WO2010092411A2

WO2010092411A2 - Metal buildings

Info

Publication number: WO2010092411A2
Application number: PCT/GR2010/000008
Authority: WO
Inventors: Christophoros Diakopoulos
Original assignee: Individual
Current assignee: Individual
Priority date: 2009-02-13
Filing date: 2010-02-16
Publication date: 2010-08-19
Anticipated expiration: 2011-08-13
Also published as: EP2396478A2; WO2010092411A3; GR1006818B

Abstract

This invention describes ecologically sound, economical steel buildings with high insulation against noise, heat transfer and with fire protection, of low cost and speedy construction, and with potential for full, or in large part, energy self-sufficiency. These buildings consist of prefabricated components, which form internal and external walls, floors, ceilings and roofs, and which are constructed in the form, structure and strength specified in the architectural, structural and electromechanical design of the building to be constructed. The invention also describes a method of constructing buildings using prefabricated components, which can be placed by crane into slots which are either integrated, during manufacture in some of the prefabricated metal panels, or formed by the columns and beams in the corners of the building and its interior spaces.

Description

Title: METAL BUILDINGS

This invention describes ecologically sound, economical steel buildings with high insulation against noise and heat transfer, fire protection, low cost, speedy construction, and potential for full, or in large part, energy self-sufficiency .

PREVIOUS STATE OF THE ART

Buildings which are currently constructed on-site have several drawbacks, such as, among others:

- Both construction time (1-3 years) and cost are quite high.

- They are not environmentally sustainable in that they act as collectors. They are absorbing cold in winter (especially during the night) and hot in summer (especially in the daytime) as they transfer cold and heat between the interior of the building and the surrounding environment.

- Reinforced concrete and brick buildings are heavy and lack flexibility, and, in strong earthquakes, may suffer severe damage or collapse.

For these reasons, a new method of building construction is needed, for every building type and size, which method will require virtually no cement, sand, hydrated lime and bricks in the construction. Such buildings will weigh less in comparison to today's conventional buildings, and therefore, will need less steel support. Consequently, such construction will be much faster and less expensive than is currently the case.

SUMMARY OF THE INVENTION:

This invention describes prefabricated components of interior and exterior building walls, floors, ceilings and roofs of the building, which are constructed with any possible form, size, structure and strength according to the architectural design. The prefabricated pieces include:

- metal panels (Fig. 2-6, 11-13) of various sizes, shapes and strength,

- covering with metal plate, preferably steel, or with cement sheet, on both sides on the largest flat surfaces of each metal panel (Fig. 4 (a) I and II and Fig 5 (a) I and II), which cover is reinforced on either side with corrugated steel plates (Fig. 17, also Fig. 18 (a) I-II-III and Fig. 18 (b) I-II-III and Fig. 19 I-II-III-IV),

- insulation for protection, inter alia, from fire, heat, cold, and noise, placed inside and/or outside of the metal panel and on largeest flat surfaces thereof.

These prefabricated components of interior and exterior building walls, floors, ceilings and roofs, are characterised in that

- the metal panels are assembled by inserting them into pre-designed tracks of a depth of up to 20cm, see Fig 20 (a) and (b) and Fig 22 (a) and (b),

- the metal panels include pre-designed tracks of a depth of 20cm as part of the metal panel, see Fig. 12 (a) I, 12 (b) I & 12 (c) I, also Fig. 13 (a) I and 13 (b) I and Fig 16 I and II, Fig. 20 (a) and (b) and Fig. 22 (a) and (b),

- insulation inside the metal panel is achieved by an air vacuum,

- on the outside of at least one side of one or both of the covered surfaces of the panels there will be a grid or other anchorage for positioning insulation to protect, inter alia, from fire, heat, cold, and noise.

Preferably, the prefabricated building components of the invention have metal panels made of steel. Advantageously, the metal panels of the invention that will be used as bearing structure of the building, such as the exterior walls panels and the flooring and ceiling panels that will be used for bearing the load of the building, can be reinforced by the introduction of internal bars and/or beams and that these beams can be placed in various positions and can have different shapes and patterns, including upright arch D and/or inverted arch U (Fig. 2), V and/or inverted V shape (Λ), X shape (Fig. 12 and 14), vertical braces with or without a capital and foot ( Fig 4 (b)) and/or with the use of corner struts (supports), see Fig. 3 (a) and 3 (b) and Fig 22 (c). Also Fig. 2, Fig. 12b and 12c, Fig. 14.

Prefabricated building components in the scope of this invention, external walls, floors, ceilings, roofs can be of standard thickness, formed with hollow beams of Ishaped cross section, herein referred to also as IPE and shown in Fig. 1 (b) left hand side or with U-shaped hollow beams, herein referred to also as UPN and shown in Fig. 1 (b) right hand side welded together (Fig. 13 and 15) or by both types of braces together, and the ceiling can be smooth (Fig. 13A (b) or can have interstices such as hollow structures between the beams. (Fig. 13A (a)).

