Method for preparing and stacking steel rib prestressed concrete composite slab

Abstract

The application discloses a kind of preparation and stacking method of steel rib prestressed concrete composite slab, belong to the field of fabricated building, the present application is provided with support block on steel rib, and make the upper support structure and the lower support structure of support block respectively cast in concrete upper flange and prestressed concrete bottom plate, and the top end surface of upper support structure and the bottom end surface of lower support structure are flush with the top surface of concrete upper flange and the bottom surface of prestressed concrete bottom plate respectively.Setting support block has the effect of steel rib limiting, preventing steel rib and steel rib and concrete upper flange from being inclined deformation, can also be used as the stacking support device of steel rib prestressed concrete composite slab.The present application is high in production efficiency, simple in structure, convenient in installation and positioning, can effectively limit steel rib displacement, improve steel rib stability, prevent steel rib and concrete upper flange from being inclined deformation, optimize the stress of stacking, safe and reliable in stacking, prevent concrete from being crushed.

Description

Technical Field

[0001] This invention relates to the field of prefabricated buildings, and in particular to a method for preparing and stacking steel-ribbed prestressed concrete composite slabs. Background Technology

[0002] Prefabricated construction is gradually becoming a major trend in China's construction industry. To adapt to the rapid development of prefabricated construction, various types of prefabricated floor slabs and composite slabs have emerged in the construction market. Traditional prefabricated floor slabs and composite slabs mainly suffer from drawbacks such as heavy weight, high cost, poor structural integrity, and low efficiency of factory production. Steel-ribbed prestressed concrete composite slabs have solved these problems to some extent. A steel-ribbed prestressed concrete composite slab includes steel ribs, a concrete upper flange, and a bottom slab. The top and bottom of the steel ribs are cast within the concrete upper flange and bottom slab, respectively.

[0003] The existing technology for producing steel-ribbed prestressed concrete composite slabs mainly involves two steps: Step 1: Invert the steel ribs, set up the mold for the upper concrete flange, arrange the upper flange reinforcement as needed, pour the upper flange concrete, cure until the concrete reaches the design strength, and then remove the mold to form an integral component of the upper concrete flange and steel ribs. Step 2: Set up the mold for the base slab, rotate the integral component of the upper concrete flange and steel ribs 180 degrees, arrange the base slab reinforcement as needed, pour the base slab concrete, and remove the mold after the base slab concrete has cured to the design strength, obtaining the integral steel-ribbed prestressed concrete composite slab.

[0004] In step 1, there are problems with the positioning and limiting of the steel ribs, as well as poor stability. Due to the long length and thin thickness of the steel ribs, they are also prone to lateral deformation or torsion. In step 2, there are problems with the steel ribs not being straight with the upper flange of the concrete, and they are prone to tilting or collapsing.

[0005] Furthermore, existing steel-ribbed prestressed concrete composite slabs are prone to damage to the upper flange and steel ribs during stacking. To address this issue, pads (such as flat timber) are typically placed at both ends of the lower layer of steel-ribbed prestressed concrete composite slabs near the steel ribs, and the upper layer is then placed on these pads. While this stacking method avoids damage to the upper flange and steel ribs due to pressure, the thinness of the base slab means that the pressure from the stacking can cause cracks through the pads. To ensure stacking quality, the timber surface must be flat and uniform in size, and the placement of the timber on the upper surface of the base slab must be smooth and even. This adds unnecessary quality control steps, increases production costs, and hinders widespread application. Summary of the Invention

[0006] This invention provides a method for preparing and stacking prestressed concrete composite slabs with steel ribs. It has high production efficiency, simple structure, convenient installation and positioning, and high safety. It can effectively limit the displacement of steel ribs, improve the stability of steel ribs, prevent the steel ribs and the upper flange of concrete from tilting and deforming, optimize the stress of stacking, and ensure safe and reliable stacking, preventing damage to the concrete.

