A hollow prefabricated part with a filling body embedded in the back

Abstract

The present invention relates to a hollow prefabricated component with a filler body embedded in the back and a manufacturing method thereof, and belongs to the field of general building construction. The prefabricated component comprises a main body (1) and a filler body (2), wherein the main body is provided with no less than 3 longitudinal ribs (4) and no less than 5 transverse ribs (5), wherein the net height of the longitudinal ribs and the transverse ribs is ≥40 mm, and after the concrete of the main body is hardened, the longitudinal ribs, the transverse ribs and the bottom plate (7) form a pit (6) for embedding the filler body, and the bottom plate is provided with bottom plate longitudinal ribs (8) and bottom plate transverse ribs (9). When the main body is formed, two longitudinal side molds (10), two transverse side molds (11), a top mold (12) and a bottom mold base (13) are also involved, wherein the top mold is composed of a top seat (14) and a core mold (15), and the core mold is fixed below the top seat. The prefabricated component of the present invention has a light weight, a large applicable span, and is easy to transport and install. The present invention has good economy and applicability, and promotes the development of construction technology.

Description

(I) Technical field

[0001] The invention relates to an assembled reinforced concrete hollow floor structure, in particular to a filling body rear embedded hollow prefabricated component and a manufacturing method thereof, belonging to the field of general building construction. (II) Background technology

[0002] Prefabricated buildings have the characteristics of high degree of factory production, fast construction speed and low overall cost. This type of structure is currently being vigorously promoted by the country.

[0003] For prefabricated floor slabs with a span of less than 5m, ordinary composite slabs can solve the problem; however, for floor slabs with a span of more than 5m, especially those with a span of more than 7m, if ordinary solid floor slabs are used, the structure will be heavy, have poor seismic performance, and have low comprehensive economic indicators. For floor slab structures, whether cast-in-place or composite structures, hollowing is a technical means to solve the problem of large spans.

[0004] In 2017, I proposed the technologies of "a wide hollow composite slab" (CN107254930A) and "a prestressed hollow composite slab" (CN107313539A), which overcome the defects of small width, heavy weight and unsuitability for two-way slabs of prefabricated parts. However, in the technologies of CN107254930A and CN107313539A, if the traditional cast-in-place hollow slab method is used to make prefabricated parts, the following defects exist: 1. The positioning and anti-floating process between the filling bodies is relatively complicated, resulting in low production efficiency; 2. The filling bodies are easily damaged during the production, transportation and hoisting of prefabricated parts; 3. Since the filling bodies are pre-installed, it is difficult to arrange pipelines during on-site construction. In addition, unlike the traditional composite slab where the top of the precast component is in full cross-section contact with the composite layer, the precast and cast-in-place concrete in the hollow composite slab are only in contact with the solid ribs between the filling bodies, and the contact area is small. If the bonding force between the new and old concrete is insufficient, the composite slab may produce splitting cracks along the contact surface in the horizontal direction, resulting in a decrease in the bearing capacity of the component.

[0005] In this case, developing a composite slab technology that overcomes the above-mentioned defects has become an urgent problem to be solved in the current prefabricated composite floor slabs. (III) Summary of the invention

[0006] In the existing prefabricated composite floor technology, there are the following problems: 1. The solid prefabricated parts have a small span, heavy weight and low rigidity; 2. The solid prefabricated components have a small width; 3. The hollow prefabricated parts have low production efficiency, the filling body is easily damaged, and the pipeline construction is difficult. The purpose of the present invention is to provide a hollow prefabricated part with a post-embedded filling body.

[0007] To achieve the above purpose, on the basis of the prior art, the technical solution adopted by the present invention is: a hollow prefabricated part with a post-embedded filling body, comprising a reinforced concrete body and a filling body to be embedded in the future, the body being a strip structure with a width ≥1800mm and ≤3500mm, a length ≥5000mm and ≤10000mm, and a height ≥100mm and ≤300mm, the body being provided with no less than 3 longitudinal ribs and no less than 5 transverse ribs, the net height of the longitudinal ribs and the transverse ribs being ≥40mm, after the body concrete hardens, the longitudinal ribs, the transverse ribs and the bottom plate form a pit for embedding the filling body, the bottom plate is provided with bottom plate longitudinal reinforcement and bottom plate transverse reinforcement, the bottom plate longitudinal reinforcement extends from the bottom plate concrete by a length ≥50mm, and the body is formed by 2 longitudinal side molds, 2 transverse side molds, a top mold and a bottom mold base, the top mold is composed of a top seat and a core mold, the core mold is fixed below the top seat, and the bottom shape of the core mold is adapted to the bottom shape of the filling body.