Advantageously, the insulation in the prefabricated building components of walls, floors, ceilings, and roofs is succeded by air vacuum, after both sides are covered with steel plates. In this case of air vacuum, preferably the strength of said steel plates is enhanced by adding inside or outside of the panel an additional corrugated steel plate, see Fig. 17, also Fig 18 (a) I - II-III and 18 (b) I - H - DI and Fig 19 I - II-IH - IV.

Preferably, the prefabricated building components bear plaster on top of the refractories and of the thermal insulation.

Preferably, the thermal insulation and the fire protection for the prefabricated building components of the invention include refractory materials resistant to temperatures in each case more than 900 ° C.

The invention also discloses a method of constructing buildings using prefabricated building components, which are placed in tracks which

- are incorporated in the design of metal panels and the prefabricated building components (Fig. 10) and/or

- are formed by the metal steel beams and columns in the corners of the building and its interior spaces, see Fig 12 (a) I, 12 (b) I, 12 (c) I and also 16 I, 16 II and 16 III, Fig. 10.

In a preferred embodiment of the invention, the base and the top of the metal frameworks that form the load-bearing walls, namely the walls and floors which bear the weigh of the building connect firmly with hollow sections or metal beams, which serve as both tracks and base for the metal floor and ceiling panels (Fig. 16 1 and II).

For the purposes of this invention, the load-bearing walls are the external walls and any internal walls that have been designated as load-bearing in the structural design. Advantageously, in the construction method described in this invention, the prefabricated building components are secured together by a firm welding of the metal panels of prefabricated building components and metal beams, preferably steel beams.

Preferably, the assembly of the prefabricated metal panels with each other and with the beams, such as UPN and IPE-type beams, as described in this invention, will be by welding or by using laser, or by using pins or bolts and nuts (Fig. 7 I) or using metal links in various forms, see Fig 8 (a) and Fig 6 (a) I and 6 (b) I, or by some other means.

UPN are preferably used at the base and the roofs of the building. Between the base and the roof, IPE are preferably used for connections between the different floors.

The buildings constructed using the prefabricated components and the method for assembly described in this invention have the following advantages:

1. Substantial savings in construction costs of about 50-60%, not including floor surfacing with wood, marble, etc.; installation of walls plumbing fixtures, etc, because the invention provides the following possibilities: a) Sand, hydrated lime and cement and bricks are almost entirely eliminated. Sand and cement are used only for production of a thin layer of 0.02-0.03 cm to cover and protect the insulation of the building with refractories and the sound insulation that cover the metal panels.

In this invention, the weigh of the building is supported by the metal frame which comprises the load-bearing walls and floors.

. b) The weight and cost of iron used is much reduced because the weight of the ' building is reduced by the removal of the items mentioned in a) above. Substantially reducing the weight of the building substantially reduces the quantity of iron needed for the frame. c) The cost of labor is reduced by about 90%, since the inter-connecting parts of the building will be prefabricated in fully automated factories, transferred to the building site, placed in the building by crane and connected by (automatic or otherwise) laser or electric welding machines. d) The excavation of the walls for plumbing and electrical fittings, for the installation of water (cold and hot) and sewer pipes and cable passage, are completely eliminated. During the construction of the building according to the invention, hot and cold water pipes and electrical cables will be installed according to engineering and technological designs. The invention allows much of the conduits for water pipes and cables to be installed within the interior walls and to be metal and accessible. If and where necessary to install pipes on exterior walls or in the floor, the conduits will be plastic and will be glued on a layer of fire-resistant material and thermal and noise insulation, and then covered with a coating or cement to stabilize their position.

The thermal and noise insulation, as well as the fire protection of the ecological steel buildings of this invention is the best possible. The steel external walls are protected against heat and noise with the vacuum of air (air vacuum). The metal panels, preferably made of steel, the load-bearing external walls and the steel floors and ceilings are build with refractories and thermal insulating and sound proofing materials in sufficient thickness to protect the building from fire and also againt heat exchange with the external atmosphere and the external noises.

2. Construction time is significantly reduced at the worksite.

The construction with pre-fabricated metal building components, using the method described by this invention, can be completed in approximately one to three months, depending on the size of the building, not including the time for laying the floors (with wood, marble or other materials), wall-dressing, purchase and placement of kitchen furnishings and appliances, as well as purchase and placement of bath furnishings and sanitary fixtures.

At the factory, the prefabricated parts will be ready by the completion of excavations and preparation of the foundation of the building.

