Floor thickness control device and process integrated with protective layer cushion block

Abstract

The invention discloses a floor thickness control device and process integrated with a protective layer cushion block, and aims to solve the problems that a traditional steel bar protective layer cushion block is easy to displace, and the floor thickness needs to be additionally controlled. The device consists of a cake-shaped cushion block, a U-shaped metal bracket and a hard plastic sleeve, wherein the cake-shaped cushion block is integrally cast with the U-shaped metal bracket by adopting cement mortar or fine aggregate concrete; the U-shaped metal support comprises a thin steel plate strip and two vertical steel bar end rods welded to the two ends, when the device is installed, the thin steel plate strip is tightly attached to the bottom face of a floor lower layer stressed steel bar, and the vertical end rods are limited to avoid displacement of the cushion block. After a floor reinforcement cage is bound, the vertical end rod is tightly sleeved with a hard plastic sleeve, and the sum of the height of the sleeve and the thickness of the cushion block is equal to the designed thickness of a floor; when concrete is poured and plastered, accurate control over the thickness of the floor slab is achieved through the height of the top face of the sleeve, open holes are formed in the side wall of the sleeve in a staggered mode, an inner cavity is filled with cement paste, and floor slab holes are prevented. Double precise control over the floor slab protection layer and the thickness is synchronously achieved through the integrated composite component, the working procedure is simplified, the efficiency is improved, and the cast-in-place floor slab construction technology is efficiently improved.

Description

TECHNICAL FIELD

[0001] The present application belongs to the field of main structure construction of building engineering, and particularly relates to a device and process for controlling the reinforcement protection layer and the thickness of a cast-in-place floor slab. BACKGROUND

[0002] Cast-in-place reinforced concrete floor slab is a core component of building structure, and the construction quality thereof needs to control the thickness of the reinforcement protection layer and the overall thickness of the floor slab, which directly determines the load-bearing performance, durability and structural safety of the floor slab.

[0003] In traditional construction, the reinforcement protection layer is realized by relying on independent pads, such as cement mortar blocks and plastic pads. Such pads have scattered sizes, and are prone to displacement due to collisions caused by steel binding and lashing and impacts caused by concrete vibrating during construction, resulting in uneven thickness of the protection layer. Too thin thickness of the protection layer will expose the steel to rust, and too thick thickness of the protection layer will weaken the effective stress section of the floor slab, which will cause structural hidden dangers. In order to reduce displacement, additional labor is required to adjust the positions of the pads and increase the layout density, which greatly increases the process cost and working hours.

[0004] The thickness of the floor slab needs to be controlled by separately inserting a marker, leveling by a line, or detecting by a thickness detector after construction. The marker is prone to tilting due to vibrating, and the line is prone to relaxation due to construction interference, resulting in thickness deviation exceeding the specification. When the deviation is found by post-construction detection, the floor slab needs to be chiseled and re-poured or reinforced, which not only wastes materials but also delays the construction period. Especially in large-area floor slab construction, the protection layer control and the thickness control are two independent processes, which need to be separately supervised by labor, and the process coordination is poor. Under the superposition of double errors, the construction efficiency and quality are difficult to be considered.

[0005] The prior art lacks an integrated solution that can simultaneously solve the two control requirements, and the industry urgently needs an integrated construction device that can simplify the process and improve the precision and efficiency to make up for the shortcomings of the traditional process. SUMMARY

[0006] The present application discloses a floor slab thickness control device and process integrated with a protection layer pad, which aims to simultaneously solve the problems of easy displacement of the reinforcement protection layer pad and the need for additional control of the thickness of the floor slab in traditional construction, and to realize integrated and accurate control of the reinforcement protection layer and the thickness of the floor slab in cast-in-place floor slab construction.