[0008] The length, width and height of the main body are limited to the scope that the existing hoisting equipment can be used for large-span structures while controlling the weight of prefabricated parts. The main body is provided with no less than 3 longitudinal ribs and no less than 5 transverse ribs to ensure the hollowness of the main body and make the composite board to be formed in the future more evenly stressed. The net height of the longitudinal ribs and transverse ribs refers to the height difference between the top of the longitudinal ribs and transverse ribs and the lowest point of the top of the bottom plate. The requirement of a net height of ≥40mm is to make the ribs as high as possible and improve the longitudinal and transverse stiffness of the main body. The longitudinal ribs, transverse ribs and bottom plate form a pit, which can be embedded in the filling body after the pipeline is constructed. The technical solution of embedding the filling body after the filling body is embedded can avoid the phenomenon of the filling body being damaged during the production, transportation and hoisting of the prefabricated parts. During on-site construction, the pipelines and lamp holders that need to be embedded in the composite board can be installed in the thinnest concrete area under the filling body to reduce the workload of concrete cutting and opening holes; when the pipelines and the like conflict with the position of the filling body, corresponding treatment is performed on the filling body that is easy to cut and drill, which can facilitate the construction of the pipeline. The length of the bottom plate longitudinal reinforcement extending from the bottom plate concrete is ≥50mm to ensure that the bottom plate longitudinal reinforcement has a basic anchoring length when it extends into the support. The top formwork is composed of a top seat and a core formwork. During the main body support process, the deadweight of the top seat can resist the buoyancy generated during the concrete pouring process; the core formwork is fixed under the top seat, so there is no need to take additional measures to solve the positioning problem between the filling bodies. The top seat can be a frame erected vertically and horizontally, or a base formed by a whole steel plate or other integral means; in order to shorten the demoulding time, when the main body is pressed and formed by dry hard concrete, the top seat is particularly required to have higher strength and greater rigidity. The shape of the bottom of the core formwork is adapted to the shape of the bottom of the filling body. The shape of the bottom of the core formwork can be completely consistent with the shape of the bottom of the filling body, or it can be inconsistent, but at least the size of the filling body shall not be larger than the corresponding size of the bottom of the core formwork.

[0009] The invention is characterized in that the top seat is composed of longitudinal beams and transverse beams. The frame structure composed of longitudinal beams and transverse beams can solve the problem of core mold positioning, facilitate concrete pouring, and has low production cost.

[0010] The invention is characterized in that the longitudinal side mold, the transverse side mold and the top mold are combined into one body. Various molds are combined into one body, which solves the problem of positioning and calibration between different molds in factory production and improves construction efficiency.

[0011] The invention is characterized in that the transverse side formwork has notches at positions corresponding to the longitudinal reinforcements of the bottom plate. The purpose of providing the notches is to allow the reinforcements to extend from the formwork.

