An MF thermal insulation and sound insulation prefabricated concrete composite slab

Abstract

The present invention discloses an MF thermal insulation and sound insulation assembled concrete composite slab, which comprises an MF thermal insulation board, a precast truss reinforced concrete composite slab, and MF special fittings; the MF thermal insulation board comprises a plurality of small boards placed horizontally, and the plurality of small boards are connected by H-shaped steel channels. The MF thermal insulation board is arranged below the precast truss reinforced concrete composite slab, and self-tapping anchor bolts are vertically passed through the MF thermal insulation board from below to connect the bottom slab of the precast truss reinforced concrete composite slab, so as to solve the problems of thermal insulation, sound insulation and fire prevention of the precast composite slab. The MF thermal insulation board extends out of the bottom of the precast composite slab and enters the post-cast strip, avoiding secondary formwork for the post-cast strip, eliminating slurry leakage at the slab joints, and avoiding problems that affect the installation efficiency. At the same time, the connection strength and energy dissipation capacity after installation combine the advantages of ultra-high performance materials and precast technology, exert the material performance, and reduce the influence of manufacturing costs.

Description

Technical Field

[0001] The present invention belongs to the field of construction engineering, and in particular relates to an MF thermal insulation and sound insulation assembled concrete composite board. Background Art

[0002] With the rapid development of my country's construction industry, the country is actively promoting the transformation and upgrading of the construction industry. Prefabricated buildings have experienced rapid development due to their favorable economic, environmental, and social benefits. With the increasing demand for energy-saving and environmentally friendly buildings, the insulation technology of building structures is also being strengthened. In particular, floor insulation and sound insulation technology have experienced rapid development and have become an important building energy-saving technology in my country.

[0003] Green building and sponge city concepts are mandatory in major Chinese prefabricated concrete structure design codes. These require that insulation, fire protection, and sound insulation be incorporated into prefabricated component designs. Currently, in engineering practice, insulation and sound insulation technologies for building maintenance structures are limited to exterior wall systems, while prefabricated composite floor slabs, the most widespread and high-volume structures, still require secondary insulation and sound insulation.

[0004] The bottom reinforcement of the composite slab, along at least one direction, extends into the laminated layers of surrounding components to improve the connection and integrity of the precast composite slab to the structure. However, a large amount of steel reinforcement is often left in the surrounding components of the precast composite slab. The bottom reinforcement extending from the sides of the precast composite slab interferes with the surrounding components during installation, greatly increasing the difficulty of installing the bottom formwork for the post-cast strip of the precast composite slab, reducing construction efficiency and resulting in low utilization efficiency.

[0005] With advancements in building materials technology, MF (mineral wool) insulation board has seen significant development as a new material. MF insulation board, short for MF Insulated Non-Removable Formwork, is made primarily from slag wool and vitrified microspheres, with functional admixtures added and processed through a specialized process. It boasts exceptional properties such as ultra-high strength, high toughness, high impermeability, and high corrosion resistance, making it a promising foundational material for next-generation infrastructure. It serves as a permanent, non-removable formwork in the construction of cast-in-place concrete structures (post-cast joints). It is a multifunctional integrated building product that combines formwork, insulation, sound insulation, and fire protection. However, because composite slab post-cast joints utilize secondary formwork, on-site pouring is relatively rare. The initial cost of insulation, sound insulation, and fire protection in floor slabs is extremely high, making it less commonly used in prefabricated building structures.

