U.S. patent application number 11/460865 was filed with the patent office on 2008-01-31 for mobile manufacturing plants for producing prefab elements.
This patent application is currently assigned to BIT TECHNOLOGIES LIMITED. Invention is credited to Valente Carmine FRANCO, Peccolo MAURIZIO.
Application Number | 20080022609 11/460865 |
Document ID | / |
Family ID | 38984707 |
Filed Date | 2008-01-31 |
United States Patent
Application |
20080022609 |
Kind Code |
A1 |
FRANCO; Valente Carmine ; et
al. |
January 31, 2008 |
MOBILE MANUFACTURING PLANTS FOR PRODUCING PREFAB ELEMENTS
Abstract
The present invention concerns a mobile plant for producing
prefab elements for the building industry. The mobile plant
comprises a covering canopy structure (A) that can be dismantled,
such as a large tent or a hall, assembly tables (1, 1.1, 1.2, 1.3)
for producing elements in brick material and mortar, an
installation (14) for preparing the reinforcing irons for the panel
elements of brick and mortar, a concrete mixer plant (3) for
supplying the mortar, and/or a plant for generating auxiliary means
(steam, electric current, compressed air, etc.) and/or a service
container (7) for the personnel and for managing the plant. All
these equipment elements are mounted on trailers and/or in
containers that can be transported by road or by rail to the
building site or the buildings to be erected. The main advantage of
the mobile plant is seen in the maximum work rationalisation that
yields considerable savings in time and in means.
Inventors: |
FRANCO; Valente Carmine;
(Villa Latina, IT) ; MAURIZIO; Peccolo; (Lugano,
CH) |
Correspondence
Address: |
GREENBLUM & BERNSTEIN, P.L.C.
1950 ROLAND CLARKE PLACE
RESTON
VA
20191
US
|
Assignee: |
BIT TECHNOLOGIES LIMITED
London
GB
|
Family ID: |
38984707 |
Appl. No.: |
11/460865 |
Filed: |
July 28, 2006 |
Current U.S.
Class: |
52/83 |
Current CPC
Class: |
B28B 15/002 20130101;
B28B 7/082 20130101; E04H 15/18 20130101 |
Class at
Publication: |
52/83 |
International
Class: |
E04B 7/14 20060101
E04B007/14 |
Claims
1. Mobile plant for producing prefab elements of brick material and
cement mortar for the construction of residential and industrial
buildings comprising at least the following equipment elements: a
covering canopy (A) as a roof that can be dismantled, one or more
assembly tables (1, 1.1, 1.2, 1.3) for producing panel elements of
brick material and cement mortar, a plant (14) for preparing the
reinforcing irons for the panel elements of brick material an
cement mortar, a concrete mixing plant (3) for preparing the cement
mortar to be supplied to the assembly tables (1, 1. 1, 1.2, 1.3),
and/or a station (6) for generating auxiliary means such as steam,
electric current, compressed air, with the corresponding pumps,
and/or a service container (7) for offices, sanitary stations,
dormitories for workers, and the canteen, where the individual
equipment elements are mounted on trailers and/or in containers
transportable by road or by rail to the building site where the
buildings are to be realised, and which can be arranged according
to a suitable lay-out plan for producing prefab panel elements.
2. Mobile plant according to the claim 1, characterised in that the
covering canopy is a large tent (A).
3. Mobile plant according to the claim 1 characterised in that the
covering canopy is a steel strut structure with covering plates,
that can dismantled.
4. Mobile plant according to the claim 1, characterised in that the
equipment elements (1 through 6) are arranged within the covering
canopy (A) in such a manner that the production of the panel
elements of brick material and concrete mortar can be effected
according to a principle of one-way direction, the starting
materials entering at one side of the canopy (A) and the assembled
panel elements emerging at the opposite side of the covering canopy
(A).
5. Mobile plant according to the claim 1, characterised in that the
assembly table (1) is mounted on a trailer (12) of a truck and is
provided with a horizontal hinge (13) permitting pivoting of the
assembly table (1) from a vertical transport and filling position
to a horizontal working and unpacking position.
