HIGH-RISE SELF-SUPPORTING FORMWORK BUILDING SYSTEM

[0001] There are various types of building systems. In general, the most common building systems cannot satisfy the demands of industrialization and the need of intelligent and smart construction.

[0002] One possible solution to the overall complexity and resource inefficiency issues of traditional construction is the use of prefabricated construction technologies. Generally, a prefabricated system includes a primary framing structure and a secondary enclosure of panels, assembled on-site. Although there have been certain improvements in prefabricated building construction systems, including panels, walls, buildings, methods of making building panels, methods of constructing walls, wall systems and buildings systems, there are still unmet needs and a wide field of developments of more efficient and ambitious systems. Prefabricated construction systems are increasingly common in single-family home building, but are virtually absent at a large scale in high-rise building. This is primarily due to the difficulty and complexity of structure and equipment, the cost of investing in building facilities, the risk of trying a new construction method, and the startup cost of research and development.

[0003] There is a need in the construction industry for the necessary improvements in lightweight building panels and systems to reach a high-rise building with a clear and simple system that attends the different needs of this typology. The present disclosure provides the art with a construction system that overcomes all the disadvantages of the previous systems and can fulfill the requirement of high-rise building.

[0004] Some embodiments include a single, self-supporting and formwork panel, which behaves like a temporal structure. Said formwork is to be casted in concrete on-site, with division of space at the same time. Thus, a standard building system contains various construction elements assembled on-site. Aspects of the disclosed subject matter include wall panel, slab panel and truss/facade frame, that integrate all constructive elements needed: structural capacity (once the steel-frame formwork is casted in concrete), thermal and acoustic insulation, impermeability, and pre-installations in a very efficient and flexible manner.

[0005] Some embodiments include a system having modular panels for simplifying the constructions of buildings and/or interior spaces, as well as methods for using those panels to construct those buildings and/or interior spaces. In some embodiments, the panels include a number of functional layers to endow the panels with desired properties. In some embodiments, the panels provide buildings and interior spaces with walls, floors, and ceilings. In some embodiments, the panels are configured to be lightweight for easier construction, assembly and concreting.

[0006] In some embodiments, the panels have an internal structure. In some embodiments, the panels are self-supporting during construction works. In some embodiments, the internal structure includes both horizontal and vertical components. In some embodiments, the internal structure includes the structural corrugated steel bars attached to the formwork as a reinforcement for the in-site cast concrete. In some embodiments, the internal structure profiles constitutes the formwork for the cast concrete. In some embodiments, panels include the structural corrugated steel bars attached to the formwork. In some embodiments, panels are connectable to adjacent panels via the internal structure. In some embodiments, the internal structure includes extension areas configured to interface with adjacent panels. In some embodiments, panels include recessed areas for accepting the extensions of adjacent panels. In some embodiments, the internal structure includes longitudinal components. In some embodiments, the internal structure is comprised of C and U shaped profiles as temporal beams and joists. In some embodiments, internal structure components are combined with fasteners, such as screws. In some embodiments, adjacent panels are combined with such fasteners.

[0007] In some embodiments, the components of the internal structure define interior space within each panel. In some embodiments, the functional layers are provided in the interior space. In some embodiments, the functional layers are a modular block sized to fit the interior spaces defined by the modular internal structure and an outer layer.

[0008] In some embodiments, wall panels include at least one outer layer forming a side of the panel. In some embodiments, the internal structure, comprised of C and U shaped profiles constituting the formwork for the on-site casted concrete. In some embodiments, wall panels include the structural corrugated steel bars attached to the formwork. In some embodiments, wall panels include the structural corrugated steel bars attached to the formwork as a reinforcement for the on-site casted concrete. In some embodiments, wall panels include at least one acoustic insulation layer. In some embodiments, wall panels include at least one filler layer. In some embodiments, the filler layer is a thermal insulating layer. The thickness of the wall panels is of any desired size, and configured to connect to adjacent panels on at least a horizontal axis and a vertical axis. In some embodiments, the outer layer is connected directly to the internal structure. In some embodiments, an additional outer layer is provided on the side opposite the first outer layer of the wall panel.

[0009] In some embodiments, wall lintels include at least one outer layer forming a side of the panel. In some embodiments, the internal structure, comprised of C and U shaped profiles, constitute the formwork for the on-site casted concrete. In some embodiments, wall lintels include the structural corrugated steel bars attached to the formwork. In some embodiments, wall lintels include at least one acoustic insulation layer. In some embodiments, wall lintels include at least one filler layer. The thickness of the wall lintels is of any desired size, and configured to connect to adjacent panels. In some embodiments, the outer layer is connected directly to the internal structure. In some embodiments, an additional outer layer is provided on the side opposite to the first outer layer of the wall lintel.