[0006] Due to the inherent characteristics of MF insulation panels and the advantages of prefabricated concrete building structure formwork, combining the two can maximize their advantages while avoiding their associated disadvantages. The need to combine insulation and formwork for precast concrete composite slabs, thereby improving construction efficiency, can be effectively addressed by combining MF insulation panels with precast composite slabs. This invention was developed to meet this need. Summary of the Invention

[0007] To solve the above problems, the present invention discloses an MF thermal insulation and sound insulation prefabricated concrete composite slab. The MF thermal insulation board is used at the lower connection of the precast concrete composite slab and is glued to the precast composite slab through a special connector. The precast composite slab is connected to the building cast-in-place structure through its truss reinforcement, solving the problems of thermal insulation, sound insulation and fire protection of the precast composite slab. The MF thermal insulation board extends out of the bottom of the precast composite slab and enters the post-cast strip, avoiding the secondary formwork of the post-cast strip, eliminating the leakage of mortar from the slab joint, and avoiding the problem of affecting the installation efficiency. At the same time, the connection strength and energy dissipation capacity after installation combine the advantages of ultra-high performance materials and prefabrication technology, giving full play to the material performance and reducing the impact of manufacturing costs.

[0008] To achieve the above object, the technical solution of the present invention is as follows:

[0009] An MF thermal insulation and sound insulation prefabricated concrete composite slab, comprising an MF thermal insulation board, a precast truss reinforced concrete composite slab, and MF special fittings; the MF special fittings include an H-shaped steel and self-tapping anchor bolts. The MF thermal insulation board includes a number of small plates placed flat, and the small plates are connected by the H-shaped steel (the sides of the small plates are stuck in the grooves of the H-shaped steel). The MF thermal insulation board is arranged below the precast truss reinforced concrete composite slab, and the self-tapping anchor bolts vertically penetrate upward from below through the MF thermal insulation board to connect the bottom plate of the precast truss reinforced concrete composite slab.

[0010] The precast truss reinforced concrete composite slab refers to dividing the floor slab into two parts along the thickness direction. The bottom is a precast bottom plate, and the upper part is a post-cast concrete composite layer. The precast bottom plate with truss reinforcement at the bottom is used as a part of the floor slab and bears the load as a formwork for the post-cast concrete composite layer during the construction stage, forming an integral composite concrete member with the post-cast concrete layer.

[0011] The MF special fittings include an H-shaped steel and self-tapping anchor bolts, and also include corner grooves and dovetail nails. The H-shaped steel has elongated slots parallel to the length direction on one side and elongated slots parallel to the direction on the other side, and is inlaid at the corners for assembling with the MF thermal insulation board of another composite slab, which is used to improve the formwork operation of two adjacent composite slabs in the post-cast strip; the MF special fittings are installed on the front of the MF thermal insulation board through self-tapping anchor bolts passing through the MF thermal insulation board in the vertical direction for anchoring the FM thermal insulation board and the precast composite slab; the corner groove is used for the combination of the MF thermal insulation board and the composite slab at the floor slab drop position; the dovetail nail is used for the support and anchorage of the MF thermal insulation composite slab in the post-cast strip.

[0012] Preferably, the MF thermal insulation board has test reports such as thermal insulation, sound insulation, and fire protection, and its thickness is consistent with the reserved thickness of the precast concrete bottom plate. The batching size meets the requirements of the drawing of the precast composite slab.

[0013] Preferably, the MF special self-tapping anchor bolt can be set to a flat head; the anchoring length of the self-tapping anchor bolt must be arranged after the pull-out test is completed. One end is anchored into the MF board, and the other end is tied to the bottom distribution steel bars to further improve the bonding ability between the precast MF insulation board and ordinary concrete.

[0014] Preferably, the surface of the H-channel steel connector is coated with an anti-corrosion layer to improve durability; according to the on-site construction plan, it can also be installed after the precast concrete floor slab is hoisted into the building structure.

[0015] Preferably, the flatness of the bottom formwork of the precast truss reinforced concrete composite slab shall not be greater than 2 mm, and the thickness of the reserved MF insulation board shall be left around the side formwork to ensure sufficient support strength between the stacked layers during stacking and transportation.