Reduction of construction time is of great economic importance because reduces lost interest (equity and interest charged on outside capital borrowed for building construction) and speeds the receipt of income and, thus, the return on the investment. The faster the building is completed and sold by the developer/builder, the faster the return on capital invested. If a developer, instead of constructing and selling one apartment building within three years, can build and sell six to eight buildings with the same capital in the same time, he increases the efficiency of his capital. The same holds true for the owner who builds his own building.

3. The thermal and noise insulation of ecological metal buildings in this invention is the best possible. The metal walls are insulated with air vacuum. The metal frame, preferably made of steel, as shown in a preferred embodiment of the invention, namely the external walls and load-bearing exterior walls and floors, which are also ceilings, will be lined with refractories, which is also thermal insulating and soundproofing, in sufficient thickness to protect the building both in case of fire and also against heat exchange with the atmosphere.

The refractories to be used will withstand temperatures above 900 degrees Celsius while the temperature encountered in office and residential building fires usually reaches 800 degrees Celsius.

The strength of the refractory material to be used at temperatures higher than 900 degrees Celsius and the thickness of this material on the walls and floors will be enough to protect the life of the building (load-bearing external and internal walls and floors), and to protect it against collapse, even if fire extinguishing services are delayed for any reason.

Therefore, the external temperature of the atmosphere and noise will not touch the frames of steel buildings and the buildings will not be collectors of cold or heat.

4. The buildings in this invention, which will be made mainly of metal, preferably steel, will be lighter and much more flexible than conventional ones. Therefore, they will be much stronger than conventional buildings against earthquakes. Greater weight causes stronger oscillations in opposite directions during the vibrations of earthquakes, due to inertia forces. 5. The metal buildings in the present invention are ecologically sound. Because of the high level of thermal and sound insulation (as already described above), they have low energy needs for heating and cooling, which may, in many parts of the world, be entirely or largely met with current technology, in particular: a) photovoltaic modules and wind turbines mounted on the roof of the building, and/or b) geothermal pumps using groundwater, which is warmer in winter and cooler in summer than the temperature of the outer atmosphere. The energy needed for heating- cooling with geothermal pumps is very low. Ground water may be replaced by rain water collected in deep water.

6. The ecological buildings described in this invention will provide greater-than- conventional fire protection because: a) The walls and floors are covered with fire-resistant material in a thickness adequate to protect them from fire and b) They are required to be equipped with automatic fire-detection and fire-fighting systems.

BRIEF DESCRIPTION OF THE FIGURES.

Preferred applications of the invention are presented in Figures 1 to 25.

Of these, Figure 1 presents the raw materials which may be used.

Figure 2 shows prefabricated sections with reinforcement against vertical pressure via the introduction of braces or arches in the section.

Figures 3 (a) and 3 (b) show the corresponding support frame using angles.

Figures 4 (a) and 4 (b) and 5 (a) and 5 (b) show two different types of window openings in the prefabricated sections. Openings may be any window shape and size depending on the architectural plans.

Figures 6 (a) and 6 (b) show the connection of two exterior wall sections with two fastener s(I).

Figure 7 shows the means of securing the connection of steel frames using fasteners and alien and pin type screws (I).

Figure 8 shows how to connect adjacent wall frames with staples (a). There is also a drawing showing another form of fastener, see Figures 13 (a) and 13 (b).

Figure 9 shows the connection, with a fastener plate, of the end beams of two successive wall panels with hollow-beam frames (I).

Figure 10 shows the connection, with a fastener plate (I) of the end beams of two successive wall panels with IPE beams.

Figure 11 shows a floor-ceiling section panel made of hollow square beam. Figures 12 (a), 12 (b) and 12 (c) presents a floor-ceiling panel made of IPE or hollow square beams, and the medium parallel to the long sides of the panel of equilateral cross bar

Figures 13 (a) and 13 (b) show the association of two successive floor-ceiling panels with two opposing steel fasteners (I).

Figure 13 A has a metal frame floor and ceiling formed of beams, in a) with one side fitted to the other and in b) with one at some distance from the other.

Figure 14 shows the metal beam of this invention, particularly enhanced. Figure 15 shows reinforced beams with more IPE.

Figure 16 shows a corner column construction made of IPE located within UPN (I and

II).

Figure 17 shows a corrugated steel plate which is welded on the steel panel sides of the external walls to enhance their strength against the pressure exercised by the atmosphere.

Figures 18 (a) and 18 (b) display a wall with an opening at its center. The wall consists of prefabricated wall sections of the present invention, each of which are fastened to the wall by blades with nerves (I, II and III) formed with corrugated steel plate.

Figure 19 shows an outer wall around the window that has such corrugated plates (I, II, III and IV).

Figure 20 shows a corner column, which is based in a UPN (c) forming a corner. Figure 21 shows two wall panels which, with the corner column (a) form a corner wall.

