Gypsum-based prefabricated flooring modules, flooring systems and their construction methods

Abstract

This invention provides a gypsum-based prefabricated flooring module, a flooring system, and a construction method thereof. The gypsum-based prefabricated flooring module includes a main layer, which comprises multiple cast-in-place unit modules and a filler layer. The unit modules are assembled together, each unit module having a square block structure. A first channel, which is annular and extends through all four side walls of the unit module, is provided on the surface of the unit module facing the main layer. The second channel is located at the top corner of the unit module and connects to the first channel. The filler layer fills the first and second channels to secure the multiple unit modules together. This structural design allows for direct assembly of the unit modules on-site without the need for cement-sand leveling or gypsum-based self-leveling compound construction, effectively solving the problems associated with these methods.

Description

Technical Field

[0001] This invention belongs to the field of flooring technology, specifically relating to a gypsum-based prefabricated flooring module, flooring system, and construction method thereof. Background Technology

[0002] Traditional cement-sand leveling construction process is labor-intensive on-site, and cracks and hollow spots are common on the leveled ground, making it difficult to meet customer acceptance standards. In addition, the procurement of river sand is becoming increasingly difficult, especially high-quality river sand that meets the requirements of the national standard GB / T14684-2022 "Construction Sand".

[0003] The currently popular gypsum-based self-leveling mortar leveling construction process, although it almost no longer uses river sand in the materials, suffers from poor construction conditions at the construction site / project site and uneven quality of on-site construction personnel. As a result, various problems may occur on the finished surface, such as air bubbles, inconsistent surface color, low surface strength, powdering, cracking, etc., which may make it difficult to meet customer requirements.

[0004] In southern my country, heating is not provided during winter. To address this, there is a need to develop a gypsum-based prefabricated flooring module, flooring system, and construction method for non-underfloor heating systems. Summary of the Invention

[0005] The purpose of this invention is to provide a gypsum-based prefabricated flooring module, flooring system and its construction method, so as to solve the problems existing in the above-mentioned cement sand leveling construction or gypsum-based self-leveling construction, and to apply it to areas in southern my country without heating.

[0006] To achieve the above objectives, the present invention provides the following technical solution:

[0007] A gypsum-based prefabricated flooring module, the gypsum-based prefabricated flooring module comprising a main layer, the main layer comprising:

[0008] Multiple cast-in-place unit modules are spliced ​​together. Each unit module has a square block structure. A first channel is provided on the side wall of each unit module. The first channel has a ring structure and penetrates all four sides of the unit module. A second channel is provided on the surface of each unit module facing the main body layer. The second channel is located at the top corner of the unit module and is connected to the first channel.

[0009] A filling layer is provided to fill the first channel and the second channel to fix the multiple unit modules together.

[0010] In an optional embodiment of the present invention, the second channel is a square channel that extends through the two adjacent edges at the top corner of the unit module;

[0011] The side length of the square channel is 10mm-20mm.

[0012] In an optional embodiment of the present invention, the first channel is located in the middle of the side wall of the unit module.

[0013] In an optional embodiment of the present invention, the thickness of the unit module is 50mm-150mm;

[0014] The first channel is a square channel, one side of which is on the same plane as the corresponding side of the unit module, and the dimension of the square channel along the thickness direction of the unit module is 10mm-20mm.

[0015] In an optional embodiment of the present invention, the thickness of the unit module is 50mm-150mm;

[0016] The first channel is a semi-circular channel, and the diameter side of the semi-circular channel is on the same plane as the corresponding side of the unit module. The diameter of the semi-circular channel is 10mm-20mm.

[0017] In an optional embodiment of the present invention, the thickness of the unit module is 50mm-150mm; the first channel is a triangular channel, one side of the triangular channel is on the same plane as the corresponding side of the unit module, and the maximum dimension of the triangular channel along the thickness direction of the unit module is 10mm-20mm.

[0018] In an optional embodiment of the present invention, the gypsum-based prefabricated flooring module further includes a terrazzo surface layer and an insulation base layer. The terrazzo surface layer is disposed on one surface of the main body layer, and the insulation base layer is disposed on the other side of the main body layer opposite to the terrazzo surface layer.

[0019] The present invention also proposes a flooring system, which includes a gypsum-based prefabricated flooring module, a construction base layer, a leveling layer and an adhesive layer as described above. The leveling layer is disposed on the surface of the construction base layer, and the main layer of the gypsum-based prefabricated flooring module is fixedly connected to the surface of the leveling layer facing away from the construction base layer through the adhesive layer.

