wall of the column, the supporting beam and the column are attached to each other via the reinforcements, pouring concrete into the space between the formwork, and pouring concrete within the circumferential wall of the column.

CN 111 379 339 A discloses the manufacture of a pre-manufactured concrete building module, see figure 4. The concrete floor plate is however cast before the walls are manufactured via 3D printing. Moreover this document does not disclose a floor plate having integrated floor beams, which are to be connected to a vertical pillar.

HARALD KLOET ET AL: "Bewehrungsstrategien fr den Beton-3D- Druck", BETON- UND STAHLBETONBAU, JOHN WILEY, HOBOKEN, USA, vol. 115, no. 8, July 6, 2020 (2020-07-06), pages 607-616, XP071133715, ISSN: 0005-9900, DOT: 10.1002/BEST. 202000032, teaches the "upside-down" hybrid manufacturing of a concrete plate, i.e. the ribs are 3D printed on a cast concrete plate. Due to the orientation of the plate during manufacturing, the method of described in this document is technically incompatible with the manufacturing process of CN 111 379 339 A. DE 10 2020 004417 Al discloses as well the combined techniques of 3D-printing and casting of concrete, however the final product as shown in figures 17 and 18 is a plate and not a spatial module having walls on a plate. It therefore fails the steps of the characterizing portion of claim 1 and does therefore not suggest the solution of claim 1.

Preferably, the module further comprises a concrete slab attached to the supporting beam, characterized in that the formwork that is arranged for the concrete supporting beam, is arranged in such a way that it is also suitable for the forming of the concrete slab, and that, before the concrete slab is formed, a reinforcing wire mesh for the concrete slab is placed on the surface.

Furthermore, the module preferably comprises a cavity wall, which is attached to the concrete slab and which comprises two leaves located at a distance from each other, whereby during the 3D concrete printing of the layers of the circumferential wall of the column on the supporting slab, the leaves of the cavity wall are also printed on the substrate.

Preferably, the pouring of concrete takes place in the space between the formwork during or after the 3D concrete printing of the layers of the leaves of the cavity wall.

By first printing the cavity wall and the circumferential wall of the column that is to be formed at a distance above the substrate, the pouring of concrete for the concrete slab, the concrete supporting beam and the concrete column can take place directly behind each other so that only one amount of concrete to be poured needs to be prepared. Moreover, any 3D concrete printing process that is already running does not have to be interrupted and can be continued without interruption.

An embodiment of the method according to the invention is characterized in that, before the supporting plate is arranged, reinforcing bars bent at right angles each consisting of two legs at right angles to each other, are inserted into the reinforcing wire basket with a first of the legs and are inserted through a hole present in the supporting plate with the other, second leg. In this way, the supporting beam and column to be formed can be firmly attached to each other to obtain a strong construction, so that the module can be moved relatively easily without having to be supported additionally.

One way in which the supporting plate is well supported is characterized in that before the supporting plate is installed, reinforcing bars bent at right angles each consisting of two legs at right angles to each other, are inserted into the reinforcing wire basket with a first of the legs and support the supporting plate with the other second leg. Hereby the second legs are held vertically and are preferably bent at right angles at the free end, the bent parts supporting the supporting plate.

In order to obtain a better attachment of the supporting 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 supporting plate is U-shaped and during installation the reinforcing wire cage is arranged through the opening inside the U-shape and next to the second legs of the reinforcing bars. This makes it possible to obtain a firm attachment of the column to the supporting beam. Preferably, the reinforcing wire cage is arranged over a length of at least 40 cm along the second legs of the reinforcing bars. This eliminates the need to attach the reinforcing bars to the reinforcing wire cage. The concrete to be poured afterwards ensures a sufficiently strong connection between the reinforcing bars and the column. The same applies to the length over which the first legs of the reinforcing bars are inserted into the reinforcing wire cage.

Another way of obtaining a strong attachment of the column to be formed to the supporting beam to be formed is characterized in that the supporting plate has a rectangular shape and reinforcing wires extending in the longitudinal direction of the reinforcing wire cage are inserted with their free ends through further holes in the supporting plate when arranging the reinforcing wire cage. Preferably, these free ends are placed over a distance of at least 40 cm along the second legs of the reinforcing bars.