Figure 22 shows the corner wall of Figure 21 with a cornered beam IPE in (a) and in (b) with the corner wall ready to be inserted into the slot formed by the IPE. Figure 23 shows the IPE (a) and (b) on the corner wall around which it is already welded.

Figure 24 shows, in an application of this invention, a second floor and two floor- ceiling sections fastened together, on a UPN beam base on the ground floor and one on the IPE beam that connects the two floors.

Figure 25 shows the cornered wall of Figure 24 with the two walls completely covered by a coating (a) and (b).

DETAILED DESCRIPTION OF TFlE INVENTION

Here, specific examples of particularly advantageous applications of this invention are described. These examples are indicative and should not in any way be interpreted as restrictive to the scope of the invention described.

Raw materials to be used (see Fig 1) may be: a) Hollow beams (rounded square and rectangular cutting) (a) b) I-beams (IPE) and U-beams (UPN) (b) c) Round, square and rectangular bars, (c) d) Corner isoscelous and rectangular T-bars (d). e) Flat plates (e).

The variety of the above listed raw materials that can be used is great, depending on the size of their cutting, their length and, regards the hollow beams, the thickness of the metal plates of which they have been constructed. All raw materials are preferably protected from corrosion by galvanization or some other method.

THE WALL PANELS

The panels of the prefabricated components of the invention will have any shape required by the architectural design for the construction of a building, e.g. straight, polygonal or circular. Also, the strength of prefabricated components of the invention will be imposed by the structural design of the building. In an application of the invention, the panels can be reinforced against pressure from the top or bottom, with the introduction of beams at different locations and in different forms and shapes such as arches (Fig 2 (a) and (c)) or V or inverted V (i.e. Λ) shape (Fig. 12 (a), 12 (b) or 12 (c) or vertically (Fig. 2 (b) and Fig 3 (b) I and Fig 4 (b) III) in the panels, or through the use of angle supports (Fig 21 (b), Fig 22 (c) and Fig 23 (C)).

It has the advantage that the metal (preferably steel) panels in load-bearing walls may be strengthened in accordance with the requirements of the structural design of steel IPE-beams or hollow beams or bars of any cutting or dimension, which (beams or bars) are placed within the sections of load-bearing walls in various shapes: a) arch D or inverted U or both together (Fig. 2 (c) b) V or inverted Λ or both together forming an XX design (Fig. 12) c) X pattern d) Simple columns (Fig. 3 (b) I, Fig 2 (b)) or columns with capital and foot (Fig. 21 (C), Fig 23 (d)). e ) Simple steel angles (Fig. 21 b, Fig 22 (c) or reinforced (Fig. 3 (a).

The arch-shaped braces, inverted V (Λ), and the braces used simply or with capitals and feet reinforce the steel panels of load-bearing wall sections against pressures from the top down or from the bottom up or from both top and bottom.

The crossed columns (in X shape), whether simple or reinforced, strengthen the framework of the load-bearing wall against any deformation by vibration and earthquakes.

The sections for exterior walls of this invention exhibit openings, intended for external wall windows, which can be built anywhere on the walls of the building and have any dimension and shape, as specified in the architectural plan.

Figures 4 and 5 display some common types of windows among many possible designs. In particular:

Figure 4 shows a medium-width window opening in a wall section constructed of hollow beam. Another type of opening window is shown in Figure 5.

HORIZONTAL CONNECTION OF THE TWO CONSECUTIVE EXTERIOR WALL PANELS

Figure 6 shows the connection of two exterior wall sections, fastened by two plates (I) which are bent at both ends to embrace the two end-beams of the consecutive frames. Plates and beams are welded together so that the two sections are fully united. Plates and beams described in this description and claims of this invention are metal. Therefore, at any point in this description where we refer to beams or steelbeams, we always mean metal beams, which may consist of different metals, not only of iron. It is also understood that the shape and size of beams and other technical characteristics and are dependent on the requirements of the building and its design studies.

Other forms of horizontal connection of steel panels: i. As an alternative to Figure 6, the next section is inserted between the flanges of the previous panel it fits precisely and is installed without welding. In this case, the lower beam must be narrower in diameter at the point where it is inserted between the flanges. ii. The panels do not have flanges, but the upper and lower beams of each panel are screwed at designated intervals to the IPE beam (or U-shaped track-UPN) above and below, with flush screws (alien type) (Figure 7 I). Or with four or more screws, of which the screw and nut (with flush heads) enter from the outside and are bolted on the inside, connecting the upper and lower beam of each wall section with the top and bottom IPE beams (or U-shaped tracks - UPN, respectively). iii. Two consecutive panels in the external walls may be connected together, with steel fasteners, in accordance with Figure 8 (a). Another type of fastener is shown in Figure

13 (1).

