Concrete box-type module and production method thereof

Abstract

The invention provides a concrete box type module and a production method thereof, the box type module comprises a first prefabricated wall body, a first post-pouring wall body, a second prefabricated wall body and a second post-pouring wall body which are sequentially connected, the first prefabricated wall body and the second prefabricated wall body are oppositely arranged, and the first post-pouring wall body and the second post-pouring wall body are oppositely arranged; the first prefabricated wall body and the second prefabricated wall body each comprise a partition wall and a shear wall formwork which are sequentially connected, the face, facing the interior of the module, of the shear wall formwork serves as the inner surface of the module, and reinforcing meshes used for connecting the two adjacent edge reinforcing steel bar sets are laid on the face, back to the interior of the module, of the shear wall formwork. A truss extending in the height direction of the shear wall is fixedly connected to the position, corresponding to the position between every two adjacent edge steel bar sets, of the steel bar mesh, the first end of each truss is inserted into the shear wall formwork so that the steel bar mesh can be fixed to the shear wall formwork, and the second end of each truss faces the exterior of the module. The problems that shear wall steel bars need to be bound in a large amount on site, and a shear wall formwork does not participate in stress are solved.

Description

Technical Field

[0001] The invention relates to the technical field of modular building, in particular to a concrete box-type module and a production method thereof. Background Art

[0002] Traditional cast-in-place concrete structure buildings require a large number of templates to be loaded and unloaded during on-site construction, which consumes a lot of manpower and material resources and increases the construction period. Concrete modular construction technology has been widely used around the world due to its advantages of fast construction speed and high construction quality.

[0003] Concrete modular buildings refer to concrete structures made of standardized prefabricated concrete box modules that are completed in the factory and have usage functions, and connected through on-site assembly. Among them, the concrete box modules use prefabricated shear wall formwork as the on-site concrete pouring formwork to make shear walls, and prefabricated beam formwork as the on-site concrete pouring formwork to make beams, which greatly reduces the time for on-site formwork and internal decoration, and has a fast construction speed and high construction quality.

[0004] However, in the current concrete box modules, the shear wall formwork and the beam formwork do not participate in the force bearing and are only used as templates. During the construction process, the thickness of the shear wall formwork and the beam formwork is not calculated into the specified concrete thickness when pouring concrete, resulting in thicker walls, encroaching on the indoor usable area, and wasting materials. At the same time, during the construction process, the steel bars of the shear walls and beams need to be tied on site, which consumes a lot of time and limits production efficiency.

[0005] Moreover, in the current production process of concrete box modules, molds that fully match the modules are often designed based on the module size and shape. The mold structure and shape are relatively complex. A set of molds can often only be used for one project, and it is difficult to achieve common molds. As a result, the mold utilization rate in the production process of concrete box modules is usually low and the cost is high.

[0006] Therefore, there is an urgent need for an improved concrete box-type module and a method for producing the box-type module. Summary of the invention

[0007] 1. Technical issues to be resolved

[0008] In view of the problems existing in the above technologies, the present invention solves the problems to a certain extent at least. To this end, the present invention provides a concrete box-type module and a method for producing the box-type module.

[0009] (II) Technical solution

[0010] In order to achieve the above object, the main technical solutions adopted by the present invention include:

[0011] In a first aspect, the present invention provides a concrete box-type module, comprising a module bottom plate, a module top plate, a beam formwork shell, and a first prefabricated wall, a first post-cast wall, a second prefabricated wall, and a second post-cast wall sequentially connected around the edge of the module top plate, the first prefabricated wall and the second prefabricated wall being arranged opposite to each other, and the first post-cast wall and the second post-cast wall being arranged opposite to each other;

[0012] The first prefabricated wall and the second prefabricated wall both include a partition wall and a shear wall formwork connected in sequence, a side of the shear wall formwork facing the interior of the module serving as the inner surface of the module, a side of the shear wall formwork facing away from the interior of the module being paved with a steel mesh for connecting two adjacent edge steel bar groups, a truss extending in the height direction of the shear wall being fixedly connected to the steel mesh corresponding to a position between two adjacent edge steel bar groups, a first end of the truss being inserted into the shear wall formwork to fix the steel mesh on the shear wall formwork, and a second end of the truss being arranged toward the outside of the module;

[0013] The top of the shear wall formwork is connected to the edge of the module top plate, the top of the partition wall is connected to the edge of the module top plate through the beam formwork, the top of the first post-cast wall is connected to the edge of the module top plate, and the bottom of the second post-cast wall is connected to the edge of the module top plate; the top of the shear wall formwork is connected to the edge of the module bottom plate, the bottom of the partition wall is connected to the edge of the module bottom plate, the bottom of the first post-cast wall is connected to the edge of the module bottom plate, and the bottom of the second post-cast wall is connected to the edge of the module bottom plate; the thickness of the beam formwork is within 30 mm, and the thickness of the shear wall formwork is within 30 mm.

[0014] Optionally, when the first prefabricated wall is used as the module exterior wall, the first prefabricated wall includes an L-shaped shear wall first formwork and an L-shaped shear wall second formwork arranged opposite to the L-shaped shear wall first formwork, the L-shaped shear wall first formwork and the L-shaped shear wall second formwork are both connected to the partition wall, a side of the L-shaped shear wall first formwork facing the interior of the module serves as the inner surface of the module, and a side of the L-shaped shear wall second formwork facing away from the interior of the module serves as the outer surface of the module;

[0015] A first steel mesh for connecting two adjacent edge steel bars is laid on a side of the first formwork of the L-shaped shear wall facing away from the interior of the module, and a first truss extending in the height direction of the shear wall is fixedly connected to the first steel mesh corresponding to the position between the two adjacent edge steel bars. The first truss is in the shape of a steel mesh, and a first end of the first truss is inserted into the first formwork of the L-shaped shear wall to fix the first steel mesh on the first formwork of the L-shaped shear wall, and a second end of the first truss is arranged toward a second formwork of the L-shaped shear wall; a second formwork of the L-shaped shear wall facing the interior of the module is laid with a second steel mesh for connecting two adjacent edge steel bars, and a second truss extending in the height direction of the shear wall is fixedly connected to the second steel mesh corresponding to the position between the two adjacent edge steel bars. The first end of the second truss is inserted into the second formwork of the L-shaped shear wall to fix the second steel mesh on the second formwork of the L-shaped shear wall, and a second end of the second truss is arranged toward the first formwork of the L-shaped shear wall.

[0016] Optionally, the second formwork of the L-shaped shear wall is provided with mounting grooves and through holes which are connected in sequence from the outside to the inside, and a mounting nut is fixedly provided at the second end of the first truss, and the mounting nut corresponds to the position of the through hole; a wire mesh and a plurality of supporting steel plates are buried in the second formwork of the L-shaped shear wall, and the plurality of supporting steel plates are arranged in sequence and spaced apart in the horizontal direction, and the supporting steel plates are arranged corresponding to the positions of the mounting grooves, and the supporting steel plates are located on the inner sides of the mounting grooves, and through holes are provided on the supporting steel plates, and the supporting steel plates are welded to the wire mesh, and casting holes are provided between adjacent through holes on the supporting steel plates; the screw rod of the T-shaped mounting bolt can pass through the through hole and be threadedly connected to the mounting nut, and the head of the T-shaped mounting bolt is accommodated in the mounting groove.

[0017] Optionally, when the prefabricated wall is used as the inner wall of the module, the prefabricated wall includes a partition wall and a first T-shaped shear wall formwork connected in sequence, and the first T-shaped shear wall formwork is used to be spliced ​​with the second T-shaped shear wall formwork of the prefabricated wall of the next box-type module to form a T-shaped shear wall formwork;

[0018] A third steel mesh is laid on a side of the first formwork of the T-shaped shear wall facing away from the interior of the module, the third edge steel bar group is fixedly arranged at the first end of the first formwork of the T-shaped shear wall, the second edge steel bar group is fixedly arranged at the second end of the first formwork of the T-shaped shear wall, and both ends of the third steel mesh are fixedly connected to the third edge steel bar group and the fourth edge steel bar group respectively; the third steel mesh is fixedly connected with a third truss extending along the height direction of the shear wall at a position corresponding to the third and fourth edge steel bar groups, the third truss is in the shape of a steel mesh, the first end of the third truss is inserted into the shear wall formwork to fix the third steel mesh on the first formwork of the shear wall, and the second end of the third truss is arranged toward the outside of the module.

