A precast staircase straight section left-right universal mold, usage method and mirrored staircase

Abstract

This invention patent belongs to the technical field of precast concrete component molds, and discloses a precast staircase straight section left-right universal mold, its usage method, and mirror image staircases. It includes a bottom support and outer side formwork for the bosses on both sides thereof. Bottom end formwork and bottom flat formwork are respectively provided on the two outer side formworks for the bosses. Top end formwork and top flat formwork are provided on the two upper straight section formworks. An inner side formwork for the boss is provided on the inner side of the outer side formwork for the boss on the right side to form a left-running staircase mold, or an inner side formwork for the boss is provided on the inner side of the outer side formwork for the boss on the right side to form a right-running staircase mold. In the present invention, by adding or reducing boss mold parts on the outer side formworks for the bosses on both sides, the problem of staircase boss mirror images caused by different staircase running positions is effectively solved; for the simplified mold, by selecting a reasonable sequence during mold assembly and disassembly and a scientific pouring process, not only is the labor consumption and lifting machinery work shift reduced, but also the pouring production efficiency is improved.

Description

Technical Field

[0001] This invention patent belongs to the technical field of precast concrete component molds, and in particular discloses a universal mold for the straight section of precast stairs, a usage method, and a mirror image staircase. Background Art

[0002] At present, in the process of the construction industry moving towards prefabrication, since the external dimensions of precast stair components are determined by the bay, depth, floor height, and thickness of the stair section of the staircase, different staircases often correspond to different types of precast stairs. Similarly, in different staircases of the same building, due to the different positions of the stair runs, the external shapes of the precast stairs will also be different, that is, mirror image precast stairs. During our visits, we found that currently all construction parties generally adopt the solution of making two types of stair molds to solve the problem of stair mirror images, so there is generally a problem of high amortization cost of stair molds.

[0003] In this regard, the auxiliary molds used in the casting production of precast stairs at this stage are also different. For example, the Chinese invention patent (publication number: CN107283606A) discloses a stair casting mold and a staircase, and the Chinese invention patent (publication number: CN109278165A) discloses a precast stair mold. Although the above two published patent documents give different construction solutions in the mold design of precast stairs, they can only solve the problem of excessive amortization cost of stair molds to a certain extent. In addition, taking the precast stair mold (publication number: CN111283853A) applied by Broad Sustainable Building (Hangzhou) Co., Ltd. on April 1, 2020 as an example, although this precast stair mold can solve the problem of the applicability of precast stair dimensions in different projects, the mold structure is too fragmented. Therefore, additional work is required during mold assembly and disassembly, which will also affect the completion progress of precast stairs in the entire project. Similarly, taking the adjustable precast mold system for assembled stairs (publication number: CN216884504U) applied by Hunan Dongfanghong Housing Industry Co., Ltd. on December 15, 2021 as an example, each formwork support component and side baffle are respectively slidably connected through a screw rod slide table and an adjustment oil cylinder is used to adjust the length, thickness, and end angle of the precast stairs respectively to solve the problem of stair universality. However, this stair mold solution not only requires additional expenditure on the hydraulic system, but also has poor safety in the auxiliary operation of the hydraulic system, and there will be more uncertain factors during the operation of the entire mold. Therefore, the production cost of the entire mold is relatively high and it is not suitable for mass production. However, for the problem of high amortization cost of stair mirror images, the prior art has not been able to give a better solution and still adopts the solution of making two types of stair molds.

[0004] In order to solve the problem that traditional prefabricated staircase molds cannot solve the mirror-image staircases caused by different stair tread positions in the same building, two sets of molds need to be made separately to produce prefabricated stairs with mirror-image structures, which leads to increased overall amortization and low mold utilization. At present, it is urgent to redesign the existing staircase molds and make a set of left and right universal molds that are easy to assemble and disassemble and can produce mirror-image structure stairs at the same time. This research direction has always been a technical problem that our industry wants to solve but cannot achieve. Summary of the invention

[0005] In view of the introduction of the existing stair mold technology in the above background technology, combined with the problem of mirror image of prefabricated stairs caused by the different positions of the stair runners. Therefore, in our construction industry, how to achieve the same set of stair molds to produce mirror image structure stairs has always been a technical problem that cannot be overcome in research. Although the existing stair molds can solve the basic problems of prefabricated stair production, and can even solve the problem of universal prefabricated stairs, in our industry, mirror image structure stairs are all produced using two different sets of molds. This is enough to illustrate the applicability limitations of the existing casting process to such problems, and it can also confirm the urgency of this technical problem that needs to be solved urgently.