Figure 9 shows the connection of the hollow beams at the edge (end beams) of two successive panels forming external walls.. The two end beams are connected by two rectangular plates (shown under I in Fig. 9). The plates are welded to a beam (Fig. 9 (a) and form a slot (track) into which the end beam of the next panel will be inserted and welded, forming a single body with the previous wall(s) (Fig. 9 b).

Figure 10 shows the same as Figure 9, except that the two end beams of the two consecutive panels are constructed of IPE beam (not hollow beam as in Figure 9).

STEEL FLOOR AND CEILING PANELS (the underside of a floor is a ceiling) a) Figure 11 presents a floor-ceiling panel made of square hollow beam. The two isoscelous angles beams are ready to be welded to the steel wall, and then to IPE beam which form the capital of the wall sections of each storey and the base of the storey just above. On these isoscelous angles will sit the floor panel, as detailed below. The openings between the hollow beams will be covered with plates of sufficient thickness to prevent it from moving in use, thus creating the floor surface. Otherwise, angle braces can be attached so as to make the openings smaller and allow the use of thinner plates. b) Figure 12 shows panels made of IPE beam (shown under I in Fig. 12) and square hollow beams, with an isoscelous beam placed in the middle, parallel to the long sides of the panel. On this framework, in this Figure, rectangular plates will be welded to form the floor. c) It is understood that the floor panels mentioned above can be made from any material referred to in Figure 1. d) The floor-ceiling panels are welded to the steel wall and to each other, so that the framework forms a single whole. It may also be joined together with fasteners, as shown in Figure 13, where the the fasteners are shown under (I). g) Floor-ceiling panels shown in Figures 11 and 12 have side beams strong enough and of sufficient size to be suitable for roofs of luxury buildings, because they provide for the formation of square or rectangular roof recessed panel. Figure 13 shows the connection of two successive floor-ceiling panels with two opposing steel fasteners (I). Please note that the methods mentioned for connecting two consecutive wall panels shall apply respectively to the connection of consecutive floor-ceiling panels , and vice versa.

There are other types of floor-ceiling panels of equal thickness constructed by IPE beam and/or hollow beams welded together, as shown in Figure 13 A.

Advantageously, the prefabricated metal, preferably steel, floor-ceiling panels: a) form røcøssed panels in the ceilings of interior spaces, if required by the architectural design b) are of equal thickness and the roof of the building can be flat as required by the architectural design.

LOAD-BEARING BEAMS AND COLUMNS AND THE CORNER COLUMNS OF THE STRUCTURE

It is often necessary in a building to use load-bearing columns or beams to support a wide expanse of floor or a large window opening. This can be achieved in various ways. Indicatively, we describe some advantageous applications of columns of the buildings according to the present invention: a) with the metal panel as described in this invention, specifically reinforced as shown in Figure 14. This panel can be made from I beam (IPE) and can be reinforced with an arch of strong bar, of rectangular, square or circular cross section, and, if necessary, by braces of bars hollow-section or circular, rectangular or square cross- section. The supports strengthen the beam and prevent deformation in cas of an earthquake. b. With more IPE beams as shown in Figure 15. c. Figure 16 shows a structure's corner columns made from IPE beams placed within U-shaped beam (UPN), said UPN shown under I and II in Fig. 16. The IPE beam bear plates as covering on the sides, said plates (shown under III in Fig. 16) are also inserted within the UPN beam and thus, form tracks ready to receive steel exterior wall panels in the space formed between such plates at each side of the corner (see related Figure 9).

THERMAL/ACOUSTIC INSULATION OF THE BUILDING WALLS BY AIR- VACUUM, AND FHlE PROTECTION OF THE WALLS AND FLOOR- CEILING PANELS WITH HIGHLY FIRE-RESISTANT MATERIALS

1. In a preferred embodiment of the invention, the best possible thermal/acoustic insulation is achieved, by an air-vacuum within the building frame and the external walls and between the surfaces of these walls, at a lower cost than with any other non- burning material (such as perlite and rockwool). Perlite or rockwool require stone extraction, transportation, smelting and special treatment. This involves the use of power equipment, energy and labor to produce and package the finished product, while creation of an air- vacuum requires the use of a machine which, with today's technology, can function automatically or with minimal labor. An air-vacuum has the advantage that while its cost is many times lower than that of the above two insulating materials, it weighs nothing and, therefore, the building is lighter and needs less support.

2. The best possible fire protection of the frame, in a preferred embodiment of the invention, is achieved with strong fire-resistant material (e.g. inflated), so that besides fire protection, thermal and acoustic insulation is also achieved. Highly fire resistant materials, in the present invention, mean not just those which delay the destruction of the building in case of fire long enough for people to be evacuated, but also materials that protect the building until the fire can be extinguished.