[0007] The technical solution provided by this invention is as follows:

[0008] A method for preparing a steel-ribbed prestressed concrete composite slab, the steel-ribbed prestressed concrete composite slab comprising a prestressed concrete base slab, wherein at least one set of upper structures are provided on the prestressed concrete base slab, each set of upper structures comprising a concrete upper flange, steel ribs and at least four support blocks, the concrete upper flange being located at a predetermined height above the prestressed concrete base slab, the steel ribs being located between the prestressed concrete base slab and the concrete upper flange, the lower end and the upper end of the steel ribs being respectively cast into the prestressed concrete base slab and the concrete upper flange;

[0009] The support block includes a block body, on the top and bottom surfaces of which a vertical upper support structure and a lower support structure are respectively provided; the block bodies of the two support blocks are respectively fixed on both sides of the designed position of the web of the steel rib, with a set distance between two adjacent designed positions; the upper support structure and the lower support structure are respectively cast in the concrete upper flange and the prestressed concrete base plate, and the top surface of the upper support structure and the bottom surface of the lower support structure are respectively flush with the top surface of the concrete upper flange and the bottom surface of the prestressed concrete base plate;

[0010] The preparation method includes:

[0011] S1: Fabricate the steel ribs and the support blocks according to the design requirements;

[0012] S2: For each designed position of the steel rib, the block bodies of the two support blocks are fixedly connected to both sides of the designed position of the steel rib.

[0013] S3: Invert the steel rib with support block on the mold table, so that the top surface of the upper support structure is placed on the upper surface of the mold table, support the upper flange mold, pour the upper flange concrete, and remove the mold after curing until the upper flange concrete reaches the design strength, forming an integrated component of concrete upper flange, steel rib and support block.

[0014] S4: After flipping the integrated component 180 degrees, place it on the mold table, so that the bottom end face of the lower support structure is placed on the upper surface of the mold table. Set up the base plate mold, pour the base plate concrete, and after curing until the base plate concrete reaches the design strength, remove the mold to obtain the overall steel rib prestressed concrete composite slab.

[0015] Furthermore, the block body is a solid cuboid plastic block, and the upper support structure and lower support structure are support plates or support legs made of plastic material, and the support plates or support legs are integrally formed with the solid cuboid plastic block.

[0016] Furthermore, the prestressed concrete base slab includes prestressed steel bars and transversely distributed steel bars, and the upper concrete flange includes longitudinal steel bars and transversely distributed steel bars.

[0017] The length direction of the support plate is parallel to the length direction of the steel rib. The support plate or support leg is staggered from the prestressed steel bars and longitudinal steel bars. The support block as a whole is staggered from the transversely distributed steel bars of the bottom plate and the transversely distributed steel bars of the upper flange.

[0018] S3 also includes the following steps before pouring the upper flange concrete:

[0019] Apply a release agent to the inner surface of the upper flange mold, and tie the longitudinal reinforcing bars and the transversely distributed reinforcing bars of the upper flange.

[0020] Before pouring the foundation slab concrete, step S4 also includes:

[0021] A release agent is applied to the inner surface of the base plate mold, and transverse reinforcing bars are laid out. Prestressed reinforcing bars are then tensioned.

[0022] Furthermore, the top and bottom ends of the web are respectively provided with an upper flange plate and a lower flange plate, the height of the block body is not greater than the net height of the web plate, and the upper support structure and the lower support structure are respectively located on the outside of the upper flange plate and the lower flange plate.

[0023] Furthermore, the cross-section of the steel rib is Z-shaped, C-shaped, or H-shaped.

[0024] Furthermore, the upper and lower flange plates are provided with casting anchoring holes, and the web plate is provided with through holes.

[0025] Furthermore, the design position is located outside the hoisting point of the steel rib prestressed concrete composite slab, the distance between the design position and the end of the upper flange of the concrete is no more than 300mm, and the distance between two adjacent design positions on the steel rib is no more than 2200mm.

[0026] The support block is made of polyvinyl chloride or polycarbonate. The length of the block body is not less than 100mm, the width is not greater than 1 / 2 of the width of the upper flange of the concrete, and the height is not less than 95mm. The bottom of the block body is provided with chamfers and grooves.

