Production process of fabricated floor support plate

Abstract

This invention discloses a manufacturing process for prefabricated floor decking, comprising: a) fabricating transverse trusses; b) arranging the upper and lower chord reinforcement bars of multiple longitudinal trusses perpendicularly intersecting with multiple transverse trusses and fixing them together to form a transition reinforcement cage, and fixing the web reinforcement bars of the longitudinal trusses to a bottom formwork that can be removed; or, welding and fixing the upper chord reinforcement bars and web reinforcement bars of the longitudinal trusses to form a transition reinforcement cage perpendicularly intersecting with the transverse trusses, wherein the lower chord reinforcement bars of the longitudinal trusses are fixed to the bottom formwork; c) assembling to form prefabricated floor decking. This invention has good overall structural integrity, easily ensures assembly accuracy, facilitates automated and industrialized production, and has high production efficiency.

Description

Technical Field

[0001] This invention relates to the field of prefabricated floor decking technology for prefabricated buildings, and particularly to a production process for prefabricated floor decking. Background Technology

[0002] In current building construction technology, the steel truss floor decks used employ unidirectional triangular steel trusses, with each truss having two web members and two bottom chords. In actual projects, the bottom reinforcement is often excessive. Furthermore, after the concrete above the deck is poured and cured, the web members become ineffective, leading to material waste. Additionally, the secondary web members of traditional steel truss floor decks need to be interlaced on-site, resulting in low construction efficiency. Moreover, the rebar tying requires a large workforce, leading to high construction costs and complex construction procedures for existing steel truss floor decks.

[0003] Therefore, existing technology has developed a production process for composite floor slabs, employing a concrete composite floor slab with a two-way steel truss. The two-way planar steel truss and precast concrete are connected as an integral component through casting. The production process includes the fabrication of the two-way steel truss, specifically welding the first planar steel truss to the upper structure of the planar truss, then welding the first planar steel truss to the second lower chord steel reinforcement, and finally welding the second lower chord steel reinforcement to the upper structure of the planar truss. The method also includes the fabrication of the concrete composite floor slab, specifically fixing the formwork, pouring concrete, placing reinforcement and vibrating the concrete, steam curing or curing the concrete, and demolding. This invention has a high degree of industrialization, standardized materials, and a wide range of applications. It reduces costs to a certain extent, solves the problem of labor-intensive and time-consuming processing in general reinforced concrete composite floor slab manufacturing, addresses efficiency issues, and can achieve a significant increase in both output and quality.

[0004] However, this existing technology still requires operations such as formwork erection, concrete pouring, curing, and demolding during production. Furthermore, the reinforcing cage is pre-assembled and then connected to the concrete base slab. During welding and fixing, the reinforcing cage lacks necessary support, making it prone to deformation due to welding stress, thus compromising installation accuracy. Therefore, the existing technology still suffers from problems such as wet operation, low production efficiency, complexity and difficulty in industrial production, and poor assembly precision. Summary of the Invention

[0005] In view of the shortcomings of the prior art, the technical problem to be solved by the present invention is to provide a production process for prefabricated floor decking, which solves the problems of low production efficiency, inconvenience of industrial production, and poor assembly accuracy of the prior art.

[0006] To solve the above-mentioned technical problems, the present invention adopts the following technical solution:

[0007] A manufacturing process for prefabricated floor decking includes the following steps:

[0008] a. Construct the horizontal truss;

[0009] Take the top chord and bottom chord bars of the transverse truss and arrange them in parallel. Place the web bars of the transverse truss between the top chord and bottom chord bars to form the transverse truss.

[0010] b. Arrange the upper and lower chord reinforcement bars of multiple longitudinal trusses perpendicularly to multiple transverse trusses and fix them to form a transition reinforcement cage, and fix the web reinforcement bars of the longitudinal trusses to the bottom formwork that does not need to be removed.

[0011] Alternatively, the upper chord reinforcement of the longitudinal truss is welded and fixed to its web reinforcement, and then perpendicularly connected to the transverse truss to form a transition reinforcement cage, with the lower chord reinforcement of the longitudinal truss fixed to the bottom formwork.

