An assembled cast-in-place concrete space box structure system

Abstract

The present invention discloses an assembled cast-in-place concrete space box structure system, comprising at least one cast-in-place box unit, wherein the cast-in-place box unit comprises a floor panel located at the top, walls, an upper ring beam and a lower ring beam distributed around, the middle part and both sides of the outer side of the wall are thickened in the vertical direction, and the steel bars of the floor panel, the wall, the upper ring beam and the lower ring beam in the cast-in-place box unit are tied together into a steel cage, and then cast into a cast-in-place structure at the same time. The present invention adopts the method of integrally tying the steel cage and then integrally casting to make the cast-in-place box unit, and the prefabrication rate and assembly rate are both above 90%, which conforms to the industrialized construction method of the building. The combination of thick wall and thin wall is adopted, which can bear vertical and horizontal loads, and greatly reduce the dead weight and steel consumption, save material costs, and save transportation and hoisting costs. A variety of vertical seam connection and horizontal seam connection methods ensure the integrity of the box structure system and improve the seismic performance of the structure.

Description

Technical Field

[0001] The present invention relates to the technical field of prefabricated buildings, and in particular to a prefabricated integrally cast concrete space box structure system. Background Art

[0002] Prefabricated buildings have become the direction of transformation of my country's construction industry due to their advantages such as easy quality assurance, fast construction speed, green and low-carbon environmental protection. Among the existing prefabricated buildings, prefabricated modular buildings are a type of prefabricated building with a high degree of assembly and prefabrication, and are an important form of realizing building industrialization.

[0003] Prefabricated modular buildings, also known as box buildings, are a type of building that uses a single room as a prefabricated unit. The prefabricated unit is processed in the factory and then transported to the construction site for assembly between units. Box buildings can be made of steel or concrete. Steel structures have the advantages of light weight, easy production and installation, making them the main structural form of box buildings. In recent years, builders and residents of steel-structured box buildings have found that steel has poor fire and corrosion resistance, poor thermal insulation, and reduced living comfort and safety. On the contrary, concrete structures have good integrity, high living comfort, good durability, and good thermal insulation, heat insulation, and sound insulation performance, but they are heavy, have complex prefabrication processes, and high lifting and transportation costs. In addition, the existing module units have poor integrity, the force mode of the lateral force resistance system is unclear, and most of them are used in buildings below three floors, which greatly limits the application scope of box buildings.

[0004] Therefore, how to solve the problems in the prior art of heavy concrete box units, low mold utilization, high transportation and hoisting requirements, and limited maximum applicable height has become an important technical problem to be solved by those skilled in the art. Summary of the invention

[0005] The present invention provides an assembled integrally cast concrete space box structural system to solve the problems of heavy deadweight of existing concrete box units, low mold utilization, high requirements for transportation and hoisting, and limited maximum applicable height.

[0006] The technical solution adopted by the present invention is: to provide an assembled integrally cast concrete space box structure system, including at least one integrally cast box unit, wherein the integrally cast box unit includes a floor panel located at the top, walls, an upper ring beam and a lower ring beam distributed around, the middle part and both sides of the outer side of the wall are thickened in the vertical direction, and the steel bars of the floor panel, wall, upper ring beam and lower ring beam in the integrally cast box unit are tied together into a steel cage, and then cast simultaneously into an integrally cast structure.

[0007] Furthermore, double-row bidirectional steel bars are used for reinforcement in thickened walls, and single-row bidirectional steel bars are used for reinforcement in other locations.

[0008] Furthermore, when tying the steel cage, positions for door openings, window openings and pipeline openings are reserved, and corresponding holes are formed after pouring.

[0009] Furthermore, the thickness of the upper ring beam and the lower ring beam in the integrally cast box unit is consistent with the thickness of the thickened wall.

[0010] Furthermore, the vertical seams between adjacent cast-in-place box units on the same layer are connected by a first tensile component, and the unthickened portions of adjacent walls on the same layer form cavities; the horizontal seams between the upper and lower cast-in-place box units are connected by a second tensile component.

[0011] Furthermore, the first tensile component and the second tensile component are both arranged at the thickened wall, and the first tensile component is connected by through-rod bolts; the second tensile component is connected by through-rod bolts, grouting sleeves or grout anchor overlaps.

[0012] Furthermore, when the wall in the integrally cast box unit is used as a surrounding wall, an insulation board or an insulation structure integrated sandwich wall panel is laid on the outer surface of the wall.

[0013] Furthermore, the thickness of the thickened wall is 120-200 mm, and the thickness of the unthickened wall is 60-100 mm.

[0014] Furthermore, the concrete used in pouring the integrally cast box unit is ordinary concrete, ceramsite concrete or high-strength concrete.

