Preparation method of prefabricated floor slab and prefabricated composite floor slab

Abstract

The preparation method of precast base slabs and precast composite floor slabs relates to the construction field. The preparation method of precast base slabs includes the following steps: Step 1. Preparing a precast base slab mold; Step 2. Placing a wire mesh plate on the precast base slab mold, and setting a first reinforcing bar above the wire mesh plate; inserting truss reinforcing bars into the openings, and welding the top of the truss reinforcing bars to the first reinforcing bar; Step 3. Pouring precast concrete mortar onto the precast base slab mold until the precast concrete mortar buries the first reinforcing bar; Step 4. After the precast concrete mortar dries, demolding to obtain a precast base slab, wherein the precast base slab has protrusions corresponding to the slots at the corresponding positions.

Description

Technical Field

[0001] This invention relates to the field of construction, and more specifically to composite panels. Background Technology

[0002] To improve the thermal insulation performance of buildings and reduce their energy consumption, insulation layers are often added inside the wall panels. Currently, there are no observed cases of adding insulation layers to floor slabs, but in reality, it is both feasible and necessary. Summary of the Invention

[0003] The purpose of this invention is to provide a method for preparing a precast base slab, thereby providing a physical basis for adding an insulation layer to the floor slab.

[0004] The purpose of this invention is to provide a method for preparing prefabricated composite slabs, thereby preparing floor slabs with insulation layers.

[0005] The technical problem solved by this invention can be achieved by the following technical solutions:

[0006] The method for preparing a precast base plate is characterized by comprising the following steps:

[0007] Step 1. Prepare a precast base plate mold, the precast base plate mold includes a plate-shaped base plate, the base plate has an upward-facing slot, the spacing between the slot walls gradually increases from bottom to top, and the base plate also has an upward-facing opening.

[0008] Step 2. Place a wire mesh plate on the precast base plate mold, and set the first load-bearing steel bar above the wire mesh plate; insert truss steel bars into the opening, and weld the top of the truss steel bars to the first load-bearing steel bar;

[0009] Step 3. Pour precast concrete mortar onto the precast base slab mold until the precast concrete mortar embeds the first load-bearing steel bar;

[0010] Step 4. After the precast concrete mortar dries, demold to obtain a precast base plate. The precast base plate has protrusions that match the slot at the corresponding positions.

[0011] A method for preparing precast composite floor slabs includes preparing a precast base slab and preparing a cast-in-place concrete layer; characterized in that,

[0012] The method for preparing the precast base plate includes the following steps:

[0013] Step 1. Prepare a precast base plate mold, the precast base plate mold includes a plate-shaped base plate, the base plate has an upward-facing slot, the spacing between the slot walls gradually increases from bottom to top, and the base plate also has an upward-facing opening.

[0014] Step 2. Place a wire mesh plate on the precast base plate mold, and set the first load-bearing steel bar above the wire mesh plate; insert truss steel bars into the opening, and weld the top of the truss steel bars to the first load-bearing steel bar;

[0015] Step 3. Pour precast concrete mortar onto the precast base slab mold until the precast concrete mortar embeds the first load-bearing steel bar;

[0016] Step 4. After the precast concrete mortar dries, demold to obtain a precast base plate, wherein the precast base plate has protrusions that match the groove at the position corresponding to the groove.

[0017] The method for preparing the cast-in-place concrete layer includes the following steps:

[0018] Step 1: Connect the first reinforcing bar of the precast base slab to the steel reinforcement structure of the building to fix the precast base slab, with the convex side of the precast base slab facing upwards.

[0019] Step 2: Lay insulation material and second reinforcing steel bars on the precast base slab, and weld the truss steel bars to the second reinforcing steel bars;

[0020] Step 3: Pour concrete mortar on top of the precast base slab until the insulation material and the second load-bearing steel bars are embedded in the concrete mortar;

[0021] Step 4: After the cast-in-place concrete mortar dries, a precast composite floor slab with an insulation layer is obtained.

[0022] Another method for preparing precast composite floor slabs includes preparing a precast base slab and preparing a cast-in-place concrete layer; characterized in that,

[0023] The method for preparing the precast base plate includes the following steps:

[0024] Step 1. Prepare a precast base plate mold, the precast base plate mold includes a plate-shaped base plate, the base plate has an upward-facing slot, the spacing between the slot walls gradually increases from bottom to top, and the base plate also has an upward-facing opening.

[0025] Step 2. Place a wire mesh plate on the precast base plate mold, and set the first load-bearing steel bar above the wire mesh plate; insert truss steel bars into the opening, and weld the top of the truss steel bars to the first load-bearing steel bar;

[0026] Step 3. Pour precast concrete mortar onto the precast base slab mold until the precast concrete mortar embeds the first load-bearing steel bar;

[0027] Step 4. After the precast concrete mortar dries, demold to obtain a precast base plate, wherein the precast base plate has protrusions that match the groove at the position corresponding to the groove.

