Composite integral assembled floor and preparation method thereof

Abstract

The present invention relates to a composite integral assembled floor and a preparation method thereof. The preparation method comprises the following steps: laying a surface layer in a mold, and applying slurry to the surface of the surface layer; pouring medium aggregate concrete, and placing steel bars in both directions, pouring coarse aggregate concrete; pouring fine aggregate concrete, and placing steel bars in both directions; steam curing; demolding, and obtaining the floor. The floor comprises a surface layer, a bonding layer, a medium-grained concrete layer, a coarse-grained concrete layer, and a fine-grained concrete layer arranged in sequence from top to bottom, wherein the thickness of the coarse-grained concrete layer is greater than the thickness of the medium-grained concrete layer, and the thickness of the medium-grained concrete layer is greater than the thickness of the fine-grained concrete layer. In this way, not only the connection strength of the composite integral assembled floor with high flatness and good firmness is quickly produced, but also the labor intensity of workers at the construction site is greatly reduced, and the common quality problems such as poor bottom flatness, hollowing of the fabric, and water accumulation on the reverse slope are completely eliminated, and the construction efficiency is improved.

Description

Technical Field

[0001] The invention belongs to the field of building materials, and in particular relates to a composite integral assembled floor and a preparation method thereof. Background Art

[0002] The traditional method of ground block construction is generally to pour the base concrete on the finished subbase, then make a leveling layer, and then lay the ground blocks. This traditional operation construction method has a long construction cycle, high labor intensity and high consumption, especially the flatness and firmness (hollowness) of the block surface when sticking the block to the base is greatly affected by human operation. It is urgent to propose a solution to solve the problem that the flatness and firmness of the ground blocks are difficult to guarantee and the workers have to work on site for a long time. Summary of the invention

[0003] The purpose of the present invention is to provide a composite integral assembled floor and a preparation method thereof, so as to solve the problems in the prior art that the flatness and firmness of floor blocks are difficult to ensure and the workers have to work on site for a long time.

[0004] In order to achieve the above object, the present invention adopts the following technical solutions:

[0005] A method for preparing a composite integral assembled floor comprises the following steps:

[0006] Lay the surface layer in the mold and spread the slurry on the surface of the surface layer;

[0007] Pour medium aggregate concrete, place steel bars in both directions, and pour coarse aggregate concrete;

[0008] Pour fine aggregate concrete and place steel bars in both directions;

[0009] Steam curing;

[0010] After removing the mold, the floor is obtained.

[0011] In a possible design, the strength grade of the medium aggregate concrete is C30 or C35; the strength grade of the coarse aggregate concrete is C20 or C25; and the strength grade of the fine aggregate concrete is C30 or C35.

[0012] In a possible design, the particle size of the medium aggregate in the medium aggregate concrete is 1 to 1.3 cm; the particle size of the coarse aggregate in the coarse aggregate concrete is 2 to 4 cm; and the particle size of the fine aggregate in the fine aggregate concrete is 0.5 to 1.0 cm.

[0013] In a possible design, the pouring thickness of the medium aggregate concrete is 8 to 12 cm; the pouring thickness of the coarse aggregate concrete is 12 to 16 cm; and the pouring thickness of the fine aggregate concrete is 5 to 8 cm.

[0014] In a possible design, the steel bar is a hot-rolled ribbed steel bar.

[0015] In a possible design, the steam curing time is 44 to 52 hours.

[0016] A composite integral assembled floor comprises a surface layer, a bonding layer, a medium-grained concrete layer, a coarse-grained concrete layer and a fine-grained concrete layer which are arranged in sequence from top to bottom, wherein the thickness of the coarse-grained concrete layer is greater than that of the medium-grained concrete layer, and the thickness of the medium-grained concrete layer is greater than that of the fine-grained concrete layer.

[0017] In a possible design, the pouring thickness of the medium-grained concrete layer is 8 to 12 cm; the pouring thickness of the coarse-grained concrete layer is 12 to 16 cm; and the pouring thickness of the fine-grained concrete layer is 5 to 8 cm.