[0019] Optionally, when the prefabricated wall is used as the inner wall of the module, the prefabricated wall includes a partition wall and a T-shaped shear wall second formwork connected in sequence, and the T-shaped shear wall second formwork is used to be spliced ​​with the T-shaped shear wall first formwork of the prefabricated wall of the previous box-type module to form a T-shaped shear wall wall formwork;

[0020] A fourth steel mesh for connecting the third and fourth edge steel bars is laid on the side of the second formwork of the T-shaped shear wall facing away from the interior of the module. The fourth steel mesh is fixedly connected to a fourth truss extending along the height direction of the shear wall at a position corresponding to the third and fourth edge steel bars. The first end of the fourth truss is inserted into the second formwork of the T-shaped shear wall to fix the fourth steel mesh on the second formwork of the T-shaped shear wall, and the second end of the fourth truss is arranged toward the outside of the module.

[0021] Optionally, the second formwork of the T-shaped shear wall is provided with an installation groove and a through hole which are connected in sequence from the outside to the inside, and a mounting nut is fixedly arranged on the second end of the third truss; the first formwork of the T-shaped shear wall and the second formwork of the T-shaped shear wall are spliced ​​to form a T-shaped shear wall formwork, the mounting nut corresponds to the position of the through hole, the screw rod of the T-shaped mounting bolt can pass through the through hole and be threadedly connected with the mounting nut, and the head of the T-shaped mounting bolt is accommodated in the installation groove.

[0022] Optionally, the beam mold shell is used to be spliced ​​with the beam mold shell of the previous box-type module to form a beam mold; an installation hole is opened on the beam mold shell, and after the beam mold shell is spliced ​​with the beam mold shell of the previous box-type module to form a beam mold, the installation hole corresponds to the position of the installation hole opened on the beam mold shell of the previous box-type module, and the tension bolt can pass through the two installation holes in sequence, and the tension bolt can be fastened to the beam mold through the tension nut.

[0023] In a second aspect, the present invention provides a method for producing the concrete box-type module as described above, comprising:

[0024] S1, installing the first prefabricated wall and the second prefabricated wall on the first side and the second side opposite to each other in the mold of the module respectively;

[0025] S2, installing the first steel cage and the second steel cage on the third side and the fourth side opposite to each other in the mold of the module, respectively, the two ends of the first steel cage cooperate with the first prefabricated wall and the second prefabricated wall to form a steel overlap structure, and the two ends of the second steel cage cooperate with the first prefabricated wall and the second prefabricated wall to form a steel overlap structure;

[0026] S3, installing the top plate of the prefabricated module on the top of the mold inside the module, and the top of the first prefabricated wall, the top of the second prefabricated wall, the top of the first steel cage, and the top of the second steel cage respectively cooperate with the edge of the top plate of the prefabricated module corresponding to their positions to form a steel bar overlap structure;

[0027] S4. Install the module outer mold at positions corresponding to the first steel cage, the second steel cage, and the steel overlap structure to form a first casting cavity; pour concrete into the first casting cavity to form a pentahedral module.

[0028] S5. After the pentahedral module has a certain strength, the mold of the cast-in-place wall is removed, and then the bottom plate reinforcement is tied on the bottom mold platform, and finally the module bottom plate is cast to form a complete hexahedral module.

[0029] Optionally, S1 also includes the production process of L-type shear wall formwork:

[0030] A01. Forming a first steel mesh, a second steel mesh, a first edge steel bar group, a second edge steel bar group, a first truss, and a second truss by automated welding; connecting two ends of the first steel mesh to the first edge steel bar group and the second edge steel bar group, connecting the first end of the first truss to the first steel mesh, and connecting the first end of the second truss to the second steel mesh by automated welding; pouring concrete into the first straight formwork, the second formwork, and the third formwork, respectively;

[0031] A02. Before the concrete in the first formwork is solidified, the first end of the first truss is pressed into the concrete, and the first steel mesh is located above the concrete, and the first prefabricated component is formed after demoulding; before the concrete in the second formwork is solidified, the first end of the second truss is pressed into the concrete, and the second steel mesh is located above the concrete, and the second prefabricated component is formed after demoulding; before the concrete in the third formwork is solidified, the first steel bar group is pressed into the concrete, and the third prefabricated component is formed after demoulding;

[0032] A03. Connect the first end of the third prefabricated component with the second end of the first prefabricated component to form an L shape, arrange the first prefabricated component and the second prefabricated component face to face, connect the second end of the first truss with the second steel mesh by automated welding, and connect the two ends of the second steel mesh with the first edge steel bar group and the second edge steel bar group respectively to obtain an L-shaped shear wall formwork.

[0033] Optionally, before S1, the production process of the first formwork of the T-shaped shear wall and the second formwork of the T-shaped shear wall is also included:

[0034] B01. Forming a third steel mesh, a third truss, a fourth steel mesh, a fourth truss, a third edge steel bar group and a fourth edge steel bar group by automated welding; connecting the third edge steel bar group and the fourth edge steel bar group to both ends of the third steel mesh, connecting the first end of the third truss to the third steel mesh, and connecting the first end of the fourth truss to the fourth steel mesh by automated welding; pouring concrete into the fourth, fifth, sixth and seventh straight formwork platforms respectively;

[0035] B02. Before the concrete in the fourth mold platform solidifies, the first end of the third truss is pressed into the concrete, and the third steel mesh is located above the concrete, and the first wall mold is formed after demoulding; before the concrete in the fifth mold platform solidifies, the first end of the fourth truss is pressed into the concrete, and the fourth steel mesh is located above the concrete, and the second wall mold is formed after demoulding; before the concrete in the sixth mold platform solidifies, the tension bars of the second steel bar group are pressed into the concrete, and the third wall mold is formed after demoulding; before the concrete in the seventh mold platform solidifies, the tension bars of the third steel bar group are pressed into the concrete, and the fourth wall mold is formed after demoulding;

[0036] Step B03, connect the second end of the first wall formwork with the first end of the third wall formwork to form an L shape, and obtain the first formwork shell of the T-type shear wall; connect the second end of the second wall formwork with the first end of the fourth wall formwork to form an L shape, and obtain the second formwork shell of the T-type shear wall.

[0037] (III) Beneficial effects

[0038] The beneficial effects of the present invention are:

[0039] In the concrete box-type module provided by the present invention, a part of the internal steel bar group of the shear wall is pre-embedded on the shear wall formwork included in the first prefabricated wall and the second prefabricated wall, so that the connection of the shear wall steel bars is produced during the production process of the box-type module, reducing the amount of on-site connection of the shear wall steel bars during the construction process, and the steel bars embedded in the shear wall formwork are a two-dimensional structure, which is convenient for the automatic binding or welding of the steel bars during the production process of the box-type module, thereby improving production efficiency. In addition, by arranging a truss on the shear wall formwork, pouring concrete to form a shear wall during construction, the truss can effectively overlap with the concrete of the shear wall, and jointly participate in the structural force, so that the shear wall formwork becomes a part of the shear wall, that is, the shear wall formwork also becomes a load-bearing component, rather than just being adapted as a temporary formwork, thereby improving the material utilization rate and increasing the indoor usable building area. BRIEF DESCRIPTION OF THE DRAWINGS

[0040] The present invention is described with the aid of the following drawings:

[0041] Figure 1 It is a schematic diagram of the three-dimensional structure of the concrete box-type module of Example 1;

[0042] Figure 2 It is a schematic diagram of the top view of the concrete box-type module of Example 1, in which the mold inside the module is shown;

[0043] Figure 3 This is a schematic diagram of the assembly structure of a prefabricated wall used as a module exterior wall in Example 1;

[0044] Figure 4 It is a schematic diagram of the overall structure of the L-shaped shear wall of Example 1;

[0045] Figure 5 It is a schematic diagram of the decomposed structure of the L-shaped shear wall of Example 1;

[0046] Figure 6 is a structural schematic diagram of the first truss of Example 1;

[0047] Figure 7 is a schematic diagram of the three-dimensional structure of the first truss of Example 1;

[0048] Figure 8 It is a structural schematic diagram of a steel wire mesh and a plurality of supporting steel plates embedded in the second formwork of an L-shaped shear wall of Example 1;

[0049] Fig. 9 It is a schematic diagram of the assembly structure of the L-shaped shear wall of the embodiment;

[0050] Fig.10 This is a schematic diagram of the assembly structure of a prefabricated wall used as a module inner wall in Example 1;

[0051] Fig.11 This is a schematic diagram of the overall structure of the T-shaped shear wall of Example 1;

[0052] Fig.12 It is a schematic diagram of the decomposed structure of the T-shaped shear wall of Example 1;

[0053] Fig.13 It is a schematic structural diagram of two transversely spliced ​​concrete box modules of an embodiment;

[0054] Fig.14 for Fig.13 A schematic cross-sectional view at AA in the middle shows a module layer;

[0055] Fig.15 for Fig.13 A schematic cross-sectional view at BB in the middle, showing two module layers;

[0056] Fig.16 for Fig.13 A schematic cross-sectional view at CC in the middle, showing two module layers;

[0057] Fig.17 for Fig.13 Schematic cross-sectional view at DD in the figure, showing two module layers.