[0007] The device core is composed of three components, and each component is cooperatively adapted. One is a pie-shaped cushion block, which is integrally cast with a U-shaped metal support by using cement mortar or fine stone concrete, has a diameter of 50-80 mm and a thickness of 20-30 mm, can accurately support the lower layer of the floor stress reinforcement, and forms a required reinforcement protection layer. Two is the U-shaped metal support, which is built-in and fixed on the top surface of the pie-shaped cushion block, is composed of a thin steel strip with a diameter of the cushion block and two vertical reinforcement end rods welded at both ends, and when installed, the thin steel strip is tightly attached to the bottom surface of the lower layer of the floor stress reinforcement, and the vertical end rods are located on both sides of the reinforcement, which can effectively limit the displacement of the cushion block and ensure the stability of the reinforcement protection layer thickness. Three is a hard plastic sleeve, which is tightly sleeved on the vertical reinforcement end rod after the floor reinforcement cage is bound and tied, and has 5-8 mm diameter staggered holes on the side wall at intervals of 2-3 cm along the axial direction, which can be filled with cement mortar to fill the internal cavity of the sleeve during concrete pouring, so as to avoid the formation of holes in the floor. The sum of the height of the sleeve and the thickness of the pie-shaped cushion block is equal to the design thickness of the floor, and when pouring and finishing, the top surface height of the sleeve is used as the reference, so that the accurate control of the floor thickness can be realized.

[0008] On the construction process, only the process of "laying cushion block → binding reinforcement cage → sleeving sleeve → pouring concrete" is needed, through the integrated design of components, the double control of reinforcement protection layer and floor thickness can be completed simultaneously without additional process, which significantly simplifies the construction steps, improves the construction efficiency and quality accuracy, and is suitable for various cast-in-place reinforced concrete floor construction scenes. BRIEF DESCRIPTION OF DRAWINGS

[0009] The application will be further described below in combination with the drawings and specific embodiments.

[0010] Figure 1 It is a three-dimensional perspective view of the integrated protection layer cushion block floor thickness control device of the application. In the figure, the pie-shaped cushion block (1) is integrally cast with the U-shaped metal support (2) by using cement mortar (11) or fine stone concrete (12); before the lower layer of the floor stress reinforcement (4) is bound, the pie-shaped cushion block (1) is placed on the top surface of the formwork at the bottom of the floor; when installed, the thin steel strip (21) of the U-shaped metal support (2) is tightly attached to the bottom surface of the lower layer of the floor stress reinforcement (4), and the vertical reinforcement end rod (22) is located on both sides of the lower layer of the floor stress reinforcement (4) to limit the displacement of the cushion block and ensure the stability of the floor protection layer thickness.

[0011] Figure 2 It is a three-dimensional structure detail view of the U-shaped metal support in the device of the application. In the figure, the U-shaped metal support (2) is composed of a thin steel strip (21) and two vertical reinforcement end rods (22), and the two vertical reinforcement end rods (22) are welded to the top surface of the thin steel strip (21); the length of the thin steel strip (21) is adapted and smaller than the diameter of the pie-shaped cushion block (1), and the height of the vertical reinforcement end rod (22) is 3-6 cm, which can provide firm support for the hard plastic sleeve (3) that is sleeved subsequently.

[0012] Figure 3 Three-dimensional perspective view of the hard plastic sleeve tightly sleeved on the vertical steel bar end rod of the U-shaped metal support in the device of the application. In the figure, the hard plastic sleeve (3) is tightly sleeved on the vertical steel bar end rod (22), and the height of the hard plastic sleeve (3) and the thickness of the cake-shaped cushion block (1) are equal to the design thickness of the floor slab, so as to realize accurate control of the thickness of the cast-in-place concrete floor slab; the side wall of the hard plastic sleeve (3) is provided with staggered openings (31), the openings are arranged at an interval of 2-3 cm along the axial direction of the sleeve, and the hole diameter is 5-8 mm, so that the cement slurry fills the internal cavity of the sleeve during concrete pouring, and holes are avoided in the floor slab. DETAILED DESCRIPTION

[0013] In order to make the technical means, creative features, purposes and effects realized by the present application easy to understand, the following will further describe the present application in combination with specific drawings.

