Note: Descriptions are shown in the official language in which they were submitted.
CA 02278210 1999-07-19
CONSTRUCTION METHOD
The present invention relates to the construction of buildings, and, more
particularly, to a construction method according to Claim 1, a machining
center for
building construction, and construction elements for buildings.
Products of all kinds are currently manufactured more often in serial
production
than individually, with computer-aided methods being increasingly used. Thus
the
utilization of a CAD/CAM system for mechanical design is known in the
construction of
machinery and equipment; see for example Siemens-Albis-Berichte [Siemens-Albis
Reports] 38 (1986). Furthermore, a method for product configuring designed for
ease of
installation is known from "Robotersysteme [Robot Systems] 3, 37-45 (1987)."
U.S. Patent
5,587,914 describes how a sheet building material can be folded or bent by
machine
without the tool which is used for such purpose interfering with the bending
of the
component parts. The arrangement of fold lines is known as such from cardboard
cartons;
compare for example German patent 1 95 43 579 A1.
In the field of building construction, manufactured houses are designed which
are
largely prefabricated on an industrial basis, whereby the production site is
centrally located
and the individual parts of the manufactured house being constructed are
transported over
long distances to the construction site. The transport distance entails high
logistics costs
and is susceptible to disturbance because individual single construction
components can
be lost as a result of transport damage, delaying work at the construction
site as a whole.
Manufactured houses are also used only for comparatively small houses.
Complicating
factors are the strongly varied use of buildings, the differing geographic
factors of the
construction site, etc. Total prefabrication of a complete house in a central
production
facility is therefore not possible on a practical basis.
Furthermore, certain construction elements such as installation systems for
sanitary
fixtures are prefabricated as modular units. German Published Patent 2809135
presents an
example. Even with the use of system components for installations, however,
construction
-1-
CA 02278210 1999-07-19
tolerances arise which make assembly difficult. In particular in the case of
systems of this
type, it is easily possible for the lines of an installation to be laid by a
worker on site
completely differently than intended.
Different systems for the construction and/or planning of buildings or parts
thereof
have also been suggested; compare for example U.S. Patent No. 5,227,983 or
U.S. Patent
No. 4,847,778.
In conventionally constructed buildings which are planned and constructed as
originals and in which the assembly, i.e., the shell or wall construction, the
laying of
electrical lines, plumbing, air conditioning systems, etc., are carried out by
hand, no
detailed planning of fixtures and supply lines is possible or meaningful. In
large buildings
such as high-rise buildings with open-plan offices or the like, it can occur
that lines can be
found several meters to the side of the very crudely specified location. Thus
lines such as
hot and cold water or incoming and outgoing heating lines located close
together are easy
to confuse. For this reason it is necessary in the operation of the building,
despite definition
by the construction plans, to measure after construction, which increases
construction
costs. The actual material consumption with respect to electrical lines, etc.,
can be
predicted only with difficulty, which is detrimental to cost projection and
construction
supervision.
The obj ect of the present invention is to provide something new for the
commercial
application, and in particular, but not exclusively, to facilitate a
predictable construction
result at a reduced expenditure in time and money for buildings constructed as
originals.
The obj ect of the present invention is achieved through the independent
claims,
whereby the preferred embodiments are indicated in the dependent claims.
A basic idea of the invention thus consists of, even in the case of a one-of a-
kind
building, not only specifying the planning with respect to the fixtures and
supply lines such
as air conditioning and ventilation systems, electrical lines, arrangement of
wall plugs and
-2-
CA 02278210 1999-07-19
switches, plumbing installations, etc., and then leaving it to the craftsman
to determine in
the execution where he will actually lay the lines, but rather first carrying
out precise
planning even with respect to these elements and then compelling the execution
of this
planning through the provision of construction components according to the
exact plan for
the defined receiving of the multiplicity of fixtures and supply lines.