[0012] The present invention is characterized in that a metal tie bracket is embedded in at least two longitudinal ribs in the body, each tie bracket is composed of a horizontal rod and a plurality of herringbone legs, the top height of the horizontal rod exceeds the top of the longitudinal rib by ≥20mm, and the lower part of the legs is anchored in the concrete of the longitudinal rib. In the verification test of CN107254930A and CN107313539A, I found that when two prefabricated parts are spliced, the closer to the joint area, the more likely horizontal splitting cracks will appear between the prefabricated parts and the superimposed layer. Therefore, the solid ribs near the joint area are weak parts, and special measures should be taken to strengthen the tie. The lower part of the leg is anchored in the prefabricated part, and the upper part is anchored in the post-cast superimposed layer of the composite slab. The main function of the leg is to strengthen the tie between the new and old concrete to prevent the occurrence of splitting cracks. After the concrete at the bottom of the herringbone leg hardens, the herringbone structure has triangular stability. The leg extending out of the prefabricated part is combined with the horizontal rod to form a space frame structure, which not only enhances the rigidity of the prefabricated part, but also forms multiple hanging points of linear divisions on the horizontal rod, which is convenient for the hoisting and transportation of the prefabricated part. Multiple triangular legs allow the horizontal rod to withstand greater vertical forces and realize the stacking and transportation of multiple prefabricated parts. The height of the top of the horizontal rod exceeds the top of the longitudinal rib by ≥20mm, which can effectively increase the longitudinal rigidity of the body. During on-site construction, the upper steel bars of the composite slab can be placed on the tie bracket and then tied. The tie bracket also plays the role of a stirrup or a reinforcement bar, which can save related material costs and production costs.

[0013] The present invention is characterized in that a tie bracket is embedded in part of the transverse ribs in the body, and a tie steel bar is embedded in part of the longitudinal ribs or transverse ribs, and the embedding depth and exposed length of the tie steel bar in the body concrete are both ≥30mm. Although the tie effect of the tie bracket embedded in part of the transverse ribs in the body is not as good as that of the longitudinal ribs, when the width of the prefabricated part exceeds 2500mm, the protection effect on the filling body and the effect of realizing the stacking and transportation of multiple prefabricated parts are still relatively significant. Another technical problem that the present invention needs to solve is the splitting phenomenon caused by insufficient tie force between the hollow prefabricated part and the laminated layer concrete. Embedding the tie bracket in the longitudinal rib can solve this problem, but the cost of the tie bracket is relatively high and the installation is slightly complicated. After configuring a part of the tie bracket and solving the problems of hoisting, transportation and protection of the prefabricated part and the filling body, in order to further improve the anti-splitting ability, embedding the tie steel bar to prevent horizontal shear damage is a cheap, simple and efficient technical solution. The steel bar only plays a pin role, so whether it is embedded or exposed, it does not need to be too long, as long as it is ≥30mm.

[0014] The invention is characterized in that there is a vertical slurry leakage hole in the middle of the core mold, the upper end of the slurry leakage hole is a funnel shape with a large upper part and a small lower part, and the lower end is an inverted funnel shape with a small upper part and a large lower part. The vertical slurry leakage hole is provided in the core mold, and an additional concrete pouring channel is provided. The upper funnel greatly accelerates the speed of concrete flowing into the slurry leakage hole; and the lower funnel can ensure that the coarse aggregate in the concrete can flow to the lower part of the core mold quickly and unimpeded, ensuring that the concrete is poured densely.

[0015] The invention is characterized in that all or part of the bottom plate longitudinal reinforcement in the body is high-strength prestressed reinforcement. The use of prestressed reinforcement can not only reduce the amount of steel bars and the cost of prefabricated parts, but also improve the crack resistance of the composite plate during normal use, making the structure more durable.

[0016] The present invention is characterized in that the longitudinal side mold and the transverse side mold are made of wood, hard plastic or metal, the longitudinal beam and the transverse beam are made of, but not limited to, square steel, angle steel, channel steel or I-beam, and the core mold is made of hard plastic, metal plate or concrete.

[0017] The invention discloses a method for manufacturing a hollow prefabricated part with a filler body embedded therein. The hollow prefabricated part comprises a reinforced concrete body and a filler body to be embedded therein in the future. The body is a strip structure with a width of ≥1800 mm and ≤3500 mm, a length of ≥5000 mm and ≤10000 mm, and a height of ≥100 mm and ≤300 mm. The body is provided with no less than 3 longitudinal ribs and no less than 5 transverse ribs, and the net height between the longitudinal ribs and the transverse ribs is ≥40 mm. After the body concrete is hardened, the longitudinal ribs, the transverse ribs and the bottom plate form a pit for embedding the filler body. The bottom plate is provided with bottom plate longitudinal reinforcements and bottom plate transverse reinforcements, and the bottom plate longitudinal reinforcements extend out of the bottom plate concrete by a length of ≥50 mm. When the body is formed, two longitudinal side molds, two transverse side molds, a top mold and a bottom mold base are also involved. The top mold is composed of a top seat and a core mold. The core mold is fixed below the top seat, and the bottom shape of the core mold is adapted to the bottom shape of the filler body.