[0014] It should be understood that the structures, proportions, sizes, etc. shown in the drawings attached to the present specification are only used to cooperate with the content disclosed in the specification, so as to be understood and read by those skilled in the art, and do not define the limiting conditions for the implementation of the present application, and therefore do not have technical substantive significance. Any modification of structure, change of proportion relationship or adjustment of size, without affecting the effects and purposes that can be achieved by the present application, should still fall within the scope of the technical content disclosed by the present application. At the same time, the terms such as "upper", "lower", "left", "right", "middle" and "one" used in the present specification are only for the convenience of clear description, and are not used to limit the scope of the implementation of the present application. The change or adjustment of the relative relationship is also considered as the implementation of the present application without substantial change of technical content. The present application will be described in detail below in combination with the drawings.

[0015] The specific implementation of the present application needs to be operated in five steps of "component prefabrication → site layout → steel reinforcement cage binding → sleeve installation → concrete pouring", to ensure that the double control is accurately landed, and the specific steps are as follows: The first step is component prefabrication. Three core components are processed according to design parameters: cake-shaped cushion block (1) is integrally poured with U-shaped metal support (2) using cement mortar (11) or fine stone concrete (12), the diameter is controlled to be 50-80 mm, and the thickness is controlled to be 20-30 mm; the length of the thin steel strip (21) of the U-shaped metal support (2) is slightly smaller than the diameter of the cushion block, and two vertical steel bar end rods (22) are welded on the top surface of the steel strip, and the height is uniform at 3-6 cm; at the same time, the hard plastic sleeve (3) is prefabricated, the sleeve height is calculated according to the design thickness of the floor slab (sleeve height = design thickness - cushion block thickness), and staggered openings (31) are provided on the side wall of the sleeve, the hole diameter is 5-8 mm, and the axial interval is 2-3 cm.

[0016] The second step is to lay the cushion block. On the top surface of the floor bottom formwork, uniformly lay the prefabricated pie-shaped cushion block (1) according to the spacing (usually 250-500 mm) of the lower layer of force-bearing steel bars (4) of the floor; place the lower layer of force-bearing steel bars (4) of the floor on the cushion block, ensure that the thin steel strip (21) of the U-shaped metal support (2) is tightly attached to the bottom surface of the steel bar, and the vertical steel bar end rod (22) is respectively located on both sides of the steel bar to limit the displacement of the cushion block and preliminarily fix the thickness of the protective layer.

[0017] The third step is to bind the steel cage. According to the conventional construction specification, the upper and lower steel bars of the floor are bound to form a complete steel cage, and the prefabricated pie-shaped cushion block (1) is avoided to collide during the process to prevent the thickness of the protective layer from deviating.

[0018] The fourth step is to sleeve the hard plastic sleeve. After the steel cage is bound, the prefabricated hard plastic sleeve (3) is tightly sleeved on the vertical steel bar end rod (22), the height of the top surface of the sleeve is checked, and it is ensured that the sum of the thickness of the hard plastic sleeve (3) and the pie-shaped cushion block (1) accurately matches the design thickness of the floor.

[0019] The fifth step is to pour concrete. When pouring concrete, the top surface of the hard plastic sleeve (3) is used as the reference for troweling and leveling; during the vibrating process, the cement slurry fills the internal cavity through the sleeve opening (31) to avoid forming a hole; after pouring is completed, maintenance is carried out according to the specification, and finally the double-precision control of the steel bar protective layer and the thickness of the floor is realized. Embodiment