[0020] This invention also proposes a construction method for a flooring system, the construction method comprising the following steps:

[0021] Step 1: A square block structure is formed by casting gypsum-based self-leveling mortar. A first annular channel is opened around the side wall of the square block structure, and a second channel connecting the first channel is opened at the top corner of one surface of the square structure to obtain a unit module.

[0022] Step two, repeat step one to obtain multiple unit modules;

[0023] Step 3: Apply a layer of adhesive to one surface of each unit module, and then fix multiple unit modules to the surface of the leveling layer with adhesive after splicing them together. Then, pour gap filling slurry into the second channel through the first channel. After hardening, the gypsum-based prefabricated flooring module is obtained.

[0024] In an optional embodiment of the present invention, in step one, the gypsum-based self-leveling mortar includes building gypsum powder, cement, polycarboxylate superplasticizer, calcium sulfate dihydrate, and flexible fibers, wherein...

[0025] The mass ratio of building gypsum powder to cement is (970-1000):(1-30). The amount of polycarboxylate superplasticizer is 0.1-0.13% of the total mass of building gypsum powder and cement. The amount of calcium sulfate dihydrate is 1-1.5% of the total mass of building gypsum powder and cement. The amount of flexible fiber is 0.3-0.4% of the total mass of building gypsum powder and cement.

[0026] Beneficial effects:

[0027] The gypsum-based prefabricated flooring module of the present invention includes a main layer, which comprises multiple cast-in-place unit modules and a filling layer. The unit modules are assembled together, and each unit module has a square block structure. A first channel, which is annular and extends through all four side walls of the unit module, is provided on the surface of the unit module facing the main layer. The second channel is located at the top corner of the unit module and connects to the first channel. The filling layer fills the first and second channels to secure the multiple unit modules together. This structural design allows for direct assembly of the unit modules on-site without the need for cement-sand leveling or gypsum-based self-leveling compound construction, effectively solving the problems associated with these methods. The gypsum-based prefabricated flooring module of the present invention can be widely used in non-heated areas of southern my country. Attached Figure Description

[0028] The accompanying drawings, which form part of this specification, are used to provide a further understanding of the invention. The illustrative embodiments of the invention and their descriptions are used to explain the invention and do not constitute an undue limitation of the invention. Wherein:

[0029] Figure 1 This is a cross-sectional structural schematic diagram of an embodiment of the gypsum-based prefabricated flooring module of the present invention;

[0030] Figure 2 for Figure 1 A structural diagram of the main body layer from another perspective;

[0031] Figure 3 for Figure 2A structural diagram of a single unit module;

[0032] Figure 4 for Figure 2 A structural diagram of a single unit module from another perspective;

[0033] Figure 5 for Figure 2 A cross-sectional structural diagram of a single unit module from another perspective;

[0034] Figure 6 for Figure 2 A cross-sectional structural schematic diagram of another embodiment of a single unit module;

[0035] Figure 7 for Figure 2 A cross-sectional structural schematic diagram of another embodiment of a single unit module;

[0036] Figure 8 for Figure 2 A structural schematic diagram of a single unit module in another embodiment;

[0037] Figure 9 for Figure 2 A structural schematic diagram of another embodiment of a single unit module;

[0038] Figure 10 This is a cross-sectional structural schematic diagram of another embodiment of the gypsum-based prefabricated flooring module of the present invention;

[0039] Figure 11 This is a cross-sectional structural diagram of an embodiment of the flooring system of the present invention;

[0040] Figure 12 This is a cross-sectional structural schematic diagram of another embodiment of the flooring system of the present invention.

[0041] Numbering in the diagram: 1-Main layer; 11-Unit module; 111-First channel; 112-Second channel; 12-Filling layer; 2-Terrain stone surface layer; 3-Insulation base layer; 4-Adhesive layer; 5-Leveling layer; 6-Construction base layer. Detailed Implementation

[0042] The technical solutions in the embodiments of the present invention will be clearly and completely described below. Obviously, the described embodiments are only a part of the embodiments of the present invention, and not all of them. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention are within the scope of protection of the present invention.

[0043] The present invention will now be described in detail with reference to embodiments. It should be noted that, unless otherwise specified, the embodiments and features described in the embodiments of the present invention can be combined with each other.