[0058] [Description of Reference Numerals]

[0059] 1: Module top plate;

[0060] 2: The first prefabricated wall;

[0061] 21: L-shaped shear wall first formwork; 22: L-shaped shear wall second formwork; 23: first steel mesh; 24: first truss; 25: second steel mesh; 26: second truss; 27: first edge steel bar group; 28: second edge steel bar group; 29: first steel bar group;

[0062] 211: first straight portion; 212: second straight portion;

[0063] 221: mounting groove; 222: through hole; 223: wire mesh; 224: supporting steel plate; 225: casting hole;

[0064] 241: mounting nut; 242: T-type mounting bolt; 243: first plane reinforcement; 244: first truss vertical reinforcement; 245: supporting reinforcement; 246: first vertical reinforcement;

[0065] 261: Second plane reinforcement; 262: Third plane reinforcement;

[0066] 281: longitudinal reinforcement for wall installation; 282: tension reinforcement;

[0067] 3: The first post-cast wall;

[0068] 4: The second prefabricated wall;

[0069] 41: first formwork of T-type shear wall; 42: second formwork of T-type shear wall; 43: third steel mesh; 44: third truss; 45: fourth steel mesh; 46: fourth truss; 47: third edge steel bar group; 48: fourth edge steel bar group;

[0070] 411: third straight portion; 412: fourth straight portion;

[0071] 421: fifth straight portion; 422: sixth straight portion;

[0072] 5: The second post-cast wall;

[0073] 61: beam form shell; 63: tension bolt; 64: raised part;

[0074] 71: spiral stirrups; 72: connecting steel bars; 73: threaded sleeves. DETAILED DESCRIPTION

[0075] Example 1

[0076] like Figure 1 and Figure 2As shown, the box-type module includes a module top plate 1, and a first prefabricated wall 2, a first post-cast wall 3, a second prefabricated wall 4, and a second post-cast wall 5 that are sequentially connected around the edge of the module top plate 1. In this embodiment, the first prefabricated wall 2 and the second prefabricated wall 4 are arranged opposite to each other, and the first post-cast wall 3 and the second post-cast wall 5 are arranged opposite to each other, and the box-type module is in the shape of a cuboid.

[0077] The shear wall formwork generally includes a first shear wall formwork and a second shear wall formwork that are relatively arranged. A flat cavity is formed between the first shear wall formwork and the second shear wall formwork. A steel cage is accommodated in the flat cavity. The steel cage includes an edge steel bar group and an internal steel bar group for connecting two adjacent edge steel bar groups. The edge steel bar group refers to a cage-shaped structure made of steel bars used to construct edge hidden columns, edge end columns, and edge corner walls in a concrete structure.

[0078] The first prefabricated wall 2 and the second prefabricated wall 4 both include a partition wall and a shear wall formwork connected in sequence, wherein the side of the shear wall formwork facing the interior of the module serves as the inner surface of the module, and the side of the shear wall formwork facing away from the interior of the module is paved with a steel mesh for connecting two adjacent edge steel bar groups, and the steel mesh is fixedly connected with a truss extending along the height direction of the shear wall at a position corresponding to the position between the two adjacent edge steel bar groups, the first end of the truss is inserted into the shear wall formwork to fix the steel mesh on the shear wall formwork, and the second end of the truss is arranged toward the outside of the module.

[0079] The top of the shear wall formwork is connected to the edge of the module top plate 1, the top of the partition wall is connected to the edge of the module top plate 1 through the beam formwork 61, the top of the first post-cast wall 3 is connected to the edge of the module top plate 1, and the bottom of the second post-cast wall 5 is connected to the edge of the module top plate 1; the top of the shear wall formwork is connected to the edge of the module bottom plate, the bottom of the partition wall is connected to the edge of the module bottom plate, the bottom of the first post-cast wall 3 is connected to the edge of the module bottom plate, and the bottom of the second post-cast wall 5 is connected to the edge of the module bottom plate.

[0080] Among them, the thickness of the beam formwork shell is within 30mm, and the thickness of the shear wall formwork shell is within 30mm.

[0081] In the concrete box-type module thus configured, a part of the internal steel bar group of the shear wall is pre-embedded on the shear wall formwork included in the first prefabricated wall 2 and the second prefabricated wall 4, so that the connection of the shear wall steel bars is produced during the production process of the box-type module, reducing the amount of on-site connection of the shear wall steel bars during the construction process, and the steel bars embedded in the shear wall formwork are two-dimensional structures, which facilitates the automatic binding or welding of the steel bars during the production of the box-type module, thereby improving production efficiency. In addition, by arranging trusses on the shear wall formwork, the concrete is poured during the construction process to form the shear wall, and the trusses can be effectively overlapped with the concrete of the shear wall, and jointly participate in the structural force, so that the shear wall formwork becomes a part of the shear wall, that is, the shear wall formwork also becomes a load-bearing component, rather than just being adapted as a temporary formwork, thereby improving the material utilization rate and increasing the indoor usable building area.

[0082] Depending on whether the prefabricated wall is used as a module interior wall or a module exterior wall, the structure of the prefabricated wall is different, which is described in detail below.

[0083] When the prefabricated wall (which may be the first prefabricated wall 2 or the second prefabricated wall 4) is used as a module exterior wall, Figure 3 As shown, the prefabricated wall includes a first shear wall formwork and a second shear wall formwork arranged opposite to the first shear wall formwork, the first shear wall formwork and the second shear wall formwork are both connected to the partition wall, the side of the first shear wall formwork facing the inside of the module serves as the inner surface of the module, and the side of the second shear wall formwork facing away from the inside of the module serves as the outer surface of the module. A first steel mesh 23 for connecting two adjacent edge steel bar groups is laid on the side of the first shear wall formwork facing away from the inside of the module, and the first steel mesh 23 is fixedly connected with a first truss 24 extending along the height direction of the shear wall at a position corresponding to the position between the two adjacent edge steel bar groups, the first end of the first truss 24 is inserted into the first shear wall formwork to fix the first steel mesh 23 on the first shear wall formwork, and the second end of the first truss 24 is arranged toward the second shear wall formwork. A second steel mesh sheet 25 for connecting two adjacent edge steel bars is laid on one side of the second formwork of the shear wall facing the inside of the module. A second truss 26 extending along the height direction of the shear wall is fixedly connected to the second steel mesh sheet 25 corresponding to the position between the two adjacent edge steel bars. The first end of the second truss 26 is inserted into the second formwork of the shear wall to fix the second steel mesh sheet 25 on the second formwork of the shear wall. The second end of the second truss 26 is arranged toward the first formwork of the shear wall. The second end of the first truss 24 is fixedly connected to the second steel mesh sheet 25.

[0084] In this way, a part of the internal steel bar group of the shear wall is also pre-embedded on the second formwork of the shear wall, which reduces the amount of on-site connection of the shear wall steel bars during construction, and the steel bars embedded in the second formwork of the shear wall are a two-dimensional structure, which is convenient for the automatic binding or welding of the steel bars during the production of the box-type modules, thereby improving production efficiency; in addition, by arranging the second truss 26 on the second formwork of the shear wall, concrete is poured during construction to form the shear wall, and the second truss 26 can be effectively overlapped with the concrete of the shear wall to jointly participate in the structural force, so that the second formwork of the shear wall becomes a part of the shear wall, that is, the second formwork of the shear wall also becomes a load-bearing component, rather than just being adapted as a temporary formwork, thereby improving the material utilization rate and increasing the indoor available building area.

[0085] Preferably, if Figure 3 As shown, when the first prefabricated wall 2 is used as a module exterior wall, the first prefabricated wall 2 includes a partition wall and an L-shaped shear wall first formwork 21 connected in sequence, and an L-shaped shear wall second formwork arranged opposite to the L-shaped shear wall first formwork.

[0086] like Figures 4 to 9 As shown, preferably, the first formwork 21 of the L-shaped shear wall has a first straight portion 211 and a second straight portion 212, the second end of the first straight portion 211 and the second straight portion 212 are connected to form an L shape, and the second formwork 22 of the L-shaped shear wall is straight and is arranged corresponding to the first straight portion 211; the first edge steel bar group 27 is fixedly arranged at the first end of the first straight portion 211, and the second edge steel bar group 28 is fixedly arranged at the second end of the first straight portion 211, and the two ends of the first steel mesh 23 are respectively fixedly connected to the first edge steel bar group 27 and the second edge steel bar group 28, and the two ends of the second steel mesh 25 are respectively fixedly connected to the first edge steel bar group 27 and the second edge steel bar group 28.