[0028] The method for preparing the cast-in-place concrete layer includes the following steps:

[0029] Step 1: Connect the second reinforcing bar to the steel structure of the building. Weld the ends of the truss reinforcing bars and the ends of the first reinforcing bars of the precast base plate to the second reinforcing bar, so that the precast base plate is suspended below the second reinforcing bar, with the convex side of the precast base plate facing upward.

[0030] Step 2: Lay insulation material on the precast base slab;

[0031] Step 3: Pour concrete mortar on top of the precast base slab until the insulation material and the second load-bearing steel bars are embedded in the concrete mortar;

[0032] Step 4: After the cast-in-place concrete mortar dries, a precast composite floor slab with an insulation layer is obtained.

[0033] Beneficial Effects: 1. The precast composite floor slab of this invention incorporates insulation material, which can effectively improve the building's thermal insulation performance and reduce its energy consumption. 2. This invention uses an inverted method to fabricate the precast base slab. On the one hand, this avoids the problem of inconsistent protrusions in the precast base slab caused by the collapse of the precast concrete mortar; on the other hand, it reduces the difficulty of fixing the truss reinforcement and allows for adjustment of the position of the first load-bearing reinforcement using the truss reinforcement. 3. This invention optimizes the structure of the precast base slab mold and improves the preparation method of the precast base slab, allowing for adjustment of the position of the wire mesh plate and the first load-bearing reinforcement using the truss reinforcement. Detailed Implementation

[0034] To make the technical means, creative features, objectives and effects of this invention easier to understand, the invention is further described below.

[0035] The preparation method of precast composite floor slabs includes preparing a precast base slab and preparing a cast-in-place concrete layer.

[0036] Preparation method of precast base plate

[0037] Includes the following steps:

[0038] Step 1. Prepare a precast base slab mold. The precast base slab mold includes a plate-shaped base plate with upward-facing slots. The spacing between the slot walls gradually increases from bottom to top. The base plate also has upward-facing openings. These openings can be located between adjacent slots. This area is thicker, allowing for deeper openings and thus more exposed truss reinforcement, facilitating the connection between the truss reinforcement and the second load-bearing reinforcement. More importantly, the precast base slab is recessed at this point, allowing for thicker filling of insulation material or cast-in-place concrete mortar. The truss reinforcement located here ensures a tighter connection between the layers. The slots can be strip-shaped grooves, preferably evenly spaced. Alternatively, the slots can be divided into two groups with different extension directions. Slots within the same group are evenly spaced, while slots in different groups are perpendicularly arranged. The slots can also be arranged in triangular, quadrilateral, or pentagonal shapes.

[0039] Step 2. Place a wire mesh plate on the precast base slab mold, and set the first reinforcing bar above the wire mesh plate; insert truss reinforcing bars into the openings, and weld the top of the truss reinforcing bars to the first reinforcing bar. The wire mesh plate can be a flat wire mesh or a corrugated wire mesh. When using corrugated wire mesh, it is preferable that the outline of the corrugated wire mesh is the same as the outline of the precast base slab mold, that is, the corrugated wire mesh has protrusions at the positions corresponding to the slots, and after the wire mesh plate is placed, the protrusions are inserted into the slots. The corrugated wire mesh not only provides good support for the protrusions of the formed precast base slab, reducing damage to the protrusions during the process, but also increases the connection strength and resistance to thermal expansion and contraction of the final precast composite floor slab. The wire mesh plate can be connected to the truss reinforcing bars by binding the reinforcing bars or welding, thereby using the truss reinforcing bars to adjust the position of the wire mesh plate. When the wire mesh is corrugated, it is preferable that the corrugated wire mesh rests against the precast base slab mold. At this time, the distance between the corrugated wire mesh and the first reinforcing bar is maximized, thus allowing for a reduction in the thickness of the precast base slab. The precast base slab mold may have through holes on its side, with the end of the first reinforcing bar extending from these holes. In this case, the first reinforcing bar on the obtained precast base slab extends beyond the precast base slab, exhibiting a side-mounted reinforcing bar design. Alternatively, the precast base slab mold may have upward-facing insertion holes arranged along its side, with both ends of the first reinforcing bar bent and inserted into these holes. In this case, the first reinforcing bar on the obtained precast base slab extends from the side of the precast base slab with protrusions, exhibiting a side-mounted reinforcing bar design. An insulation material receiving groove is formed between two adjacent protrusions on the precast base slab; preferably, the end of the first reinforcing bar extends from the outermost insulation material receiving groove. The truss reinforcement is selected in the shape of a rod, and the truss reinforcement has ring-shaped fins, which are used to block the opening and prevent the precast concrete mortar from entering the opening and increasing the difficulty of demolding.