6. Mobile plant according to the claim 5, characterised in that on
a trailer (12) two assembly tables (1, 1.1) are mounted on each
longitudinal side of the trailer (12), each of which can be pivoted
about its own horizontal hinge (13) from a of the a vertical
transporting and filling position to a horizontal working and
unpacking position.
7. Mobile plant according to the claim 5, characterised in that the
vertical filling position of the assembly table also is its
transporting position on a trailer (12) of a truck.
8. Mobile plant according to the claim 1, characterised in that it
contains different types of assembly tables such as: assembly
tables for flat panels (1, 1. 1), assembly tables for posts and
pilasters (1.2) assembly tables for stairs (1.3), other types of
assembly tables for producing different element types (1.4).
9. Mobile plant according to the claim 1, characterised in that
within the covering canopy (A) or in its close vicinity furthermore
a storage area (20) is provided for the assembled individual
elements of brick material and mortar.
10. Mobile plant according to the claim 6, characterised in that
the vertical filling position of the assembly table also is its
transporting position on a trailer (12) of a truck.
Description
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention concerns an autonomous manufacturing
plant, called "mobile plant" in the following, for producing prefab
elements, according to the introductory part of the claim 1.
[0003] 2. Discussion of Background Information
[0004] The term prefab elements in this context is understood in
particular as building elements of brick material and cement mortar
for producing panels for the building industry (residential and
industrial buildings) such as e.g. described in the European patent
application EP-01810973.6 published as EP-1273729 A2 on the 21 Aug.
2003.
SUMMARY OF THE INVENTION
[0005] In this specific case elements of brick material are
concerned that can be assembled, using reinforcing irons and cement
mortar filled in, to form the most different types of prefab
structures (box-type structures, walls, floors or ceilings,
etc.).
[0006] It is to be underlined that the mobile plant described and
claimed here in general is apt to produce "on the building site"
just about every type of prefab structure consisting of elements of
brick material (or tile material) interconnected using cement
mortar in order to form a rigid structure of any form and
application desired.
[0007] The "mobile plant" thus is created as required for the task,
apt to generate a large number of prefab elements in real time, and
to reduce cost of transport of materials.
[0008] A new technology for high quality is concerned here, apt to
activate a "door to door" industrial process directly on the
building site where the buildings are to be erected.
[0009] It represents the realisation of matured direct experience
in the field of prefabrication, for the benefit of all users,
manufacturers and engineers.
[0010] The validity of the inventive idea can be comprehended also
from the fact that the structures used in the present prefab
element manufacturing practice were made use of in stationary and
permanent work environments (e.g. halls), where the only advantage
was gained from the repetition of the elements produced, but where
the problems of transport and of assembly could not be dealt with.
The present invention aims at eliminating all the problems once and
for all concerning transport to, and assembly of the prefabricated
elements on, the building site where the planned building is to be
built.
[0011] For realising these objectives the inventive mobile plant is
characterised in that it comprises a whole series of equipment
devices, required in their combination, which constitute the
characterising part of the claim 1. In its general concept the
mobile plant thus comprises a covering canopy or roof erected
temporarily, i.e. just for the time required for producing the
prefab elements in close vicinity of the building site where the
planned building is to be realised, under which canopy the
equipment indispensably required for manufacturing the elements is
placed. The equipment according to the present invention comprises
at least one assembly table for producing single layer elements of
brick material and cement mortar, equipment for preparing the
reinforcing iron rods, a concrete mixing plant, facilities for
generating auxiliary means (electric current, steam, compressed
air, etc.) and possibly a service container with offices and
personnel rooms as required.
[0012] A characteristic of the present invention is that the
various equipment elements are mounted on trailers and/or in
containers that can be transported, by road or by rail all the way
to the building site where the planned building or buildings are to
be erected, where the equipment can be arranged according to a
suitable lay-out plan as required for rationalising the work
process.