[0044] To address the challenges of existing cement-sand leveling or gypsum-based self-leveling leveling methods, this invention provides a gypsum-based prefabricated flooring module.

[0045] like Figures 1 to 5 As shown, the gypsum-based prefabricated flooring module of the present invention includes a main layer 1, which comprises multiple cast-in-place unit modules 11 and a filling layer 12. The multiple unit modules 11 are spliced ​​together. Each unit module 11 has a square block structure (including square and rectangular block structures). A first channel 111 is provided on the side wall of each unit module 11. The first channel 111 has a ring structure and penetrates all four sides of the unit module 11. A second channel 112 is provided on the surface of each unit module 11 facing the main layer 1. The second channel 112 is located at the top corner of each unit module 11 and connects to the first channel 111. The filling layer 12 fills the first channel 111 and the second channel 112 to splice and fix the multiple unit modules 11. This structural arrangement allows for direct splicing of the unit modules 11 on-site without the need for cement-sand leveling or gypsum-based self-leveling construction, effectively solving the problems associated with cement-sand leveling or gypsum-based self-leveling construction. The gypsum-based prefabricated flooring module of the present invention can be widely used in areas of southern my country where heating is not provided.

[0046] It should be noted that when assembling unit modules 11 at the construction site, multiple unit modules 11 are first assembled at the construction site. Then, gap-filling grout is added into the second channel 112. The gap-filling grout enters the first channel 111 and fills the gaps between unit modules 11. After hardening, it forms a filling layer 12, which firmly connects two adjacent unit modules 11. This effectively ensures the overall firmness and stability of the main layer 1 and prevents materials from entering the gaps between unit modules 11 during the next construction process, thus avoiding any adverse effects on the unit modules 11.

[0047] In the gypsum-based prefabricated flooring module of the present invention, the unit module 11 of the main layer 1 is formed by casting. Compared with the traditional cement and sand on-site mixing and filling construction process, it has the following advantages: the product quality is guaranteed, while the quality of raw materials used on-site in the traditional process is difficult to guarantee, especially the mud content of sand is difficult to control, and the possibility of hollow cracking in the later stage is very high. This modular construction can effectively avoid the occurrence of hollow cracking. Compared with the self-leveling construction process, the casting and molding process of this invention has the following significant advantages: the construction operation is relatively simple, and the casting and molding are carried out in-house, greatly improving the casting conditions compared with the self-leveling construction site. Secondly, the casting technicians are fixed, and the company's technicians will train the casting technicians before casting and test the product quality, which can effectively guarantee the product quality. That is, the unit module 11 of this invention is pre-engineered and is a finished product. On the construction site, workers only need to assemble it like building blocks before laying the underfloor heating pipes. In contrast, self-leveling is a semi-finished product, and the on-site construction process is complex, requiring high levels of worker skills and expertise. The on-site foundation layer treatment must be standardized, the interface agent application must meet the requirements, the water volume during casting must be strictly controlled, the site must be sealed during construction, and cutting is required later. Every detail of the work must be strictly operated according to the procedures to ensure the quality of the project. Otherwise, various quality problems such as low strength, powdering, cracking, and hollowing will occur.

[0048] The unit module 11 of the present invention is cast using inorganic materials (such as cement-based self-leveling compound, gypsum-based self-leveling compound, or grouting material, etc.). The cast unit module 11 has a compressive strength ≥20MPa and a flexural strength ≥8MPa. That is, the material of the gypsum-based prefabricated floor module is inorganic material. Compared with the existing traditional modules (most of which use organic materials), the gypsum-based prefabricated floor module of the present invention has the following advantages: (1) The inorganic material gypsum-based prefabricated floor module has strong durability (the light-density organic material floor module has low strength and is easily deformed under load, especially under long-term load, while the inorganic material floor module has high strength and strong load-bearing capacity; the light organic material floor module has a short service life, while the inorganic material floor module has a long service life); (2) The inorganic material gypsum-based prefabricated floor module has good heat dissipation (the good heat dissipation of the inorganic material floor module mainly refers to the fact that the heat dissipation of the inorganic material itself is significantly higher than that of the organic lightweight board). Good heat dissipation means that when other conditions are the same (such as the density of the underfloor heating pipe, the specifications of the underfloor heating pipe, the inlet water temperature, the inlet water flow rate, and the insulation performance of the user's room are the same), the floor paved with the inorganic material floor module with good heat dissipation will be better. The heat dissipation efficiency of the heating pipe is higher, the room temperature rises faster, and the insulation temperature is higher. When the same insulation effect is achieved, the user's cost is relatively small; (3) The inorganic material gypsum-based prefabricated floor module has strong overall bonding force (the lightweight organic material floor module has low strength and is an organic material. The two characteristics determine that its bonding force with other inorganic materials is not high); (4) The inorganic material gypsum-based prefabricated floor module has a high safety factor. The lightweight organic material module may burn and support combustion when exposed to high temperature or high temperature open flame, or emit highly irritating toxic dust or produce toxic gas. The inorganic material gypsum-based prefabricated floor module will not burn and support combustion when exposed to high temperature or high temperature open flame, and will not produce irritating toxic dust or gas. At the same time, if the material used in the gypsum-based prefabricated floor module is gypsum-based self-leveling, the bound water in the dihydrate gypsum will be automatically released at high temperature, which is helpful for fire extinguishing.