[0040] Step 3. Pour precast concrete mortar onto the precast base slab mold until the precast concrete mortar embeds the first reinforcing steel bar. This prevents the first reinforcing steel bar from being exposed. The upper surface of the precast concrete mortar is preferably a flat surface, which facilitates transportation and ensures a flat lower surface of the final precast composite floor slab. The precast concrete mortar is preferably composed of the following raw materials in the following mass percentages: cement: medium-coarse sand: gravel: water: silica fume: silica densifier: water-reducing agent = 1:1.5:2:0.34:0.03:0.04:0.15. This raw material composition of the precast concrete mortar is selected for the inverted precast base slab preparation method of the present invention. This raw material composition of the precast concrete mortar is not only less prone to collapse, but also less prone to cracking during demolding. The first reinforcing steel bar includes a first transverse reinforcing steel bar and a first longitudinal reinforcing steel bar. The first transverse reinforcing steel bar and the first longitudinal reinforcing steel bar are interlaced and welded at the intersection, thereby increasing the structural strength of the first reinforcing steel bar. Further optimization involves ensuring that the welding points of the truss reinforcement and the first stressed reinforcement coincide with the welding points of the first transverse stressed reinforcement and the first longitudinal stressed reinforcement. This reduces the number of welding points.

[0041] Step 4. After the precast concrete mortar dries, demold to obtain the precast base slab. The precast base slab has protrusions at the positions corresponding to the grooves. Preferably, demolding is done after the precast concrete mortar is completely dry. During demolding, it is preferable to invert the mold containing the precast base slab before demolding. Demolding after inversion can effectively prevent deformation of the truss reinforcement during demolding. In addition, after inversion, the heavier lower part of the precast base slab can receive better support from the ground.

[0042] The precast base slabs are prefabricated in a prefabrication plant and need to be transported to the construction site for use. During transportation, it is preferable to stack the precast base slabs, with the raised side of the lower slab facing upwards and the raised side of the upper slab facing downwards. The raised sides of the adjacent base slabs should abut against each other, and the truss reinforcement bars should be located between the two adjacent raised sides. This utilizes the grooves formed between the raised sides to accommodate the truss reinforcement bars, preventing them from being exposed and easily damaged or deformed during transportation.

[0043] For precast slabs with side-reinforced sections, the method for preparing the cast-in-place concrete layer includes the following steps: Step 1: Fix the precast slab in a designated position, with the convex side facing upwards. The first reinforcing bar of the precast slab is connected to the reinforcing steel structure within the walls, beams, and columns of the building, thus fixing the precast slab. Step 2: Lay insulation material and the second reinforcing bar on the precast slab, and weld the truss reinforcing bars to the second reinforcing bar. Preferably, both ends of the second reinforcing bar are connected to the reinforcing steel structure within the walls, beams, and columns of the building. The insulation material is preferably a strip-shaped or plate-shaped insulation board. Where truss reinforcing bars are provided, the truss reinforcing bars penetrate the insulation material. Step 3: Cast-in-place concrete mortar above the precast slab until the mortar buries the insulation material and the second reinforcing bar. Step 4: After the cast-in-place concrete mortar dries, a precast composite floor slab with an insulation layer is obtained.

[0044] For precast slabs with unreinforced sides, the method for preparing the cast-in-place concrete layer includes the following steps: Step 1: Fix the second reinforcing bar by welding the ends of the truss reinforcing bars and the ends of the first reinforcing bars of the precast slab to the second reinforcing bar, thereby fixing the precast slab below the second reinforcing bar. Step 2: Lay insulation material on the precast slab. The insulation material is preferably granular, and the granules are preferably filled between two adjacent protrusions of the precast slab. Step 3: Pour concrete mortar on top of the precast slab until the insulation material and the second reinforcing bar are embedded in the mortar. Step 4: After the concrete mortar dries, a precast composite floor slab with an insulation layer is obtained. Precast slabs with unreinforced sides can avoid contact with other building components during lifting and assembly.

[0045] The foregoing has shown and described the basic principles, main features, and advantages of the present invention. Those skilled in the art should understand that the present invention is not limited to the above embodiments. The embodiments and descriptions in the specification are merely illustrative of the principles of the invention. Various changes and modifications can be made to the invention without departing from its spirit and scope, and all such changes and modifications fall within the scope of the present invention as claimed. The scope of protection of this invention is defined by the appended claims and their equivalents.

Claims

1. A method for preparing a precast base plate, characterized in that, Includes the following steps: Step 1. Prepare a precast base plate mold, the precast base plate mold includes a plate-shaped base plate, the base plate has an upward-facing slot, the spacing between the slot walls gradually increases from bottom to top, and the base plate also has an upward-facing opening. Step 2. Place a wire mesh plate on the precast base plate mold, and set the first load-bearing steel bar above the wire mesh plate; insert truss steel bars into the opening, and weld the top of the truss steel bars to the first load-bearing steel bar; Step 3. Pour precast concrete mortar onto the precast base slab mold until the precast concrete mortar embeds the first load-bearing steel bar; Step 4. After the precast concrete mortar dries, demold to obtain a precast base plate. The precast base plate has protrusions that match the slot at the corresponding positions.