[0027] Furthermore, the support plate is a straight plate or a corrugated plate, and each support block has two support legs.

[0028] Furthermore, the block body is bonded and fixed to the side of the web of the steel rib using an adhesive.

[0029] Alternatively, bolt holes are provided on the web of the steel rib and the block body, and the block body is fixedly connected to the steel rib by bolts.

[0030] Furthermore, each superstructure includes multiple steel ribs, which are arranged parallel to each other at intervals, and the block body is fixed to the web of the outermost steel rib.

[0031] A method for stacking steel-ribbed prestressed concrete composite slabs, wherein the steel-ribbed prestressed concrete composite slabs are prepared by the aforementioned method for preparing steel-ribbed prestressed concrete composite slabs.

[0032] The stacking method includes:

[0033] S10: The bottom steel-ribbed prestressed concrete composite slab is smoothly placed into the specified position using a lifting device;

[0034] S11: Place a flexible pad on the top surface of the concrete upper flange at the support block, and ensure that the flexible pad is located on the upper support structure. The horizontal dimension of the flexible pad is not greater than the overall horizontal dimension of the two support blocks, and the center position of the flexible pad is consistent with the overall center position of the two support blocks.

[0035] S12: Use a hoist to smoothly place the upper layer of steel-ribbed prestressed concrete composite slab onto the flexible pad of the lower layer of steel-ribbed prestressed concrete composite slab, and ensure that the lower support structure of the upper layer presses on the flexible pad of the lower layer; repeat this process until the stacking is completed, and the number of stacked layers shall not exceed 9.

[0036] The present invention has the following beneficial effects:

[0037] This invention features support blocks mounted on steel ribs, with the upper and lower support structures of the support blocks cast within the concrete upper flange and prestressed concrete base slab, respectively. Furthermore, the top surface of the upper support structure and the bottom surface of the lower support structure are flush with the top surface of the concrete upper flange and the bottom surface of the prestressed concrete base slab, respectively. The support blocks serve to limit the movement of the steel ribs, prevent tilting and deformation of the steel ribs and the concrete upper flange, and also function as a stacking support device for steel-ribbed prestressed concrete composite slabs.

[0038] In the process of preparing steel-ribbed prestressed concrete composite slabs, when pouring the upper flange of the concrete and the steel ribs, the support block can act as a support, limiting, and stabilizing device for the steel ribs, preventing them from shifting, twisting, or tilting. When pouring the bottom slab concrete, the support block can also act as a support, limiting, and stabilizing device for the integrated steel ribs and the upper flange of the concrete, preventing misalignment, shifting, twisting, or tilting deformation. In other words, this invention effectively uses the support block to limit, support, and fix the steel ribs and the upper flange of the concrete, effectively solving problems such as instability, misalignment, and tilting deformation of the steel ribs and the upper flange of the concrete during the pouring of the precast bottom slab, thereby improving the production quality and efficiency of steel-ribbed prestressed concrete composite slabs.

[0039] After the steel-ribbed prestressed concrete composite slab is fabricated, the support block forms an integral whole with the upper flange and precast base plate of the slab. The support block can serve as a stacking device to bear the vertical load of the upper layer. During stacking, the support block can be quickly located, and flexible pads can be placed on it. The slabs are stacked layer by layer, ensuring accurate positioning, optimal stress distribution, and high safety, preventing damage to the concrete upper flange, steel ribs, and prestressed concrete base plate. Attached Figure Description

[0040] Figure 1 This is a cross-sectional view of the steel-ribbed prestressed concrete composite slab of the present invention.