[0049] The arrangement of the first channel 111 and the second channel 112 can effectively and quickly fill the gaps between the laid unit modules 11. The shapes of the first channel 111 and the second channel 112 are not limited and are both within the protection scope of this invention.

[0050] In an optional embodiment of the present invention, the second channel 112 is a square channel that runs through the two adjacent edges at the top corner of the unit module 11. That is, two sides of the square channel are the two adjacent edges at the top corner of the unit module 11. This design facilitates the opening operation of the second channel 112.

[0051] Optionally, the side length of the square channel is 10mm-20mm (e.g., 10 mm, 12mm, 14mm, 16mm, 18mm, 20mm, and any range between the two endpoints).

[0052] Of course, in some other embodiments, such as Figure 8 As shown, there can be two second channels 112, which are located at two adjacent top corners of the unit module 11. This allows the gap filling slurry to fill the gaps between the laid unit modules 11 through the two second channels 112, making the filling operation faster and filling the gaps more fully, thus improving the overall stability of the main layer 1.

[0053] Of course, in other embodiments, such as Figure 9 As shown, the second channel 112 can be set to four, with two second channels 112 located at the four top corners of the unit module 11 respectively. In this way, the gap filling slurry can fill the gaps between the laid unit modules 11 through the four second channels 112, making the filling operation faster and able to fully fill the gaps, thereby improving the overall stability of the main layer 1.

[0054] In an optional embodiment of the present invention, the first channel 111 is located in the middle of the side wall of the unit module 11, which can ensure better and faster filling of the gaps between the laid unit modules 11.

[0055] In a specific embodiment of the present invention, such as Figure 4 and Figure 5 As shown, the first channel 111 is a square channel (such as a square or rectangular channel) that surrounds the four side walls of the unit module 11. One side of the square channel is on the same plane as the corresponding side of the unit module 11. Optionally, the thickness of the unit module 11 is 50mm-150mm (such as 50mm, 80mm, 100mm, 120mm, 150mm and any range between two endpoints); the dimension of the square channel along the thickness direction of the unit module 11 is 10mm-20mm (such as 10mm, 12mm, 14mm, 16mm, 18mm, 20mm and any range between two endpoints).

[0056] In another specific embodiment of the present invention, such as Figure 6 As shown, the first channel 111 is a semi-circular channel, and the diameter side of the semi-circular channel is on the same plane as the corresponding side of the unit module 11. Optionally, the diameter of the semi-circular channel is 10mm-20mm (e.g., 10 mm, 12mm, 14mm, 16mm, 18mm, 20mm and any range between the two endpoints).

[0057] In another specific embodiment of the present invention, such as Figure 7 As shown, the first channel 111 is a triangular channel, with one side of the triangular channel on the same plane as the corresponding side of the unit module 11. Optionally, the maximum dimension of the triangular channel along the thickness direction of the unit module 11 is 10mm-20mm (e.g., 10 mm, 12mm, 14mm, 16mm, 18mm, 20mm, and any range between the two endpoints).

[0058] Of course, in other embodiments, the shape of the first channel 111 can also be other reasonable shapes, all of which are within the protection scope of the present invention.