[0016] A manufacturing and construction method of an MF insulation and sound insulation assembled concrete composite slab includes the following steps:

[0017] (1) First, purchase and prepare MF insulation boards. All test values meet the manufacturing quality of heat preservation, sound insulation, and fire prevention. The MF insulation boards are cut into several small boards according to the specifications of the precast truss reinforced concrete composite slab.

[0018] (2) According to the specifications of the precast truss reinforced concrete composite slab, configure the mold. Set the side formwork on the conventional precast composite slab table formwork. The thickness of the MF insulation board is increased by 20 mm at the bottom of the side formwork (20 mm + 60 mm), and 20 mm is embedded as the space for the concrete corner. Fix the side formwork to the other end side formwork at a certain interval through positioning bolts. The side formwork and the table formwork are fitted with a slurry stop strip to stop the slurry.

[0019] (3) Anchor the MF special self-tapping anchor bolt into the MF insulation small board. Before anchoring, lay out the lines and position. Drill the depth of the flat head of the anchor bolt at the bottom with a hand-held drill. After the MF special self-tapping anchor bolt is anchored, it does not exceed the bottom surface of the MF insulation board, so that the flat head of the anchor bolt is closely attached to the table formwork, avoiding protrusions on the flat head of the anchor bolt that cause gaps between the MF insulation small board and the table formwork, resulting in slurry leakage.

[0020] (4) Assemble and combine several MF insulation small boards using H-grooves according to the component drawing dimensions. After the combination of the MF insulation board and the composite slab is assembled, lay it flat in the mold. Bind the bottom steel bars of the composite slab on the MF insulation board combination, and then bind the truss steel bar mesh. Use binding wire to bind and fix the exposed thread part of the MF special self-tapping anchor bolt to the bottom steel bars to form a reliable whole.

[0021] (5) If there are embedded parts or reinforcement bars for hole reinforcement, check the drawings. After the concealed works acceptance is completed, pour concrete; vibrate automatically on the vibrating platform and perform surface roughening treatment.

[0022] (6) After final setting, it enters the curing kiln for steam curing.

[0023] The beneficial effects of the present invention are:

[0024] (1) The present invention increases the thermal insulation, sound insulation and fire prevention functions of the prefabricated truss reinforced concrete composite slab, eliminates the secondary special thermal insulation and sound insulation work, avoids the problem of poor adhesion between the thermal insulation board and the concrete during the installation process and the interference between the work types, improves the construction efficiency, reduces the labor cost, and is conducive to the promotion and application of prefabricated concrete structures.

[0025] (2) The present invention adopts MF special accessories, which are flexible to install and have adjustable errors, thus reducing the precision requirements for the manufacture of prefabricated composite panels and the installation of MF insulation panels, further reducing production costs and improving construction efficiency; and the MF special self-drilling anchor bolts are anchored in, thereby improving the seismic resistance and energy dissipation capacity.

[0026] (3) The present invention achieves a one-time combination of various functions in the factory through prefabrication technology, while solving the problems of low viscosity, poor precision, and difficult construction. The reduction in manufacturing costs is conducive to the promotion and application of MF insulation board materials.

[0027] (4) The present invention eliminates the problems of poor flatness and grout leakage of the post-casting strip by using the formwork function of the extended portion. The secondary formwork process of the post-casting strip is eliminated, which saves template construction costs and is conducive to the promotion and application of prefabricated concrete structures. BRIEF DESCRIPTION OF THE DRAWINGS

[0028] Figure 1 This is a three-dimensional side view of the MF thermal insulation, sound insulation and fireproof assembled concrete composite panel of the present invention;

[0029] Figure 2 This is a three-dimensional schematic diagram of the MF thermal insulation, sound insulation and fireproof assembled concrete composite panel of the present invention;

[0030] Figure 3 This is a top view of the assembly of the table mold and the side mold of the present invention;

[0031] Figure 4 This is a three-dimensional side view schematic diagram of the assembly of the post-casting strip bottom formwork of the present invention;