[0015] Furthermore, the casting method of the integrally cast box unit includes:

[0016] Building an interior wall formwork and applying a release agent, wherein the interior wall formwork includes side panels located around and a top panel located on the top;

[0017] Tie the integrally formed steel cage around the inner wall formwork, place embedded parts and pipelines, and reserve door openings, window openings and pipeline openings when tying the steel cage; double-row bidirectional steel bars are used in the middle and both sides of the steel cage in the vertical direction, double-row bidirectional steel bars are used at the top, and single-row bidirectional steel bars are used for the rest of the steel cage;

[0018] Building an exterior wall formwork, with a release agent applied in advance to the exterior wall formwork and grouting holes reserved, the exterior wall formwork comprising side panels located on all sides and a top panel located on the top, the exterior wall formwork being recessed outward at the top and bottom of the side panels to form the positions of the upper ring beam and the lower ring beam, and being recessed outward at the middle and both sides along the vertical direction to form the position of the thickened wall;

[0019] Carry out pressure grouting, curing and demoulding.

[0020] The beneficial effects of the present invention are:

[0021] The present invention adopts the method of integrally tying steel cages and then integrally casting to manufacture the integrally cast box units. The integrally cast box units are processed in a factory and then transported to the construction site for assembly, or directly cast on site. The prefabrication rate and assembly rate are both above 90%, which is in line with the industrialized construction method of buildings.

[0022] The wall of the integrally cast box unit proposed by the present invention adopts a combination of thick wall and thin wall, which can bear vertical and horizontal loads, greatly reduce the deadweight and steel consumption, save material costs, and save transportation and hoisting costs. The concave and convex parts of the outer surface of the wall will form a cavity to achieve the effect of thermal insulation and sound insulation.

[0023] The present invention proposes a variety of vertical seam connection and horizontal seam connection methods, which ensure the integrity of the box structure system, improve the seismic performance of the structure, and solve the problem of limited maximum applicable height of modular buildings. BRIEF DESCRIPTION OF THE DRAWINGS

[0024] Figure 1 3D structural diagram of the integrally cast box unit in an embodiment of the present invention;

[0025] Figure 2 Schematic diagram of the exploded structure of the integrally cast box unit in an embodiment of the present invention;

[0026] Figure 3 Schematic diagram of the structure of the integrally cast box unit wall and cavity in an embodiment of the present invention;

[0027] Figure 4 Schematic diagram of a steel cage of a cast-in-place box unit in an embodiment of the present invention;

[0028] Figure 5 It is a schematic diagram of the manufacturing and construction of the integrally cast box unit in an embodiment of the present invention;

[0029] Figure 6 Schematic diagram of vertical seam connection between adjacent integrally cast box units on the same layer in an embodiment of the present invention;

[0030] Figure 7 Schematic diagram of horizontal seam connection between upper and lower layer integrally cast box units in an embodiment of the present invention;

[0031] Figure 8 It is a schematic structural diagram of the through-rod bolt connection between integrally cast box units in an embodiment of the present invention.

[0032] Figure numerals: 1-integrally cast box unit, 2-vertical seam connection, 3-horizontal seam connection, 4-floor panel, 5-wall, 6-door opening, 7-window opening, 8-pipeline opening, 9-upper ring beam, 10-lower ring beam, 11-rebar cage, 12-thick wall, 13-thin wall, 14-cavity, 15-double-row bidirectional steel bars, 16-single-row bidirectional steel bars, 17-inner wall formwork, 18-external wall formwork, 19-grouting hole, 20-water and electricity pipeline, 21-horizontal seam operation hand hole, 22-horizontal seam cross-thread screw, 23-vertical seam operation hand hole, 24-vertical seam cross-thread screw. DETAILED DESCRIPTION

[0033] In order to make the purpose, technical solutions and advantages of the present invention more clear, the present invention will be further described in detail below with reference to the accompanying drawings, but the embodiments of the present invention are not limited thereto.

[0034] Embodiment 1:

[0035] See also Figure 1 , 2 4. This embodiment discloses an assembled cast-in-one concrete space box structure system, including at least one cast-in-one box unit 1, wherein the cast-in-one box unit 1 includes a floor panel 4 at the top, walls 5 distributed around, an upper ring beam 9 and a lower ring beam 10, the middle and both sides of the outer side of the wall 5 are thickened in the vertical direction, and the steel bars of the floor panel 4, wall 5, upper ring beam 9 and lower ring beam 10 in the cast-in-one box unit 1 are tied together into a steel cage 11, and then cast simultaneously into a cast-in-one structure.