[0087] Preferably, the first steel bar group 29 is fixedly arranged on the second straight portion 212, and the stirrups of the first steel bar group 29 extending out of the second straight portion 212 and the stirrups of the second edge steel bar group 28 extending out of the first straight portion 211 are staggered and overlapped to form an overlapping portion, and the wall longitudinal reinforcement 281 extending along the height direction of the shear wall is inserted into the overlapping portion, and the second edge steel bar group 28 and the first steel bar group 29 are both fixedly connected to the wall longitudinal reinforcement 281.

[0088] Preferably, the projection shape of the overlapping part on the horizontal plane is a rectangle, four wall longitudinal bars 281 are inserted into the overlapping part and are respectively located at the four corners of the overlapping part, and the second edge steel bar group 28 and the first steel bar group 29 are fixedly connected to each wall longitudinal bar 281.

[0089] It should be noted that the first edge steel bar group 27, the second edge steel bar group 28 and the first steel bar group 29 are all structures in which stirrups are added around the vertical bars; the first edge steel bar group 27, the second edge steel bar group 28 and the first steel bar group 29 all have tie bars 28 fixedly connected to the vertical bars, and the parts of the tie bars 28 extending out of the stirrups are buried in the L-shaped shear wall formwork, so that the first edge steel bar group 27, the second edge steel bar group 28 and the first steel bar group 29 are fixedly set on the L-shaped shear wall formwork.

[0090] Preferably, the second formwork 22 of the L-shaped shear wall is provided with a mounting groove 221 and a through hole 222 which are connected in sequence from the outside to the inside, and a mounting nut 241 is fixedly provided at the second end of the first truss 24, and the mounting nut 241 corresponds to the position of the through hole 222; the screw of the T-shaped mounting bolt 242 can pass through the through hole 222 and be threadedly connected with the mounting nut 241, and the head of the T-shaped mounting bolt 242 is accommodated in the mounting groove 221. In this way, the first formwork 21 of the L-shaped shear wall and the second formwork 22 of the L-shaped shear wall can form a tension connection, and lateral stress is formed between the first formwork 21 of the L-shaped shear wall and the second formwork 22 of the L-shaped shear wall to prevent the formwork from being deformed or broken during the subsequent construction process.

[0091] Preferably, the first truss 24 includes a first plane steel bar 243 and a first truss vertical bar 244 extending along the height direction of the shear wall. The first plane steel bar 243 is formed by continuously bending a steel bar to form a triangular waveform. The first plane steel bar 243 has a relative first end and a second end in the direction from the first mold shell to the second mold shell. The first plane steel bar 243 is vertically arranged to the first steel mesh 23. The first end of the first plane steel bar 243 is fixedly connected to the first steel mesh 23 through the first truss vertical bar 244. The first end of the first plane steel bar 243 is bent and inserted into the first mold shell, and the second end of the first plane steel bar 243 is fixedly connected to the second steel mesh 25.

[0092] Furthermore, the mounting nut 241 is fixed to the second end of the first planar steel bar 243 .

[0093] Further preferably, the first end of the supporting steel bar 245 extending from the first formwork 21 of the L-shaped shear wall to the second formwork 22 of the L-shaped shear wall is bent and inserted into the first formwork 21 of the L-shaped shear wall, and the second end of the supporting steel bar 245 is fixedly connected to the mounting nut 241. In this way, the supporting steel bar 245 can support the mounting nut 241, which is conducive to the stable installation of the mounting nut 241 on the first truss 24. Furthermore, the first end of the supporting steel bar 245 is also fixedly connected to the first steel mesh 23.

[0094] Preferably, the second truss 26 includes a second plane steel bar 261, a third plane steel bar 262 and a second truss 26 vertical bar extending in the height direction of the shear wall, the second plane steel bar 261 and the third plane steel bar 262 are both formed by continuously bending a steel bar to form a triangular waveform, and the second plane steel bar 261 and the third plane steel bar 262 have a first end and a second end opposite to each other in the direction from the first formwork to the second formwork; the angle between the second plane steel bar 261 and the second steel mesh 25 is consistent with the angle between the third plane steel bar 262 and the second steel mesh 25; the first end of the second plane steel bar 261 is fixedly connected to the first end of the third plane steel bar 262 through the second truss 26 vertical bar, the second end of the second plane steel bar 261 is bent and inserted into the second formwork 22 of the L-shaped shear wall, and the second end of the third plane steel bar 262 is bent and inserted into the second formwork 22 of the L-shaped shear wall; the second truss 26 is located between two adjacent first trusses 24. Further, the second truss 26 is spaced apart from the first steel mesh 23.

[0095] Preferably, the horizontal steel bars in the first steel mesh 23 are stress-bearing steel bars, and the horizontal steel bars in the second steel mesh 25 are stress-bearing steel bars; the second steel mesh 25 has a first vertical bar 246, and the first vertical bar 246 is fixedly connected to the second end of the first plane steel bar 243, and the first truss vertical bar 244 and the first vertical bar 246 are stress-bearing steel bars. In this way, a double-layer bidirectional (horizontal direction and shear wall height direction) stress-bearing steel cage is formed, which saves steel material and amount while ensuring the stability of the steel cage structure, and reduces costs. Specifically, the diameter of the stress-bearing steel bar is 10 to 16 mm.

[0096] Preferably, a wire mesh 223 and a plurality of support steel plates 224 are embedded in the second formwork 22 of the L-shaped shear wall, and the plurality of support steel plates 224 are arranged in sequence in a horizontal direction; the support steel plates 224 are arranged corresponding to the position of the nut installation slot 221, the support steel plates 224 are located on the inner side of the nut installation slot 221, a through hole 222 for the T-shaped installation bolt 242 to pass through is opened on the support steel plate 224, the support steel plate 224 is welded on the wire mesh 223, the support steel plate 224 extends from the top of the second formwork to the bottom of the second formwork, and a casting hole 225 is opened between adjacent through holes 222 on the support steel plate 224. In this way, the structural strength of the second formwork is improved, the connection between the installation nut 241 and the T-shaped installation bolt 242 is stabilized, and the casting and forming of the second prefabricated component is facilitated through the casting hole 225.

[0097] When the prefabricated wall (which may be the first prefabricated wall 2 or the second prefabricated wall 4) is used as the module inner wall, Fig.10As shown, the prefabricated wall includes a partition wall and a T-shaped shear wall first formwork 41 connected in sequence, and the prefabricated wall is used to be spliced ​​with the T-shaped shear wall second formwork 42 of the prefabricated wall of the next box-type module to form a T-shaped shear wall formwork. The first formwork 41 of the T-shaped shear wall has a third straight portion 411 and a fourth straight portion 412, the second end of the third straight portion 411 and the fourth straight portion 412 are connected to form an L shape, the third straight portion 411 is paved with a third steel mesh 43 on a side facing away from the interior of the module, the third edge steel bar group 47 is fixedly arranged at the first end of the third straight portion 411, the fourth edge steel bar group 48 is fixedly arranged at the second end of the third straight portion 411, and both ends of the third steel mesh 43 are fixedly connected to the third edge steel bar group 47 and the fourth edge steel bar group 48 respectively; the third steel mesh 43 is fixedly connected with a third truss 44 extending along the height direction of the shear wall at a position corresponding to the position between the first and fourth edge steel bar groups 48, the first end of the third truss 44 is inserted into the shear wall formwork to fix the third steel mesh 43 on the shear wall formwork, and the second end of the third truss 44 is arranged toward the outside of the module.

[0098] In this way, most of the T-shaped shear wall steel bars are preset in the first T-shaped shear wall formwork 41, and a small part of the T-shaped shear wall steel bars are preset in the second T-shaped shear wall formwork 42. When the box-type modules are assembled during construction, it is convenient to move the second T-shaped shear wall formwork 42 of the rear module to align with the first T-shaped shear wall formwork 41 of the previous module to form a T-shaped shear wall formwork, thereby reducing the occurrence of steel bar collision during the splicing process.

[0099] When a prefabricated wall (which can be the first prefabricated wall 2 or the second prefabricated wall 4) is used as an inner wall of a module, the prefabricated wall includes a partition wall and a T-shaped shear wall second mold shell 42 connected in sequence, and the prefabricated wall is used to be spliced ​​with the T-shaped shear wall first mold shell 41 of the prefabricated wall of the previous box-type module to form a T-shaped shear wall wall mold. The second formwork 42 of the T-shaped shear wall has a fifth straight portion 421 and a sixth straight portion 422. The second end of the fifth straight portion 421 and the sixth straight portion 422 are connected to form an L shape. The fourth steel mesh 45 for connecting the first and fourth edge steel bar groups 48 is laid on the side of the fifth straight portion 421 facing away from the interior of the module. The fourth steel mesh 45 is fixedly connected with a fourth truss 46 extending along the height direction of the shear wall at a position corresponding to the position between the first and fourth edge steel bar groups 48. The first end of the fourth truss 46 is inserted into the second formwork 42 of the T-shaped shear wall to fix the fourth steel mesh 45 on the second formwork 42 of the T-shaped shear wall, and the second end of the fourth truss 46 is arranged toward the outside of the module.