[0032] Figure 5 This is a three-dimensional top view schematic diagram of the assembly of the post-casting strip bottom formwork of the present invention;

[0033] Figure 6 This is a physical diagram of the MF special accessories of the present invention;

[0034] Figure 7 Schematic diagram of the self-drilling anchor bolts anchored into the MF insulation board according to the manufacturing and construction method of the present invention;

[0035] Figure 8Installation drawing of the self-tapping anchor bolt of the present invention;

[0036] Figure 9 MF insulation board of the manufacturing and construction method of the present invention is fixed by H-groove;

[0037] Figure 10 Binding truss steel bars of the manufacturing and construction method of the present invention;

[0038] Figure 11 Concrete pouring example diagram of the present invention;

[0039] Figure 12 Top surface finishing and roughening treatment diagram of the present invention;

[0040] Figure 13 Entity diagram of the component after forming of the present invention. Detailed implementation manners

[0041] The present invention will be further clarified below in conjunction with the accompanying drawings and specific implementation manners. It should be understood that the following specific implementation manners are only used to illustrate the present invention and not to limit the scope of the present invention. It should be noted that the words "front", "rear", "left", "right", "upper" and "lower" used in the following description refer to the directions in the drawings, and the words "inner" and "outer" respectively refer to the directions towards or away from the geometric center of a specific component.

[0042] As shown in the figure, for a kind of MF thermal insulation and sound insulation precast concrete composite slab of the present invention, in the factory, the MF insulation board is first cut and assembled, and then self-tapping anchor bolts are anchored from the reverse side. The spacing of the self-tapping anchor bolts is ≤500 mm; the depth extending into the concrete is ≥40 mm; the small MF insulation boards are assembled by H-channel steels, as Figure 9 shown; the drill bit is used to expand the hole at the position of the self-tapping anchor bolt at the bottom of the MF insulation board, and the flat head of the self-tapping anchor bolt is flush with the bottom surface, as Figure 8 shown.

[0043] According to the specifications and dimensions of the precast concrete bottom slab, side forms are set on the conventional precast composite slab table form, and the MF insulation board components are fixed close to the side forms at a certain interval, and the side forms are pasted with slurry-stop strips and release agent is applied.

[0044] After assembling the MF insulation board at their predetermined positions, the bottom steel bars of the composite slab are bound; the truss steel bars are installed; the protective layer pads are placed, as Figure 10 shown.

[0045] The side forms are fixed on the table form by magnetic boxes, and the positions of the side forms are adjusted back and forth. After reaching the appropriate positions, all the magnetic boxes are tightened, as Figure 11 shown.

[0046] After the concealed acceptance of the precast truss reinforced concrete composite slab is qualified, it is anchored into the concrete by self-tapping anchor bolts and poured together. When the concrete is in the initial setting stage, the top surface of the MF thermal insulation and sound insulation assembled concrete composite slab is finished and roughened, as Figure 12 shown.

[0047] The technical means disclosed in the solution of the present invention are not limited to the technical means disclosed in the above embodiments, but also include technical solutions composed of any combination of the above technical features.