[0018] After adopting the above scheme, the present invention has the following beneficial effects compared with the prior art:

[0019] The present invention firstly overcomes the shortcomings of traditional solid composite slabs, such as small applicable span and heavy self-weight of prefabricated parts. Compared with the prior arts such as CN107254930A and CN107313539A, the present invention has obvious effects and solves the problems of low production efficiency of hollow prefabricated parts, easy damage of filling bodies, difficulty in pipeline construction, and the more likely horizontal splitting cracks to appear between hollow composite slab prefabricated parts and composite layers. In addition: 1. The tie bracket increases the rigidity of the prefabricated parts and facilitates the transportation of the components; 2. Multiple lifting points of linear divisions are formed on the horizontal rods of the tie bracket, which is convenient for the lifting of the prefabricated parts; 3. The tie bracket can be used as the erection reinforcement of the upper steel bars in the later construction, which can save relevant manpower and material resources.

[0020] The hollow prefabricated member with a filling body embedded in the back of the present invention has a light weight, a fast production speed, good bonding between the prefabrication and the laminated layer concrete, a large applicable span, can be applied to a two-way slab, and is easy to transport and install. The present invention has good economy and applicability, and promotes the development of construction technology. (IV) Description of the drawings

[0021] The present invention is further described below in conjunction with the accompanying drawings.

[0022] Figure 1 It is a plan view of the prefabricated part of the present invention when it is made

[0023] Figure 2 This is a schematic diagram of the present invention in which the filler is embedded in the main body to form a prefabricated part.

[0024] Figure 3 Schematic diagram of the tie bracket structure

[0025] Figure 4 yes Figure 1 AA profile in

[0026] Figure 5 yes Figure 1 Left side view

[0027] Figure 6 This is a schematic diagram of the vertical section structure of the core mold.

[0028] Figure 7 This is the bottom view of the core mold

[0029] In the figure: 1. body, 2. filling body, 3. concrete, 4. longitudinal ribs, 5. transverse ribs, 6. pits, 7. bottom plate, 8. bottom plate longitudinal reinforcement, 9. bottom plate transverse reinforcement, 10. longitudinal side formwork, 11. transverse side formwork, 12. top formwork, 13. bottom formwork base, 14. top seat, 15. core formwork, 16. longitudinal beam, 17. transverse beam, 18. notch, 19. anchor bracket, 20. horizontal rod, 21. leg, 22. anchor steel bar, 23. leakage hole, 24. prestressed tendon. (V) Specific implementation methods

[0030] The present invention is implemented in the following manner:

[0031] exist Figure 1 , Figure 2 , Figure 4 , Figure 5 In the illustrated embodiment, a hollow prefabricated part with a post-embedded filling body comprises a main body 1 of reinforced concrete and a filling body 2 to be embedded in the future. The main body is a strip structure with a width of ≥1800mm and ≤3500mm, a length of ≥5000mm and ≤10000mm, and a height of ≥100mm and ≤300mm. The main body is provided with no less than 3 longitudinal ribs 5 and no less than 5 transverse ribs 5, and the net height of the longitudinal ribs and the transverse ribs is ≥40mm. After the main body concrete hardens, the longitudinal ribs, the transverse ribs and the bottom plate 7 form a pit 6 for embedding the filling body. The bottom plate is provided with bottom plate longitudinal reinforcement 8 and bottom plate transverse reinforcement 9, and the bottom plate longitudinal reinforcement extends from the bottom plate concrete by a length of ≥50mm. When the main body is formed, two longitudinal side molds 10, two transverse side molds 11, a top mold 12 and a bottom mold base 13 are also involved. The top mold is composed of a top seat 14 and a core mold 15. The core mold is fixed below the top seat, and the bottom shape of the core mold is adapted to the bottom shape of the filling body.