[0041] Figure 2 A three-dimensional view of the steel ribs;

[0042] Figure 3 A perspective view of one embodiment of the support block;

[0043] Figure 4 For steel ribs and Figure 3 A partial schematic diagram of the support blocks after they are fixedly connected;

[0044] Figure 5 A perspective view of another embodiment of the support block;

[0045] Figure 6 For steel ribs and Figure 5 A partial schematic diagram showing the support blocks after they are fixedly connected;

[0046] Figure 7 For steel ribs and Figure 3 A schematic diagram of the overall structure after the support blocks are fixedly connected;

[0047] Figure 8 A schematic diagram of an integrated component consisting of a concrete upper flange, steel ribs, and support blocks;

[0048] Figure 9 A schematic diagram of the steel-ribbed prestressed concrete composite slab of the present invention;

[0049] Figure 10 This is a schematic diagram showing the stacking of the steel-ribbed prestressed concrete composite slab of the present invention. Detailed Implementation

[0050] To make the technical problems, technical solutions and advantages of the present invention clearer, a detailed description will be given below in conjunction with the accompanying drawings and specific embodiments.

[0051] This invention provides a method for preparing a steel-ribbed prestressed concrete composite slab, such as... Figure 1-10 As shown, the steel-ribbed prestressed concrete composite slab includes a prestressed concrete base slab 100, on which at least one set of superstructures 200 are provided. Each set of superstructures 200 includes a concrete upper flange 300, at least one steel rib 400, and at least four support blocks 500. The concrete upper flange 300 is located at a certain height above the prestressed concrete base slab 100. The steel rib 400 is located between the prestressed concrete base slab 100 and the concrete upper flange 300, and the lower and upper ends of the steel rib 400 are respectively cast into the prestressed concrete base slab 100 and the concrete upper flange 300, forming a whole steel-ribbed prestressed concrete composite slab.

[0052] The support block 500 includes a block body 1, with a vertical upper support structure 2 and a lower support structure 3 respectively provided on the top and bottom surfaces of the block body 1. The upper support structure 2 is located on the top surface of the block body 1 and extends vertically upward to a certain height. The lower support structure 3 is located on the bottom surface of the block body 1 and extends vertically downward to a certain height.

[0053] The steel rib 400 has multiple design positions, with a set distance between adjacent design positions. For each design position, the block bodies 1 of two support blocks 500 are fixed on both sides of the design position of the web 4 of the steel rib 400. Preferably, the two support blocks 500 are symmetrically arranged on both sides of the web 4. The upper support structure 2 and the lower support structure 3 are respectively cast in the concrete upper flange 300 and the prestressed concrete base plate 100. In some examples, a portion of the top and a portion of the bottom of the block body 1 are also cast in the concrete upper flange 300 and the prestressed concrete base plate 400, respectively.

[0054] The top surface of the upper support structure 2 and the bottom surface of the lower support structure 3 are flush with the top surface of the upper concrete flange 300 and the bottom surface of the prestressed concrete base plate 100, respectively.

[0055] Based on the above-mentioned steel-ribbed prestressed concrete composite slab structure, its preparation method includes:

[0056] S1: Fabricate steel ribs 400 and support blocks 500 according to design requirements.

[0057] In this step, according to the design requirements of the steel rib prestressed concrete composite slab, the steel plate needs to be cut, straightened, and bent to form steel ribs 400, and the support blocks 500 need to be processed according to the structural and dimensional design requirements of the support blocks.

[0058] S2: For each designed position of the steel rib 400, the block body 1 of the two support blocks 500 is fixedly connected to both sides of the designed position of the steel rib 400.

[0059] S3: Invert the steel rib 400 with support block 500 on the mold table, so that the top surface of the upper support structure 2 is placed on the upper surface of the mold table, support the upper flange mold, pour the upper flange concrete, and remove the mold after curing until the upper flange concrete reaches the design strength, forming an integrated component of concrete upper flange 300, steel rib 400 and support block 500.

[0060] When manufacturing an integrated component consisting of a concrete upper flange 300, a steel rib 400, and a support block 500, the present invention supports the steel rib 400 on the mold table through the upper support structure 2 of the support block 500. The support block 500 provides support and limit for the steel rib 400. The steel rib 400 can be positioned without the need for an additional positioning structure. The steel rib has good stability and will not have problems such as lateral deformation or torsion.

[0061] The upper support structure 2 has a set height to allow for a set gap between the block body 1 and the mold table, so that the upper flange 300 of the concrete can form a concrete protective layer of a certain thickness above the block body 1.