[0010] In some embodiments, floor and/or ceiling panel, referred to herein as “slab” panel, also include at least one outer layer, forming the side of the slab panel. In some embodiments, the internal structure, comprised of C and U shaped profiles and the metal layer form the formwork for the on-site casted concrete for beams and joists. In some embodiments, the metal layer is a corrugated metal sheet. In some embodiments, the slab panel includes the structural corrugated steel bars attached to the formwork.

[0011] In some embodiments, truss/facade panels, referred to herein as “truss/facade”, include at least one outer layer forming a side of the truss/facade. In some embodiments, the internal structure, comprised of C and U shaped profiles, constitutes the formwork for the on-site casted concrete. In some embodiments, the truss/facade includes the structural corrugated steel bars attached to the formwork. The thickness of the truss/facade is of any desired size, and configured to connect to adjacent panels. In some embodiments, the truss/facade includes at least a curtain wall system. In some embodiments, the curtain wall system in the aforementioned truss/facade frame is a fixed window or a panel. In some embodiments, the fixed window serves as acoustic and thermal insulation. In some embodiments, the truss/facade frame is the enclosure element which satisfies the demand for illumination and ventilation. In some embodiments, the truss/facade frame is connected with adjacent wall panel, slab panel and truss/facade panel.

[0012] The panels of the present disclosure can be manufactured on an assembly line and easily transported. The modular nature of the panels also enables advantageous quality control, cost reduction, waste reduction, improvement of working conditions for workers, use of specialized equipment, and reduction of construction times, complexity, and injury risk. Further, the panels provide for advantageous ductility and tolerances. The panels are assembled and casted in concrete in phases. The assembling phases correspond to the logic of construction, being assembled by element and level.

[0013] The disclosure includes a plurality of elements, which is capable to be prefabricated and hoisted on-site. The elements in current disclosure include, but not limited to, the shaft cabinet element, stair elements, bath modules, kitchen module, elevators door module and technical floor. All the elements in the disclosure have internal structure and are self-supporting. In some embodiments, the element is prefabricated with plumbing, electrical and mechanical fixtures. In some embodiments, the installation fixture is prefabricated in a modular manner.

[0014] In some embodiments, elements include different types of interior functional features of the building. In some embodiments, elements are prefabricated with the necessary features to be connected between each other. In some embodiments, elements are prefabricated with the necessary features to be connected with the building mechanical, piping and electrical features. In some embodiments, elements satisfy the comfort and usability needs of the building.

[0015] The elements of the present disclosure can be manufactured on an assembly line and easily transported. The modular nature of the elements also enables advantageous quality control, cost reduction, waste reduction, improvement of working conditions for workers, use of specialized equipment, and reduction of construction times, complexity, and injury risk. Further, the panels provide for advantageous ductility and tolerances. The elements are assembled in phases. The assembling phases correspond to the logic of construction, being assembled by level and element.

[0174] The standard building system of the present disclosure contains various construction elements assembled on-site, aspects of the disclosed subject matter include different categories of panels: four categories of wall panels, one category of wall lintel, one category of slab panel and eight categories of truss/facade.

[0175] The standard building system of the present disclosure contains various prefabricated elements assembled on-site, aspects of the disclosed subject matter include different categories of elements: one category of shaft cabinet element, two category of stairs, two categories of bath modules, one category of kitchen module, one category of elevators doors module and one category of technical floor.

[0176] In some embodiments, a plurality of wall panels is provided as a kit wherein the plurality of the wall panels is of the same type. In some embodiments, a plurality of wall panels is provided as a kit, wherein wall panels come in a plurality of different types. In some embodiments, four different types are complementary in denomination, i.e., the wall panels could come in four types: a type with a door opening, a type without opening, a type with a closed end and a type with an opening without door. The size of each type of the wall panel is ultimately the decision of the user and depends upon the following non-limiting list of factors: human-scale, space quality, industrial sizes, and transportation margins.

[0177] Referring to FIG. 1, in some embodiments, the wall panels “Bottom” for using with the system of the present disclosure have internal structures configured to operate as a support skeleton. In some embodiments, the main internal structure is comprised of columns U-profiles 5 and C-profiles 6 which is configured as the formwork for in-site casted concrete. Referring to FIGS. 1, 4 and 5, secondary structure 15 is composed by C-profiles 4 and U-profiles 3. In some embodiments the secondary structure 15 referring to FIGS. 1 and 4 support the functional layer 19. Referring to FIGS. 2, 3 and 4, functional layer 19 comprises a thermal and acoustic insulation 14 and sideboard 13. In some embodiments, the panels are self-supporting during construction work. In some embodiments, the panels have a vertical crush resistance of at least 2000 pounds per linear foot; length of said wall panel when tested according to ASTM E72, and using a safety factor of 3. In some embodiments, the panels have a bending resistance when subjected to uniform loading in accord with ASTM E72 of up to 2000 pounds per square foot surface area.