[0032] exist Figure 1 , Figure 4 , Figure 5 In the illustrated embodiment, the top seat 14 is composed of a longitudinal beam 16 and a transverse beam 17 .

[0033] exist Figure 1 , Figure 4 , Figure 5 In the illustrated embodiment, the longitudinal side mould 10, the transverse side mould 11 and the top mould 12 are combined into one body.

[0034] exist Figure 1 , Figure 5 In the illustrated embodiment, the transverse side form 11 has a notch 18 at a position corresponding to the bottom plate longitudinal rib 8 .

[0035] exist Figure 1-Figure 5 In the illustrated embodiment, a metal anchor bracket 19 is embedded in at least two longitudinal ribs 4 in the main body 1. Each anchor bracket is composed of a horizontal rod 20 and a plurality of herringbone legs 21. The top of the horizontal rod is ≥20 mm higher than the top of the longitudinal rib, and the lower part of the leg is anchored in the concrete of the longitudinal rib.

[0036] exist Figure 1-Figure 5 In the illustrated embodiment, the tie brackets 19 are embedded in part of the transverse ribs 5 in the body 1, and the tie steel bars 22 are embedded in part of the longitudinal ribs or transverse ribs. The embedding depth and exposed length of the tie steel bars in the body concrete are both ≥30 mm.

[0037] exist Figure 1 , Figure 4-Figure 7 In the illustrated embodiment, a vertical slurry leakage hole 23 is provided in the middle of the core mold 15. The upper end of the slurry leakage hole is in the shape of a funnel with a larger upper portion and a smaller lower portion, while the lower end is in the shape of an inverted funnel with a smaller upper portion and a larger lower portion.

[0038] exist Figure 1 , Figure 2 , Figure 4 , Figure 5 In the illustrated embodiment, all or part of the bottom plate longitudinal reinforcement 8 in the body 1 is a high-strength prestressed reinforcement 24 .

[0039] exist Figure 1-Figure 7 In the illustrated embodiment, the longitudinal side mold 10 and the transverse side mold 11 are made of wood, hard plastic or metal, the longitudinal beam 16 and the transverse beam 17 are made of, including but not limited to, square steel, angle steel, channel steel or I-beam, and the core mold 15 is made of hard plastic, metal plate or concrete.

[0040] exist Figure 1 , Figure 2 , Figure 4 , Figure 5In the illustrated embodiment, a method for manufacturing a hollow prefabricated component with a filler body embedded therein is as follows: the prefabricated component includes a main body 1 of reinforced concrete and a filler body 2 to be embedded therein in the future, the main body being a strip structure with a width of ≥1800mm and ≤3500mm, a length of ≥5000mm and ≤10000mm, and a height of ≥100mm and ≤300mm, the main body being provided with no less than 3 longitudinal ribs 5 and no less than 5 transverse ribs 5, the net height of the longitudinal ribs and the transverse ribs being ≥40mm, the longitudinal ribs, the transverse ribs and the bottom plate 7 forming a pit 6 for embedding the filler body after the main body concrete hardens, the bottom plate being provided with bottom plate longitudinal ribs 8 and bottom plate transverse ribs 9, the bottom plate longitudinal ribs extending from the bottom plate concrete by a length of ≥50mm, and the main body being formed by 2 longitudinal side molds 10, 2 transverse side molds 11, a top mold 12 and a bottom mold base 13, the top mold being composed of a top seat 14 and a core mold 15, the core mold being fixed below the top seat, and the bottom shape of the core mold being adapted to the bottom shape of the filler body.