[0036] Specifically, Figure 2 As shown, the integrally cast box unit 1 includes five surfaces, namely, the upper floor panel 4 and the walls 5 on the four surrounding surfaces. The walls 5 in the integrally cast box unit 1 are provided with door openings 6, window openings 7 and pipeline openings 8 according to the actual needs of the building function, so as to realize the connection between different integrally cast box units 1. The walls 5 of the integrally cast box unit 1 are respectively arranged with an upper ring beam 9 and a lower ring beam 10 above and below to ensure the integrity of the structure.

[0037] like Figure 3As shown, the thickness of the wall 5 in the cast-in-place box unit 1 is uneven, and the thickened wall 5 is a thick wall 12, that is, thick walls 12 are arranged at the corners (both sides of the wall 5) and in the middle of the wallboard, and thin walls 13 are arranged at other positions, so that the deadweight of the cast-in-place box unit 1 is greatly reduced. Preferably, the thickness of the thick wall 12 is 120-200mm, and the thickness of the thin wall 13 is 60-100mm. The thickness of the upper ring beam 9 and the lower ring beam 10 in the cast-in-place box unit 1 is consistent with the thickness of the thick wall 12, that is, the thick wall 12 and the thin wall 13 are aligned indoors, which does not affect the utilization of the indoor space, and the thick wall 12 and the thin wall 13 are uneven outdoors. When the cast-in-place box units 1 on the same layer are spliced, the concave and convex parts of the outer surface of the wall 5 will form a cavity 14, achieving the effect of thermal insulation and sound insulation. When the wall 5 in the integrally cast box unit 1 is used as a surrounding wall 5, insulation boards or sandwich wall panels with integrated insulation structures can be laid on the inner and outer surfaces of the wall 5 according to energy-saving design requirements.

[0038] like Figure 4 As shown, the steel bars in the floor panel 4, the wall 5, the upper ring beam 9, and the lower ring beam 10 in the integrally cast box unit 1 are tied together into a steel cage 11, and then cast into an integrally cast structure at the same time. Furthermore, the steel bars in the thick wall 12 in the integrally cast box unit 1 use double-row bidirectional steel bars 15 (i.e., a "well"-shaped structure), and the steel bars in the thin wall 13 use single-row bidirectional steel bars 16 (i.e., a "cross"-shaped structure), which greatly reduces the amount of steel used.

[0039] like Figure 6 As shown, the vertical joint connection 2 between adjacent integrally cast box units 1 of the same layer is connected by a first tensile component, which is arranged at the adjacent thick wall 12 to provide vertical joint tensile and shear bearing capacity, and the first tensile component can be connected by rod-type bolts.

[0040] like Figure 7 As shown, the horizontal seam connection 3 between the upper and lower layers of the integrally cast box units 1 is connected by a second tensile component, and the second tensile component is arranged at the thick walls 12 of the upper and lower layers to provide horizontal seam tensile and shear bearing capacity. The second tensile component can be connected by through-rod bolt connection, grouting sleeve connection, grout anchor lap connection, etc.

[0041] Figure 8An example of the vertical seam connection 22 between adjacent integrally cast box units 1 on the same layer and the horizontal seam connection 3 between upper and lower integrally cast box units 1 using through-rod bolt connection is provided. A plurality of horizontal seam operation hand holes 21 and vertical seam operation hand holes 23 are provided at the thick wall 12, upper ring beam 9 and lower ring beam 10 of the integrally cast box unit 1. After the adjacent integrally cast box units 1 on the same layer and the upper and lower integrally cast box units 1 are spliced ​​and aligned, horizontal seam cross-threading screws 22 are provided at the positions of the horizontal seam operation hand holes 21, and vertical seam cross-threading screws 24 are provided at the positions of the vertical seam operation hand holes 23, so as to realize the connection of different integrally cast box units 1.

[0042] The concrete used in pouring the integrally cast box unit 1 is selected from ordinary concrete, ceramsite concrete or high-strength concrete.

[0043] Specifically, the casting method of the integral casting box unit 1 includes:

[0044] S1, build an inner wall formwork 17, and apply a release agent, wherein the inner wall formwork 17 includes side panels located around and a top panel located at the top;

[0045] S2. Tie the integrally formed steel cage 11 around the inner wall formwork 17, place embedded parts and pipelines, and reserve door openings 6, window openings 7 and pipeline openings 8 when tying the steel cage 11; double-row bidirectional steel bars 15 are used for the steel bars in the middle and both sides along the vertical direction around the steel cage 11, double-row bidirectional steel bars 15 are used for the top steel bars, and single-row bidirectional steel bars 16 are used for the remaining steel bars;

[0046] S3, build an exterior wall formwork 18, the exterior wall formwork 18 is pre-coated with a release agent, and a grouting hole 19 is reserved. The exterior wall formwork 18 includes side panels located on all sides and a top panel located on the top. The exterior wall formwork 18 is concave outward at the top and bottom of the side panels to form the positions of the upper ring beam 9 and the lower ring beam 10, and is concave outward in the middle and both sides along the vertical direction to form the position of the thickened wall 12;

[0047] S4. Carry out pressure grouting, curing and demoulding.