[0178] In some embodiments, panels are configured to be connected to other panels and/or a building foundation. In some embodiments, the connections are made via the internal structures of adjacent panels and via rebars 17. In some embodiments, the connection between the various panels and/or the connection between the panels and the foundation is reversible. In some embodiments, panels are connected directly to a foundation using any suitable means. In some embodiments, an interface is provided to stabilize the connection between a panel and the foundation.

[0179] Referring to FIGS. 1-7, 1 wall panels “Bottom” 57 is provided. Referring to FIG. 5, in some embodiments, U-profile 5 and C-profile 6 constitute the steel frame and act as the formwork 18 for in-site casted concrete 16. In some embodiments the steel frame comprises rebars 17 that allow for connection with panels installed above them, as will be discussed in the construction process below. In some embodiments wall panels are connected with other wall panels “Bottom” 57. In some embodiments wall panels are connected with other wall panels “Top” 72. In some embodiments wall panels are connected with slab panel unit 79. In some embodiments panels are connected with truss/facade “Core Bottom” 59. In some embodiments panels are connected with truss/facade “Core Top” 74.

[0180] Referring again to FIGS. 3-4, the wall panel includes at least two sideboards 13. In some embodiments, side boards are disposed on opposing sides of the interior space of wall panel. In some embodiments, side boards are comprised of at least one of wood, cement, fiber cement, drywall, suitable metal sheets, and the like. In some embodiments, the thickness of sideboards 13 is approximately 0.5-1 inches.

[0181] In some embodiments, wall panel further includes at least one acoustic insulation layer (such as Rockwool) 14. In some embodiments, the thickness and composition of Rockwool are configured to provide the desired level of sound insulation to wall panel. In some embodiments, the thickness of Rockwool is approximately 45-50 mm (2 inch) in each side. In some embodiments, the Rockwool is filled in the inner space of substructure 15.

[0182] The overall thickness of wall panel is the summation of at least the layers described in the above paragraphs. In some embodiments, the overall thickness of wall panel is adapted according to local needs, such as climate conditions, building codes, constructions budget, and the like. In some embodiments, the total thickness of wall panel is approximately 32½ inches. In some embodiments, this thickness includes the internal structure. In some embodiments, the main internal structure is disposed between functional layers 19 and the substructure is disposed between formwork 18 and the sideboard 13.

[0183] In some embodiments, the wall panels have internal structure. In some embodiments, the internal structure includes a main structure and a substructure. In some embodiments, the main structure comprises some profiles such as U-profile 5 and C-profiles 4. In some embodiments, the main structure serves as formwork 18 for on-site casted concrete 16. In some embodiments, a plurality of prefabricated rebars 17 is contained in the formwork 18 for the possible connection to the upper panels. In some embodiments, the distance between two sides of the formwork 18 is 24 inches.

[0184] In some embodiments, the formwork 18 is held and fastened by one substructure 15 on each side. In some embodiments, any other functional layer 19 disposed are held between profiles such as U-profiles 3 and C-profiles 4 from FIG. 7. In some embodiments, these profiles form substructure 15 of panel. In some embodiments, the horizontal distance between two C-profiles 4 in the substructure is 2 feet. In some embodiments, the profiles in substructure along with the functional layers held there between defines a functional layer block that can be stacked with other functional layer blocks to fill the interior space of a panel. In some embodiments, two functional layer blocks are attached on both side of the structural formwork 18.

[0185] Referring to FIGS. 3, 4 and 6, the wall panel integrates a door 20. In some embodiments, the door 20 is a double flush door. In some embodiments, the door 20 is directly connected to the substructure 15.

[0186] Referring to FIGS. 8-14, the wall panels “End Bottom” 58 have similarities in internal structure, layers and differences in the structural opening and in the finished dimensions. In some embodiments, the internal structure of wall comprises profiles which form the main structural formwork 18. In some embodiments, substructures with functional layers are installed on both side of formwork 18 like the wall panel “Bottom” 57. In some embodiments, the components and order of functional layers in the wall panels “End Bottom” 58 are the same as those in wall panels “Bottom” 57.

[0187] Referring to FIGS. 15-21, the wall panels “Top” 72 have similarities in internal structure, layers and differences in the structural opening and in the finished dimensions. In some embodiments, the internal structure of wall comprises profiles which form the main structural formwork 18. In some embodiments, substructures with functional layers are installed on both side of formwork 18 like the wall panel “Bottom” 57. In some embodiments, the components and order of functional layers in the wall panels “Top” 72 are the same as those in wall panels “Bottom” 57.

[0188] Referring to FIGS. 22-28, the wall panels “Top w/Opening” 73 have similarities in internal structure, layers and differences in the structural opening and in the finished dimensions. In some embodiments, the wall panels “Top w/Opening” 73 integrate a structural opening 21. In some embodiments, the internal structure of wall comprises profiles which form the main structural formwork 18. In some embodiments, substructures with functional layers are installed on both side of formwork 18 like the wall panel “Bottom” 57. In some embodiments, the components and order of functional layers in the wall panels “Top w/Opening”73 are the same as those in wall panels “Bottom” 57.