[0006] For this reason, we made the side molds all assembled in the early stage of designing the horizontal molds for prefabricated stairs. At the same time, the side molds are divided into two groups at the straight section stairwell boss, one group is the whole stair section mold; the other group is the straight section boss mold. This group of molds can adjust the position of the straight section boss of the prefabricated staircase by adding or reducing parts, that is, adjust the position of the staircase in the stairwell without changing the overall staircase mold. Based on the above design ideas, we proposed a universal left and right mold for the straight section of prefabricated stairs, a method of use, and a mirrored staircase.

[0007] To achieve the above-mentioned purpose, the present invention adopts the following technical scheme: a universal left and right mold for prefabricated straight sections of stairs, comprising a bottom support, side block templates are connected to the left and right sides of the bottom support respectively by bolts, and also comprising two boss inner block templates, the two of which have the same shape and are mirror images of each other in structure, the cross section of the boss inner block template is a right-angled trapezoid, which is composed of a triangular template and a boss template, the bottom support comprises a base frame and a plurality of connecting legs, the plurality of connecting legs are divided into two groups and are symmetrically and equidistantly arranged on both sides of the base frame along the center line of the base frame, and screw holes are provided on each connecting leg for bolting the side block templates, a plurality of support plates are vertically fixedly connected to the base frame, and the plurality of support plates fix the base plate to the base frame, the two side block templates have the same shape and are mirror images of each other in structure, and both are divided into three parts: a stair section block template, an upper straight section block template and a lower straight section block template, the cross section of the stair section block template is a rectangle, and the upper straight section block template comprises a right-angled surface, a large inclined surface and a small inclined surface, The cross-section of the lower straight section blocking template is a right-angled trapezoid, and a boss outer blocking template is connected to the inclined surface of each lower straight section blocking template by bolts, the boss outer blocking template is integrally formed, and its shape is the same as the shape of the boss inner blocking template, the inclined surface of each boss outer blocking template is flush with the top surface of the stair section blocking template, a bottom end template is connected between the two boss outer blocking templates by bolts, the bottom end template is located on one side of the right-angle surface of the two boss outer blocking templates, a bottom flat template is connected between the two boss outer blocking templates by bolts, the bottom flat template is located on one side of the top surface of the two boss outer blocking templates, a top template is connected between the small inclined surfaces of the two upper straight section blocking templates by bolts, a top flat template is connected on the large inclined surfaces of the two upper straight section blocking templates by bolts, and the top surface of the top flat template contacts the side surface of the top template, the two triangular templates are respectively connected to the inner sides of the two boss outer blocking templates by bolts, and any one of the two boss templates is connected to the inner side of the corresponding boss outer blocking template by bolts.

[0008] As a further supplementary explanation of the above technical solution, two first positioning holes are provided on the top flat template, and two second positioning holes are provided on the bottom flat template, and both the first positioning holes and the second positioning holes are used to insert tooling before pouring.

[0009] As a further explanation and limitation of the above technical solution, the support plate is divided into three parts: a stair section support plate, an upper straight section support plate and a lower straight section support plate, and the positions of the three parts correspond to the stair section retaining plate, the upper straight section retaining plate and the lower straight section retaining plate, respectively; the base plate is divided into three parts: a stair tread panel, an upper straight panel and a lower straight panel, and the shapes of the three parts correspond to the stair section support plate, the upper straight section support plate and the lower straight section support plate, respectively.

[0010] As a further explanation and limitation of the above technical solution, the chassis is welded by two longitudinal beams and multiple cross beams, and the multiple cross beams are equidistantly distributed between the two longitudinal beams. The multiple connecting feet are evenly welded in two groups on the outer sides of the two longitudinal beams.