[0059] Furthermore, in an optional embodiment of the present invention, the gypsum-based prefabricated flooring module of the present invention further includes a terrazzo surface layer 2. The terrazzo surface layer 2 is disposed on one surface of the main body layer 1. Specifically, the terrazzo surface layer 2 is directly laid on the surface of the main body layer 1. The thickness of the terrazzo surface layer 2 is 5-15mm (e.g., 5mm, 7mm, 10mm, 12mm, 15mm, and any range between two endpoints). The terrazzo in the terrazzo surface layer 2 can be any type of terrazzo listed in the industry standard JC / T507-2022 "Terrace Stone for Building Decoration". Laying the terrazzo surface layer 2 on the surface of the main body layer 1 can significantly improve the hardness and wear resistance of the gypsum-based prefabricated flooring module, while also improving its aesthetics (like a ceramic tile surface), and eliminating the need for subsequent floor tiles.

[0060] like Figure 10 As shown in the specific embodiment of the present invention, the gypsum-based prefabricated flooring module further includes an insulation base layer 3, which is disposed on the other side of the main layer 1 opposite to the terrazzo surface layer 2. The bottom insulation layer can be made of organic insulation board with a fire resistance rating of A1 or inorganic insulation mortar.

[0061] like Figure 11 As shown, the present invention also provides a flooring system, which includes a gypsum-based prefabricated flooring module, a construction base layer 6, a leveling layer 5, and an adhesive layer 4 as described above. The leveling layer 5 is disposed on the surface of the construction base layer 6, and the main layer 1 of the gypsum-based prefabricated flooring module is fixedly connected to the surface of the leveling layer 5 facing away from the construction base layer 6 through the adhesive layer 4. The main layer 1 of the gypsum-based prefabricated flooring module of the present invention is fixed by adhesive, which is simple to operate and has good firmness. The leveling material can also be replaced with loose inorganic building materials (these loose building materials harden themselves over time and become a whole, such as the M15 floor mortar in GB / T 25181-2019 "Premixed Mortar" which meets the construction requirements). During construction, workers first level the loose material with the help of equipment, then apply adhesive to the back of the module, and then lay the unit module 11.

[0062] Optionally, the material for the leveling layer 5 can be a thermal insulation and sound insulation mortar that meets the requirements of the national standard GB / T 20473-2021 "Building Thermal Insulation Mortar" or the national standard GB / T 2600-2010 "Expanded Vitrified Microsphere Thermal Insulation Mortar" or the industry standard JG / T 283-2010 "Expanded Vitrified Microsphere Lightweight Mortar" BW thermal insulation and sound insulation mortar.

[0063] It should be noted that the thickness of the leveling layer 5 is mainly determined by the overall flatness of the construction base layer 6. If the difference between the lowest and highest points of the construction base layer 6 is 10mm, then the thickness of the leveling layer 5 should not be less than 10mm, and 15mm can be selected. If the difference between the lowest and highest points is 20mm, then the thickness of the leveling layer 5 should not be less than 20mm, and 25mm can be selected. The construction base layer 6 is generally a concrete or mortar layer for the floor, which is an inherent structure of the building. Its thickness depends on the viewing angle, and it is required that the construction base layer be firm and clean.

[0064] like Figure 12 As shown, in another specific embodiment of the flooring system of the present invention, the gypsum-based prefabricated flooring module further includes an insulation base layer 3, which is fixedly connected to the surface of the leveling layer 5 facing away from the construction base layer 6 via an adhesive layer 4. The insulation base layer 3 provides the gypsum-based prefabricated flooring module with good thermal insulation performance. Optionally, the insulation base layer 3 can be made of inorganic thermal insulation mortar, or alternatively, organic thermal insulation materials such as fire-resistant A1-grade polyurethane foam, polystyrene board, EPS, XPS, and phenolic foam can be used.

[0065] Furthermore, the material of the insulation base layer 3 can be a sound insulation material, such as a thermal insulation and sound insulation mortar that meets the requirements of the national standard GB / T20473-2021 "Building Thermal Insulation Mortar", or the DW thermal insulation and sound insulation mortar that meets the requirements of the national standard GB / T 2600-2010 "Expanded Vitrified Microsphere Thermal Insulation Mortar", or the BW thermal insulation and sound insulation mortar in the industry standard JG / T 283-2010 "Expanded Vitrified Microsphere Lightweight Mortar".

[0066] It should be noted that the thickness of the insulation layer 3 is determined according to user needs. Optionally, the thickness of the insulation layer 3 is not less than 20mm, preferably 20-40mm (such as 20mm, 25mm, 30mm, 35mm, 40mm and any range between two endpoints).