[0062] S4: After flipping the integrated component 180 degrees, place it on the mold table so that the bottom end of the lower support structure 3 is placed on the upper surface of the mold table. Set up the base plate mold, pour the base plate concrete, and remove the mold after curing until the base plate concrete reaches the design strength.

[0063] After demolding, the concrete upper flange 300, steel rib 400, support block 500 and prestressed concrete base plate 100 become an organic whole, resulting in an integral steel rib prestressed concrete composite slab.

[0064] In the fabrication of the prestressed concrete base slab 100, the present invention uses support blocks 500 to support, limit, and prevent tilting and deformation of the steel ribs 400 and the upper concrete flange 300, thereby preventing the steel ribs 400 and the upper concrete flange 300 from tilting or falling over, and preventing problems such as misalignment of the steel ribs and the upper concrete flange due to deformation of the steel ribs 400.

[0065] The lower support structure 3 has a set height to allow for a set gap between the block body 1 and the formwork, so that the prestressed concrete base plate 100 can form a concrete protective layer of a certain thickness under the block body 1.

[0066] The above-mentioned methods for stacking prestressed concrete composite slabs with steel ribs include:

[0067] S10: Transport and hoist the steel-ribbed prestressed concrete composite slabs to the storage site, and place the bottom layer of steel-ribbed prestressed concrete composite slabs smoothly into the designated position using a hoisting device, and then remove the hoisting device.

[0068] S11: Place flexible pads such as wood or rubber on the top surface of the concrete upper flange at the support block, and ensure that the flexible pads are located above the upper support structure. The horizontal dimension of the flexible pads is not greater than the overall horizontal dimension of the two support blocks, and the center position of the flexible pads is consistent with the overall center position of the two support blocks.

[0069] S12: Use a hoist to smoothly place the upper layer of steel-ribbed prestressed concrete composite slab onto the flexible pad of the lower layer of steel-ribbed prestressed concrete composite slab, and ensure that the lower support structure of the upper layer presses on the flexible pad of the lower layer; repeat this process until the stacking is completed, and the number of stacked layers shall not exceed 9.

[0070] When stacking multi-layer steel-ribbed prestressed concrete composite slabs, the vertical load generated by the steel-ribbed prestressed concrete composite slabs is borne by the support blocks. The vertical load is directly transmitted vertically through the pads, upper flange and support blocks, and finally transferred to the foundation. The stacking process is simple, saves labor, is low in cost, safe and reliable, and will not damage the concrete upper flange, steel ribs and prestressed concrete base slab.

[0071] This invention features support blocks mounted on steel ribs, with the upper and lower support structures of the support blocks cast within the concrete upper flange and prestressed concrete base slab, respectively. Furthermore, the top surface of the upper support structure and the bottom surface of the lower support structure are flush with the top surface of the concrete upper flange and the bottom surface of the prestressed concrete base slab, respectively. The support blocks serve to limit the movement of the steel ribs, prevent tilting and deformation of the steel ribs and the concrete upper flange, and also function as a stacking support device for steel-ribbed prestressed concrete composite slabs.

[0072] In the process of preparing steel-ribbed prestressed concrete composite slabs, when pouring the upper flange of the concrete and the steel ribs, the support block can act as a support, limiting, and stabilizing device for the steel ribs, preventing them from shifting, twisting, or tilting. When pouring the bottom slab concrete, the support block can also act as a support, limiting, and stabilizing device for the integrated steel ribs and the upper flange of the concrete, preventing misalignment, shifting, twisting, or tilting deformation. In other words, this invention effectively uses the support block to limit, support, and fix the steel ribs and the upper flange of the concrete, effectively solving problems such as instability, misalignment, and tilting deformation of the steel ribs and the upper flange of the concrete during the pouring of the precast bottom slab, thereby improving the production quality and efficiency of steel-ribbed prestressed concrete composite slabs.