[0100] In this way, when the box-type modules are assembled during construction, it is convenient to move the second T-shaped shear wall formwork 42 of the latter module to align with the first T-shaped shear wall formwork 41 of the former module to form a T-shaped shear wall formwork, thereby reducing the occurrence of steel bar collision during the splicing process.

[0101] It should be noted that "front" and "back" refer to the order in which the box-type modules are installed during the construction process.

[0102] like Fig.11 and Fig.12 As shown, preferably, the second steel bar group is fixed on the fourth straight portion 412, and the third steel bar group is fixed on the sixth straight portion 422; the first T-shaped shear wall formwork 41 and the second T-shaped shear wall formwork 42 are spliced ​​to form a T-shaped shear wall formwork, and the second steel bar group and the fourth edge steel bar group 48 extend out of the protruding portion of the third straight portion 411, and the third steel bar group are arranged in sequence in the horizontal direction.

[0103] It should be noted that the third edge steel bar group 47, the fourth edge steel bar group 48, the second steel bar group and the third steel bar group are all structures in which stirrups are added around the vertical bars; the third edge steel bar group 47, the fourth edge steel bar group 48, the second steel bar group and the third steel bar group all have tie bars 28 fixedly connected to the vertical bars, and the parts of the tie bars 28 extending out of the stirrups are buried in the T-shaped shear wall formwork, so that the third edge steel bar group 47, the fourth edge steel bar group 48, the second steel bar group and the third steel bar group are fixedly set on the T-shaped shear wall formwork.

[0104] Preferably, the second formwork 42 of the T-shaped shear wall is provided with a mounting groove 221 and a through hole 222 which are connected in sequence from the outside to the inside, and a mounting nut 241 is fixedly provided at the second end of the third truss 44; the first formwork 41 of the T-shaped shear wall and the second formwork 42 of the T-shaped shear wall are spliced ​​to form a T-shaped shear wall formwork, the mounting nut 241 corresponds to the position of the through hole 222, the screw of the T-shaped mounting bolt 242 can pass through the through hole 222 and be threadedly connected with the mounting nut 241, and the head of the T-shaped mounting bolt 242 is accommodated in the mounting groove 221. In this way, after the first formwork 41 of the T-shaped shear wall and the second formwork 42 of the T-shaped shear wall are spliced ​​to form the T-shaped shear wall formwork, the first formwork 41 of the T-shaped shear wall and the second formwork 42 of the T-shaped shear wall can form a tension connection, and a lateral stress is formed between the first formwork 41 of the T-shaped shear wall and the second formwork 42 of the T-shaped shear wall to prevent the formwork from being deformed or broken during the subsequent construction process.

[0105] Preferably, the structure of the third truss 44 is consistent with the structure of the first truss 24 described above, and will not be described in detail herein.

[0106] Further preferably, the first end of the supporting steel bar 245 extending from the first T-shear wall formwork 41 to the second T-shear wall formwork 42 is bent and inserted into the first T-shear wall formwork 41, and the second end of the supporting steel bar 245 is fixedly connected to the mounting nut 241. In this way, the supporting steel bar 245 can support the mounting nut 241, which is conducive to the stable installation of the mounting nut 241 on the third truss 44. Furthermore, the first end of the supporting steel bar 245 is also fixedly connected to the third steel mesh 43.

[0107] Preferably, the structure of the fourth truss 46 is consistent with the structure of the second truss 26 described above, and will not be described in detail herein.

[0108] Preferably, a wire mesh 223 and a plurality of supporting steel plates 224 are also embedded in the second formwork 42 of the T-shaped shear wall. The structure of the wire mesh 223 and the plurality of supporting steel plates 224 is the same as the structure of the wire mesh 223 and the plurality of supporting steel plates 224 embedded in the second formwork 22 of the above-mentioned L-shaped shear wall, and will not be repeated here.

[0109] In summary, according to the structure of the first prefabricated wall 2 and the second prefabricated wall 4, the concrete box-type modules generally have the following four types. The first type of concrete box-type module, the first prefabricated wall 2 is used as the module exterior wall, the second prefabricated wall 4 is used as the module interior wall, and the second prefabricated wall 4 includes a partition wall and a T-shaped shear wall first formwork 41 connected in sequence. The second type of concrete box-type module, the first prefabricated wall 2 is used as the module interior wall, the first prefabricated wall 2 includes a partition wall and a T-shaped shear wall second formwork 42 connected in sequence, and the second prefabricated wall 4 is used as the module exterior wall. The third type of concrete box-type module, the first prefabricated wall 2 is used as the module interior wall, the first prefabricated wall 2 includes a partition wall and a T-shaped shear wall first formwork 41 connected in sequence, the second prefabricated wall 4 is used as the module interior wall, and the second prefabricated wall 4 includes a partition wall and a T-shaped shear wall second formwork 42 connected in sequence.

[0110] like Fig.13 and Fig.14 As shown, the beam mold generally includes two beam mold shells 61 arranged opposite to each other, and a flat cavity is formed between the two beam mold shells 61, and the flat cavity is used to accommodate the steel cage.

[0111] The tops of the partition wall, the first post-cast wall 3, and the second post-cast wall 5 are all formed with beam formwork shells 61, and the top of the beam formwork shells 61 is connected to the edge of the module top plate 1. The side of the beam formwork shell 61 facing the inside of the module serves as the inner surface of the module, and the beam formwork shell 61 is provided with mounting holes. After the beam formwork shell 61 is spliced ​​with the beam formwork shell 61 of the adjacent box-type module to form a beam formwork, the mounting holes correspond to the mounting holes opened on the beam formwork shell 61 of the adjacent box-type module, and the tension bolts 63 can pass through the two mounting holes in sequence, and the tension bolts 63 are fastened to the beam formwork through the tension nuts. The beam formwork shell 61 configured in this way, after the beam formwork shell 61 is spliced ​​with the beam formwork shell 61 of the adjacent box-type module to form a beam formwork, can form a tension connection between the two formwork shells of the beam formwork, and form lateral stress between the two formwork shells of the beam formwork, thereby preventing the beam formwork shell 61 from being deformed or broken during the subsequent construction process.

[0112] Preferably, a protrusion 64 is provided on one side of the beam formwork shell 61 facing the outside of the module at a position corresponding to the mounting hole, and the mounting hole is provided through the protrusion 64. In this way, the structural strength of the beam formwork shell 61 is improved, and the connection between the tension bolt 63 and the tension nut is stabilized.

[0113] Example 2

[0114] like Figures 13 to 17 As shown, based on the concrete box-type modules provided in Example 1, this embodiment provides a concrete modular building formed by splicing the concrete box-type modules provided in Example 1.

[0115] The concrete modular building comprises at least two vertically connected concrete module layers, each concrete module layer comprises at least two transversely spliced ​​concrete box modules, the shear wall formwork in the upper concrete module layer corresponds to the shear wall formwork in the lower concrete module layer, and the upper shear wall formwork and the lower shear wall formwork of corresponding positions are overlapped by steel bars.

[0116] Specifically, the L-shaped shear wall formwork in the upper concrete module layer corresponds to the position of the L-shaped shear wall formwork in the lower concrete module layer, and the T-shaped shear wall formwork in the upper concrete module layer corresponds to the position of the T-shaped shear wall formwork in the lower concrete module layer.

[0117] In the upper L-shaped shear wall formwork and the lower L-shaped shear wall formwork corresponding to the positions, the spiral stirrups 71 are respectively vertically inserted into the first edge steel bar group 27 and the second edge steel bar group 28 of the lower L-shaped shear wall formwork, and the spiral stirrups 71 are fixedly connected to the first edge steel bar group 27 and the second edge steel bar group 28, and the spiral stirrups 71 extend upwardly from one end of the lower L-shaped shear wall formwork and are inserted into the first edge steel bar group 27 and the second edge steel bar group 28 of the upper L-shaped shear wall formwork; the first edge steel bar group 27 of the lower L-shaped shear wall formwork is fixedly connected to ... The vertical bars at both ends of the truss 24 are inserted upward into the upper L-shaped shear wall formwork; the connecting steel bar 72 is vertically inserted into the first steel bar group 29 of the lower L-shaped shear wall formwork, the first end of the connecting steel bar 72 is fixedly connected to the first steel bar group 29, the second end of the connecting steel bar 72 extends upward from the lower L-shaped shear wall formwork and is inserted into the first steel bar group 29 of the upper L-shaped shear wall formwork, and the second end of the connecting steel bar 72 has a screw sleeve 73 for threaded connection with the first end of the connecting steel bar 72 vertically inserted into the upper L-shaped shear wall formwork.