[0013] The equipment elements of the mobile plant are conceived for
a number of production functions: [0014] Using the same assembly
tables various element types can be produced, [0015] Panels of
various thickness can be produced, [0016] On each trailer two
operating units including their storage are transported, [0017]
Production always is effected at a level above ground, damp and
grimy conditions thus being avoided, [0018] Surfaces of up to 250
square meters or 450 square meters, respectively, can be produced
per work day, [0019] The same equipment can be applied for
traditional work methods, [0020] The plant structure is
particularly suited for large building tasks such as e.g. entire
developments or settlements, etc.
[0021] The mobile plant can be managed technically for production
control from outside using particular software programs conceived
for organising production on a fixed basis, not just for planning
but also for production control and the assembly of the
elements.
[0022] The principles described of the present invention refer to
an innovative technique in the field of building construction based
on the production concept.
[0023] The essential characteristics of the novel method of
assembling are known according to the state of the art e.g. from a
particular element of brick material (the European Patent
Application EP-12737729A2 cited above), using which it was possible
already to reach a series of advantages described in detail in the
document cited.
[0024] Practical experience has shown that assembly of all these
types of wall or ceiling elements can be effected owing to
particular equipment elements, which can be transported easily to
the building sites where the equipment is placed and rendered
operative within a few hours.
[0025] The manufacturing facility is laid out in such a manner that
a certain number of elements of brick material amalgamated with
cement mortar and reinforcing iron can be stored, which are the
panel elements ready to be used (transport and mounting).
[0026] The assembly concepts shown here thus are aimed at
eliminating the inconveniences caused by transports, and by the
lack of trained personnel.
[0027] The objective of the present invention thus is to be
understood as an improvement of the known techniques in building
construction, known as traditional, as well as production of prefab
elements in stationary plants.
[0028] The result obtained owing to the application of the
constructive concept cited, known from the state of the art, from
the element in brick material cited in the EP-1273729A2, permits
e.g. assembly of up to 15 types of panel elements not only
differing from each other but also of different thickness.
[0029] These objectives are met owing to studies of the particular
elements of equipment, used also within the frame of the present
invention, and which constitute a revalidation of the use of
commonly known materials and yield cost reductions owing to the
application of a novel construction process.
[0030] The mobile plant according to the present invention thus
represents the consequent improvement of the rationalised assembly
of elements that constitute the prefab element.
[0031] Work times required are optimised and independent of
inconvenient weather conditions, particularly during winter time,
the problems created by transports and building sites thus being
eliminated.
[0032] The present invention thus permits production of large
number of panel elements directly on the spot, all of which are
obtained at better quality, profits and speed.
[0033] The "mobile" plant preferentially is laid out in the sense
of a one way street, where the starting materials enter on one side
and where the assembled product leaves on the opposite side.
[0034] Using the proposed production system with the particular
equipment the "mobile" plant offers the following principal
advantages: [0035] Standardised production process for all types of
prefab elements (e.g. the ones described in EP-1273729A2); [0036]
Possibility of obtaining larger panel dimensions in length and in
width, all inconveniences caused by transports being avoided;
[0037] Homogenous load bearing structures, or filling or dividing
structures are assembled using one single assembly process for high
quality; [0038] A large number of flat panel surfaces are produced
without specialised operators, owing to a controlled production
process. [0039] Absolute control of the production and of the
quality of all products assembled.
BRIEF DESCRIPTION OF THE DRAWINGS
[0040] The present invention is described in more detail in the
following with reference to illustrated realisation examples. It is
shown in the:
[0041] FIG. 1 A canopy or roof (tent, transportable roof structure
with steel struts and cover panels, etc.) protecting against
adverse weather influences covering the following equipment
elements, seen from above and from the side;
[0042] FIG. 2 Lay-out of the mobile plant with its basic
equipment;
[0043] FIG. 3 Lay-out of the mobile plant with its basic equipment,
seen in a section;
[0044] FIG. 4 A schematic plan of the equipment transport;
[0045] FIG. 4.1 A schematic plan of operation of the equipment;
[0046] FIG. 5 A schematic production plan for the mobile plant;
[0047] FIG. 6 A plan, side view and section of an assembly table
for producing walls with double layer elements of brick material,
mounted on a trailer, during the transport phase;
[0048] FIG. 6.1 A plan, side view and section of an assembly table
for producing walls with double layer elements of brick material,
mounted on a trailer, during the working phase on the ground;
[0049] FIGS. 7 and 7.1 A plan, side view and section of a container
for preparing reinforcing rods;
[0050] FIG. 8 A plan, side view and section of the complete mobile
plant for preparing concrete mortar.