[0189] Referring to FIGS. 29-34, the wall “lintel” 78 have similarities in internal structure, layers and differences in the structural dimensions. In some embodiments, the internal structure of wall comprises profiles which form the main structural formwork 18. In some embodiments, substructures with functional layers are installed on both side of formwork 18 like the wall panel “Bottom” 57. In some embodiments, the components and order of functional layers in the wall “lintel” 78 are the same as those in wall panels “Bottom” 57.

[0190] Referring to FIGS. 35-41, in some embodiments, a slab panel is provided: “Slab Panel Unit” 79. In some embodiments, slab panels unit are approximately 8′ 0″ in width and approximately 39′ 0″ in length. In some embodiments, slab panels unit are approximately 8′ 0″ in width and approximately 32′ 0″ in length. The size of slab panel is ultimately the decision of the user and depends upon the following non-limiting list of factors: structure feasibility, building code, human-scale, space possibility, industrial sizes, and transportation margins. In some embodiments, the slab panels have steel frame as seen in FIG. 37. In some embodiments, the steel frame includes an internal structure which are formed by steel profiles groups 22 which have a C-profile 2 jammed in a U-profile 1. In some embodiment, the internal structure is divided into five modules. In some embodiment a U-profiles 23 are connected on the periphery of the internal structure as the bottom of formwork for on-site casted concrete 26. In some embodiment a transversal U-profile 24 is connected between two parts as bottom of formwork for on-site casted concrete 26. Referring to FIGS. 36-38, in some embodiment, a plurality of metal corrugated sheet 25 are fixed upon the internal structure served as the formwork 28 of on-site casted concrete 26. In some embodiments, metal corrugated sheet 25 has a thickness of approximately 2-3 inches (54 mm). In some embodiments the steel frame comprises prefabricated rebars 27. Referring to FIG. 39-41, in some embodiment, the steel rebars could be attached on the slab panel and casted in concrete with the internal structure and profiles in-between. In some embodiment, the steel rebars in the slab panel could fasten with the rebars on wall panel. In some embodiments, the rebars could be casted in concrete on either side. In some embodiments, concrete 26 could cover the metal corrugated sheet 25 and the rebars 27 of slab panel.

[0191] Referring to FIGS. 42-49, in some embodiments, the truss/facade “Core Bottom” 59 for use with the system of the present disclosure have a structure configured to operate as a support skeleton. Referring to FIG. 42, in some embodiments, the main internal structure is composed by columns 33, diagonals 34 and horizontal 35. In some embodiments columns 33, diagonals 34 and horizontal 35 are comprised of U-profiles 7 and C-profiles 8 which is configured as the formwork of on-site casted concrete 30. In some embodiments, the secondary structure 36 referring to FIG. 44 integrate constructive elements needed such as steel frame, exterior curtain wall system 29 with window 37 and panel 38. In some embodiments, the trusses are self-supporting during construction work. In some embodiments, the panels have a vertical crush resistance of at least 2000 pounds per linear foot; length of said wall panel when tested according to ASTM E72, and using a safety factor of 3. In some embodiments, the trusses have a bending resistance when subjected to uniform loading in accord with ASTM E72 of up to 2000 pounds per square foot surface area.

[0192] As shown in FIGS. 42-46, the internal structures component of the trusses provide space for the application of functional layers to endow each panel with not only structural stability, but desired properties derived from the composition of materials filling that space. In some embodiments, the panels can have different interior spaces based on the purpose of the panel and the needs of the system user. Some embodiments are discussed below in FIGS. 47-49.

[0193] In some embodiments, trusses are configured to be connected to other panels. In some embodiments, the connections are made via the internal structures of adjacent panels and via rebars 81. Referring to FIGS. 42-46, in some embodiments, U-profile 7 and C-profile 8 constitute the steel frame and act as the formwork 32 for on-site casted concrete 30. In some embodiments the steel frame comprises main rebars 31 and other rebars 81 that allow for connection with truss/facade “Core Top” 74 installed above them, as will be discussed in the construction process below. In some embodiments the profile 9 enables the connection with truss/facade “Core Top” 74 installed above them. In some embodiments truss panels are connected with possible wall panels 57, 72. In some embodiments truss panels are connected with possible slab panel unit 79. In some embodiments panels are connected with possible truss/facade panels 60, 74.

[0194] Referring again to FIGS. 47-49, the truss/facade panel includes at least a main internal structure. In some embodiments, main internal structure is composed by columns 33, diagonals 34 and horizontal beams 35. In some embodiments, columns, diagonals and horizontal are composed by U-profile 7 and C-profile 8. In some embodiments, main internal structure is configured as the formwork 32 of on-site casted concrete 20. In some embodiments, formwork 32 comprises main rebars 31 and other rebars 81 for structural connection.