[0073] After the steel-ribbed prestressed concrete composite slab is fabricated, the support block forms an integral whole with the upper flange and precast base plate of the slab. The support block can serve as a stacking device to bear the vertical load of the upper layer. During stacking, the support block can be quickly located, and flexible pads can be placed on it. The slabs are stacked layer by layer, ensuring accurate positioning, optimal stress distribution, and high safety, preventing damage to the concrete upper flange, steel ribs, and prestressed concrete base plate.

[0074] In this invention, one specific implementation of the support block is as follows: the block body 1 is a solid cuboid plastic block, and the upper support structure 2 and lower support structure 3 are plastic support plates or support legs, which are integrally formed with the solid cuboid plastic block. This design offers advantages such as simple process, low production cost, high production efficiency, convenient on-site installation and positioning, and high safety, thus meeting the needs of mass production and transportation in factories.

[0075] The support plate can be a straight plate or a corrugated plate, and the support legs can be cylindrical. Each support block with a diameter of 500 can have two support legs, making the support more stable.

[0076] The aforementioned prestressed concrete base slab 100 may further include prestressed steel bars 5 and transverse distribution steel bars 6, with the prestressed steel bars 5 arranged along the entire length of the prestressed concrete base slab 100. The concrete upper flange 300 includes longitudinal steel bars 7 and transverse distribution steel bars 8, with the longitudinal steel bars 7 arranged along the entire length of the concrete upper flange 300.

[0077] The length of the support plate is parallel to the length of the steel rib 400 and the prestressed steel bar 5, preventing obstruction of the installation of the prestressed steel bar 5 and the longitudinal steel bar 7, allowing the support plate or support leg to be staggered from the prestressed steel bar 5 and the longitudinal steel bar 7. The length of the support block 500 is less than the spacing between the adjacent transverse distributed steel bars 6 of the bottom slab and the transverse distributed steel bars 8 of the upper flange, so that the support block 500 can be staggered from the transverse distributed steel bars 6 of the bottom slab and the transverse distributed steel bars 8 of the upper flange as a whole. This prevents the support block 500 from adversely affecting the reinforcement layout of the prestressed concrete bottom slab 100 and the concrete upper flange 300.

[0078] Accordingly, S3 mentioned above, before pouring the upper flange concrete, also includes: applying a release agent to the inner surface of the upper flange mold to facilitate demolding; and tying the longitudinal reinforcing bars 7 and the transversely distributed reinforcing bars 8 of the upper flange to form a reinforcing mesh for the concrete upper flange.

[0079] Similarly, S4 mentioned above also includes, before pouring the base slab concrete, applying a release agent to the inner surface of the base slab mold, arranging the transverse distribution steel bars 6 of the base slab, and tensioning the prestressed steel bars 5.

[0080] The top and bottom ends of the web 4 of the steel rib 400 are respectively provided with an upper flange plate 9 and a lower flange plate 10. The cross-section of the steel rib can be Z-shaped, C-shaped, or H-shaped. The height of the block body 1 is less than the net height of the web 4. Preferably, the height of the block body 1 can be equal to the net height of the web 4. The upper support structure 2 and the lower support structure 3 are located on the outer sides of the upper flange plate 9 and the lower flange plate 10, respectively.

[0081] Anchor holes 11 can be provided on the upper flange plate 9 and the lower flange plate 10 to form concrete dowels at the anchor holes during concrete pouring, thereby enhancing the anchoring effect. Through holes 12 can be provided on the web plate 4 for passing reinforcing bars and pipelines through the prestressed concrete composite slab with steel ribs during use. Both the anchor holes 11 and the through holes 12 can be circular holes, and they can be machined during the fabrication of the steel ribs 400 in S1.

[0082] The aforementioned design location is located outside the hoisting point of the steel rib prestressed concrete composite slab. The distance between the design location and the end of the upper flange 300 of the concrete is no more than 300mm, and the distance between two adjacent design locations on the steel rib 400 is no more than 2200mm.