[0012] c. Place the transition steel cage on the non-removable bottom formwork, and fix the upper and lower chord steel bars of the longitudinal truss to its web bars to form a longitudinal truss, or fix the lower chord steel bars of the longitudinal truss to its web bars and the lower chord steel bars of the transverse truss, so that the transverse truss and the longitudinal truss form a two-way steel cage fixed on the non-removable bottom formwork, and make the two-way steel cage and the bottom formwork fixed to it form a prefabricated floor deck.

[0013] As an optimization, in step b...

[0014] The web reinforcement of the longitudinal truss is welded to the side of its upper chord reinforcement that is perpendicular to the plane containing its upper and lower chord reinforcements;

[0015] Alternatively, the top and bottom chord bars of the longitudinal truss may be placed on opposite sides, opposite sides, or the same side of the top and bottom chord bars of the transverse truss.

[0016] As an optimization, in step c...

[0017] The web reinforcement of the longitudinal truss is welded to the side of the lower chord reinforcement that is perpendicular to the plane containing the upper chord reinforcement and the lower chord reinforcement;

[0018] Alternatively, the web reinforcement of the longitudinal truss is welded to the side of the upper and lower chord reinforcement that is perpendicular to the plane containing the upper and lower chord reinforcement.

[0019] As an optimization, the web reinforcement is wavy, with its crests and troughs welded and fixed to one side of the upper chord reinforcement and the lower chord reinforcement, respectively, perpendicular to the plane containing the upper chord reinforcement and the lower chord reinforcement.

[0020] As an optimization, the ends of the web reinforcement bars are bent vertically for fixed connection with steel beams or reinforcing bars in the building structure during construction.

[0021] As an optimization, the bottom formwork can be a precast / cast-in-place concrete slab, a metal slab, a cement substrate, or a calcium silicate board.

[0022] As an optimization, the bottom formwork is fixedly connected to the bidirectional reinforcing cage by a connector, wherein the connector includes a steel structure component or a steel-plastic composite component.

[0023] As an optimization, the steel structure component includes a steel strip covering the surface of the bottom formwork, and the reinforcing cage is connected to the steel strip.

[0024] Compared with the prior art, this application has the following advantages:

[0025] This invention,

[0026] 1. Reduce processing costs: This invention can greatly reduce the use of manual labor and lower labor costs.

[0027] 2. Adopting industrialized production methods can shorten the production cycle, improve production efficiency, and increase product competitiveness.

[0028] 3. The adoption of industrialized production has improved the production quality of products and effectively avoided issues such as manual incomplete welding and welding deformation.

[0029] 4. The floor decking using bidirectional single-piece steel truss can be processed into bidirectional slabs, increasing the spacing of temporary supports and enabling unsupported conditions under general spans, making it better suited for prefabricated buildings.

[0030] 5. Improve on-site construction efficiency: The steel bars in both directions are prefabricated in the factory, eliminating the need for on-site steel bar installation; only partial steel bar connection is required. Attached Figure Description

[0031] Figure 1 This is a schematic diagram of the transverse truss structure in this invention;

[0032] Figure 2 This is a schematic diagram of the transition steel cage structure in Embodiment 2 of the present invention;

[0033] Figure 3 This is a schematic diagram of the bottom mold assembly in Embodiment 2 of the present invention;

[0034] Figure 4 This is a schematic diagram showing the completed assembly of Embodiment 2 of the present invention;

[0035] In the diagram, 1 is the transverse truss, 2 is the longitudinal truss, 3 is the top chord reinforcement, 4 is the bottom chord reinforcement, 5 is the web reinforcement, 6 is the bottom formwork, and 7 is the steel strip. Detailed Implementation

[0036] The present invention will now be described in further detail with reference to the accompanying drawings.

[0037] For specific implementation: see: Figure 1-4 ,

[0038] A manufacturing process for prefabricated floor decking includes the following steps:

[0039] Example 1,

[0040] a. Construct horizontal truss 1;