Yet another way of obtaining a strong attachment of the column to be formed to the supporting beam to be formed is characterized in that the supporting plate has a rectangular shape and the reinforcing wire cage is fitted onto the supporting plate and rests on the supporting plate. Preferably, the second legs of the reinforcing bars are arranged over a distance of at least 40 cm along the reinforcing wire cage.

Yet another embodiment of the method according to the invention is characterized in that the support has a foot provided with a hole, which is arranged on the surface, and a vertical tube fixed to the foot around the hole on which the supporting plate is present or around which the supporting plate provided with a central hole is arranged. This tube can later be used to connect two modules on top of each other in a vertical direction. Preferably, the second legs of the reinforcing bars or the vertical tube are provided with external screw thread on which a nut is screwed, wherein after fitting the supporting plate the height of the supporting plate is adjusted by turning the nut or the nuts.

The invention also relates to a module manufactured according to the method described above, comprising: a poured concrete supporting beam provided with an elongated reinforcement wire basket, a supporting plate present on or next to the concrete support beam, and a concrete column present on the supporting plate and attached to the supporting beam and provided with an elongated reinforcing wire cage, which column comprises a circumferential wall manufactured by means of 3D concrete printing, within which the reinforcing wire cage is present and in which concrete has been poured, wherein the concrete supporting beam and the concrete column are fixed to each other via the reinforcing wire basket and the reinforcing wire cage and/or via reinforcing bars.

Preferably, the module according to the invention furthermore has a concrete slab, which is attached to the supporting beam and being provided with a reinforcing wire mat.

Furthermore, the module according to the invention preferably has a cavity wall, which is attached to the concrete slab and which comprises two leaves that are spaced apart.

An embodiment of the module according to the invention is characterized in that it further comprises a support on which the supporting plate is present and which is located next to the concrete supporting beam, wherein reinforcing bars bent at right angles extend with a first leg into the reinforcing wire cage and extend with the other, second leg in the longitudinal direction of the column into the reinforcing wire cage or under the supporting plate, the support further comprising a foot provided with a hole and a tube attached at the foot around the hole. Due to this support, the circumferential wall of the column to be printed can be better supported.

A favorable construction in which it is not necessary to fix the reinforcing bars to the reinforcing wire basket and to the reinforcing wire cage is characterized in that the reinforcing bars 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 reinforcing wire cage or under the supporting plate.

A further embodiment of the module according to the invention is characterized in that the tube protrudes through a hole in the supporting plate and partly protrudes above the supporting plate and is provided with a number of holes in the side wall, wherein elements are mounted on the side wall of the tube, which elements are provided with through-hole holes which are in connecting with the holes in the side wall of the tube, and in which bolts are screwed, which, when screwed further into the elements, enter in the tube to secure a rod, that may be present in the tube, in the tube. This provides a facility with which two modules stacked on top of each other can be connected in vertical direction.

Preferably, the part of the pipe projecting above the supporting plate extends over a distance of at least 40 cm in the longitudinal direction of the column in the column, so that the pipe need not be fixed to the reinforcing wire cage to obtain a sufficiently strong connection, become.

In order to have good access to the bolts, preferably, an opening is present in the circumferential wall of the column at the location of the bolts, via which the bolts are accessible.

The invention furthermore relates to a building composed of a number of modules as described above, of which a number of modules (1) are present on further modules, wherein in at least one column (15) of a lower module a rod (41) is present in the column, which rod partly projects upwards from the column and extends into the tube (31) of the support (19) of the further module on top this module and which rod is clamped by the bolts.