DETAILED DESCRIPTION OF THE PRESENT INVENTION
[0051] In the FIG. 1 a canopy A or covering roof is shown in the
form of a large tent 1. It easily can be imagined as a circus tent,
but it is obvious that according to the invention any suitable
cover structure that can be dismantled (e.g. a structure of steel
struts and cover plates) could be used as well.
[0052] The form and the dimensions of the canopy A are chosen in
function of the size of the mobile plant to be realised. Of
importance is just the fact that the canopy can be easily
dismantled and transported.
[0053] In the FIG. 2 an imaginable lay-out plan is shown of the
inventive mobile plant in a practical form of realisation. The
reference numbers in the Figure indicate the following working
elements: [0054] 1. Pivotable and tiltable assembly table, [0055]
1.1 Assembly table for tunnel system, [0056] 1.2 Assembly table for
pillars, [0057] 1.3 Assembly table for stairs, [0058] 1.4 Various
productions, [0059] 1.5 Electric lifting winch.
[0060] It is to be noted here that in the FIG. 2 a mobile plant is
represented, which is apt to produce a whole series of different
elements of brick material. The arrangement of assembly tables 1
through 1.3, required according to the present invention, thus
depends on the type of building construction to be realised and is
easily adapted to the requirements. Also the size of the canopy A
is to be chosen according to the specific requirements that can
vary according to the buildings to be erected, be it an industrial
building (large tent) or an urban residential building or a
multi-storey building, etc.
[0061] A water tank reservoir is indicated with 2 (always required
except in cases where a sufficient local water supply can be relied
on, while 3 indicates a concrete mixer.
[0062] In the FIGS. 3.1 and 3.2 each a deposit for inert materials
and a cement mortar distributor are shown, i.e. elements for work
rationalisation in the mobile plant. In the FIG. 4 a storage
deposit area is shown for the brick elements required for producing
the various panel elements of brick material and mortar (compare
the description in the EP-1273729A2 cited), whereas in the FIG. 5.1
a shop for preparing reinforcing iron rods for the panel elements
of brick material and mortar is shown. In the FIG. 6 an
installation is shown for generating auxiliary means (steam,
electric current, compressed air, etc.), and in the FIG. 7 a
container is shown for offices, sanitary installations, dormitories
for workers, canteen, etc.
[0063] Evidently the presence of these services can depend on the
local requirements where the building activity takes place.
Conditions permitting dormitories for workers thus will be
dispensed with, etc., and the facilities available locally will be
relied on. In any case the mobile plant can be provided with all
these services in such a manner that it can operate autonomously
with respect to the working conditions in its environment. It is to
be noted here also, that in the example of practical realisation
according to the FIG. 2, also transportable floor planks 10 are
provided permitting easier transport of the panel elements
produced, and a lifting winch 11 for facilitating internal
transport. It is clear that provision of such transport equipment
elements will be adapted to each task of the mobile plant, of which
in the FIG. 2 just a practical example is shown. All and any
variation of the lay-out described here of a mobile plant for
producing prefab elements must be considered as fitting into the
frame of the present invention, under the condition that every
equipment element, which is part of the mobile plant, be mounted on
trailers and/or in containers transportable by road or by rail to
the building site. This actually is the basic characteristic of the
present invention.
[0064] In the FIG. 3 the lay-out of the mobile plant according to
the FIG. 2 is shown schematically in a section demonstrating that
the individual equipment elements 1, 1.1, 1.2, 1.3 are mounted onto
trailers and thus can be easily transported by road. In the FIG. 4
the base plan of transport of the equipment shows that the assembly
tables 1, . . . 1.3 can be transported by road in their transport
configuration. An analogue solution easily can be imagined for
transport by rail.