[0118] In the upper T-shaped shear wall formwork and the lower T-shaped shear wall formwork corresponding to the positions, spiral stirrups 71 are respectively vertically inserted into the first edge steel bar group 27 and the second edge steel bar group 28 of the lower T-shaped shear wall formwork, and the spiral stirrups 71 are fixedly connected to the first edge steel bar group 27 and the second edge steel bar group 28, and the spiral stirrups 71 extend upward from one end of the lower T-shaped shear wall formwork and are inserted into the first edge steel bar group 27 and the second edge steel bar group 28 of the upper T-shaped shear wall formwork; both ends of the third truss 44 of the lower T-shaped shear wall formwork The vertical reinforcement is inserted upward into the upper T-shaped shear wall formwork; the connecting steel bars 72 are vertically inserted into the second steel bar group and the third steel bar group of the lower T-shaped shear wall formwork respectively, the first end of the connecting steel bar 72 is fixedly connected to the second steel bar group and the third steel bar group, the second end of the connecting steel bar 72 extends upward from the lower L-shaped shear wall formwork and is inserted into the second steel bar group and the third steel bar group of the upper L-shaped shear wall formwork, and the second end of the connecting steel bar 72 has a screw sleeve 73 for threaded connection with the first end of the connecting steel bar 72 vertically inserted into the upper L-shaped shear wall formwork.

[0119] The above arrangement makes the connection between the upper and lower concrete module layers more stable.

[0120] Example 3

[0121] This embodiment provides a method for producing a concrete box-type module as described in Embodiment 1, comprising the following steps:

[0122] Step S1, respectively install the first prefabricated wall and the second prefabricated wall on the first side and the second side opposite to each other in the mold of the module, the first end of the first prefabricated wall corresponds to the first end of the second prefabricated wall, and the second end of the first prefabricated wall corresponds to the second end of the second prefabricated wall.

[0123] Step S2, installing the first steel cage on the third side of the mold inside the module and located between the first prefabricated wall and the second prefabricated wall, the first end of the first prefabricated wall cooperates with the first end of the first steel cage to form a steel lap structure, and the first end of the second prefabricated wall cooperates with the second end of the first steel cage to form a steel lap structure; installing the second steel cage on the fourth side of the mold inside the module and located between the first prefabricated wall and the second prefabricated wall, the second end of the first prefabricated wall cooperates with the first end of the second steel cage to form a steel lap structure, and the second end of the second prefabricated wall cooperates with the second end of the second steel cage to form a steel lap structure.

[0124] Step S3, installing the prefabricated module top plate on the top of the mold inside the module, the prefabricated module top plate is located in the enclosed area of ​​the first prefabricated wall, the second prefabricated wall, the first steel cage and the second steel cage, the top of the first prefabricated wall, the top of the second prefabricated wall, the top of the first steel cage and the top of the second steel cage respectively cooperate with the edge of the prefabricated module top plate corresponding to their positions to form a steel lap structure.

[0125] Step S4, installing the module outer mold at the position corresponding to the first steel cage, the second steel cage, and the steel overlap structure to form a first casting cavity; pouring concrete into the first casting cavity to form a first post-cast wall at the first steel cage, and a second post-cast wall at the second steel cage, and connecting the prefabricated module top plate with the first prefabricated wall, the second prefabricated wall, the first post-cast wall, and the second post-cast wall.

[0126] Step S5, installing the steel bar structure at the bottom of the mold inside the module, and the bottom of the first prefabricated wall, the bottom of the second prefabricated wall, the bottom of the first steel cage, and the bottom of the second steel cage respectively cooperate with the steel bar structures corresponding to their positions to form a steel bar lap structure.

[0127] Step S6: Install the module outer mold at the position corresponding to the steel bar overlap structure to form a second casting cavity; pour concrete into the second casting cavity to obtain a concrete box-type module.

[0128] It should be noted that the inner mold of the module refers to the mold used to match the internal shape and structure of the concrete box-type module, and the outer mold of the module refers to the mold used to match the external shape and structure of the concrete box-type module.

[0129] The production method of concrete box modules as described above has low requirements for module molds. There is no need to design the mold to completely match the shape and size of the module, which makes the shape and structure of the mold simpler, improves the applicability of the mold, and further improves the utilization rate of the mold, so that the mold can be applied to multiple projects and reduce costs.

[0130] Preferably, before step S1, a production process of an L-shaped shear wall formwork is also included, such as Fig. 9As shown in the figure, the production process of L-type shear wall formwork includes:

[0131] Step A01, forming a first steel mesh, a second steel mesh, a first edge steel bar group, a second edge steel bar group, a first truss and a second truss by automated welding; connecting the two ends of the first steel mesh to the first edge steel bar group and the second edge steel bar group respectively by automated welding, connecting the first end of the first truss to the first steel mesh, and connecting the first end of the truss to the second steel mesh; pouring concrete into the first formwork, the second formwork and the third formwork respectively.

[0132] Among them, the first formwork platform corresponds to the first straight portion, the second formwork platform corresponds to the second formwork shell of the L-shaped shear wall, and the third formwork platform corresponds to the second straight portion.

[0133] Wherein, step A01 may also include: welding a plurality of supporting steel plates to a steel wire mesh to form a supporting structure, installing the supporting structure in a second formwork platform, and then pouring concrete into the second formwork platform.

[0134] Step A02: Before the concrete in the first formwork solidifies, the first end of the first truss is pressed into the concrete, and the first steel mesh is located above the concrete, and a first prefabricated component is formed after curing and demolding; before the concrete in the second formwork solidifies, the first end of the truss is pressed into the concrete, and the second steel mesh is located above the concrete, and a second prefabricated component is formed after curing and demolding; before the concrete in the third formwork solidifies, the first steel bar group is pressed into the concrete, and a third prefabricated component is formed after curing and demolding.

[0135] Wherein, step A02 may also include: before the concrete in the first formwork solidifies, pressing the tension bars of the first edge steel bar group and the second edge steel bar group into the concrete, and the stirrups of the first edge steel bar group and the second edge steel bar group are located above the concrete.

[0136] Wherein, step A02 may further include: before the concrete in the third formwork is solidified, pressing the tension bars of the first steel bar group into the concrete, and the stirrups of the first steel bar group are located above the concrete.

[0137] Step A03, connect the first end of the second straight portion with the second end of the first straight portion to form an L shape, arrange the first prefabricated component and the second prefabricated component face to face, connect the second end of the first truss with the second steel mesh by automated welding, and connect the two ends of the second steel mesh with the first edge steel bar group and the second edge steel bar group respectively to obtain an L-shaped shear wall formwork.

[0138] Wherein, step A03 may further include: connecting the T-shaped mounting bolt and the mounting nut.

[0139] Among them, step A03 can also include: the stirrups extending from the first straight part of the first edge steel bar group and the stirrups extending from the second straight part of the first steel bar group are staggered and overlapped to form an overlapping part, the wall longitudinal reinforcement is inserted into the overlapping part, and the second steel bar group and the first steel bar group are fixedly connected to the wall longitudinal reinforcement.

[0140] In this way, during the production process of the first prefabricated component and the second prefabricated component, the automated binding or welding of the first internal steel bar group can be achieved, which greatly reduces the amount of steel bar binding and steel bar welding in on-site construction and significantly improves production efficiency.

[0141] Preferably, before step S1, it also includes a production process of a first prefabricated wall, and the production process of the first prefabricated wall occurs after the production process of an L-shaped shear wall mold. The production process of the first prefabricated wall includes: connecting the L-shaped shear wall mold and the partition wall mold, and separating the L-shaped shear wall mold cavity and the partition wall mold cavity, pouring concrete into the partition wall mold cavity, and forming the first prefabricated wall after curing and demolding.

[0142] Preferably, before step S1, the process further includes the production process of the first formwork of the T-shaped shear wall and the second formwork of the T-shaped shear wall. The production process of the first formwork of the T-shaped shear wall and the second formwork of the T-shaped shear wall includes:

[0143] Step B01, forming a third steel mesh, a third truss, a fourth steel mesh, a fourth truss, a third edge steel bar group and a fourth edge steel bar group through automated welding; connecting the first edge steel bar group and the second edge steel bar group to the two ends of the third steel mesh, connecting the first end of the third truss to the third steel mesh, and connecting the first end of the fourth truss to the fourth steel mesh through automated welding; pouring concrete into the fourth, fifth, sixth and seventh formworks respectively.