[0020] For the construction of a certain 5-story cast-in-place industrial building floor, the floor area of each floor is 1000 square meters, the design adopts C30 concrete, the floor thickness is 120 mm, the environmental category is 2a, and the 20 mm steel bar protective layer thickness requirement needs to be met. Based on this parameter, the present application is landed according to the logic of "standardized prefabrication-precise layout-standardized construction-process control", and the specific implementation process is as follows: In the component prefabrication stage, the quality is strictly controlled according to the design parameters: the pie-shaped cushion block is poured with M20 cement mortar (cement:sand:water=1:3:0.5 ratio), the mold is shaped to ensure a diameter of 60 mm and a thickness of 20 mm, and the U-shaped metal support is embedded simultaneously during pouring-the thin steel strip of the support is made of 1.5 mm thick galvanized sheet, the cutting length is 50 mm (slightly smaller than the diameter of the cushion block to avoid exposure), two vertical steel bar end rods are made of 10 mm diameter first-class steel bars, and after cutting, they are welded to the top surface of the steel strip with a weld height of 3 mm to ensure firmness, and the final end rod height is uniform at 6 cm; the hard plastic sleeve is made of PVC material, the height is calculated according to "sleeve height = floor design thickness - cushion block thickness", the height is determined to be 100 mm, the outer diameter is 16 mm, the wall thickness is 3 mm, and the staggered openings (31) are drilled on the side wall of the sleeve using a mechanical drill, the hole diameter is 5 mm, and the axial interval is 2.5 cm.

[0021] In the field construction phase, four steps are orderly promoted: first, before laying the cushion block, the top surface of the floor bottom formwork is cleaned, the grid line is popped at an interval of 400 mm, the prefabricated pie-shaped cushion block is evenly placed along the grid point, and it is ensured that 16-18 cushion blocks are laid per square meter to ensure uniform stress; second, the lower layer of the floor stress reinforcement is placed, the reinforcement is placed on the cushion block, the levelness of the reinforcement is calibrated by using the level, and the position of the cushion block is adjusted at the same time, so that the thin steel strip of the U-shaped metal support is tightly attached to the bottom surface of the reinforcement, the vertical reinforcement end rod is located on both sides of the reinforcement respectively, a "two-side limiting" structure is formed, and the displacement of the cushion block in the subsequent process is avoided; third, the reinforcement cage is bound, the floor reinforcement is bound according to the specification (12 mm diameter reinforcement is used, and the interval is 200 mm), the upper layer of reinforcement is supported by using the horse stool reinforcement during the process, and the bound reinforcement is accepted after the bound reinforcement is completed, so that it is ensured that the cushion block is not displaced, the reinforcement spacing meets the requirements; fourth, the hard plastic sleeve is installed, the sleeve is tightly sleeved on the vertical reinforcement end rod, the top surface elevation of the sleeve is reviewed point by point by using the laser sweeping instrument, it is ensured that the top surface of the sleeve of the whole layer is at the same level, and the sum of the thicknesses of the sleeve and the cushion block is accurately 120 mm, and the deviation is controlled within ±1 mm.

[0022] In the concrete pouring stage, the quality is controlled based on the sleeve: before pouring, it is checked whether the sleeve is stable, the C30 concrete slump is controlled within 180±20 mm, the flat vibrator is used for vibration, the vibration rod is inserted to avoid the sleeve and the cushion block, and the component displacement is prevented; when the surface is troweled, the 2m screed is used to find the level by the top surface of the sleeve, and the floor surface flatness is ensured; after pouring, the plastic film is covered for 7 days of moisture curing.