[0041] Automated equipment can be used to pick up the top chord reinforcement 3 and the bottom chord reinforcement 4 and arrange them in parallel. In this embodiment, the wavy web reinforcement 5 is arranged between the top chord reinforcement 3 and the bottom chord reinforcement 4, and the crests and troughs of the web reinforcement 5 are welded and fixed to the side of the top chord reinforcement 3 and the bottom chord reinforcement 4 perpendicular to the plane where the top chord reinforcement 3 and the bottom chord reinforcement 4 are located using automated welding equipment. Of course, it is not limited to this. In this welding method, the contact area between the web reinforcement 5 and the top chord reinforcement 3 and the bottom chord reinforcement 4 is larger. Alternatively, the inflection points of the crests and troughs of the web reinforcement 5 can be welded to the opposite side of the top chord reinforcement 3 and the bottom chord reinforcement 4. The specific welding connection method is selected according to the structural stress and the overall structure of the reinforcement cage. Furthermore, the web reinforcement 5 is not limited to being welded to the upper chord reinforcement 3 or the lower chord reinforcement 4 at the crest and trough positions. It can also extend beyond the upper chord reinforcement 3 or the lower chord reinforcement 4 to form an extended beard reinforcement. Specifically, the beard reinforcement can extend within the plane where the web reinforcement 5 is located, or it can be bent to one side and extend to the plane where the upper chord reinforcement 3 or the lower chord reinforcement 4 is located.

[0042] b. Weld and fix the upper chord steel bar 3 of the longitudinal truss 2 to the wavy web reinforcement bar 5. The web reinforcement bar 5 of the longitudinal truss 2 is welded to the side of the upper chord steel bar 3 that is perpendicular to the plane where the upper chord steel bar 3 and the lower chord steel bar 4 are located, and is perpendicularly connected to the transverse truss 1 to form a grid-like transition steel cage. Specifically, the transition structure formed by the welded upper chord steel bar 3 and web reinforcement bar 5 of the longitudinal truss 2 is erected from top to bottom on the upper chord steel bar 3 of the transverse truss 1, and the crests and troughs of the web reinforcement bar 5 of the longitudinal truss 2 and the web reinforcement bar 5 of the transverse truss 1 are aligned at the same intersection point. Specifically, they can be located on the same side or on different sides. Then, the upper chord steel bar 3 of the longitudinal truss 2 and the upper chord steel bar 3 of the transverse truss 1 are welded together using a welding machine to form the transition steel cage.

[0043] Specifically, the formed bidirectional reinforcing cage includes multiple vertically intersecting single-piece transverse trusses 1 and longitudinal trusses 2, which are vertically arranged in actual use. Each of the transverse trusses 1 and longitudinal trusses 2 includes parallel upper chord bars 3 and lower chord bars 4. Web bars 5 are provided between the upper chord bars 3 and lower chord bars 4. Specifically, the web bars 5 are wavy, and the inflection points of their crests and troughs are welded and fixed to one side of the upper chord bars 3 and lower chord bars 4 that is perpendicular to the plane in which the upper chord bars 3 and lower chord bars 4 are located, in order to maximize the welding area and improve the connection strength.

[0044] The upper chord reinforcement 3 and / or lower chord reinforcement 4 and / or web reinforcement 5 of the transverse truss 1 and / or longitudinal truss 2 are fixedly connected to the bottom formwork 6 on the corresponding side.

[0045] In practical implementation, the prefabricated floor deck is used in steel structure buildings. When the deck ends are connected to the steel beams, the truss web reinforcement 5 is vertically bent at the ends and connected to the upper and lower chord reinforcement 4. During construction, the end vertical web reinforcement 5 is fixedly connected to the reinforcement. Furthermore, different materials can be selected for the bottom formwork 6 depending on the building type. The non-removable bottom formwork 6 can be made of precast concrete, metal slabs, cement-based boards, or finished boards such as calcium silicate boards, or finished boards with steel strips 7 on the surface. When the bottom formwork 6 is precast concrete, metal slabs, or finished boards with steel strips 7 on the surface, the reinforcement cage is fixedly connected to the bottom formwork 6 through the longitudinal truss 2 web reinforcement 5. When the bottom formwork 6 is a cement-based board or a finished board such as calcium silicate board, the bottom formwork 6 and the reinforcement cage are fixedly connected through connectors, where the connectors are steel structural components or steel-plastic composite components.

[0046] It is worth noting that when the prefabricated floor decking described in this invention is applied to floor slab structures, a bottom formwork 6 is set on one side to form a floor slab framework that can be cast in place. Of course, the structure of this invention can also be applied to plate-like structures such as shear walls or infill walls, and a bottom formwork 6 can be set on both sides to form a wall panel framework that can be cast in place, thus exhibiting good versatility and applicability.