[0065] In the FIG. 4.1 a particular preferred realisation form of
the present invention is shown, in which the assembly table 1 is
mounted on a trailer 12 (compare also the FIG. 4) of a truck (not
shown) and is provided with a horizontal hinge 13 permitting
pivoting of the assembly table 1 from a vertical filling and
transport position (FIG. 4) into a horizontal working and unpacking
position indicated in the FIG. 4.1. This system facilitates work in
the mobile plant.
[0066] In the FIG. 5 then a possible block plan is shown of the
inventive mobile plant. This illustration is self-explanatory and
shows the base constitution of the inventive mobile plant.
[0067] In the FIG. 6 a plan, a side view and a section are shown of
an assembly table 1 for producing wall panels with double layer
elements of brick material on the trailer 12, during transport,
whereas in the FIG. 6.1 a plan, a side view and a section are shown
of an assembly table 1 for producing wall panels with double layer
elements of brick material on the trailer 12, during the working
phase on the ground.
[0068] In the FIG. 7 a plan, a side view and a section are shown of
a container for preparing the reinforcing iron rods for producing
the panel elements of brick material and mortar. Also this
container is provided with walls that tilt down and can be opened,
which container contains e.g. the following items: reinforcing iron
bender 15 (left), work bench 16, reinforcing iron bender 17
(right), reinforcing net cutter 18, reinforcing net bender 19.
[0069] In the FIG. 8 finally the complete concrete mixer plant is
shown in a plan and in a side view, which also is mounted on a
trailer 12 for easy transport to the building site according to the
teachings of the present invention. In this Figure, shown at the
upper right, a possible location is indicated of the equipment
element 3 under the canopy structure A.
[0070] According to a preferred realisation form of the present
invention it is provided that the equipment elements 1 through 6 be
disposed under the canopy structure A in such a manner that the
production of the panel elements of brick material and mortar is
effected according to the one-way principle, where the starting
materials enter at one side of the canopy structure A whereas the
assembled panel elements of brick material and mortar emerge at the
opposite side of the canopy structure A. This can be seen e.g. e.g.
from the schematic block plan according to the FIG. 5, where the
starting materials (brick material elements, etc.) enter at the
left hand side whereas the finished panel elements emerge (towards
the building site) at the right hand side in a straight linear
flow. This procedure, rationalising the production process,
certainly is not new as such, but is novel and original as applied
in the framework of a mobile plant like the inventive one
described.
[0071] The advantages of the inventive mobile plant basically are
the rationalisation of the construction of residential and
industrial buildings, especially if large building projects are
dealt with (e.g. building of new settlements or residential
developments for tourists, or rebuilding after nature disasters,
etc.) with corresponding savings in building cost, owing to the
fact that after completion of the buildings the mobile plant easily
can be dismantled and be transported to another building site. Not
to be neglected are the ecologic advantages owing to the
elimination of transports otherwise required for bringing personnel
and prefab panel elements built elsewhere to the installation site,
in cases over hundreds of kilometres.
REFERENCE NUMERALS
[0072] A canopy (tent, temporary hall) [0073] 1,1.1,1.2,1.3
pivotable and tiltable assembly table [0074] 2 water tank,
reservoir [0075] 3 concrete mixer plant [0076] 4 storage area of
brick elements [0077] 5 office and storage [0078] 5.1 installation
for preparing reinforcing irons [0079] 6 plant for generating
auxiliary means [0080] 7 containers for personnel and management
[0081] 10 transportable foot planks [0082] 11 lifting winch [0083]
12 trailer [0084] 13 horizontal assembly table hinge [0085] 14
container for preparing reinforcing items [0086] 15 reinforcing
iron bender (left) [0087] 16 work bench [0088] 17 reinforcing iron
bender (right) [0089] 18 reinforcing net cutter [0090] 19
reinforcing net bender [0091] 20 storage area for assembled
elements
* * * * *