[0018] In a possible design, the medium-grained concrete layer is formed by mixing medium aggregate and concrete, wherein the particle size of the medium aggregate is 1 to 1.3 cm; the coarse-grained concrete layer is formed by mixing coarse aggregate and concrete, wherein the particle size of the coarse aggregate is 2 to 4 cm; the fine-grained concrete layer is formed by mixing fine aggregate and concrete, wherein the particle size of the fine aggregate is 0.5 to 1.0 cm.

[0019] In a possible design, steel bars are laid in the medium-grained concrete layer; and steel bars are laid in the fine-grained concrete layer. The provision of steel bars ensures the overall strength of the composite integral assembled floor, and reduces the damage caused by collision, knock, vibration and handling during storage, transportation and construction.

[0020] In a possible design, a floor panel is provided with a groove at one end and a flange at the other end, so that when a plurality of floor panels are connected, the flange of one floor panel can be inserted into the groove of an adjacent floor panel.

[0021] In a possible design, when multiple floors are connected, water stop strips are provided in the gaps between adjacent floors. The water stop strips can expand to fill the gaps when encountering water, thereby preventing rainwater from penetrating into the floor substrate through the gaps.

[0022] In a possible design, the surface layer is a stone slab, a tile, a composite board or a wooden board.

[0023] In one possible design, the slurry is a high-strength adhesive.

[0024] Beneficial effects: Through the above technical solution, since the fabric (stone, ceramic tile, etc.) is placed in the steel formwork, the flatness of the first layer, i.e. the surface layer, is effectively guaranteed. The slurry of the second bonding layer is selected from the mixture that has been adapted many times in the laboratory. Due to the large overall compressive strength, the pull-out strength is greatly improved after combining with the surface layer (first layer), and the anti-rolling performance is much better than the ground with the traditional construction method. The setting of the medium-grained concrete layer, the coarse-grained concrete layer and the fine-grained concrete layer can further enhance the strength and waterproofness of the floor.

[0025] The floor made in this way has high production efficiency, short production cycle, strong controllability, strong plasticity, wide application, can meet the choice of surface materials for different users, and the total thickness of the floor is adjustable. Under the condition of the same materials, the floor can improve the quality, appearance and durability of the floor with less material consumption. At the same time, it also greatly reduces the manual operation steps and time on the construction site. For example, there will be no temporary processing of the leftover materials at the corners of the stone, so there will be no noise and dust. It not only reduces the waste of on-site construction materials, but also avoids the pollution of dust to the air, which is in line with the current modern production concept of energy saving and environmental protection.

[0026] Other features and advantages of the present invention will be described in detail in the following detailed description. BRIEF DESCRIPTION OF THE DRAWINGS

[0027] The accompanying drawings are used to provide a further understanding of the present invention and constitute a part of the specification. Together with the following specific embodiments, they are used to explain the present invention but do not constitute a limitation of the present invention. In the accompanying drawings:

[0028] Figure 1 is a top view of a composite integral assembled floor in one embodiment;

[0029] Figure 2 is a front view of a composite integral assembled floor in one embodiment;

[0030] Figure 3 is a cross-sectional view of a composite integral assembled floor in one embodiment;

[0031] Figure 4 It is a cross-sectional view of a composite integral assembled floor in one embodiment.

[0032] Description of Reference Numerals

[0033] 1-surface layer, 2-bonding layer, 3-medium-grained concrete layer, 4-coarse-grained concrete layer, 5-fine-grained concrete layer, 6-groove, 7-flange. DETAILED DESCRIPTION

[0034] The specific implementation of the present invention is described in detail below in conjunction with the accompanying drawings. It should be understood that the specific implementation described here is only used to illustrate and explain the present invention, and is not used to limit the present invention.

[0035] According to the first aspect of the present disclosure, a method for preparing a composite integral assembled floor is provided, which can prepare a floor with high strength, good flatness and reliable quality, so that workers can greatly reduce labor intensity and shorten working time when laying the floor, thereby improving overall construction efficiency. The preparation method of the floor will be described below in combination with figures and texts.