Although assembly takes place by hand, it is thus ensured that only slight
tolerances will occur. In contrast to the state of the art, where as a result
of unforeseen and
unintended construction processes, errors and deviations from plans occur
specifically at
the transitions between different systems, the construction results can be
unambiguously
predicted with the present invention. This is achieved in that planning and
assembly, i.e.,
the actual execution of the structure, are more closely joined together than
has been usual
in the past through the prefabrication of construction elements exactly
according to the
plan for selected areas.
Planning takes place in precisely such a manner that, at least in essential
areas such
as utility shafts, etc., the location of individual lines, connectors,
switches, etc., is
unambiguous. This is easily possible with the use of CAD/CAM systems, whereby
even
after appropriate implementation of planning regulations, ergonomic aspects or
requirements of sound and thermal insulation can be automatically taken into
consideration. Starting with these detailed plans in which, for example, the
routes for the
supply lines are defined along which the individual lines run parallel without
mutual
interference, components can be prepared for select areas according to plan
for defined
locating of the particular fixtures and supply lines.
It is not necessary according to the invention for the building to be
completely
prefabricated as in prefabricated houses; instead it is sufficient if basic
components are
prepared according to plan only for critical areas, so that fixtures and
supply lines to be
provided in the rough construction are brought precisely into the correct
relative position,
making the installation of the individual fixtures and supply lines by
craftsmen more easy
and less susceptible to errors. If in finishing the rough construction, the
basic components
-3-
CA 02278210 1999-07-19
prepared according to plan are installed in the selected areas, subsequently
the fixtures and
supply lines can be fastened in or on the initial components prepared for this
purpose. The
fixtures and supply lines can for this purpose even be partially prepared in a
shop so that
less tools are needed on site. At the same time, an activity is made possible
for the
craftsman in his shop even during periods of bad weather independent of the
degree of
completion of the rough construction. Thus, for example, it is possible to
prefabricate
electric supply lines from a central fuse box to different stories of a
building which extend
through a central utility shaft in the manner of a wiring harness known from
automobile
construction; this harness need only be laid in the construction parts
prepared according
to plan and then connected appropriately; in like manner in the area of
plumbing, pipes,
etc., including all elbows, and the like can be prepared in advance. This
reduces the time
required for assembly. Thanks to the exact planning according to the
invention, there is no
need to fear that the different fixtures and supply lines will interfere with
each other.
The starting components prepared for selected areas according to plan for
defined
accommodation always ensure that at most only tolerances so slight as to be
negligible will
occur. If the entire rough construction is not prefabricated, the absolute
location of fixtures
and supply lines in the building will indeed not be determined with millimeter
precision,
but nevertheless their relative location to each other will be highly exact.
At the same time
it is possible due to modern measuring methods to construct the rough
construction itself
adequately precisely so that the absolute location is determined with
satisfactory precision.
The use of components prepared according to plan makes the construction
results
more predictable and more exact and at the same time makes any subsequent
dismantling
and recycling of the systems used easier. In the same way it is easily
possible to retrofit an
existing system without relatively great expense due to the existing plans and
without the
necessity of measuring the actual structure. In addition, the component can
likewise be
prepared as required. In total, the invention thus results in clear gains in
time, cost, and
quality.
-4-
CA 02278210 1999-07-19
Even if for prefabricating related to a one-of a-kind building, some areas
must be
planned with significantly more precision than is customary for normal
architectural
planning, which if possible will require a longer planning time; this excess
expenditure
will thus be more than offset.
It is preferred that the initial components be produced in standard sizes
through
processing of building materials. The use of standard sizes further reduces
the cost of the
structure. If locally available building materials are used for the initial
components and
such are prepared locally, i.e., at the construction site or only a small
distance from it,
transportation over long distances becomes unnecessary, which reduces the
logistics
expense, lowers costs, and in addition ensures more rapid replacement in the
event of
damage of a prepared component due to the shorter transportation times, if
any.