[0023] From the process effect, the application has the following advantages: first, the control precision is greatly improved, through the reinforcement position detector, the reinforcement cover thickness qualified rate is improved from 85% of the traditional process to 99%, the floor thickness error is controlled within ±2 mm, and the specification requirement is far exceeded; second, the construction efficiency is obviously improved, the integrated design saves the two processes of "separately laying the cushion block + additionally inserting the thickness control marker" in the traditional process, 2 workers are reduced per layer, 10 workdays are saved (according to the industrial construction labor unit price of 300 yuan / workday, 3000 yuan of cost is saved), and the construction time of each layer is shortened by 8 hours; third, the quality and durability are more guaranteed, the staggered holes of the PVC sleeve allow the cement paste to fully fill the internal cavity, the ultrasonic detection shows that the floor has no hole defect, the M20 cement mortar cushion block and the galvanized support have strong anti-corrosion ability in the two a environment, compared with the aging problem of the traditional plastic cushion block, the service life of the component of the application is longer, and the later maintenance cost is reduced.

[0024] The application integrates the cushion block and the thickness control function, simultaneously solves the problems of the cushion block displacement and the thickness control complexity in the traditional process, greatly improves the control precision, simplifies the process, saves the working hours and the cost, has strong component adaptability and good durability, and is suitable for various cast-in-place floor construction, and efficiently guarantees the structure quality.

[0025] The above shows and describes the basic principles, main features and advantages of the present application. Those skilled in the art should understand that the present application is not limited to the above-mentioned embodiments, and the above-mentioned embodiments and descriptions in the specification are only to illustrate the principles of the present application. Various changes and improvements can be made to the present application without departing from the spirit and scope of the present application, and these changes and improvements all fall within the scope of the claimed present application. The scope of protection of the present application is defined by the appended claims and their equivalents.

Claims

1. A floor slab thickness control device and process integrating protective layer pads, characterized in that, The device includes a disc-shaped pad, a U-shaped metal bracket, and a rigid plastic sleeve. The disc-shaped pad is prefabricated with cement mortar or fine aggregate concrete, supporting the bottom layer of reinforcing steel bars in the slab and forming a protective layer for the reinforcing steel bars. The U-shaped metal bracket is built into and fixed to the top surface of the pad, and is composed of a thin steel strip welded with two vertical reinforcing steel end rods. During installation, the thin steel strip is attached to the bottom surface of the bottom layer of reinforcing steel bars in the floor slab, and the vertical reinforcing steel end rods are located on both sides of the bottom layer of reinforcing steel bars in the floor slab to prevent displacement and ensure the stability of the protective layer thickness. The rigid plastic sleeve is tightly fitted onto the vertical reinforcing steel end rods, and its height plus the thickness of the pad is equal to the design thickness of the floor slab, used to control the floor slab thickness. The side wall of the sleeve has staggered openings for cement grout to fill the internal cavity and prevent holes in the floor slab.

2. The floor slab thickness control device and process for an integrated protective layer pad block according to claim 1, characterized in that, The disc-shaped pad is integrally cast with cement mortar or fine stone concrete and a U-shaped metal bracket. The pad has a diameter of 50-80mm and a thickness of 20-30mm, which is suitable for the thickness of the concrete cover of the floor slab reinforcement.

3. The floor slab thickness control device and process for an integrated protective layer pad block according to claim 1, characterized in that, The length of the thin steel strips of the U-shaped metal bracket is adapted to the diameter of the disc-shaped pad, and the bracket and the pad are prefabricated simultaneously; the vertical steel bar end rod is 3-6cm high, providing a firm support for the rigid plastic sleeve.

4. The floor slab thickness control device and process for an integrated protective layer pad block according to claim 1, characterized in that, The rigid plastic sleeve is tightly fitted onto the vertical end rod after the steel cage is tied. The staggered arrangement of the sleeve openings is set at 2-3cm intervals along the axial direction, with a hole diameter of 5-8mm. During concrete pouring, cement slurry fills the internal cavity to prevent holes in the floor slab.

5. The floor slab thickness control device and process for an integrated protective layer pad block according to claim 1, characterized in that, The sum of the height of the rigid plastic sleeve and the thickness of the disc-shaped pad is equal to the designed thickness of the floor slab. When pouring and finishing concrete, the height of the top surface of the sleeve is used to achieve precise control of the floor slab thickness.

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