Claims

1. A hollow prefabricated part with a filler body embedded therein, comprising a reinforced concrete body (1) and a filler body (2) to be embedded therein, characterized in that The main body is a strip structure with a width of ≥1800mm and ≤3500mm, a length of ≥5000mm and ≤10000mm, and a height of ≥100mm and ≤300mm. The main body is provided with no less than 3 longitudinal ribs (4) and no less than 5 transverse ribs (5). The net height of the longitudinal ribs and the transverse ribs is ≥40mm. After the concrete of the main body is hardened, the longitudinal ribs, the transverse ribs and the bottom plate (7) form a pit (6) for embedding the filling body. The bottom plate is provided with bottom plate longitudinal ribs (8) and bottom plate transverse ribs (9). The bottom plate longitudinal ribs extend out of the bottom plate concrete by a length of ≥50mm. When the main body is formed, two longitudinal side molds (10), two transverse side molds (11), a top mold (12) and a bottom mold base (13) are also involved. The top mold is composed of a top seat (14) and a core mold (15). The core mold is fixed below the top seat. The bottom shape of the core mold is adapted to the bottom shape of the filling body.

2. A hollow prefabricated component with a filling body embedded in the back according to claim 1, characterized in that The top seat (14) is composed of a longitudinal beam (16) and a transverse beam (17).

3. The hollow prefabricated component with a filling body embedded in the back according to claim 1, characterized in that The longitudinal side mold (10), the transverse side mold (11) and the top mold (12) are combined into one body.

4. The hollow prefabricated component with a filler body embedded in the back according to claim 1, characterized in that The transverse side mold (11) is provided with a notch (18) at a position corresponding to the bottom plate longitudinal reinforcement (8).

5. The hollow prefabricated component with a filler body embedded in the back according to claim 1, characterized in that Anchor brackets (19) made of metal are embedded in at least two longitudinal ribs (4) in the body (1). Each anchor bracket is composed of a horizontal rod (20) and a plurality of herringbone legs (21). The top of the horizontal rod is ≥20 mm higher than the top of the longitudinal rib, and the lower part of the leg is anchored in the concrete of the longitudinal rib.

6. The hollow prefabricated component with a filler body embedded in the back according to claim 1, characterized in that Anchor brackets (19) are pre-embedded in some transverse ribs (5) in the body (1), and anchor steel bars (22) are pre-embedded in some longitudinal ribs or transverse ribs. The embedding depth and exposed length of the anchor steel bars in the body concrete are both ≥30 mm.

7. The hollow prefabricated component with a filler body embedded in the back according to claim 1, characterized in that A vertical slurry leakage hole (23) is provided in the middle of the core mold (15), the upper end of the slurry leakage hole is a funnel shape with a large top and a small bottom, and the lower end is an inverted funnel shape with a small top and a large bottom.

8. The hollow prefabricated component with a filler body embedded in the back according to claim 1, characterized in that All or part of the bottom plate longitudinal reinforcement (8) in the main body (1) are high-strength prestressed reinforcement (24).

9. The hollow prefabricated component with a filler body embedded in the back according to claim 2, characterized in that The longitudinal side mold (10) and the transverse side mold (11) are made of wood, hard plastic or metal, the longitudinal beam (16) and the transverse beam (17) are made of, but not limited to, square steel, angle steel, channel steel or I-beam, and the core mold (15) is made of hard plastic, metal plate or concrete.

10. The method for manufacturing a hollow prefabricated component with a filler embedded therein according to claim 1, characterized in that The prefabricated part comprises a reinforced concrete body (1) and a filler body (2) to be embedded in the future, characterized in that the body is a strip structure with a width of ≥1800mm and ≤3500mm, a length of ≥5000mm and ≤10000mm, and a height of ≥100mm and ≤300mm. The body is provided with no less than 3 longitudinal ribs (4) and no less than 5 transverse ribs (5), and the net height between the longitudinal ribs and the transverse ribs is ≥40mm. After the concrete of the body is hardened, the longitudinal ribs, the transverse ribs and the bottom plate are connected. (7) forming a recess (6) for embedding the filling body, the bottom plate is provided with bottom plate longitudinal reinforcement (8) and bottom plate transverse reinforcement (9), the bottom plate longitudinal reinforcement protruding from the bottom plate concrete by a length of ≥50 mm, and the main body is also formed by two longitudinal side molds (10), two transverse side molds (11), a top mold (12) and a bottom mold base (13), the top mold is composed of a top seat (14) and a core mold (15), the core mold is fixed below the top seat, and the bottom shape of the core mold is adapted to the bottom shape of the filling body.

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