[0083] The compressive strength of the support block 500 should be the same as or slightly higher than that of the upper flange 300 of the concrete. Its material can be polyvinyl chloride (PVC) or polycarbonate (PC), etc. The length of the block body 1 should not be less than 100mm, and the width should not be greater than half the width of the upper flange, for example, 60mm. Furthermore, the height of the block body 1 can be determined according to the design, for example, it can be adjusted according to the total height of the composite slab to adapt to different production requirements of steel-ribbed prestressed concrete composite slabs, but should not be less than 95mm, for example, 105mm. The bottom of the block body 1 can be chamfered and grooved to avoid conflict between the block body 1 and the prestressed steel bars 5 of the prestressed concrete base slab 100.

[0084] In this invention, the block body 1 can be bonded and fixed to the side of the web 4 of the steel rib 400 using an adhesive. During fixing, adhesive is applied to the inner side of the block body 1 and the contact surface with the web 4, and then bonded, so that the steel rib and the support block form a whole. The adhesive can be a fast-drying adhesive such as epoxy resin.

[0085] When the height of the block body 1 is equal to or slightly less than the net height of the web 4, adhesive can be applied to the upper and lower end faces of the block body 1 and the upper flange plate 9 and lower flange plate 10 of the steel rib 400 and bonded to enhance the bonding effect.

[0086] Alternatively, the block body 1 can be fixedly connected to the web plate 4 of the steel rib 400 by bolts 13. In this case, bolt holes 14 are provided on the web plate 4 of the steel rib 400 and the block body 1. The bolt hole on the web plate 4 of the steel rib 400 can be one of the aforementioned through holes 12.

[0087] The steel rib 400 of the upper structure of the present invention can be one or more. When each upper structure includes multiple steel ribs 400, the multiple steel ribs 400 are arranged in parallel with each other at intervals, and the block body 1 is fixed on the web of the outermost steel rib.

[0088] The above description represents the preferred embodiments of the present invention. It should be noted that those skilled in the art can make various improvements and modifications without departing from the principles of the present invention, and these improvements and modifications should also be considered within the scope of protection of the present invention.

Claims

1. A method for preparing a steel-ribbed prestressed concrete composite slab, characterized in that, The steel-ribbed prestressed concrete composite slab includes a prestressed concrete base slab, on which at least one set of superstructures is provided. Each set of superstructures includes a concrete upper flange, steel ribs, and at least four support blocks. The concrete upper flange is located at a set height above the prestressed concrete base slab. The steel ribs are located between the prestressed concrete base slab and the concrete upper flange. The lower end and upper end of the steel ribs are respectively cast into the prestressed concrete base slab and the concrete upper flange. The support block includes a block body, on the top and bottom surfaces of which a vertical upper support structure and a lower support structure are respectively provided; the block bodies of the two support blocks are respectively fixed on both sides of the designed position of the web of the steel rib, with a set distance between two adjacent designed positions; the upper support structure and the lower support structure are respectively cast in the concrete upper flange and the prestressed concrete base plate, and the top surface of the upper support structure and the bottom surface of the lower support structure are respectively flush with the top surface of the concrete upper flange and the bottom surface of the prestressed concrete base plate; The preparation method includes: S1: Fabricate the steel ribs and the support blocks according to the design requirements; S2: For each designed position of the steel rib, the block bodies of the two support blocks are fixedly connected to both sides of the designed position of the steel rib. S3: Invert the steel rib with support block on the mold table, so that the top surface of the upper support structure is placed on the upper surface of the mold table, support the upper flange mold, pour the upper flange concrete, and remove the mold after curing until the upper flange concrete reaches the design strength, forming an integrated component of concrete upper flange, steel rib and support block. S4: After flipping the integrated component 180 degrees, place it on the mold table, so that the bottom end face of the lower support structure is placed on the upper surface of the mold table. Set up the base plate mold, pour the base plate concrete, and after curing until the base plate concrete reaches the design strength, remove the mold to obtain the overall steel rib prestressed concrete composite slab.

2. The method for preparing a steel-ribbed prestressed concrete composite slab according to claim 1, characterized in that, The block body is a solid cuboid plastic block, and the upper support structure and lower support structure are support plates or support legs made of plastic material. The support plates or support legs are integrally formed with the solid cuboid plastic block.