THE THERMAL/ ACOUSTICAL INSULATION PROCEDURE WITH AN AIR- VACUUM AND FIRE PROTECTION OF IRON WALLS AND FLOORS- CEILINGS. Columns and beams that are around the panels are not covered. Because: a) The beams fit into the spaces between the feet of the IPE beams, when EPE beams are used. The IPE beams are installed at the top of all the exterior wall panels and, simultaneously, serve as the base track for all the exterior wall panels of the storey above.

In a preferred embodiment of the present invention, the lower beams of the wall panels that form the first floor walls on the basis of the building, as well as the upper beams of the last floor, are secured, in that they fit into a track formed by a UPN beam in reverse placement: below the first floor u and above the last [— i • b) In another preferred embodiment of this invention, the side column on one edge of a wall panel enters horizontally the track of the previous section, and the column on its other edge has a track for the next panel. Therefore, the beams and columns should be totally free of any covering material.

In another other preferred embodiment of this invention, the two large surfaces of a wall panel are covered with plates to form a wall and to close the openings between the four sides of the panel. To achieve this without affecting the columns and beams, in a preferred embodiment of this invention, an upright isosceles angle brace can be welded on the inside corners formed by the outer columns and beams of the wall panel, forming flanges on which the plate can be welded.

Figure 17 shows a plate, where the panel described in this invention has the plate welded on one side. Obviously, one can be attached on the other side in the same way, in another preferred embodiment of this invention. Because the air in the void spaces of the wall panel will be removed, pressure will be exerted by the outside atmosphere on the covering plates and they may be deformed. Therefore, in a preferred embodiment of this invention, the surface plates of the wall section may be covered by another corrugated plate with studs placed more densely toward the center of the surface where the pressure is greater. The plate with extra studs also appears in the Plan 17. Studs can also be mounted internally to the panel, made of plates or of isosceles cross-section rods.

Figure 18 shows a preferred embodiment of a wall with an opening (e.g. for a window) at its center, which wall consists of prefabricated wall sections according to the present invention. On this wall are welded plates with studs, in particular one plate on each prefabricated section whichforms the wall. Figure 19 shows an outer wall around the window that has such plates.

All these operations can be executed in the pre-fabrication of the wall and floor- ceiling panelsof the building.

THE ASSEMBLY OF THE BUILDING

In a preferred embodiment of this invention, the Figure 20 shows a corner column formed of IPE beams, which column is fitted into a U-shaped track (of UPN) forming a corner, see Figures 20(a) and 20(b). Each side of the corner column has two flanges (c) (see also Fig 16 as described above and Fig. 21 (a)) welded to the UPN track, flush with the base. The two wall panels on either side of the corner will be inserted and will fit into the tracks formed by the UPN (Fig. 20 (a) and Fig. 20 (b)) and the two pairs of flanges f(c) ormed by the plates. For each wall panel, one of the columns fits into tracks formed by the UPN and the flanges of the corner column. The other column of the same panel has flanges that form with the UPN a track to receive the next column and so on.

Figure 21 shows two panels which, together with the corner column form a cornered wall, in an application of this invention.

Figure 22 shows the cornered wall of Figure 21 with a cornered beam made of IPE beam, ready to be placed on to the edge of the corner wall and to fit the track formed by the IPE beam, in an application of this invention. Thus, the corner walls are secured and the IPE beam forms also the base track for the insertion of the corner wall panels and corner column of the adjacent (next) floor.

Figure 24 shows, in an embodiment of this invention: a) a second floor. The corner column of the second floor fits into the slot (track) of the IPE beam that connects the groundfloor with the first floor, and to which both floors are welded. The two wall panels that form a corner are fit into the track formed by the corner column flanges and the open space of the IPE beam, and so on. b) two floor-ceiling panels attached, the first panel fit into a UPN beam at the base of the ground floor and the other fit onto the I beam that connects the two floors. In practice, the floor-ceiling panels may be seated in tracks formed of -iron angle plates welded to the IPE beam. Said IPE beam form the capital of each floor, which stabilizes its walls, and supports in the perimeter external walls of a floor, while, at the same time, it forms the base into which the walls of the next storey are fit.

The floor-ceiling panels are then welded to the IPE beams of two opposite walls. If the floor-ceiling expanse is great, it can be supported in the center by means of load- bearing wall sections or with strong beams supported by columns of sufficient strength.

Figure 25 shows the corner wall of Figure 24, where the two walls (a) and (b) are completely covered with coating.

On the base of the described panels of the load-bearing walls (exterior and interior) and of the floor-ceiling panels as well as corner columns, different types of prefabricated panels can be built, which can not be included in the present description because of lack of space and time and which would be dependent on the design specifications for construction of a building.