[0195] In some embodiments, the truss/facade panel includes at least a substructure 36. In some embodiments, the substructure 36 is composed by U-profile 11 and C-profile 12. In some embodiments, a U-profile 9 is fastened to the substructure 36 to enable connection with other panels. In some embodiments, the substructure 36 is configured to operate as a support skeleton for the curtain wall system 29.

[0196] In some embodiments, truss/facade panel further includes an exterior curtain wall system 29 disposed on interior side. In some embodiments, curtain wall system 29 comprised of at least a window 37 and a panel 38. In some embodiments, window and panel can be customized according to code, climate needs and user like. In some embodiments, curtain wall system 29 is supported to internal substructure 36.

[0197] The overall thickness of truss/facade panel is the summation of at least the layers described in the above paragraphs. In some embodiments, the overall thickness of truss/facade panel is adapted according to local needs, such as climate conditions, building codes, constructions budget, and the like. In some embodiments, the thickness is 24 inches.

[0198] Referring to FIGS. 50-57, the truss/facade “Core Top” 74 has similarities in internal structure, layers and differences in the structural dimensions and in the dimension of the structural elements. In some embodiments, the internal structure of truss comprises columns, diagonals and horizontal which forms the main structural formwork 32. In some embodiments, substructure 36 and curtain wall system 29 are installed on interior side of formwork 32 like the truss “Core Bottom” 59. In some embodiments, a profile 10 is fastened to the substructure 36 to enable connection with other panels. In some embodiments, the components and other elements in the truss “Core Top” 74 are the same as those in trusses “Core Bottom” 59.

[0199] Referring to FIGS. 58-65, the truss/facade “Long Bottom” 60 has similarities in internal structure, layers and differences in the structural dimensions and in the dimension of the structural elements. In some embodiments, the internal structure of truss comprises columns, diagonals and horizontal which forms the main structural formwork 32. In some embodiments, substructure 36 and curtain wall system 29 are installed on interior side of formwork 32 like the truss “Core Bottom” 59. In some embodiments, a profile 9 is fastened to the substructure 36 to enable connection with other panels. In some embodiments, the components and order elements in the truss “Long Bottom” 60 are the same as those in trusses “Core Bottom” 59.

[0200] Referring to FIGS. 66-73, the truss/facade “Long Top” 75 has similarities in internal structure, layers and differences in the structural dimensions and in the dimension of the structural elements. In some embodiments, the internal structure of truss comprises columns, diagonals and horizontal which forms the main structural formwork 32. In some embodiments, substructure 36 and curtain wall system 29 are installed on interior side of formwork 32 like the truss “Core Top” 74. In some embodiments, a profile 10 is fastened to the substructure 35 to enable connection with other panels. In some embodiments, the components and order elements in the truss “Long Top” 75 are the same as those in trusses “Core Top” 74.

[0201] Referring to FIGS. 74-81, the truss/facade “Short Bottom” 61 has similarities in internal structure, layers and differences in the structural dimensions and in the dimension of the structural elements. In some embodiments, the internal structure of truss comprises columns, diagonals and horizontal which forms the main structural formwork 32. In some embodiments, substructure 36 and curtain wall system 29 are installed on interior side of formwork 32 like the truss “Core Bottom” 59. In some embodiments, a profile 9 is fastened to the substructure 36 to enable connection with other panels. In some embodiments, the components and order elements in the truss “Short Bottom” 61 are the same as those in trusses “Core Bottom” 59.

[0202] Referring to FIGS. 82-89, the truss/facade “Short Top” 76 has similarities in internal structure, layers and differences in the structural dimensions and in the dimension of the structural elements. In some embodiments, the internal structure of truss comprises columns, diagonals and horizontal which forms the main structural formwork 32. In some embodiments, substructure 36 and curtain wall system 29 are installed on interior side of formwork 32 like the truss “Core Top” 74. In some embodiments, a profile 10 is fastened to the substructure 36 to enable connection with other panels. In some embodiments, the components and order elements in the truss “Short Top” 76 are the same as those in trusses “Core Top” 74.

[0203] Referring to FIGS. 90-97, the truss/facade “100X34 Bottom” 62 has similarities in internal structure, layers and differences in the structural dimensions and in the dimension of the structural elements. In some embodiments, the internal structure of truss comprises columns, diagonals and horizontal which forms the main structural formwork 32. In some embodiments, substructure 36 and curtain wall system 29 are installed on interior side of formwork 32 like the truss “Core Bottom” 59. In some embodiments, a profile 10 is fastened to the substructure 36 to enable connection with other panels. In some embodiments, the components and order elements in the truss “100X34 Bottom” 62 are the same as those in trusses “Core Bottom” 59.