Claims

1. A manufacturing and construction method of an MF thermal insulation and sound insulation precast concrete composite slab. The MF thermal insulation and sound insulation precast concrete composite slab includes an MF thermal insulation board, a precast truss reinforced concrete composite slab, and MF special fittings; the MF special fittings include H-shaped steel and self-tapping anchor bolts. The MF thermal insulation board includes a number of small plates placed flat, and the small plates are connected by H-shaped steel. The MF thermal insulation board is arranged below the precast truss reinforced concrete composite slab, and the self-tapping anchor bolts vertically penetrate upward through the MF thermal insulation board from below to connect the bottom plate of the precast truss reinforced concrete composite slab. It is characterized in that: The manufacturing and construction method includes the following steps: (1) First, purchase and prepare MF insulation boards, and cut them into small MF insulation boards according to the specifications and dimensions of precast truss reinforced concrete composite slabs; (2) Configure the mold according to the specifications and dimensions of precast truss reinforced concrete composite slabs. Set the side mold on the conventional precast composite slab table mold. Increase the thickness of the MF insulation board by 20 mm at the bottom of the side mold, and embed 20 mm as the space for the concrete corner. Fix the side mold tightly against the other end side mold at a certain interval through positioning bolts. The side mold and the table mold are fitted with a slurry stop strip to stop the slurry; (3) Anchor the MF special self-tapping anchor bolts into the small MF insulation boards. Before anchoring, lay out the lines and position. Drill the depth of the flat head of the anchor bolt at the bottom with a hand-held drill. After the MF special self-tapping anchor bolts are anchored, they do not protrude beyond the bottom surface of the MF insulation board, and the flat head of the anchor bolt is closely fitted with the table mold to avoid protrusions at the flat head of the anchor bolt, resulting in gaps between the small MF insulation boards and the table mold and causing slurry leakage; (4) Assemble and combine several small MF insulation boards according to the component drawing dimensions using H-shaped steel. After the combined body of the MF insulation board and the composite slab is assembled, lay it flat in the mold. Tie the bottom steel bars of the composite slab on the combined body, and then tie the truss steel bar mesh. Use binding wire to tie and fix the exposed thread part of the MF special self-tapping anchor bolts to the bottom steel bars to form a reliable whole; (5) If there are embedded parts or reinforcement bars for hole reinforcement, check the drawings. After the concealed works acceptance is completed, pour the concrete; vibrate automatically on the vibrating platform and perform surface roughening treatment; (6) After final setting, enter the curing kiln for steam curing to make MF insulation and sound insulation prefabricated concrete composite slabs.

2. The manufacturing and construction method of the MF thermal insulation and sound insulation assembled concrete composite slab according to claim 1, characterized in that: The precast truss reinforced concrete composite slab refers to dividing the floor slab into two parts along the thickness direction. The bottom is the precast bottom slab, and the upper part is the post-cast concrete composite layer.

3. The manufacturing and construction method of the MF thermal insulation and sound insulation prefabricated concrete composite slab according to claim 1, characterized in that: The MF special fittings include H-shaped steel and self-tapping anchor bolts, and also include corner grooves and dovetail nails; the H-shaped steel has long slotted holes parallel to the length direction on one side and long slotted holes parallel to the direction on the other side, and is inlaid at the corners for assembling with the MF insulation board of another composite slab, which is used to improve the formwork operation of two adjacent composite slabs at the post-cast strip; the self-tapping anchor bolts pass through the MF insulation board in the vertical direction and are installed on the front surface of the MF insulation board for anchoring the FM insulation board and the precast composite slab; the corner grooves are used for the combination of the MF insulation board and the composite slab at the floor slab drop position; the dovetail nails are used for the support and anchoring of the MF insulation composite slab post-cast strip.

4. The manufacturing and construction method of the MF thermal insulation and sound insulation precast concrete composite slab according to claim 1, characterized in that: The flatness of the bottom mold of the precast truss reinforced concrete composite slab ≤ 2 mm, and the thickness of the MF insulation board is reserved around the side mold.

5. The manufacturing and construction method of the MF thermal insulation and sound insulation precast concrete composite slab according to claim 2, characterized in that: The thickness of the MF insulation board is consistent with the reserved thickness of the precast bottom slab.

6. The manufacturing and construction method of the MF thermal insulation and sound insulation prefabricated concrete composite slab according to claim 1, characterized in that: The self-tapping anchor bolts are flat head bolts; one end of the self-tapping anchor bolts is anchored into the MF insulation board, and the other end is tied to the bottom distribution steel bars.

7. The manufacturing and construction method of the MF thermal insulation and sound insulation assembled concrete composite slab according to claim 1, characterized in that: The surface of the H-shaped steel connecting piece is plated with an anti-corrosion layer.

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