[0047] c. Place the transition reinforcement cage on the bottom formwork 6 from top to bottom. Weld and fix the lower chord reinforcement 4 of the longitudinal truss 2 to the web reinforcement 5. The web reinforcement 5 of the longitudinal truss 2 is welded to the side of the lower chord reinforcement 4 that is perpendicular to the plane containing the upper chord reinforcement 3 and the lower chord reinforcement 4 to form the longitudinal truss 2. The transverse truss 1 and the longitudinal truss 2 form a two-way reinforcement cage fixed on the bottom formwork 6, and the two-way reinforcement cage and the bottom formwork 6 fixed to it form a prefabricated floor deck. The lower chord reinforcement 4 of the longitudinal truss 2 is fixed to the steel strip 7 or the connector on the bottom formwork 6 by welding. When using finished plates with steel strip 7 on the surface, the steel strip 7 is fixed to the plate by snap-fit. When using cement-based or calcium silicate board finished plates, the connector is fixed to the bottom plate by self-tapping screws.

[0048] It is worth noting that in this embodiment, since the longitudinal truss 2 is erected on the transverse truss 1 from top to bottom, the upper chord reinforcement 3 of the longitudinal truss 2 is above the upper chord reinforcement 3 of the transverse truss 1, while the lower chord reinforcement 4 of the longitudinal truss 2 is below the lower chord reinforcement 4 of the transverse truss 1. Therefore, the height between the crests and troughs of the web reinforcement 5 of the longitudinal truss 2 is greater than that of the web reinforcement 5 of the transverse truss 1. Thus, in actual production, it is necessary to process two different specifications of corrugated web reinforcement 5, which will bring certain inconveniences to automated processing equipment, such as requiring two welding parameters or two different processing equipment or parameters. Therefore, in order to further improve production efficiency and simplify the configuration of automated processing equipment, this invention also proposes an embodiment two.

[0049] Example 2 differs from Example 1 in that...

[0050] In step b, the upper chord reinforcement 3 and lower chord reinforcement 4 of the longitudinal truss 2 are perpendicularly connected to the transverse truss 1 to form a transition reinforcement cage, and the wavy web reinforcement 5 is fixed to the steel strip 7 of the base plate. The upper chord reinforcement 3 and lower chord reinforcement 4 of the longitudinal truss 2 are positioned on opposite sides, opposite sides, or the same side as the upper chord reinforcement 3 and lower chord reinforcement 4 of the transverse truss 1. This allows for flexible arrangement of the positions of the upper chord reinforcement 3 and lower chord reinforcement 4 according to actual needs. For example, the upper chord reinforcement 3 of the longitudinal truss 2 can be positioned below the upper chord reinforcement 3 of the transverse truss 1, and the lower chord reinforcement 4 can be positioned below the lower chord reinforcement 4 of the transverse truss 1, thus ensuring uniform specifications of the web reinforcement 5, facilitating automated welding, simplifying the configuration parameters of automated equipment, and improving production efficiency.

[0051] In step c, the upper chord steel bar 3 and the lower chord steel bar 4 of the longitudinal truss 2 are fixedly connected to the web reinforcement bar 5 to form the longitudinal truss 2. The web reinforcement bar 5 of the longitudinal truss 2 is welded to the side of the upper chord steel bar 3 and the lower chord steel bar 4 that is perpendicular to the plane in which the upper chord steel bar 3 and the lower chord steel bar 4 are located.

[0052] Example 3 differs from the examples described above.

[0053] In step b, the upper chord reinforcement 3 of the transverse truss 1, the upper chord reinforcement 3 of the longitudinal truss 2, and the web reinforcement 5 of the transverse truss 1 can be welded together to form a transition reinforcement cage. Then, the lower chord reinforcement 4 of the transverse truss 1, the lower chord reinforcement 4 of the longitudinal truss 2, and the web reinforcement 5 of the longitudinal truss 2 can be fixed on the bottom formwork 6 to form two completely symmetrical parts of the two reinforcement cages.

[0054] Then, in step c, the transition steel cage is joined to the bottom formwork 6 and welded together to form the steel cage, ultimately forming a complete floor slab. Of course, the steel cage can also be formed separately by this welding method and then fixed to the bottom formwork 6.