[0204] Referring to FIGS. 98-105, the truss/facade “100X34 Top” 77 has similarities in internal structure, layers and differences in the structural dimensions and in the dimension of the structural elements. In some embodiments, the internal structure of truss comprises columns, diagonals and horizontal which forms the main structural formwork 32. In some embodiments, substructure 36 and curtain wall system 29 are installed on interior side of formwork 32 like the truss “Core Top” 74. In some embodiments, a profile 10 is fastened to the substructure 36 to enable connection with other panels. In some embodiments, the components and order elements in the truss “100X34 Top” 77 are the same as those in trusses “Core Top” 74.

[0205] In some embodiments, a plurality of prefabricated elements is provided as a kit wherein the plurality of the elements is of the same type. In some embodiments, a plurality of elements is provided as a kit, wherein prefabricated elements come in a plurality of different types. In some embodiments, these different types are complementary in denomination. The size of each type of the elements is ultimately the decision of the user and depends upon the following non-limiting list of factors: human-scale, space quality, industrial sizes, and transportation margins.

[0206] Referring to FIG. 106-109, a “Shaft Cabinet” 65 is provided as a prefabricated element. In some embodiments, the shaft cabinet is 20′ 0″ in length, 7′ 2″ in width and approximately 8′ 6″ in height. In some embodiments, the shaft cabinet includes a plurality of non-structural self-supporting walls. In some embodiments, the walls of shaft cabinet include an internal structure and at least one functional layer 39. In some embodiments, the functional layer 39 includes thermal and acoustic thermal insulation 41 and cement board as finishing layer 40, similar as the functional layer in wall panels. In some embodiments, the internal structure is comprised of C-profiles 44 and U-profiles 45. In some embodiments, two installation cabinets and two doors 46 are integrated in the shaft cabinet. In some embodiments, the shaft cabinets include the floor steel structure, comprised of C-profiles 44, U-Profiles 45 and corrugated metal sheet 43. In some embodiments, the piping 47, ducts 48 or conduits 49 correspondent to the installation are partly hold in the functional layer and partly fixed in the installation cabinet. In some embodiments the installation cabinet is accessible via a cabinet door 46. In some embodiments, two access door 52 are integrated in the walls of the “Shaft Cabinet” 65 elements. In some embodiments, the “Shaft Cabinet” element includes a corrugated metal sheet 43 for the on-site casted concrete in the construction process. The shaft cabinet can be applied in construction modules, as seen in FIGS. 138-157.

[0207] Referring to FIG. 110-113, a “Stair Type 1” 63 is provided as a prefabricated element. In some embodiments, the “Stair Type 1” element is 20′ 0″ in length, 4′ 4″ in width and approximately 8′ 6″ in height. In some embodiments, the “Stair Type 1” element includes a plurality of non-structural self-supporting walls. In some embodiments, the walls of “Stair Type 1” element include an internal structure and at least one functional layer 39. In some embodiments, the functional layer 39 includes thermal and acoustic insulation 41 and cement board as finishing layer 39, similar as the functional layer in wall panel. In some embodiments, the internal structure is comprised of C-profiles 44 and U-profiles 45. In some embodiments, one prefabricated stair is integrated in the “Stair Type 1” element. In some embodiments, the prefabricated stair is composed of a plurality of prefabricated steps 50 and prefabricated landing 51. The “Stair Type 1” element can be applied in construction modules, as seen in FIGS. 138-157.

[0208] Referring to FIG. 114-117, a “Stair Type 2” 64 is provided as a prefabricated element. In some embodiments, the “Stair Type 2” element is 20′ 0″ in length, 4′ 4″ in width and approximately 8′ 6″ in height. In some embodiments, the “Stair Type 2” element includes a plurality of non-structural self-supporting walls. In some embodiments, the walls of “Stair Type 2” element include an internal structure and at least one functional layer 39. In some embodiments, the functional layer 39 includes thermal and acoustic insulation and cement board as finishing layer 40, similar as the functional layer in wall panel. In some embodiments, the internal structure is comprised of C-profiles 44 and U-profiles 45. In some embodiments, two access door 52 are integrated in the walls of the “Stair Type 2” element. In some embodiments, one prefabricated stair is integrated in the “Stair Type 2” element. In some embodiments, the prefabricated stair is composed of a plurality of prefabricated steps 50 and prefabricated landing 51. The “Stair Type 2” element can be applied in construction modules, as seen in FIGS. 138-157.

[0209] Referring to FIG. 118-121, a “Bath Module” 66 is provided as a prefabricated element. In some embodiments, the bath module is 15′ 3″ in length, 9′ 0″ in width and approximately 7′ 6″ in height. In some embodiments, the bath module includes a plurality of non-structural self-supporting walls. In some embodiments, the walls of bath module include an internal structure and at least one functional layer 39. In some embodiments, the functional layer 39 includes thermal and acoustic thermal insulation 41 and cement board as finishing layer 40, similar as the functional layer in wall panels. In some embodiments, the internal structure is comprised of C-profiles 44 and U-profiles 45. In some embodiments, plumbing fixtures 53 are integrated in the bath module. In some embodiments, the piping 47 correspondent to the installation are partly hold in the functional layer and partly fixed in the installation cabinet. In some embodiments the bath module is accessible via a door 52. In some embodiments, three access door 52 are integrated in the walls of the “Bath Module” 66 element. The shaft cabinet can be applied in construction modules, as seen in FIGS. 138-157.