[0067] The present invention also proposes a construction method for the flooring system described above, the construction method comprising the following steps:

[0068] Step 1: A square block structure is formed by casting gypsum-based self-leveling slurry. A first annular channel 111 is opened on the side wall of the square block structure along the perimeter. A second channel 112 connecting the first channel 111 is opened at the top corner of one surface of the square structure to obtain the unit module 11.

[0069] Step 2: Repeat step 1 to obtain multiple unit modules 11;

[0070] Step 3: Apply a layer of adhesive to one surface of each unit module 11. After splicing multiple unit modules 11, fix them to the surface of the leveling layer 5 with adhesive. Then, pour gap filling slurry into the second channel 112 through the first channel 111. After hardening, the gypsum-based prefabricated flooring module is obtained.

[0071] In an optional embodiment of the present invention, in step two, after hardening, a layer of terrazzo is laid on the surface of unit module 11, which is the terrazzo surface layer 2.

[0072] It should be noted that when raising and leveling floors with thermal insulation and soundproofing requirements, if the gypsum-based prefabricated flooring modules are thermal insulation and soundproofing modules (such as...), Figure 12 As shown), this includes the insulation base layer 3, and the insulation base layer 3 uses sound insulation material. The aforementioned ground surface without insulation and sound insulation requirements can be used for leveling. If the gypsum-based prefabricated flooring module is a non-insulation and sound insulation module, that is, it does not include the insulation base layer 3 (as shown). Figure 11 As shown), the leveling material used during construction can be a material with its own thermal insulation and sound insulation functions. During construction, with the help of equipment, the workers first level the bulk soft leveling material with its own thermal insulation and sound insulation functions according to the design elevation, then apply adhesive to the back of the module, then lay the unit module 11, and finally lay the terrazzo surface layer 2.

[0073] In a specific embodiment of the present invention, in step one, the gypsum-based self-leveling mortar includes building gypsum powder, cement, polycarboxylate superplasticizer, calcium sulfate dihydrate, and flexible fiber. The mass ratio of building gypsum powder to cement is (970-1000):(1-30). The amount of polycarboxylate superplasticizer is 0.1-0.13% of the total mass of building gypsum powder and cement (e.g., 0.1%, 0.11%, 0.12%, 0.13%, or any range between any two endpoints). The amount of calcium sulfate dihydrate is 1-1.5% of the total mass of building gypsum powder and cement (e.g., 1%, 1.1%, 1.2%, 1.3%, 1.4%, 1.5%, or any range between any two endpoints). The amount of flexible fiber is 0.3-0.4% of the total mass of building gypsum powder and cement (e.g., 0.3%, 0.32%, 0.34%, 0.36%, 0.38%, 0.4%, or any range between any two endpoints).

[0074] Optionally, the cement used is ordinary Portland cement with a strength grade of 42.5 (i.e., PO42.5 cement), and the flexible fiber is polypropylene fiber with a length of 10-50mm (e.g., 10mm, 20mm, 30mm, 40mm, 50mm and any range between two endpoints).

[0075] To improve the casting speed during module pouring, a suitable amount of accelerator is added to the traditional gypsum-based self-leveling mortar while the retarder is removed, reducing the setting and heating time of the gypsum-based self-leveling mortar from 3 hours to 15 minutes. To enhance the flexural strength and impact resistance of the modules, a suitable amount of polypropylene fiber is added to the gypsum-based self-leveling mortar, which significantly improves its flexural strength, impact resistance, and deflection at failure (where deflection at failure is the linear displacement perpendicular to the axis of the component or the linear displacement of the mid-surface of the plate / shell at failure under stress or non-uniform temperature changes).

[0076] In a specific embodiment of the present invention, the formula of gypsum-based self-leveling mortar is as follows: building gypsum powder: 970-1000 kg; PO42.5 cement: 0-30 kg; the above two parts may be adjusted according to different actual conditions, with a total amount of 1 t; polycarboxylate superplasticizer: 1.0-1.3 kg / t; calcium sulfate dihydrate: 10-15 kg / t; polypropylene fiber (length 10mm~50mm): 3-4 kg / t.

[0077] The traditional formula for gypsum-based self-leveling mortar is as follows: 950-1000 kg of building gypsum powder; 0-50 kg of PO 42.5 cement; the above two parts may be adjusted according to actual conditions, with a total amount of 1 t; 1.0-1.8 kg / t of polycarboxylate superplasticizer; 1.2-2.0 kg / t of vegetable oil defoamer; 0.5-1.0 kg / t of protein retarder; 0.1-0.3 kg / t of sodium gluconate; and 0.15-0.4 kg / t of 400 viscosity cellulose.