2. The method for preparing the precast base plate according to claim 1, characterized in that, The opening is made between two adjacent slots.

3. The method for preparing the precast base plate according to claim 1, characterized in that, The wire mesh is either a flat wire mesh or a corrugated wire mesh.

4. The method for preparing the precast base plate according to claim 3, characterized in that, The outline of the corrugated wire mesh is the same as that of the precast base plate mold. That is, the corrugated wire mesh has protrusions at the positions corresponding to the slots. After the wire mesh plate is placed, the protrusions are inserted into the slots.

5. The method for preparing the precast base plate according to claim 1, characterized in that, A through hole is opened on the side of the precast base plate mold, and the end of the first stressed steel bar extends out from the through hole.

6. The method for preparing the precast base plate according to claim 1, characterized in that, The precast base plate mold is provided with upward-facing insertion holes, which are arranged along the side of the precast base plate mold. The two ends of the first reinforcing bar are bent and inserted into the insertion holes.

7. A method for preparing precast composite floor slabs, comprising preparing a precast base slab and preparing a cast-in-place concrete layer; characterized in that, The method for preparing the precast base plate includes the following steps: Step 1. Prepare a precast base plate mold, the precast base plate mold includes a plate-shaped base plate, the base plate has an upward-facing slot, the spacing between the slot walls gradually increases from bottom to top, and the base plate also has an upward-facing opening. Step 2. Place a wire mesh plate on the precast base plate mold, and set the first load-bearing steel bar above the wire mesh plate; insert truss steel bars into the opening, and weld the top of the truss steel bars to the first load-bearing steel bar; Step 3. Pour precast concrete mortar onto the precast base slab mold until the precast concrete mortar embeds the first load-bearing steel bar; Step 4. After the precast concrete mortar dries, demold to obtain a precast base plate, wherein the precast base plate has protrusions that match the groove at the position corresponding to the groove. The method for preparing the cast-in-place concrete layer includes the following steps: Step 1: Connect the first reinforcing bar of the precast base slab to the steel reinforcement structure of the building to fix the precast base slab, with the convex side of the precast base slab facing upwards. Step 2: Lay insulation material and second reinforcing bars on the precast base slab, and weld the truss reinforcing bars to the second reinforcing bars; Step 3: Pour concrete mortar on top of the precast base slab until the insulation material and the second load-bearing steel bars are embedded in the concrete mortar; Step 4: After the cast-in-place concrete mortar dries, a precast composite floor slab with an insulation layer is obtained.

8. A method for preparing a precast composite floor slab according to claim 7, characterized in that, The insulation material is in the form of strips or boards. Where there are truss reinforcement bars, the truss reinforcement bars penetrate the insulation material.

9. Another method for preparing precast composite floor slabs, comprising preparing a precast base slab and preparing a cast-in-place concrete layer; characterized in that, The method for preparing the precast base plate includes the following steps: Step 1. Prepare a precast base plate mold, the precast base plate mold includes a plate-shaped base plate, the base plate has an upward-facing slot, the spacing between the slot walls gradually increases from bottom to top, and the base plate also has an upward-facing opening. Step 2. Place a wire mesh plate on the precast base plate mold, and set the first load-bearing steel bar above the wire mesh plate; insert truss steel bars into the opening, and weld the top of the truss steel bars to the first load-bearing steel bar; Step 3. Pour precast concrete mortar onto the precast base slab mold until the precast concrete mortar embeds the first load-bearing steel bar; Step 4. After the precast concrete mortar dries, demold to obtain a precast base plate, wherein the precast base plate has protrusions that match the groove at the position corresponding to the groove. The method for preparing the cast-in-place concrete layer includes the following steps: Step 1: Connect the second reinforcing bar to the steel structure of the building. Weld the ends of the truss reinforcing bars and the ends of the first reinforcing bars of the precast base plate to the second reinforcing bar, so that the precast base plate is suspended below the second reinforcing bar, with the convex side of the precast base plate facing upward. Step 2: Lay insulation material on the precast base slab; Step 3: Pour concrete mortar on top of the precast base slab until the insulation material and the second load-bearing steel bars are embedded in the concrete mortar; Step 4: After the cast-in-place concrete mortar dries, a precast composite floor slab with an insulation layer is obtained.

10. Another method for preparing the precast composite floor slab according to claim 9, characterized in that, The insulation material is in the form of granular insulation particles, which are filled between two adjacent protrusions of the precast base plate.