It is preferred that as many fixtures and supply lines as possible be included
in the
planning and in particular that different fixtures and supply lines be taken
into
consideration so that no mutual interference will occur upon assembly of the
fixtures and
supply lines.
Preparation of the component according to plan preferably includes that the
location openings, holes, etc., for the fixtures and supply lines be provided
at the planned
location of the component; the component thus represents to an extent a plan
with a scale
of 1:1 for the arrangement of the fixtures and supply lines.
It is preferred that the initial component be prepared as far as possible and
in
addition that assembly instructions be applied onto the component such as the
position in
the rough construction or the in the building to be subsequently finished.
This avoids
confusion when a number of prepared initial components are handled at the
construction
site. It is preferred that the preparation according to plan take place
locally, in particular
directly at the location of the construction site so that the initial
components are prepared
according to plan practically upon request.
-5-
CA 02278210 1999-07-19
As building material for the initial components, a basically flat material
such as
sheet metal is preferred. This material can be cut, stamped, drilled, provided
with fold
lines, and/or bent as required for preparation according to plan. The sheet
metal can be
coated, for example electrostatically with plastic powder. This increases the
corrosion
resistance, improves handling, and reduces the danger of injury on sharp
edges. In addition,
colored coatings can code the application purpose or the like.
In the event this does not take place locally at the construction site but
rather
locally in a sheet metal working operation and/or one of several processing
centers suitable
for this purpose, the lightweight unit so produced will have only a small
transport volume
if it is brought to the construction site flat or bent so as to still be
stackable and there is
brought to its final form, e.g., by hand.
In the case of installation in places subject to corrosion, e.g., bathroom
units, or if
the construction elements are formed integrally with a covering which is
visible after
completion, stainless steel and/or coated sheets are advantageously used.
In planning, ergonomic aspects with respect to size, ease of installation, and
desired
or legally required insulation measures can be automatically taken into
consideration.
Conflict-&ee installation of the individual fixtures and supply lines is
particularly
facilitated in that for integration and coordination, routes are defined in
the rough
construction within which the fixtures and supply lines pass. Routes represent
the reserved
spaces for the fixtures and supply lines in corridor form. Preferably parts
lists are prepared
fizlly automatically as a basis for requesting bids and for preparation for
installation.
Initial components are preferably prepared for areas in which different
fixtures and
supply lines are arranged close together. In so doing a route, for example, is
defined only
at a few places along a long, straight stretch and/or components are provided
at places
where the route is to be redirected in a different direction. Furthermore, it
is preferred that
components be provided for points where a transition is provided between the
course of
fixtures and supply lines planned according to the invention and
conventionally
-6-
CA 02278210 1999-07-19
constructed fixtures and supply lines; this makes it possible to reduce the
planning effort
at non-critical places without causing a deterioration of planning results.
It is possible to mount the components in the rough construction itself, in
particular
as permanent formwork. This eliminates subsequent installation and further
reduces the
cost of the construction.
It is possible for the components to be prepared according to plan for defined
accommodation of the multiplicity of fixtures and supply lines at the
construction site. For
this purpose, a mobile machining center for building construction can be used.
The center
is then brought to the construction and relevant building data are transferred
such as with
diskettes or directly through a data line from the planning office. In the
machining center,
there is a numerically controlled machine which machines the initial
components
according to the requirements. For basically flat materials such as sheet
metal, wood, tiles,
1 S insulating panels, laminated panels, etc., the numerically control machine
preferably is
provided with a water cutting head. With it, three-dimensional structures up
to a thickness
of, for example, 15 cm can be produced in lightweight concrete.
The prefabricated building component according to the invention for defined
accommodation of the multiplicity of fixtures and supply lines is preferably
self supporting
so that it does not have to be braced following installation but rather can
even easily bear
the load of the fixtures and supply lines such as, for example, all built-in
plumbing
components such as pipes, clamps, flush tanks, etc. On the other hand it can
be provided
that mounted components such as vanities and the like are fastened to
supplementary
consoles so that design of the prefabricated components for very great loads
is not
mandatory. A first component according to the invention is composed of a
basically flat
material such as sheet metal which is provided with cut, stamped, or bending
lines or
openings; a second construction element is composed of lightweight concrete.