[0078] Cost analysis of the traditional formula and the improved formula of this invention is as follows: The improved formula of this invention no longer uses 400 viscosity cellulose (47 yuan / kg), protein retarder (25.5 yuan / kg), and ordinary sodium succinate (6.5 yuan / kg), but adds dihydrate gypsum (50 yuan / ton) and fiber (9.8 yuan / kg). After the improvement, the material cost can be reduced by about 63 yuan / ton. Since the ground and surface of the non-underfloor heating pipe module are flat, the requirement for the defoaming ability of the slurry itself is reduced. At the same time, the platform on which the mold is placed during pouring is a vibrating platform, so the defoamer can be eliminated. At the same time, the expensive retarder is replaced with the inexpensive gypsum coarse setter dihydrate gypsum, which reduces the demolding time from the original 2.5-3 hours to less than 25 minutes, greatly reducing the labor cost and site usage cost when pouring the module.

[0079] The following detailed description of the gypsum-based prefabricated flooring module, flooring system, and construction method of the present invention will be provided through specific embodiments.

[0080] Example 1

[0081] The gypsum-based self-leveling mortar formula used in this embodiment is as follows:

[0082] Building gypsum powder: 970kg; PO·42.5 cement: 30kg; polycarboxylate superplasticizer: 1.0kg; calcium sulfate dihydrate: 10kg; polypropylene fiber: 3kg.

[0083] The specific steps of the construction method for the flooring system of this invention are as follows:

[0084] (1) A square block structure is obtained by casting the gypsum-based self-leveling slurry with the above formula. A first annular channel is opened on the side wall of the square block structure along the four sides. A second channel connecting the first channel is opened at the top corner of one surface of the square structure to obtain a unit module.

[0085] (2) Repeat step one to obtain multiple unit modules;

[0086] (3) A layer of adhesive is laid on one surface of each unit module. After multiple unit modules are spliced ​​together, they are fixed to the surface of the leveling layer with adhesive. Then, gap filling slurry is poured into the second channel through the first channel. After hardening, the flooring system is obtained.

[0087] Example 2

[0088] The only difference between this embodiment and Example 1 is the specific amounts of the ingredients in the gypsum-based self-leveling mortar formula: 980 kg of building gypsum powder; 20 kg of PO42.5 cement; 1.1 kg of polycarboxylate superplasticizer; 12 kg of calcium sulfate dihydrate; and 3.2 kg of polypropylene fiber. All other operations are the same as in Example 1.

[0089] Example 3

[0090] The only difference between this embodiment and Example 1 is the specific amounts of the ingredients in the gypsum-based self-leveling mortar formula: 990 kg of building gypsum powder; 10 kg of PO42.5 cement; 1.2 kg of polycarboxylate superplasticizer; 14 kg of calcium sulfate dihydrate; and 3.6 kg of polypropylene fiber. All other operations are the same as in Example 1.

[0091] Example 4

[0092] The only difference between this embodiment and Example 1 is the specific amounts of the ingredients in the gypsum-based self-leveling mortar formula: 999 kg of building gypsum powder; 1 kg of PO42.5 cement; 1.3 kg of polycarboxylate superplasticizer; 15 kg of calcium sulfate dihydrate; and 4 kg of polypropylene fiber. All other operations are the same as in Example 1.

[0093] Comparative Example 1

[0094] This comparative example uses a traditional gypsum-based self-leveling mortar formula, namely: 950 kg of building gypsum powder; 50 kg of PO 42.5 cement; 1.0 kg of polycarboxylate superplasticizer; 1.2 kg of vegetable oil defoamer; 0.5 kg of protein retarder; 0.1 kg of sodium gluconate; and 0.15 kg of 400 viscosity cellulose.

[0095] The unit modules (20cm × 20cm) prepared in Examples 1-4 and Comparative Example 1 were subjected to a free-fall test from a height of 1m (the ground was flat C30 concrete, and the 20cm × 20cm test block was placed face down during the free fall). The unit module test block of Comparative Example 1 split into many small fragments after this test (multiple sets of tests were conducted, and the test results were consistent); the unit module test blocks prepared in Examples 1-4 remained intact or developed a crack after this test (the test block with a crack was still a whole block because it contained fibers).