[0036] The preparation method comprises the following steps: laying the surface layer 1 in a mold and applying slurry to the surface of the surface layer 1; pouring medium aggregate concrete and placing steel bars in both directions, pouring coarse aggregate concrete; pouring fine aggregate concrete and placing steel bars in both directions; steam curing; and demolding to obtain the floor.

[0037] Through the above scheme, the flatness of the surface layer 1 can be ensured by the base surface of the mold, so that the slurry can be evenly applied to the surface layer of the surface layer 1, the slurry can be evenly dried, and the connection strength and barrier effect can be improved. After that, when pouring the medium aggregate concrete, it is beneficial to make the medium aggregate concrete fully contact and bond with the bonding layer 2 formed after the slurry solidifies, and the laid steel bars can improve the connection strength. After that, pouring the coarse aggregate concrete is beneficial to make it better bond with the steel bars and the medium aggregate concrete, so as to effectively transfer the built-in high-strength prestress and disperse the ground pressure, that is, improve the bending strength and compressive strength. The fine aggregate concrete can play a better barrier role, that is, prevent water from infiltration, and the laying of steel bars can effectively transfer and disperse the built-in high-strength prestress, while blocking groundwater erosion and improving the freeze-thaw resistance of the overall floor. Through steam curing, the composite integral assembled floor can be completely solidified, and the connection strength and waterproofness between different layers can be improved.

[0038] The floor made by the above scheme has high production efficiency, short production cycle, strong controllability, strong plasticity, wide application, can meet the selection of materials for the surface layer 1 by different users, and the total thickness of the floor is adjustable. Under the condition of the same materials, the floor can improve the quality, appearance and durability of the floor with less material consumption. At the same time, it also greatly reduces the manual operation steps and time at the construction site. For example, the residual materials at the corners of the stone will not be temporarily processed, so there will be no noise and dust. It not only reduces the waste of construction materials on site, but also avoids the pollution of dust to the air, which is in line with the current modern production concept of assembly of building products and energy saving and environmental protection.

[0039] On the basis of the above scheme, as an option, the strength grade of the medium aggregate concrete can be configured as C30; the strength grade of the coarse aggregate concrete can be configured as C25; and the strength grade of the fine aggregate concrete can be configured as C35.

[0040] As another option, the strength grade of the medium aggregate concrete can be configured as C35; the strength grade of the coarse aggregate concrete can be configured as C20; and the strength grade of the fine aggregate concrete can be configured as C30. Such a composite integral assembled floor has high strength and good waterproofness, and is suitable for installation in some outdoor occasions.

[0041] As another option, the strength grade of the medium aggregate concrete can be configured as C35; the strength grade of the coarse aggregate concrete can be configured as C25; and the strength grade of the fine aggregate concrete can be configured as C35.

[0042] As another option, the strength grade of the medium aggregate concrete can be configured as C30; the strength grade of the coarse aggregate concrete can be configured as C20; and the strength grade of the fine aggregate concrete can be configured as C30.

[0043] In this regard, those skilled in the art can flexibly configure according to the actual application environment and occasions, and the present disclosure is only presented here for illustrative purposes.

[0044] In one embodiment provided in the present disclosure, the particle size of the medium aggregate in the medium aggregate concrete is 1 to 1.3 cm. Specifically, the medium aggregate with a relatively uniform particle size can be configured, for example, the medium aggregate with a particle size of 1 cm, 1.2 cm or 1.3 cm. Of course, the medium aggregate with a mixed particle size within the above range can also be configured, which can be determined according to the construction requirements and economic budget.

[0045] In one embodiment provided in the present disclosure, the particle size of the coarse aggregate in the coarse aggregate concrete is 2 to 4 cm. Specifically, coarse aggregate with a relatively uniform particle size can be configured, for example, a medium aggregate with a particle size of 2 cm, 3 cm or 4 cm. Of course, mixed particle size coarse aggregate within the above range can also be configured, which can be determined according to construction requirements and economic budget.