[0144] The fourth mold platform corresponds to the third straight portion, the fifth mold platform corresponds to the fifth straight portion, the sixth mold platform corresponds to the fourth straight portion, and the seventh mold platform corresponds to the sixth straight portion.

[0145] Wherein, step B01 may also include: welding a plurality of supporting steel plates to a steel wire mesh to form a supporting structure, installing the supporting structure in a fourth mold platform, and then pouring concrete into the second mold platform.

[0146] Step B02, before the concrete in the fourth mold platform solidifies, the first end of the third truss is pressed into the concrete, and the third steel mesh is located above the concrete, and the first wall form is formed after curing and demolding; before the concrete in the fifth mold platform solidifies, the first end of the fourth truss is pressed into the concrete, and the fourth steel mesh is located above the concrete, and the second wall form is formed after curing and demolding; before the concrete in the sixth mold platform solidifies, the tension bars of the second steel bar group are pressed into the concrete, and the stirrups of the second steel bar group are located above the concrete, and the third wall form is formed after curing and demolding; before the concrete in the seventh mold platform solidifies, the tension bars of the third steel bar group are pressed into the concrete, and the stirrups of the third steel bar group are located above the concrete, and the fourth wall form is formed after curing and demolding.

[0147] Wherein, step B02 may further include: before the concrete in the fourth formwork is solidified, pressing the tension bars of the first edge steel bar group and the second edge steel bar group into the concrete, and the stirrups of the first edge steel bar group and the second edge steel bar group are located above the concrete.

[0148] Step B03, connecting the second end of the first straight portion and the first end of the second straight portion to form an L shape, to obtain a first formwork of a T-shaped shear wall; connecting the second end of the third straight portion and the first end of the fourth straight portion to form an L shape, to obtain a second formwork of a T-shaped shear wall.

[0149] In this way, during the production process of the first wall formwork and the second wall formwork, the automated binding or welding of the second internal steel bar group can be achieved, which greatly reduces the amount of steel bar binding and welding in on-site construction and significantly improves production efficiency.

[0150] Before step S1, it also includes the production process of the second prefabricated wall. The production process of the second prefabricated wall occurs after the production process of the first mold shell of the T-shaped shear wall and the second mold shell of the T-shaped shear wall. The production process of the second prefabricated wall includes: connecting the first mold shell of the T-shaped shear wall and / or the second mold shell of the T-shaped shear wall with the partition wall mold, and separating the T-shaped shear wall mold shell and the partition wall mold cavity, pouring concrete into the partition wall mold cavity, and forming the second prefabricated wall after curing and demolding.

[0151] It should be noted that the beam mold of the partition wall is formed during the production process of the first prefabricated wall and the second prefabricated wall, the connection between the beam mold of the partition wall and the top plate of the prefabricated module is formed in step S4, and the beam mold of the first post-cast wall and the beam mold of the second post-cast wall are formed in step S4.

[0152] Example 4

[0153] This embodiment provides a construction method of a concrete modular building formed by splicing concrete box-type modules provided in Embodiment 1, comprising the following steps:

[0154] Step 10: Assemble the concrete box modules in the transverse direction (i.e., horizontal direction) to form the first layer of modules.

[0155] Step 11: insert a steel lap joint structure into the shear wall membrane cavity of the first layer module, wherein a first end of the steel lap joint structure is inserted into the shear wall membrane cavity, and a second end of the steel lap joint structure extends upward out of the first layer module.

[0156] Specifically, the steel bar lap joint structure includes the spiral stirrups and connecting steel bars described in Example 2.

[0157] Step 12: Cast the first layer of modules.

[0158] Step 13: stack a second layer of modules on top of the first layer of modules, and insert the second end of the steel bar lap structure into the shear wall membrane cavity of the second layer of modules.

[0159] Step 14: Use the second layer module as the first layer module and repeat steps 11 to 13.

[0160] It should be understood that the above description of the specific embodiments of the present invention is only for illustrating the technical route and features of the present invention, and its purpose is to enable those skilled in the art to understand the content of the present invention and implement it accordingly, but the present invention is not limited to the above specific implementation methods. Any changes or modifications made within the scope of the claims of the present invention should be included in the protection scope of the present invention.

Claims

1. A concrete box module, characterized in that: The invention comprises a module bottom plate, a module top plate (1), a beam form shell (61), and a first prefabricated wall (2), a first post-cast wall (3), a second prefabricated wall (4) and a second post-cast wall (5) which are sequentially connected around the edge of the module top plate, wherein the first prefabricated wall (2) and the second prefabricated wall (4) are arranged opposite to each other, and the first post-cast wall (3) and the second post-cast wall (5) are arranged opposite to each other; The first prefabricated wall (2) and the second prefabricated wall (4) both comprise a partition wall and a shear wall formwork that are connected in sequence, the side of the shear wall formwork that faces the interior of the module being the inner surface of the module, the side of the shear wall formwork that faces away from the interior of the module being paved with a steel mesh for connecting two adjacent edge steel bar groups (27, 28), the steel mesh being fixedly connected to a position corresponding to the position between the two adjacent edge steel bar groups (27, 28) with a truss extending in the height direction of the shear wall, the first end of the truss being inserted into the shear wall formwork to fix the steel mesh on the shear wall formwork, and the second end of the truss being arranged toward the outside of the module; The top of the shear wall formwork is connected to the edge of the module top plate (1), the top of the partition wall is connected to the edge of the module top plate (1) through the beam formwork (61), the top of the first post-cast wall body (3) is connected to the edge of the module top plate (1), and the bottom of the second post-cast wall body (5) is connected to the edge of the module top plate (1); the top of the shear wall formwork is connected to the edge of the module bottom plate, the bottom of the partition wall is connected to the edge of the module bottom plate, the bottom of the first post-cast wall body (3) is connected to the edge of the module bottom plate, and the bottom of the second post-cast wall body (5) is connected to the edge of the module bottom plate; The thickness of the beam formwork shell (61) is within 30 mm, and the thickness of the shear wall formwork shell is within 30 mm.

2. The concrete box module according to claim 1, characterized in that: When the first prefabricated wall (2) is used as the module exterior wall, the first prefabricated wall (2) comprises an L-shaped shear wall first mold shell (21) and an L-shaped shear wall second mold shell (22) arranged opposite to the L-shaped shear wall first mold shell (21), the L-shaped shear wall first mold shell (21) and the L-shaped shear wall second mold shell (22) are both connected to the partition wall, the side of the L-shaped shear wall first mold shell (21) facing the inside of the module serves as the inner surface of the module, and the side of the L-shaped shear wall second mold shell (22) facing away from the inside of the module serves as the outer surface of the module; A first steel mesh sheet (23) for connecting two adjacent edge steel bars (27, 28) is laid on a side of the first formwork (21) of the L-shaped shear wall facing away from the inside of the module; a first steel mesh sheet (23) is fixedly connected to a first truss (24) extending in the height direction of the shear wall at a position corresponding to the position between the two adjacent edge steel bars (27, 28); the first truss (24) is in the shape of a steel mesh sheet; a first end of the first truss (24) is inserted into the first formwork (21) of the L-shaped shear wall to fix the first steel mesh sheet (23) on the first formwork (21) of the L-shaped shear wall; and a second end of the first truss (24) is arranged toward the second formwork (22) of the L-shaped shear wall. A second steel mesh sheet (25) for connecting two adjacent edge steel bars (27, 28) is laid on one side of the second formwork (22) of the L-shaped shear wall facing the inside of the module; a second steel mesh sheet (25) is fixedly connected to a second truss (26) extending in the height direction of the shear wall at a position corresponding to the position between the two adjacent edge steel bars (27, 28); the second truss (26) is a triangular truss; a first end of the second truss (26) is inserted into the second formwork (22) of the L-shaped shear wall to fix the second steel mesh sheet (25) on the second formwork (22) of the L-shaped shear wall; and a second end of the second truss (26) is arranged toward the first formwork (21) of the L-shaped shear wall.