CA 02278210 1999-07-19
Naturally it is not required that only self supporting prefabricated
construction
elements of one type be used in a building, but rather different types can be
combined as
necessary.
Although each prefabricated part per se is an original, it is obvious that for
a
structure such as in a series of row houses or on stories of a high rise which
are identical
as such, the same prefabrications can certainly be repeated.
The invention is described below only by way of example using the drawings,
which show the following:
Figure 1: The planned course of fixtures and supply lines in a house
and the planned location of a window relative thereto;
1 S Figure 2: The prefabricated building construction elements necessary
for the arrangement of the planned fixtures and supply lines in their position
relative to
each other;
Figure 3: A mobile machining center for the production of
construction elements prefabricated according to plan from standard building
materials;
Figure 4: The arrangement of installed pipes in the standard
components;
Figure 5: A second example of a multiplicity of fixtures and supply
lines planned for a building;
Figure 6: A section therefrom in greater detail;
Figure 7: A substantially flat building element for defined
accommodation of a multiplicity of fixtures and supply lines;
_g_
CA 02278210 1999-07-19
Figure 8: The construction element from Figure 7 in installation-ready
condition;
Figure 9: The arrangements according to the invention of fixtures and
supply lines in the routes defined by construction elements prepared for this
purpose
according to plan;
Figure 10: A detailed view of Figure 9;
Figures 11-13: The construction element used in Figure 10 in different
stages before installation;
Figures 14-15: Another exemplary embodiment of a construction element
according to the invention.
According to Figure 1, a multiplicity of fixtures and supply lines 2, which
are
depicted here as lines 2a through 2j, are provided in a plan 1 for a building.
According to Figure 1, the lines 2 can pass through different planes; for
example,
lines 2a through 2e pass through a first plane and lines 2f through 2j pass
through a second
plane. Connector links 3 can be provided between the lines of different planes
as required.
In the case of configuration of the lines as pipes, valves can be provided in
the lines and
in the case of configuration as electrical lines, outlets, switches, etc. can
be provided as
suggested in 4 and the lines can be provided with coating and/or fastening
means 5.
Connector links 3 and valves or outlets and switches 4 also represent fixtures
and
supply lines for purposes of the invention. In addition, windows, doors,
stairs, and the like
for the building are also included as fixtures and supply lines for purposes
of the
description since in particular they supply rooms with light and/or
accessibility.
-9-
CA 02278210 1999-07-19
Figure 2 shows walls 6a, 6b, on which or in which fixtures and supply lines 2
from
Figure 1 are provided. The planned fixtures and supply lines of one plane,
here the plane
defined by lines 2a through 2e, run within a room; for this purpose recesses
7a through 7f
are provided. The lines of the other plane are accessible from the adjoining
room as is
suggested by recesses 7f through 7j. The individual walls are constructed from
a
multiplicity of individual prefabricated construction components 9 which have
recesses 7
and penetrating holes 8 for the fixtures and supply lines. Construction
element 9 is
composed of material which is locally available. This can specifically be the
case for
blocks of lightweight concrete which are of such a size that no sheathing is
required.
For processing construction element 9, a machining center is provided
according
to Figure 3 with a CNC machine 11 which comprises a computer unit 12 with a
data input
device 13 for inputting of the planed building data, as well as one or several
machining
elements 14. Preferably the machining center for machining the initial
components is
mobile and is used directly at the location of the construction site.