[0048] The box unit in the cast-in-place space box structure system of the present invention adopts an integrally bound steel cage 11, which is then prefabricated in a factory using a mold casting method, and then transported to the construction site for assembly, or directly cast on site, which greatly improves the construction rate and conforms to the construction method of industrialized construction. The wall 5 of the cast-in-place box unit 1 adopts a combination of double-row bidirectional reinforcement of the thick wall 12 and single-row bidirectional reinforcement of the thin wall 13, which not only effectively reduces the dead weight of the box unit, but also greatly reduces the amount of steel used. The horizontal seams and vertical seam connections 2 between the cast-in-place box units 1 adopt a variety of connection methods such as through-rod bolt connection, grouting sleeve connection, and grout anchor lap connection at the thick wall 12 position, so that the space box structure forms a structural system with good seismic performance and good integrity, ensuring the safety of the cast-in-place box unit 1 used in low-rise, multi-story and high-rise buildings.

[0049] The above embodiments are only used to illustrate the technical solutions of the present invention, rather than to limit it. Although the invention has been described in detail with reference to the aforementioned embodiments, those skilled in the art should understand that the technical solutions described in the aforementioned embodiments may still be modified, or some of the technical features thereof may be replaced by equivalents. However, these modifications or replacements do not deviate the essence of the corresponding technical solutions from the spirit and scope of the technical solutions of the embodiments of the present invention.

Claims

1. An assembled cast-in-place concrete space box structure system. It is characterized in that The invention comprises at least one integrally cast box unit, wherein the integrally cast box unit comprises a floor panel at the top, walls, an upper ring beam and a lower ring beam distributed around the unit, the middle part and both sides of the outer side of the wall are thickened in the vertical direction, and the steel bars of the floor panel, the wall, the upper ring beam and the lower ring beam in the integrally cast box unit are tied together into a steel cage, and then cast into an integrally cast structure at the same time; Double-row bidirectional steel bars are used for reinforcement in the thickened wall, and single-row bidirectional steel bars are used for reinforcement in other locations; When tying the steel cage, reserve the positions of door openings, window openings and pipeline openings, and form corresponding holes after pouring; The thickness of the upper ring beam and the lower ring beam should be consistent with the thickness of the wall after thickening treatment; The vertical seams between adjacent cast-in-place box units on the same floor are connected by the first tensile component, and the unthickened parts of the adjacent walls on the same floor form cavities; the horizontal seams between the cast-in-place box units on the upper and lower floors are connected by the second tensile component; The first tensile component and the second tensile component are both arranged at the thickened wall, the first tensile component is connected by through-rod bolts; the second tensile component is connected by through-rod bolts, grouting sleeves or grout anchor overlaps; Furthermore, a plurality of horizontal seam operation hand holes and vertical seam operation hand holes are arranged at the thickened wall, upper ring beam and lower ring beam of the integrally cast box unit.

2. The assembled cast-in-place concrete space box structure system according to claim 1, It is characterized in that When the wall in the integrally cast box unit is used as a surrounding wall, a thermal insulation board or a sandwich wall panel with an integrated thermal insulation structure is laid on the outer surface of the wall.

3. The assembled cast-in-place concrete space box structure system according to claim 1, It is characterized in that The thickness of the thickened wall is 120-200mm, and the thickness of the unthickened wall is 60-100mm.

4. The assembled cast-in-place concrete space box structure system according to claim 1, It is characterized in that The concrete used in pouring the integrally cast box unit is selected from ordinary concrete, ceramsite concrete or high-strength concrete.

5. The assembled cast-in-place concrete space box structure system according to claim 1, It is characterized in that The casting method of the integral casting box unit comprises: Building an interior wall formwork and applying a release agent, wherein the interior wall formwork includes side panels located around and a top panel located on the top; Tie the integrally formed steel cage around the inner wall formwork, place embedded parts and pipelines, and reserve door openings, window openings and pipeline openings when tying the steel cage; double-row bidirectional steel bars are used in the middle and both sides of the steel cage in the vertical direction, double-row bidirectional steel bars are used at the top, and single-row bidirectional steel bars are used for the rest of the steel cage; Building an exterior wall formwork, the exterior wall formwork is pre-coated with a release agent, and grouting holes are reserved, the exterior wall formwork includes side panels located on all sides and a top panel located on the top, the exterior wall formwork is concave outwards at the top and bottom of the side panels to form the positions of the upper ring beam and the lower ring beam, and the middle and both sides along the vertical direction are concave outwards to form the position of the thickened wall; Carry out pressure grouting, curing and demoulding.

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