Brief description of the drawings

The invention will be explained in more detail below on the basis of exemplary embodiments of the method and the module according to the invention shown in the drawings. In the drawings:

Figure 1 shows a 3D concrete printer for forming the module with reinforcement elements on a substrate; Figure 2 shows the 3D concrete printer with a formed module;

Figures 3-6 show different steps during the formation of a simple module;

Figure 7 shows a first embodiment of the supporting plate for the column supported by reinforcing bars;

Figure 8 shows a second embodiment of the supporting plate as part of a support;

Figure 9 shows a third embodiment of the supporting plate supported by a support;

Figure 10 shows a fourth embodiment of the supporting plate present on a support and supported by reinforcing bars;

Figure 11 shows a fifth embodiment of the supporting plate supported by reinforcing bars and present around a support provided with a connecting bar;

Figure 12 shows the situation for connecting two modules of a building located one above the other;

Figure 13 shows the situation after connecting two modules of a building that are located one above the other; and

Figure 14 shows an exploded view of the reinforcement wire baskets, reinforcement wire cage and support with supporting plate.

Detailed description of the drawings

In an efficient construction method for a building, prefab modules are manufactured in a factory, which are then placed on the construction site in the building to be formed, where the building module only needs to be connected to the existing modules of the building to be formed. To manufacture the module, a suitable substrate is first formed on which the module can be manufactured. This can, for example, be a plastic platform in which slots are present at the location where reinforced concrete supporting beams are formed. These supporting beams are thicker than a concrete slab and protrude from the underside of the concrete slab to be formed. This concrete slab can, for example, form the floor of the module. Figure 1 shows a 3D concrete printer 2 in which reinforcing wire cages 11 and 12, for supporting beams and reinforcing wire mats 9 for the concrete slab to be formed, have already been arranged on the substrate. A formwork 8 for the concrete slab 3 and the supporting beams 13 is arranged around the reinforcement elements 9, 11 and 12. The 3D concrete printer 2 uses fast-curing concrete so that at the end of printing a layer, the next layer can be printed directly on top of the printed layer. After the formwork has been installed, cavity walls 5 and columns 15 are printed in a continuous 3D concrete printing process and the concrete slab 3 is poured. The latter is also preferably done with fast-hardening concrete. Figure 2 shows the situation after the pouring of the concrete slab 3 and the 3D printing of the cavity walls 5 and the columns 15.

By way of example, various steps during the formation of a simple module 1 are shown in figures 3-6. In reality, the modules will be larger and have more cavity walls, beams and columns (see for example the module shown in Figure 2). Figure 3 shows that the contours 1A of the module have been applied to a surface and a filling piece 4 has been placed which is removed again after the module has been made. Reinforcing wire cages 11 and 12 are placed next to the filling piece and a reinforcing wire mesh 9 is placed on the filling piece.

Figure 4 shows the situation after the formwork 8 has been arranged. This formwork can also be formed by means of 3D concrete printing as shown. In addition to the formwork 8, in this example the bottom layers of a cavity wall 5 to be formed have been applied by means of 3D concrete printing. Next to the ends of the reinforcing wire baskets 11 and 12, a supporting plate 21 has been arranged on which a column can be printed in a subsequent step. This supporting plate 21 is arranged on the ends of squarely bent reinforcing bars 23 which are arranged in the reinforcing wire cages 11 and 12 (this will be explained below with reference to figure 7).

Figure 5 shows the situation after printing the leaves 6 of the cavity wall 5 onto the previously printed layers of the cavity wall and the circumferential wall 16 of the column 15 onto the supporting plate 21. Subsequently, a reinforcing wire cage 18 is placed inside the circumferential wall 16 of the column 15 and concrete is poured into the space inside the circumferential wall 16 and inside the formwork 8 to form the supporting beams 13, the concrete slab 3 and the column 15, after which the module 1 shown in figure 6 is obtained.

