FAV SYSTEM-Housing Manufacturing. Start date: 01/10/2009, End date: 31/10/2011

Collaboration with Alia Coronado S.L.

 

The research project arose from analysing the traditional construction model that has barely changed in the course of history and has survived the industrial process that has been usual in other fields (automobile, appliance, textile, etc).

 

The model is an automobile factory, with the difference that once the housing modules are transported from the factory to their destination, it is necessary to make a montage on the foundations, like a puzzle or mechano , to complete the product.

 

Schematically, there are three phases in the the housing manufacturing process:

 

1ª.- FRACTAL PROJECT: once the project has been ordered, a project which satisfies the customer´s needs is drafted, like a traditional project but adapted to our modular construction system, so it can be manufactured.

2ª.- FOUNDATION: when the project is finished, the module manufacturing begins, and simultaneously the foundation begins too.

3ª.- MODULE MANUFACTURING: it is made in an assembly chain, where starting with the basic structure module, all elements necessary for the completion of the houses are incorporated in turn: partitions,thermal insulation,sound proofing, plumbing installation,electrical installation, metal carp, wood carp,coatings, painting etc.

4ª.- MODULE ASSEMBLY: the modules are transported to the place where the foundation has been made and they are assembled with cranes and then are screwed.

 

 

The basic Module design was the first step and the most important because this was the secret of the system. After several designs, numerous consultations and the coordinated work with the Castilla la Mancha University, we designed a detachable structure made ​​of galvanized steel which allows, thanks to its simplicity, lightness and geometry of the parts, to achieve the project aim: fabrication of independent modules, manageable, self-supporting and can be assembled both horizontally and vertically, with the end result a building that works exactly as if it had not been made by parts. The system was flexible because it can be adapted to any building up to five storeys high.

 

Once the system was developed a prototype was built in a basic factory with one assembly line to study the way to optimise the final product.