[0046] In one embodiment provided in the present disclosure, the particle size of the fine aggregate in the fine aggregate concrete is 0.5 to 1.0 cm. Specifically, fine aggregate with a relatively uniform particle size can be configured, for example, fine aggregate with a particle size of 0.5 cm, 0.8 cm or 1 cm. Of course, mixed particle size fine aggregate within the above range can also be configured, which can be determined according to construction requirements and economic budget.

[0047] In one embodiment provided in the present disclosure, the pouring thickness of the medium aggregate concrete is 8 to 12 cm. Specifically, the medium aggregate concrete can be configured with any suitable pouring thickness such as 8 cm, 10 cm, 12 cm, etc. In this regard, it can be determined according to the application environment. In one embodiment, the pouring thickness of the coarse aggregate concrete is 12 to 16 cm. Specifically, the coarse aggregate concrete can be configured with any suitable pouring thickness such as 12 cm, 14 cm, 16 cm, etc. In this regard, it can be flexibly selected according to the application environment. In one embodiment, the pouring thickness of the fine aggregate concrete is 5 cm to 8 cm. Specifically, the fine aggregate concrete can be configured with any suitable pouring thickness such as 5 cm, 6 cm, 8 cm, etc. In this regard, it can be determined according to the waterproof requirements and the geographical environment, and is only shown as an example here.

[0048] In one embodiment of the present disclosure, the steel bar is a hot-rolled ribbed steel bar. Specifically, it is a steel bar with a strength of HRB400. The hot-rolled ribbed steel bar has longitudinal ribs and transverse ribs on its surface, usually with two longitudinal ribs and transverse ribs evenly distributed along the length direction. Therefore, it can be well combined with medium aggregate concrete, coarse aggregate concrete and fine aggregate concrete.

[0049] In the present disclosure, the steam curing time is 44 to 52 hours. This is beneficial to help the concrete solidify and improve the connection strength. After that, the mold can be hoisted out, the product quality can be inspected, the product can be put into storage, and then put into the construction site according to demand.

[0050] For example, it can be steam curing for 44 hours or 52 hours. Generally speaking, the curing time is mostly controlled at about 48 hours. Among them, the steam curing time can be determined according to the thickness of medium aggregate concrete, coarse aggregate concrete and fine aggregate concrete and the corresponding aggregate particle size.

[0051] According to a second aspect of the present disclosure, a composite integral assembled floor is provided. Figures 1 to 4 A specific embodiment thereof is shown.

[0052] See also Figures 1 to 4 As shown, the composite integral assembled floor includes a surface layer 1, a bonding layer 2, a medium-grained concrete layer 3, a coarse-grained concrete layer 4 and a fine-grained concrete layer 5 which are arranged in sequence from top to bottom, wherein the thickness of the coarse-grained concrete layer 4 is greater than the thickness of the medium-grained concrete layer 3, and the thickness of the medium-grained concrete layer 3 is greater than the thickness of the fine-grained concrete layer 5.

[0053] Through the above technical solution, since the fabric (stone, tile, etc.) is placed in the steel formwork, the flatness of the first layer, i.e., the surface layer 1, is effectively guaranteed. The slurry of the second bonding layer 2 is selected from a mixture that has been adapted in the laboratory for many times. Due to the large overall compressive strength, the pull-out strength is greatly improved after being combined with the surface layer 1 (first layer), and the anti-rolling performance is greatly better than the ground with the traditional construction method. The setting of the medium-grained concrete layer 3, the coarse-grained concrete layer 4 and the fine-grained concrete layer 5 can further enhance the strength and waterproofness of the floor.

[0054] The floor made in this way has high production efficiency, short production cycle, strong controllability, strong plasticity, wide application, can meet the choice of different users for the material of the surface layer 1, and the total thickness of the floor is adjustable. Under the condition of the same materials, the floor can improve the quality, appearance and durability of the floor with less material consumption. At the same time, it also greatly reduces the manual operation steps and time on the construction site. For example, there will be no temporary processing of the leftover materials at the corners of the stone, so there will be no noise and dust generated, which not only reduces the waste of on-site construction materials, but also avoids the pollution of dust to the air, which is in line with the current modern production concept of energy saving and environmental protection.