Figure 7 shows the supporting plate 21 with reinforcing bars 23. The reinforcing bars 23 bent at right angles, each have two legs, of which a first leg 23A is inserted into the reinforcing wire cages 12 and 13 and the second legs 23B project vertically upwards. The ends of these second legs 23B are provided with screw thread onto which nuts 33 are screwed. Holes 25 are present in the supporting plate 21, through which the second legs 23B protrude. The supporting plate 21 rests on the nuts 33 and is thus supported by the reinforcing bars 23. The reinforcing bars rest with the first legs 23A on the inner side of the underside of the reinforcing wire cages. The height of the supporting plate 21 can be adjusted by turning the nuts 33. The supporting plate 21 has the shape of a U. After printing the circumferential wall of the column, the reinforcing wire cage is applied down to the substrate, passing through the opening between the legs of the U-shaped supporting plate 21. The lower part of the reinforcing wire cage extends next to the second legs 23B of the reinforcing bars 23. After the concrete has been poured, the supporting beams and the column form a solid whole because the reinforcing bars extend side by side over a great length.

Instead of being supported by reinforcing bars, the supporting plate can also be part of a support that is placed on the substrate. Figure 8 shows a second embodiment of the supporting plate 22 as part of a support 19. The support 19 has a foot 19B provided with a central hole at the location of which a tube 31 is attached to the foot 19B. The supporting plate 33 is herein attached to the upper end of the tube 31. The reinforcing bars 23 are present with the second legs 23B between the foot 19B and the supporting plate 22 of the support 19. In order to be able to fit between them, the second legs 23A are bent at right angles at the ends. There are holes 27 in the supporting plate 22 through which the ends of reinforcing wires of the reinforcing wire cage of the column protrude in order to be firmly anchored in the support 19 after the concrete has been poured and thereby also firmly attached via the reinforcing bars, which are also firmly anchored in the support beams.

Instead of being attached to the tube 31, the supporting plate 22 can also be present loosely around the tube 31, see figure 9. In this embodiment, the free end of the tube 31 is provided with external screw thread onto which a nut 35 is screwed. The supporting plate 22 rests on this nut 35 and by turning this nut 35, the height of the supporting plate 22 can be adjusted.

The squarely bent ends of the second legs 23B of the reinforcing bars 23 can also support the supporting plate 22 in the same way as they also bear supporting plate 21 in Figure 7. This is shown in Figure 10. The second legs 23B are provided with screw thread on which nuts 35 are screwed and protrude through holes 25 in the supporting plate 22. The reinforcing bars 23 can rest on the foot 19B of the support 19. The tube 31 of the support 19 protrudes through a central hole in the supporting plate 22. The reinforcing wire cage of the column rests on the wire plate 22. To obtain a sufficiently strong attachment of the column to the support beams, the second legs 23B of the reinforcing bars 23 protrude sufficiently far above the supporting plate 22 to extend a sufficient length into the reinforcing wire cage of the column to provide a strong connection.

In figure 11 the construction shown in figure 10 is shown again, but now with an extended tube 31. A connecting rod 41 protrudes through the tube and is attached to a rod 42 which is mounted in a column of a module present below. The tube 31 is provided with a number of holes in the side wall at the part protruding above the supporting plate 22. Elements 37 provided with through holes, which are mounted on the side wall of the tube 31, adjoin these holes. These through holes are provided with internal screw thread into which bolts 39 are screwed. When these bolts 39 are tightened, the rod 41 is clamped against the inside of the tube 31.

For clarification, figure 12 shows an exploded view of the reinforcing wire cages 11 and 12, the reinforcing wire cage 18, the support 19 with supporting plate 22 and the reinforcing bars 23.

Figures 13 and 14 show the connection of two modules of a building that are located one above the other. A rod 42 is anchored in the column 15 of the lower module. A connecting rod 41 is attached to this rod 42, see figure 13. The upper module is lowered with the tube 31 over this connecting rod 41 to the lower module, with the connecting rod 41 protruding into the tube 31, see figure 14. On site of the bolts 39 in the elements 37 fixed to the tube 31, there is an opening 43 in the peripheral wall 16 of the column 15 of the upper module. The bolts are accessible via this opening 43 and the connecting rod 41 can be clamped in the tube 31, whereby the two modules are attached to each other in vertical direction.

Although the invention has been elucidated in the foregoing with reference to the drawings, it should be noted that the invention is by no means limited to the embodiment shown in the drawings. The invention also extends to all embodiments deviating from the embodiment shown in the drawings within the scope defined by the claims.