BUILDING CONSTRUCTION WITH PRE-F ABRICATED COMPONENTS

In a preferred embodiment of the present invention, the building may be constructed with prefabricated components as follows. As stated above, the following example should not be interpreted restrictively:

1. The excavation and foundation will be carried out as is currently the practice. The prefabrication of the iron base and footing beams of the foundations is advantageous, so that the foundation can be laid in a short time. Of course, in addition to the base and footing beams made of IPE beam, the foundation also includes concrete.

2. On the first slab of reinforced concrete, the UPN-shaped track of the base will be installed and aligned with great precision, at the perimeter of the building, and into this will be inserted all the corner columns. It is noted that all the prefabricated components of the building, such as corner columns, wall panels, floor-ceiling sections, internal walls, beams, UPN-shaped beams and IPE beams, iron bases, foundations and footing beams) are transported from the factory to the building site by trucks and set into place by crane.

3. After this, the prefabricated components of the building, including the metal wall panels, will be positioned in the U-shaped track (UPN) and will be connected to the corner columns and to each other by the flanges (both at their bases and flanges) and will be welded. The welding will be performed, inside and outside the wall sections, by machine monitored by a technician trained in its use. The welding can also be done by electric arc welding. The welding of each wall panel will be completed, preferably, before the next wall panel is placed. Each panel can cover a length of wall, preferably about 7 to 10 meters, but may be smaller or larger. The panels to be installed as above have their other two outer edges clean so as to be fit into the recesses, ie the slots of the IPE beam and the column of the next wall panel. The wall panels, as mentioned, will be ready from the factory in terms of thermalacoustic insulation and fire-resistant coating (of strong refractory materials), as well as with coatings and windows. a) On the first floor above the foundation, craftsman will apply on both sides of the UPN beam a suitable grid on both sides and a plasterer will cover these areas with refractory, heat insulating and soundproofing materials and plaster. b) From the second floor and up to the top of the building, the above work will be repeated, except that, preferably, only the outer surface of the IPE beam and fastening flanges of the consecutive exterior wall panels will be covered with refractory material and plaster. This is because the interior side of the IPE beam should preferably be left free so that angle braces may be welded to this, on which the floor- ceiling panels will be fitted, and said panels will be welded to each other and also to the IPE beam.

After completion of this work, the exterior walls inside and out are ready. 5. All interior walls are placed on each floor by a crane or other means, in a selected position.

6. The floor-ceiling panels of the next storey are put in place and welded to each other and to the walls on each side. Preferably, these panels are fastened on the EPE beam that forms the capital (the cap that stabilizes the wall) of each storey and the base for the wall panels of the next storey.

It has already been mentioned that the metal floor-ceiling panels, from the factory, have been covered with a layer of refractory materials and plaster. In a preferred embodiment of this invention, because those panels will be welded to the PE beam at the top of the walls, the end beams parallel to the two walls are left uncovered. Their coverage on the ceiling side, with refractory material and plaster may be carried out immediately after they are welded.

7. Refractory cement is spread on the floor surface to fireproof the floor. Then the interior walls are set in place. The interior walls fit into a suitable slot (track) in the ceiling and in the walls on each side (which they abut). At this stage, the plumber and electrician, preferably, place the conduits for pipes and cables, as specified in the building design. A layer of concrete may then be applied to cover and protect the fireproofing, and plasterers may apply a finish to those areas where conduits have been installed. In an embodiment of this invention, the concrete adheres to the interior walls securely and covers the plumbing and electrical conduits.

8. This process continues until the top floor.

9. During the construction of exterior walls in the factory and especially after their covering with refractory and plaster, it is possible to provide for windows, balcony doors, and gates. The exterior surfaces of doors and windows may have the appearance of any wood in its natural hue. It may also be possible to cover some doors with natural wood of any thickness. Then the building will be fully insulated from external temperatures of the air, with great energy savings.

Obviously, as stated, the interior walls can also be built having an air-vacuum, providing substantially better soundproofing of the premises. Finally, every effort will be made to employ state-of-the-art technology for geothermal systems, photovoltaic cells and small wind turbines to meet the building's energy needs to the highest extent possible.

In a preferred embodiment of the present invention, certain prefabricated building components of this invention placed in a building create slots (tracks) for the insertion of many further components. Other components, while they stabilize several other compontents, at the same time create tracks for others to be placed. Some components provide tracks for the next which will be connected to it. There are other prefabricated components of this invention that generate no track, because the tracks of panels that will be placed later and in series with them are already ready.

Also, in advantageous embodiments of the invention: - The U-shaped beams (UPN) of the base may be placed around the building and on its perimeter welded to the foundation iron they form slots (track) for the corner columns of the first floor (whether this is the groud floor or the basement).