[0055] In the present disclosure, unless otherwise specified, directional words such as "upper" and "lower" generally refer to the upper and lower directions of the floor of the present disclosure under normal use.

[0056] As an option, the pouring thickness of the medium-grained concrete layer 3 is 8 to 12 cm; the pouring thickness of the coarse-grained concrete layer 4 is 12 to 16 cm; and the pouring thickness of the fine-grained concrete layer 5 is 5 to 8 cm.

[0057] Specifically, the medium-grained concrete layer 3 can be configured with any suitable pouring thickness such as 8 cm, 10 cm, 12 cm, etc.; the coarse-grained concrete layer 4 can be configured with any suitable pouring thickness such as 12 cm, 14 cm, 16 cm, etc.; the fine-grained concrete layer 5 can be configured with any suitable pouring thickness such as 5 cm, 6 cm, 8 cm, etc. In this regard, those skilled in the art can determine according to the waterproof requirements and application environment, and only exemplary display is given here.

[0058] As an option, the medium-grained concrete layer 3 is formed by mixing medium aggregate and concrete, wherein the particle size of the medium aggregate is 1 to 1.3 cm; the coarse-grained concrete layer 4 is formed by mixing coarse aggregate and concrete, wherein the particle size of the coarse aggregate is 2 to 4 cm; the fine-grained concrete layer 5 is formed by mixing fine aggregate and concrete, wherein the particle size of the fine aggregate is 0.5 to 1.0 cm.

[0059] Specifically, a medium aggregate with a relatively uniform particle size can be configured, for example, a medium aggregate with a particle size of 1 cm, 1.2 cm or 1.3 cm. Of course, a mixed medium aggregate with a particle size in the range of 1 to 1.3 cm can also be configured; a coarse aggregate with a relatively uniform particle size can be configured, for example, a medium aggregate with a particle size of 2 cm, 3 cm or 4 cm. Of course, a mixed coarse aggregate with a particle size in the range of 2 to 4 cm can also be configured; a fine aggregate with a relatively uniform particle size can be configured, for example, a fine aggregate with a particle size of 0.5 cm, 0.8 cm or 1 cm. Of course, a mixed fine aggregate with a particle size in the range of 0.5 to 1.0 cm can also be configured, which can be determined according to construction requirements and economic budget.

[0060] In one embodiment provided by the present disclosure, steel bars are laid between the medium-grained concrete layer 3 and the coarse-grained concrete layer 4, and the laid steel bars can improve the connection strength. After that, the coarse aggregate concrete is poured, which is beneficial to the good bonding of the steel bars and the formed medium-grained concrete layer 3 and the coarse-grained concrete layer 4, thereby effectively transmitting and dispersing the ground pressure of the built-in high-strength prestress, that is, improving the bending strength and compressive strength. The fine-grained concrete layer 5 is laid with steel bars, which can effectively transmit and disperse the built-in high-strength prestress, while blocking groundwater erosion and improving the freeze-thaw resistance of the overall floor.

[0061] In the present disclosure, a groove 6 is provided at one end of the floor and a flange 7 is provided at the other end, so that when multiple floors are connected, the flange 7 of one floor can be inserted into the groove 6 of the adjacent floor. That is, the floors are spliced ​​in a tongue-and-groove manner, thereby reducing the construction difficulty and improving the construction efficiency. The structure is simple and easy to manufacture.

[0062] When multiple floors are connected, water stop strips are provided in the gaps between adjacent floors. The water stop strips can expand to fill the gaps when encountering water, and can effectively block ground water from seeping along the joints, thereby satisfying the expansion and contraction of the concrete floor and effectively ensuring the flatness between the surface layers 1.