[0055] In summary, this invention involves disassembling a single-piece steel truss into two parts. One part uses a complete steel truss as the main frame to assemble and connect to form a transition steel cage, while the other part is fixedly connected to the bottom formwork. In this way, the bottom formwork ensures the position and accuracy of this part. Even if the transition steel cage deforms due to welding stress after welding, the assembly and welding of the two parts, along with the part fixed to the bottom formwork, corrects the transition steel cage, thus ensuring the assembly accuracy of the overall bidirectional steel cage. This results in better overall integrity, is more conducive to automated industrial production, and has higher production efficiency.

[0056] Therefore, the present invention,

[0057] 1. Reduce processing costs: This invention can greatly reduce the use of manual labor and lower labor costs.

[0058] 2. Adopting industrialized production methods can shorten the production cycle, improve production efficiency, and increase product competitiveness.

[0059] 3. The adoption of industrialized production has improved the production quality of products and effectively avoided issues such as manual incomplete welding and welding deformation.

[0060] 4. The floor decking using bidirectional single-piece steel truss can be processed into bidirectional slabs, increasing the spacing of temporary supports and enabling unsupported conditions under general spans, making it better suited for prefabricated buildings.

[0061] 5. Improve on-site construction efficiency: The steel bars in both directions are prefabricated in the factory, eliminating the need for on-site steel bar installation; only partial steel bar connection is required.

[0062] Although embodiments of the present invention have been shown and described, those skilled in the art will be able to make various changes, modifications, substitutions and variations to these embodiments without departing from the principles and basis of the present invention. The scope of the present invention is defined by the appended claims and their equivalents. Therefore, the embodiments of the present invention are merely illustrative examples and should not be construed as limiting the present invention in any way.

Claims

1. A manufacturing process for prefabricated floor decking, characterized in that, Includes the following steps, a. Construct the horizontal truss; Take the top chord and bottom chord bars of the transverse truss and arrange them in parallel. Place the web bars of the transverse truss between the top chord and bottom chord bars to form the transverse truss. b. Arrange the upper and lower chord bars of the longitudinal truss perpendicularly to the transverse truss and fix them to form a transition steel cage. Fix the web bars of the longitudinal truss to the bottom formwork that can be removed. The upper and lower chord bars of the longitudinal truss are set on the opposite side, opposite side, or same side of the upper and lower chord bars of the transverse truss. c. The upper and lower chord bars of the longitudinal truss are fixedly connected to the web bars to form a longitudinal truss, so that the transverse truss and the longitudinal truss form a two-way steel cage fixed on the bottom formwork that does not need to be removed, and the two-way steel cage and the bottom formwork fixedly connected to it form a prefabricated floor deck. The ends of the web reinforcement bars are bent vertically for fixed connection with steel beams or reinforcing bars in the building structure during construction.

2. The manufacturing process for prefabricated floor decking according to claim 1, characterized in that, In step c, The web reinforcement of the longitudinal truss is welded to the lower chord reinforcement and is located on the side perpendicular to the plane containing the upper chord reinforcement and the lower chord reinforcement; Alternatively, the web reinforcement of the longitudinal truss is welded to the upper and lower chord reinforcements and located on the side perpendicular to the plane containing the upper and lower chord reinforcements.

3. The manufacturing process for prefabricated floor decking according to claim 1, characterized in that, The web reinforcement is wavy, with its crests and troughs welded and fixed to the upper chord reinforcement and the lower chord reinforcement respectively, and located on one side perpendicular to the plane containing the upper chord reinforcement and the lower chord reinforcement.

4. The production process of a prefabricated floor decking according to claim 1, characterized in that, The bottom formwork is a precast / cast-in-place concrete slab, a metal slab, a cement substrate, or a calcium silicate board.

5. The manufacturing process for prefabricated floor decking according to claim 1, characterized in that, The bottom formwork is fixedly connected to the bidirectional reinforcing cage by a connector, wherein the connector includes a steel structure component or a steel-plastic composite component.

6. The manufacturing process for prefabricated floor decking according to claim 5, characterized in that, The steel structure component includes a steel strip covering the surface of the bottom formwork, and the bidirectional reinforcing cage is connected to the steel strip.

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