For the construction of a building, the building including the detail routes
of
fixtures and supply lines 2 to be determined with consideration of the
required insulation,
etc., is first planned. Then the planned data is fed into the numerically
controlled
prefabricating machine which prepares initial building material 10 for the
defined
accommodation of the fixtures and supply lines 2 using the data. The CNC
machine
provides in the initial components, i.e., the standard construction elements,
the required
holes, depressions, recesses, etc. so that the necessary construction elements
prepared
according to plan for the accommodation of fixtures and supply lines is obtain
a$er
machining as construction elements 9.
Prepared construction elements 9 obtained in such manner are used as required.
If an individual construction element 9 is destroyed or damaged during
installation,
such as through inattention, a new one can be produced with the exact same
dimensions
without delay on the basis of the existing building data.
- 10 -
CA 02278210 1999-07-19
After construction of the rough structure using construction elements 9
prepared
according to plan, fixtures and supply lines 2 are installed in the places
prepared for such
purpose; compare Figure 4.
A building in which the fixtures and supply lines are installed in defined
manner
in this way does not have to be remeasured after construction to provide exact
data for the
documentation and for building management.
If desired, the complete rough construction is completed on one hand from
standard
construction elements which are prepared according to plan and on the other
hand from
those which are not handled. The solid blocks prepared according the invention
are thus
buttressed with standard building blocks. Otherwise only partial areas are
built up in this
manner while the other areas of the building, in particular those in which no
fixtures and
supply lines must be precisely laid, are conventionally constructed.
Figure 5 shows a further example of how construction elements for selected
areas
are prepared according to plan for defined accommodation of fixtures and
supply lines,
with lightweight building blocks fabricated from basically flat basic building
material
being used.
According to Figure 5, by way of example the house service connection 15, the
installation guide 16 on ceiling, wall, and floor, the installation shaft 17
with channels and
covers, the recess on ceilings and wall breakthroughs 18 formed as permanent
formwork,
an installation wall 19, a wall installation 20, and a connection and an
installation guide
for the heating and/or solar system 21 are defined as fixtures and supply
lines 2 in the roof
with lines to be passed through a roof skin via initial components prepared
according to
plan.
Figure 6 shows a section from Figure 5 in which a bathroom unit with a bathtub
22,
a lavatory 23, a shower base 24, and two sinks 24' are provided on a wall with
integrated
shaft 17 and a wall installation 20. These fixtures and/or supply lines are
preplanned with
- 11 -
CA 02278210 1999-07-19
respect to their location and are connected through supply lines which are
precisely fixed
with respect to their position through construction elements 9 prepared
according to plan
and which lead to the particular supply routes 25 in an installation shaft 17.
The ceiling
passthrough is coordinated in the area of the installation shaft with a
construction element
17a as permanent formwork.
Construction elements 9 are formed from a basically flat building material, in
particular sheet mental, advantageously stainless steel and/or coated sheet
metal for the
bath area.
Figure 7 shows an example of a construction element 9 which is formed from a
basically flat building material through provision of bending lines 26 and
knockout
openings 27; for reasons of clarity, not all bending lines and knockout
openings are
numbered. In addition, a label 28 is provided.
For fabrication of the lightweight construction element 9, building plans are
prepared using a CAD/CAM system with precise establishment of the fixtures
and/or
supply lines including all necessary lines. The building data relevant to the
installation area
is then transferred to a CNC machine which stamps, cuts, and labels the sheet
metal in
known manner, whereby it receives all openings, holes, fastenings, labels, and
bending
edges. This preferably takes place directly at the construction site in a
mobile machining
center as in Figure 3 or in a nearby sheet-metal-working operation.
The construction part can be bent by machine into a form which preferably can
be
stacked or is brought to the installation location still flat and there is
folded up by hand. If
connecting tabs 29 are provided between areas 30, 31 arranged at angles to
each other for
bracing, the tabs being formed as one piece with the material through a
bending line on one
side, they are attached following the folding up, by such means as
interlocking, rivetting,
or, as suggested in 32, by fastening with screws. The finished, self
supporting lightweight
building block, compare Figure 8, is thus particularly stable.