3. The method for preparing a steel-ribbed prestressed concrete composite slab according to claim 2, characterized in that, The prestressed concrete base slab includes prestressed steel bars and transversely distributed steel bars in the base slab, and the concrete upper flange includes longitudinal steel bars and transversely distributed steel bars in the upper flange. The length direction of the support plate is parallel to the length direction of the steel rib. The support plate or support leg is staggered from the prestressed steel bars and longitudinal steel bars. The support block as a whole is staggered from the transversely distributed steel bars of the bottom plate and the transversely distributed steel bars of the upper flange. S3 also includes the following steps before pouring the upper flange concrete: Apply a release agent to the inner surface of the upper flange mold, and tie the longitudinal reinforcing bars and the transversely distributed reinforcing bars of the upper flange. Before pouring the foundation slab concrete, step S4 also includes: A release agent is applied to the inner surface of the base plate mold, and transverse reinforcing bars are laid out. Prestressed reinforcing bars are then tensioned.

4. The method for preparing a steel-ribbed prestressed concrete composite slab according to claim 3, characterized in that, The top and bottom ends of the web are respectively provided with an upper flange and a lower flange. The height of the block body is not greater than the net height of the web. The upper support structure and the lower support structure are respectively located on the outside of the upper flange and the lower flange.

5. The method for preparing a steel-ribbed prestressed concrete composite slab according to claim 4, characterized in that, The cross-section of the steel rib is Z-shaped, C-shaped, or H-shaped.

6. The method for preparing a steel-ribbed prestressed concrete composite slab according to claim 4, characterized in that, The upper and lower flange plates are provided with casting anchoring holes, and the web plate is provided with through holes.

7. The method for preparing a steel-ribbed prestressed concrete composite slab according to claim 4, characterized in that, The design location is located outside the hoisting point of the steel-ribbed prestressed concrete composite slab. The distance between the design location and the end of the upper flange of the concrete is no more than 300mm, and the distance between two adjacent design locations on the steel rib is no more than 2200mm. The support block is made of polyvinyl chloride or polycarbonate. The length of the block body is not less than 100mm, the width is not greater than 1 / 2 of the width of the upper flange of the concrete, and the height is not less than 95mm. The bottom of the block body is provided with chamfers and grooves.

8. The method for preparing a steel-ribbed prestressed concrete composite slab according to claim 2, characterized in that, The support plate is a straight plate or a corrugated plate, and each support block has two support legs.

9. The method for preparing a steel-ribbed prestressed concrete composite slab according to any one of claims 1-8, characterized in that, The block body is bonded and fixed to the side of the web of the steel rib by adhesive. Alternatively, bolt holes are provided on the web of the steel rib and the block body, and the block body is fixedly connected to the steel rib by bolts.

10. The method for preparing a steel-ribbed prestressed concrete composite slab according to claim 9, characterized in that, Each superstructure includes multiple steel ribs, which are spaced apart and arranged in parallel. The block body is fixed to the web of the outermost steel rib.

11. A method for stacking steel-ribbed prestressed concrete composite slabs, characterized in that, The steel-ribbed prestressed concrete composite slab is prepared by the preparation method of steel-ribbed prestressed concrete composite slab according to any one of claims 1-10; The stacking method includes: S10: The bottom steel-ribbed prestressed concrete composite slab is smoothly placed into the specified position using a lifting device; S11: Place a flexible pad on the top surface of the concrete upper flange at the support block, and ensure that the flexible pad is located on the upper support structure. The horizontal dimension of the flexible pad is not greater than the overall horizontal dimension of the two support blocks, and the center position of the flexible pad is consistent with the overall center position of the two support blocks. S12: Use a hoist to smoothly place the upper layer of steel-ribbed prestressed concrete composite slab onto the flexible pad of the lower layer of steel-ribbed prestressed concrete composite slab, and ensure that the lower support structure of the upper layer presses on the flexible pad of the lower layer; repeat this process until the stacking is completed, and the number of stacked layers shall not exceed 9.

Images