- The corner columns may have two flanges on each side of the corner.

- Each wall panel may have two beams (top and bottom) and the side beam on one side may be completely free and the one on the other side may have two flanges.

In this embodiment, the one outside side of the panel is inserted between the two flanges of the corner column and the lower beam is inserted in the hollow part of the UPN and they fit exactly.

Advantageously, the two sides aligned are welded to the flanges of the corner column and to the UPN. The next wall panel is inserted between the flanges of the previous placed and welded wall panel and into the hollow part of the UPN beam and is welded like the previous one. This process continues until the wall panels are built up to the next corner column. In the same way, from corner column to corner column, the perimeter walls of the first floor (basement or ground floor) are constructed in a preferred embodiment of the invention.

- Next, it is advantageous to put IPE beams (of H cross-section) around on the top of the walls of the first floor. The two lower sides (flanges) of the IPE beam Fit exactly over and completely cover the top beams and the tops of the columns of the wall sections of the first floor to which they are fastened.

- On the inner side of the IPE beams, angle braces may be placed to form the track for receiving the floor-ceiling panels of the first storey.

If the floor of the first storey is made of iron panels, cranes place preferably first the interior walls on the first storey floor, the refractory materials and materials for heat and sound insulation of the floor, such as cement and sand, so that a thin layer of protective cement can spread over the refractory, heat and sound insulation and subsequently the ceiling panels in the tracks of the walls formed by the IPE beams

- After this, the ceilingpanels are placed and welded together and to the IPE beams of the surrounding wall. This is continued throughout construction of the building to the roof.

As previously mentioned, it is advantageous that the wall and floor-ceiling panels may, instead of being welded together, that they can be connected with steel fasteners. This is equally true for the welding with the floor-ceiling panels and with the surrounding IPE beams of the walls.

Claims

1. Prefabricated components of interior and exterior walls, floors, ceilings, roofs,

- which are constructed with any possible form, size, structure and strength according to the architectural design,

- which include: metal panels of various sizes, shapes and strength

- covering with metal plate, preferably steel, or with cement sheet on both sides on the largest flat surfaces of each metal panel , and which cover is reinforced on either side with corrugated steel plates,

- insulation for protection, inter alia, from fire, heat, cold and noise, placed inside and/or outside the metal panel on the largest flat surfaces, wherein said components are characterized in that o the metal panels are assembled by inserting them into pre-designed tracks of a depth of up to 20cm; o the metal panels include pre-designed tracks of a depth of 20cm as part of the metal panel; o insulation inside the metal panel is achieved by an air vacuum o on the outside of at least one side of one or both of the covered surfaces of the panels there will be a grid or other anchorage for positioning insulation to protect, inter alia, from fire, heat, cold, and noise.

2. Prefabricated sections of interior and exterior building walls, floors, ceilings, roofs as described/disclosed in claim 1, in which the metal panels are made of steel.

3. Prefabricated building components for walls, floors, ceilings, roofs, according to each of claims 1 and 2, in which the metal panels of the load-bearing external walls and floors are reinforced by:

- inserting rods and/or beams inside them, which are placed in different positions and have different shapes and form, including upright arch D and/or inverted arch U, V and/or inverted V (Λ), crossbar X, vertical beams with or without a capital and foot, and/or corner struts.

4. Prefabricated components of interior and exterior building walls, floors, ceilings, according to each one of the claims 1 to 3, which are of equal thickness, made of IPE beam or welded U-shape hollow beam or by both types of beams together, wherein the ceiling may be flat or may include interstices and hollow formations.

5. Thermal insulation for prefabricated building components of walls, floors, ceilings, and roofs according to each one of the claims 1 through 4, which include refractory materials resistant to temperatures in each case more than 900 ° C.

6. Prefabricated components of interior and exterior building walls, floors, ceilings, roofs according to each of the claims 1 to 4, to which surface finishing has been applied.

7. A method of constructing buildings using prefabricated components for internal and external walls, floors, ceilings, and roofs, accordimg to which method, these prefabricated components of walls, floors, ceilings, and roofs are placed with a crane or other means, into tracks of a depth of up to 20cm which are embedded during manufacture in some of the metal panels of the said prefabricated building components and/or formed by iron beams and columns from iron beams in the corners of the building and its interior spaces.

8. The method of constructing buildings according to claim 7, wherein the base and the top of the metal panels forming the load-bearing walls and floors are firmly joined with steel hollow beams, said hollow beams serving both as track and base for the insertion of the floor and ceiling metal panels.

9. The method of construction of buildings according to each of the claims 7 and 8, wherein the firm connection of the metal panels of the prefabricated building components is accomplished by electric arc welding or using laser or using pins, screws, bolts and nuts or other types of metal connectors.