- 12 -
CA 02278210 1999-07-19
It is installed at the planned location and is ready for accommodation of the
fixtures
and/or supply lines. During assembly, the lightweight building blocks compel a
precisely
defined position of the fixtures and/or supply lines and thus ensure execution
of the
building and/or interior finishing in accordance with the plan.
Figure 9 shows a further exemplary embodiment in which the coordinated wiring
of supply lines, i.e., fixtures and/or supply lines of the present invention,
within a double
floor of an office building is achieved with the aid of components prepared
according to
plan, with initial components in turn providing defined accommodation of the
multiplicity
of fixtures and/or supply lines and at the same time representing an
installation aid. This
installation aid preferably assumes the relative dimensions and the general
design
conditions of the double floor. As shown, supply lines 2' pass within the
double floor in
routes which are defined by components 9 provided for this purpose.
Figure 10 shows in greater detail the arrangement of a construction element 9
according to the invention relative to the lines 2 and a fixture and/or supply
line 2, which
can be, for example, a convection heater.
According to Figure 11, construction element 9 of Figure 10 is prepared in a
local
or regional machining center from sheet metal through cutting and/or stamping
and
provision of bending lines 33 and 34 as well as through the drilling of holes
for fastening
35 and recesses 36 for accommodation of conventional installation straps or
the like. It is
bent by machine along bending line 34 into the shape shown in Figure 12 and is
brought
to the construction site.
At the location of the construction site, it is brought into its three-
dimensional form
around bending line 33 (Figure 13) and is mounted at the fastening points
provided.
Preferably the construction element, which thus at the same time represents a
three-dimensional realization of the building plan, is labelled sufficiently
comprehensively
(not depicted) that the installer will readily recognize the intended position
in the building,
- 13 -
CA 02278210 1999-07-19
such as relative to a double floor register, which provides assurance against
wrong
arrangements.
Following installation of construction element 9, supply lines 2, preferably
prefabricated in a shop, can, as shown in Figure 10, be mounted with
installation straps 36
or the like and a supply unit can be mounted at the end points of supply line
2, which are
thus precisely established, immediately and without extensive adaptation.
Figures 14 and 1 S a through c show a component for a permanent formwork, such
as the ceiling passthrough 17a or installation shaft 17 (Figure 6).
The invention was described above only by way of example.
Thus various numerically controlled processing systems can be used such as
milling or water cutting systems; in place of. porous concrete blocks, other
building
materials can also be used for the solid building blocks and the prepared
building
components do not to be utilized only after completion of the rough
construction.
Using the construction elements prepared according to plan, in particular
permanent
formworks for coordinated ceiling and wall, passthroughs can be created such
as in
stairwell openings or for installation shafts.
The sheet metal used for the construction elements 9 in the formation as
lightweight building blocks can be folded into their three-dimensional shape
while still in
the workshop.
Although all recesses, etc. for fixtures and/or supply lines are
advantageously
provided in one component, it is possible to provide still other fixtures
and/or supply lines
at initial components prepared according to plan, for example if a row house
community
is to be constructed with uniform basic fixtures and the buyer of one
individual house
subsequently desires special installations. Also recesses for future equipment
can be
- 14 -
CA 02278210 1999-07-19
provided in advance so that additional fixtures andlor supply lines such as
additional
telephone lines, antenna cable, sewerage lines, etc. can be installed without
problems and
without installation costs being already incurred at the time of construction.
Retrofitting
is especially simplified if covers are mounted on installation shafts such as
cover 17c in
Figure 5.
In addition, despite detailed planning, fixtures and supply lines can in part
still be
laid conventionally.
The invention can be used for all types of buildings, but is preferred for
installation-intensive buildings in which a multiplicity of different fixtures
and supply lines
must be provided such as office buildings, schools, universities, clinics,
laboratories, and
ultraclean rooms.
- 15 -