[0063] In the present disclosure, the surface layer 1 can be configured as stone slabs, ceramic tiles, composite boards or wooden boards, which can be determined according to the temperature, humidity, pressure and flow of people (or vehicles) in the application environment. It can be determined according to the indoor and outdoor applications. If it is used indoors, stone slabs, ceramic tiles, composite boards or wooden boards can be used, and if it is used outdoors, stone slabs or ceramic tiles are preferably used. Of course, according to the waterproof requirements, stone slabs or ceramic tiles are preferably used in application environments such as swimming pools, while composite boards or wooden boards can be used in exhibition halls or study rooms. In this regard, the present disclosure is only for exemplary display.

[0064] In the present disclosure, the slurry is a high-strength adhesive. Specifically, the adhesive type can be selected from thermosetting adhesives such as epoxy resins, polyurethanes, silicones, polyimides, etc., and those skilled in the art can flexibly select according to the application environment.

[0065] The preferred embodiments of the present invention are described in detail above in conjunction with the accompanying drawings. However, the present invention is not limited to the specific details in the above embodiments. Within the technical concept of the present invention, a variety of simple modifications can be made to the technical solution of the present invention, and these simple modifications all belong to the protection scope of the present invention.

Claims

1. A method for preparing a composite integral assembled floor, characterized in that: The following steps are involved: Laying the surface layer (1) in the mold, and applying slurry to the surface of the surface layer (1); Pour medium aggregate concrete, place steel bars in both directions, and pour coarse aggregate concrete; Pour fine aggregate concrete and place steel bars in both directions; Steam curing; Remove the mold and get the floor; Wherein, the strength grade of the medium aggregate concrete is C30 or C35; the strength grade of the coarse aggregate concrete is C20 or C25; the strength grade of the fine aggregate concrete is C30 or C35; The particle size of the medium aggregate in the medium aggregate concrete is 1-1.3 cm; the particle size of the coarse aggregate in the coarse aggregate concrete is 2-4 cm; the particle size of the fine aggregate in the fine aggregate concrete is 0.5-1.0 cm; The pouring thickness of the medium aggregate concrete is 8-12 cm; the pouring thickness of the coarse aggregate concrete is 12-16 cm; and the pouring thickness of the fine aggregate concrete is 5-8 cm.

2. The method for preparing the composite integral assembled floor according to claim 1, characterized in that: The steel bars are hot-rolled ribbed steel bars.

3. The method for preparing the composite integral assembled floor according to claim 1, characterized in that: The steam curing time is 44 to 52 hours.

4. A composite integral assembled floor, characterized in that: The composite integral assembled floor is prepared by the preparation method according to any one of claims 1 to 3; wherein the composite integral assembled floor comprises a surface layer (1), a bonding layer (2), a medium-grained concrete layer (3), a coarse-grained concrete layer (4) and a fine-grained concrete layer (5) arranged in sequence from top to bottom, wherein the thickness of the coarse-grained concrete layer (4) is greater than the thickness of the medium-grained concrete layer (3), and the thickness of the medium-grained concrete layer (3) is greater than the thickness of the fine-grained concrete layer (5); The strength grade of the medium aggregate concrete is C30 or C35; the strength grade of the coarse aggregate concrete is C20 or C25; the strength grade of the fine aggregate concrete is C30 or C35; The pouring thickness of the medium-grained concrete layer (3) is 8 to 12 cm; the pouring thickness of the coarse-grained concrete layer (4) is 12 to 16 cm; and the pouring thickness of the fine-grained concrete layer (5) is 5 to 8 cm. The medium-grained concrete layer (3) is formed by mixing medium aggregate and concrete, wherein the particle size of the medium aggregate is 1 to 1.3 cm; the coarse-grained concrete layer (4) is formed by mixing coarse aggregate and concrete, wherein the particle size of the coarse aggregate is 2 to 4 cm; the fine-grained concrete layer (5) is formed by mixing fine aggregate and concrete, wherein the particle size of the fine aggregate is 0.5 to 1.0 cm.

5. The composite integral assembled floor according to claim 4, characterized in that: Steel bars are laid in the medium-grained concrete layer (3); and steel bars are laid in the fine-grained concrete layer (5).

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