3. The concrete box module according to claim 2, characterized in that: The second formwork of the L-shaped shear wall is provided with a mounting groove (221) and a through hole (222) which are connected in sequence from the outside to the inside, and a mounting nut (241) is fixedly provided at the second end of the first truss (24), and the mounting nut (241) corresponds to the position of the through hole (222); A steel mesh (223) and a plurality of support steel plates (224) are embedded in the second formwork of the L-shaped shear wall. The plurality of support steel plates (224) are arranged in sequence and spaced apart in the horizontal direction. The support steel plates (224) are arranged at positions corresponding to the installation grooves (221). The support steel plates (224) are located on the inner side of the installation grooves (221). Through holes (222) are provided on the support steel plates (224). The support steel plates (224) are welded to the steel mesh (223). Casting holes (225) are provided between adjacent through holes (222) on the support steel plates (224). The screw rod of the T-shaped mounting bolt (242) can pass through the through hole (222) and be threadedly connected with the mounting nut (241), and the head of the T-shaped mounting bolt (242) is accommodated in the mounting groove (221).

4. The concrete box module according to claim 1, characterized in that: When the prefabricated wall is used as the inner wall of the module, the prefabricated wall comprises a partition wall and a first T-shaped shear wall formwork (41) connected in sequence, and the first T-shaped shear wall formwork (41) is used to be spliced ​​with the second T-shaped shear wall formwork (42) of the prefabricated wall of the next box-type module to form a T-shaped shear wall formwork; A third steel mesh sheet (43) is laid on a side of the first formwork (41) of the T-shaped shear wall facing away from the interior of the module; a third edge steel bar group (47) is fixedly arranged at a first end of the first formwork (41) of the T-shaped shear wall; a second edge steel bar group is fixedly arranged at a second end of the first formwork (41) of the T-shaped shear wall; two ends of the third steel mesh sheet (43) are respectively fixedly connected to the third edge steel bar group (47) and the fourth edge steel bar group (48); a third truss (44) extending in the height direction of the shear wall is fixedly connected to the third steel mesh sheet (43) at a position corresponding to the position between the third and fourth edge steel bar groups (48); the third truss (44) is in the shape of a steel mesh sheet; a first end of the third truss (44) is inserted into the shear wall formwork to fix the third steel mesh sheet (43) on the first formwork of the shear wall; and a second end of the third truss (44) is arranged toward the outside of the module.

5. The concrete box module according to claim 1, characterized in that: When the prefabricated wall is used as the inner wall of the module, the prefabricated wall comprises a partition wall and a T-shaped shear wall second mold shell (42) connected in sequence, and the T-shaped shear wall second mold shell (42) is used to be spliced ​​with the T-shaped shear wall first mold shell (41) of the prefabricated wall of the previous box-type module to form a T-shaped shear wall mold; A fourth steel mesh sheet (45) for connecting the third and fourth edge steel bars (48) is laid on a side of the second formwork (42) of the T-shaped shear wall facing away from the interior of the module; the fourth steel mesh sheet (45) is fixedly connected to a fourth truss (46) extending along the height direction of the shear wall at a position corresponding to the third and fourth edge steel bars (48); a first end of the fourth truss (46) is inserted into the second formwork (42) of the T-shaped shear wall to fix the fourth steel mesh sheet (45) on the second formwork (42) of the T-shaped shear wall; and a second end of the fourth truss (46) is arranged toward the outside of the module.

6. The concrete box module according to claim 4, characterized in that: The second mold shell (42) of the T-shaped shear wall is provided with a mounting groove (221) and a through hole (222) which are connected in sequence from the outside to the inside, and a mounting nut (241) is fixedly provided on the second end of the third truss (44); the first mold shell (41) of the T-shaped shear wall and the second mold shell (42) of the T-shaped shear wall are spliced ​​to form a T-shaped shear wall mold, the mounting nut (241) and the through hole (222) are located at corresponding positions, the screw rod of the T-shaped mounting bolt (242) can pass through the through hole (222) and be threadedly connected with the mounting nut (241), and the head of the T-shaped mounting bolt (242) is accommodated in the mounting groove (221).

7. The concrete box module according to claim 1, characterized in that: The beam mold shell (61) is used to be spliced ​​with the beam mold shell (61) of the previous box-type module to form a beam mold; The beam mold shell (61) is provided with a mounting hole. After the beam mold shell (61) is spliced ​​with the beam mold shell (61) of the previous box-type module to form a beam mold, the mounting hole corresponds to the mounting hole position provided on the beam mold shell (61) of the previous box-type module. The tension bolt (63) can pass through the two mounting holes in sequence, and the tension bolt (63) is fastened to the beam mold by a tension nut.

8. A method for producing a concrete box module according to any one of claims 1 to 7, comprising: S1, installing the first prefabricated wall (2) and the second prefabricated wall (4) on the first side and the second side of the mold in the module respectively; S2, installing the first steel cage and the second steel cage on the third side and the fourth side of the mold in the module respectively, the two ends of the first steel cage cooperate with the first prefabricated wall (2) and the second prefabricated wall (4) to form a steel lap joint structure, and the two ends of the second steel cage cooperate with the first prefabricated wall (2) and the second prefabricated wall (4) to form a steel lap joint structure; S3, installing the prefabricated module top plate (1) on the top of the mold inside the module, and the top of the first prefabricated wall (2), the top of the second prefabricated wall (4), the top of the first steel cage, and the top of the second steel cage respectively cooperate with the edge of the prefabricated module top plate (1) corresponding to their positions to form a steel bar overlap structure; S4. Install the module outer mold at positions corresponding to the first steel cage, the second steel cage, and the steel overlap structure to form a first casting cavity; pour concrete into the first casting cavity to form a pentahedral module. S5. After the pentahedral module has a certain strength, the mold of the cast-in-place wall is removed, and then the bottom plate reinforcement is tied on the bottom mold platform, and finally the module bottom plate is cast to form a complete hexahedral module.

9. The method for producing a concrete box module according to claim 8, characterized in that: S1 also includes the production process of L-type shear wall formwork: A01, forming a first steel mesh (23), a second steel mesh (25), a first edge steel bar group (27), a second edge steel bar group (28), a first truss (24) and a second truss (26) by automated welding; connecting the two ends of the first steel mesh (23) to the first edge steel bar group (27) and the second edge steel bar group (28) by automated welding, connecting the first end of the first truss (24) to the first steel mesh (23), and connecting the first end of the second truss (26) to the second steel mesh (25); pouring concrete into the first straight formwork platform, the second formwork platform and the third formwork platform respectively; A02. Before the concrete in the first mold platform solidifies, the first end of the first truss (24) is pressed into the concrete, and the first steel mesh (23) is located above the concrete, and a first prefabricated component is formed after demoulding; before the concrete in the second mold platform solidifies, the first end of the second truss (26) is pressed into the concrete, and the second steel mesh (25) is located above the concrete, and a second prefabricated component is formed after demoulding; before the concrete in the third mold platform solidifies, the first steel bar group is pressed into the concrete, and a third prefabricated component is formed after demoulding; A03. Connect the first end of the third prefabricated component with the second end of the first prefabricated component to form an L shape, arrange the first prefabricated component and the second prefabricated component face to face, connect the second end of the first truss (24) with the second steel mesh (25) by automated welding, and connect the two ends of the second steel mesh (25) with the first edge steel bar group (27) and the second edge steel bar group (28) respectively to obtain an L-shaped shear wall formwork.

10. The method for producing a concrete box module according to claim 8, characterized in that: The process before S1 also includes the production process of the first T-shaped shear wall formwork (41) and the second T-shaped shear wall formwork (42): B01, forming a third steel mesh (43), a third truss (44), a fourth steel mesh (45), a fourth truss (46), a third edge steel bar group (47) and a fourth edge steel bar group (48) by automated welding; connecting the third edge steel bar group (47) and the fourth edge steel bar group (48) to the two ends of the third steel mesh (43), connecting the first end of the third truss (44) to the third steel mesh (43), and connecting the first end of the fourth truss (46) to the fourth steel mesh (45) by automated welding; pouring concrete into the fourth, fifth, sixth and seventh straight formwork platforms respectively; B02, before the concrete in the fourth mold platform solidifies, the first end of the third truss (44) is pressed into the concrete, and the third steel mesh (43) is located above the concrete, and after demoulding, a first wall mold is formed; before the concrete in the fifth mold platform solidifies, the first end of the fourth truss (46) is pressed into the concrete, and the fourth steel mesh (45) is located above the concrete, and after demoulding, a second wall mold is formed; Before the concrete in the sixth mold platform solidifies, the reinforcement of the second reinforcement group is pressed into the concrete, and the third wall mold is formed after demoulding; before the concrete in the seventh mold platform solidifies, the reinforcement of the third reinforcement group is pressed into the concrete, and the fourth wall mold is formed after demoulding; Step B03, connect the second end of the first wall formwork with the first end of the third wall formwork to form an L shape, and obtain a first formwork shell (41) of a T-shaped shear wall; connect the second end of the second wall formwork with the first end of the fourth wall formwork to form an L shape, and obtain a second formwork shell (42) of a T-shaped shear wall.

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