[0210] Referring to FIG. 122-125, a “Bath Common Module” 67 is provided as a prefabricated element. In some embodiments, the bath common module is 10′ 0″ in length, 4′ 0″ in width and approximately 7′ 6″ in height. In some embodiments, the bath common module includes a plurality of non-structural self-supporting walls. In some embodiments, the walls of bath common module include an internal structure and at least one functional layer 39. In some embodiments, the functional layer 39 includes thermal and acoustic thermal insulation 41 and cement board as finishing layer 40, similar as the functional layer in wall panels. In some embodiments, the internal structure is comprised of C-profiles 44 and U-profiles 45. In some embodiments, plumbing fixtures 53 are integrated in the bath common module. In some embodiments, the piping 47 correspondent to the installation are hold in the functional layer. The bath common module can be applied in construction modules, as seen in FIGS. 138-157.

[0211] Referring to FIG. 126-129, a “Kitchen Module” 68 is provided as a prefabricated element. In some embodiments, the kitchen module is 15′ 3″ in length, 9′ 0″ in width and approximately 7′ 6″ in height. In some embodiments, the kitchen module includes a plurality of non-structural self-supporting walls. In some embodiments, the walls of kitchen module include an internal structure and at least one functional layer 39. In some embodiments, the functional layer 39 includes thermal and acoustic thermal insulation 41 and cement board as finishing layer 40, similar as the functional layer in wall panels. In some embodiments, the internal structure is comprised of C-profiles 44 and U-profiles 45. In some embodiments, plumbing fixtures 53 are integrated in the kitchen module. In some embodiments, a plurality of cabinets 54 are integrated in the kitchen module. In some embodiments, the piping 47 correspondent to the installation are partly hold in the functional layer and partly fixed in the installation cabinet. The kitchen module can be applied in construction modules, as seen in FIGS. 138-157.

[0212] Referring to FIG. 130-133, a “Elevators Doors Module” 69 is provided as a prefabricated element. In some embodiments, the “Elevators Door Module” element is 15′ 3″ in length, 6″ in width and approximately 8′ 0″ in height. In some embodiments, the wall of “Elevators Doors Module” element includes an internal structure and at least one methacrylate layer 42. In some embodiments, the internal structure is composed of galvanized profiles 45. In some embodiments, two elevator doors 55 are integrated in the internal structure of the “Elevators Doors Module” element. The “Elevators Doors Module” element can be applied in construction modules, as seen in FIGS. 138-157.

[0213] Referring to FIG. 134-137, a “Core Technical Floor” 70 is provided as a prefabricated element. In some embodiments, the “Core Technical Floor” element is 15′ 3″ in length, 5′ 8″ in width and approximately 1′ 0″ in height. In some embodiments, “Core Technical Floor” element include a steel frame structure. In some embodiments, the steel frame structure is comprised of C-profiles 44 and U-profiles 45. In some embodiments, the “Core Technical Floor” element includes a corrugated metal sheet 43 for the on-site casted concrete in the construction process. The “Core Technical Floor” element can be applied in construction module, as seen in FIGS. 138-157.

[0214] Referring now to FIGS. 138-147, in the construction module 100X50, wall panels, wall lintel, trusses/facades, slab panel and prefabricated elements are connected via rebars and other connections. In some embodiments, vertical rebars in all the element panels are connected to horizontal rebars from other element panels. In some embodiments, on-site concrete unifies the rebars on different panels and the entirety.

[0215] In some embodiments, the present disclosure is directed to a method of assembling modular panels to produce a building or interior space. In some embodiments, the modular panels are self-supporting, so individual panels can be installed one at a time and remain in place while adjacent panels are installed until a desired size and shape of the building or interior space is completed. FIGS. 138-147 portray exemplary processes for connecting panels in the construction module consistent with some embodiments of the present disclosure and as discussed above.

[0216] Referring to FIG. 138, once wall panels, wall lintel, trusses/facades, slab panel and prefabricated elements arrive at a building site, wall panels are first installed on a casted in concrete level 56. Referring to FIG. 139, wall bottom panels 57 would then be installed at the top of the casted in concrete level. Rebar connections 81 are placed on top of the installed wall bottom panels 57. Referring to FIG. 140, trusses/facades core bottom 59, trusses/facades long bottom 60 and trusses/facade short bottom 61 panels for the structural facade would then be installed at the end of the installed wall panels. Rebar connections 81 are placed on top of the installed trusses/facade panels 59, 60, 61. Referring to FIG. 141, core prefabricated elements would then be installed. Such elements include “Stair Type 1” element 63, “Stair Type 2” element 64, “Shaft Cabinet” element 65, “Elevators Doors Module” element 69 and “Technical Floor” element 70. Referring to FIG. 142, bottom prefabricated elements would then be casted in concrete. The pouring of the bottom concrete 71 would connect wall panels, trusses/facades panels and prefabricated core elements into a whole. Connecting rebar 81 would be left on top of the casted in concrete elements to connect the top wall panels, top trusses/facades to the already installed bottom prefabricated elements.