[0096] Furthermore, using the drop hammer device for impact resistance testing (consisting of a steel base with a horizontal adjustment knob, a vertical steel frame suspending an electromagnet, a conduit, and a (1±0.015) kg metal drop hammer) as specified in the JC / T 985-2017 industry standard, 20 mm thick unit modules were prepared in Examples 1-4 and Comparative Example 1. After being completely dry, these modules were subjected to a free-fall impact test from a height of 1000 mm using the drop hammer device. The test results showed that the unit module prepared in Comparative Example 1 shattered after the test, while the unit modules prepared in Examples 1-4 remained intact. That is, the 10J impact test of the unit module prepared in Comparative Example 1 failed, while the 10J impact test of the unit modules prepared in Examples 1-4 passed.

[0097] The above description is merely a preferred embodiment of the present invention and is not intended to limit the invention. Various modifications and variations can be made to the present invention by those skilled in the art. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the scope of protection of the present invention.

Claims

1. A gypsum-based prefabricated flooring module, characterized in that, The gypsum-based prefabricated flooring module includes a main layer, a terrazzo surface layer, and an insulation base layer. The terrazzo surface layer is disposed on one surface of the main layer, and the insulation base layer is disposed on the other side of the main layer opposite to the terrazzo surface layer. The main layer includes: Multiple unit modules, cast from gypsum-based self-leveling mortar, are assembled together. Each unit module has a square block structure. A first channel, which is annular and extends through all four sides of the unit module, is provided on the surface of the unit module facing the main body layer. The second channel is located at the top corner of the unit module and connects to the first channel. The second channel is a square channel that extends through the two adjacent edges at the top corner of the unit module. A filling layer is provided to fill the first channel and the second channel to fix the multiple unit modules together. The gypsum-based self-leveling mortar comprises building gypsum powder, cement, polycarboxylate superplasticizer, calcium sulfate dihydrate, and flexible fibers, wherein... The mass ratio of building gypsum powder to cement is (970-1000):(1-30). The amount of polycarboxylate superplasticizer is 0.1-0.13% of the total mass of building gypsum powder and cement. The amount of calcium sulfate dihydrate is 1-1.5% of the total mass of building gypsum powder and cement. The amount of flexible fiber is 0.3-0.4% of the total mass of building gypsum powder and cement.

2. The gypsum-based prefabricated flooring module as described in claim 1, characterized in that... The side length of the square channel is 10mm-20mm.

3. The gypsum-based prefabricated flooring module as described in claim 1, characterized in that, The first channel is located in the middle of the side wall of the unit module.

4. The gypsum-based prefabricated flooring module as described in claim 3, characterized in that, The thickness of the unit module is 50mm-150mm; The first channel is a square channel, one side of which is on the same plane as the corresponding side of the unit module, and the dimension of the square channel along the thickness direction of the unit module is 10mm-20mm.

5. The gypsum-based prefabricated flooring module as described in claim 3, characterized in that, The thickness of the unit module is 50mm-150mm; The first channel is a semi-circular channel, and the diameter side of the semi-circular channel is on the same plane as the corresponding side of the unit module. The diameter of the semi-circular channel is 10mm-20mm.

6. The gypsum-based prefabricated flooring module as described in claim 3, characterized in that, The thickness of the unit module is 50mm-150mm; The first channel is a triangular channel, one side of which is on the same plane as the corresponding side of the unit module, and the maximum dimension of the triangular channel along the thickness direction of the unit module is 10mm-20mm.

7. A flooring system, characterized in that, The flooring system includes a gypsum-based prefabricated flooring module as described in any one of claims 1-6, a construction base layer, a leveling layer, and an adhesive layer. The leveling layer is disposed on the surface of the construction base layer, and the main layer of the gypsum-based prefabricated flooring module is fixedly connected to the surface of the leveling layer facing away from the construction base layer through the adhesive layer.

8. A construction method for the flooring system as described in claim 7, characterized in that, The construction method includes the following steps: Step 1: A square block structure is formed by casting gypsum-based self-leveling mortar. A first annular channel is opened around the side wall of the square block structure, and a second channel connecting the first channel is opened at the top corner of one surface of the square structure to obtain a unit module. Step two, repeat step one to obtain multiple unit modules; Step 3: Apply a layer of adhesive to one surface of each unit module, and then fix multiple unit modules to the surface of the leveling layer with adhesive after splicing them together. Then, pour gap filling slurry into the second channel through the first channel. After hardening, the gypsum-based prefabricated flooring module is obtained.

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