[0217] Referring to FIG. 143, wall top panels 72 would then be installed at the top of the installed and casted in concrete wall bottom panels. Rebar connections 81 are placed on top of the installed wall top panels 72. Referring to FIG. 144, trusses/facades core top 74, trusses/facades long top 75 and trusses/facade short top 76 panels for the structural facade would then be installed at the end of the installed wall panels and on top of the bottom trusses/facades panels. Referring to FIG. 145, core prefabricated elements would then be installed. Such elements include “Stair Type 1” element 63, “Stair Type 2” element 64, “Shaft Cabinet” element 65, “Wall Lintel” element 78 and “Technical Floor” element 70. Referring to FIG. 146, prefabricated slab panels unit 79 would then be installed. Referring to FIG. 147, top prefabricated elements would then be casted in concrete. The pouring of the top concrete 80 would connect wall panels, trusses/facades panels, prefabricated elements and slab panels into a whole.

[0218] Referring now to FIGS. 148-157, in the construction module 100X34, wall panels, trusses/facades, slab panel and prefabricated elements are connected via rebars and other connections. In some embodiments, vertical rebars in all the element panels are connected to horizontal rebars from other element panels. In some embodiments, on-site concrete unifies the rebars on different panels and the entirety.

[0219] In some embodiments, the present disclosure is directed to a method of assembling modular panels to produce a building or interior space. In some embodiments, the modular panels are self-supporting, so individual panels can be installed one at a time and remain in place while adjacent panels are installed until a desired size and shape of the building or interior space is completed. FIGS. 148-157 portray exemplary processes for connecting panels in the construction module consistent with some embodiments of the present disclosure and as discussed above.

[0220] Referring to FIG. 148, once wall panels, wall lintel, trusses/facades, slab panel and prefabricated elements arrive at a building site, wall panels are first installed on a casted in concrete level 56. Referring to FIG. 149, wall bottom panels 57, end wall bottom panels 58 would then be installed at the top of the casted in concrete level. Rebar connections 81 are placed on top of the installed wall bottom panels 57 and end wall bottom panels 58. Referring to FIG. 150, trusses/facades 100X34 bottom 62 for the structural facade would then be installed at the end of the installed wall panels. Rebar connections 81 are placed on top of the installed trusses/facade panels 62. Referring to FIG. 151, core prefabricated elements would then be installed. Such elements include “Stair Type 1” element 63, “Stair Type 2” element 64, “Shaft Cabinet” element 65, “Bath Module” element 66, “Bath Common Module” element 67, “Kitchen Module” element 68, “Elevators Doors Module” element 69 and “Technical Floor” element 70. Referring to FIG. 152, bottom prefabricated elements would then be casted in concrete. The pouring of the bottom concrete 71 would connect wall panels, trusses/facades panels and prefabricated core elements into a whole. Connecting rebar 81 would be left on top of the casted in concrete elements to connect the top wall panels, top trusses/facades to the already installed bottom prefabricated elements.

[0221] Referring to FIG. 153, wall top panels 72 and wall top panels w/opening 73 would then be installed at the top of the installed and casted in concrete wall bottom panels. Rebar connections 81 are placed on top of the installed installed wall top panels 72 and wall top panels w/opening 73. Referring to FIG. 154, trusses/facades core 100X34 top 77 for the structural facade would then be installed on top of the bottom trusses/facades panels. Referring to FIG. 155, core prefabricated elements would then be installed. Such elements include “Stair Type 1” element 63, “Stair Type 2” element 64, “Shaft Cabinet” element 65 and “Technical Floor” element 70. Referring to FIG. 156, prefabricated slab panels unit 79 would then be installed. Referring to FIG. 157, top prefabricated elements would then be casted in concrete. The pouring of the top concrete 80 would connect wall panels, trusses/facades panels, prefabricated elements and slab panels into a whole.

[0222] In some embodiments, prefabricated groups of rebars connect wall, lintel, trusses/facades and slab panels. In some embodiments, the on-site casted concrete connects the panels into a whole. In some embodiments, any gaps at the joints between wall, lintel, truss/facade, slab panels and prefabricated elements are filled with polyurethane foam spray, which is fast-solidifying and has thermal insulation properties. In some embodiments, gaps between adjoining panels and/or truss/facade panels are stuck with adhesive. In some embodiments, construction of subsequent floors of a building begins after the underlying floor has settled. In some embodiments, the upper floor is formed by installing panels on the internal structures of the previous floor. In some embodiments, upper floors are subsequently constructed in a similar manner.