[0011] As a further supplementary description of the above technical solution, a plurality of rib plates are fixedly connected in the back groove of the stair section formwork. The rib plates are used to increase the shear strength of the side formwork and prevent deformation caused by stress concentration.

[0012] A usage method of a left-right universal mold for a precast stair straight section includes the left-right universal mold for a precast stair straight section in the above solution, and comprises the following steps:

[0013] S1. Clean the mold: Clean the residual concrete slag and joint glue on all surfaces and joints of the stair tread plate, side formwork, outer formwork of the convex platform, top formwork, top flat formwork, bottom formwork, bottom flat formwork and inner formwork of the convex platform of the bottom support, and ensure that all surfaces of the mold in contact with the concrete are clean and free of any residues that affect the appearance of the component;

[0014] S2. Install the side mold group according to the component requirements: Confirm the type of the precast stair component, that is, the position of the convex platform on the lower straight section of the precast stair; S2.1, if the convex platform is on the left side of the lower straight section of the stair, first bolt the two side formworks to the connecting feet on both sides of the bottom support, then bolt the outer formwork of the left convex platform to the left side formwork, bolt the two triangular formworks to the inner sides of the outer formworks of the convex platforms on both sides respectively, and at the same time bolt the right convex platform formwork to the inner side of the right outer formwork of the convex platform, thus assembling the left-running stair mold; S2.2, if the convex platform is on the right side of the lower straight section of the stair, keep other operations unchanged, only bolt the left convex platform formwork to the inner side of the left outer formwork of the convex platform, and at the same time remove the right convex platform formwork, thus assembling the right-running stair mold;

[0015] S3. Apply release agent: After confirming that the inner surface of the mold is clean and free of debris, use a sponge brush to evenly apply the release agent on the inner surfaces of each mold component in the order of the side formwork, outer formwork of the convex platform, inner formwork of the convex platform, bottom support, top formwork, top flat formwork, bottom formwork, bottom flat formwork, and keep the direction of the gesture consistent when applying the release agent;

[0016] S4. Hoist the steel reinforcement cage: According to the requirements of the steel bar dimensions on the drawing, place the steel reinforcement cage of the corresponding specification into the assembled mold, and use concrete pads to lift the bottom steel bars of the steel reinforcement cage and steel bar stools of the steel bar material to support the upper steel bars of the steel reinforcement cage respectively, so as to ensure the protective layer thickness of the cast stair.

[0017] S5. Embedded Binding: Fix the positioning pins to be embedded in the precast stairs respectively through the first positioning holes and the second positioning holes. At the same time, determine the positions of the embedded parts required for the railing handrails on the mold and fix them in place.

[0018] S6. End Mold Installation: On the premise of completing S4 and S5, then install and fix the top flat formwork, bottom flat formwork, top end formwork, and bottom end formwork in sequence to the bottom support, the side retaining formworks on both sides, and the outer retaining formwork of the convex platform through bolts.

[0019] S7. Mold Dimension Inspection: Check the dimensions of the outer mold against the drawing, that is, the length and width of the component. Check that the side retaining formworks on both sides are free of deformation and bending, and the deformation amount meets the technical standards.

[0020] S8. Steel Bar Inspection: Check that the varieties, grades, and specifications of the steel bars all meet the requirements of the document; the ends of the steel bars must be kept at a distance of 2 - 2.5 cm from the inner and outer sides, and this distance is the protective layer; the ties and steel bars are guaranteed to face down and not touch the bottom support, and face up and not be higher than the horizontal plane of the side retaining formworks on both sides; check whether the cushion blocks and stools are placed stably.

[0021] S9. Pouring and Vibrating: According to the mold dimensions and structural characteristics, use a pouring route from far to near and from narrow to wide; after receiving the material, start moving the pouring trolley from one end, and open the discharge door according to the width of the material to be poured; adjust the speed of the pouring trolley according to the discharging speed of the concrete to keep it at a constant speed, and perform the pouring operation to meet the requirements of uniform and full pouring in one go. After the pouring operation is completed, for the positions with corner shortages and leaks during the pouring process, the on-site personnel evenly rake the concrete; after raking, select the corresponding vibration device to vibrate the precast stairs, so that the surface of the precast stairs presents a flat and bubble-free state.

[0022] S10. Surface and Initial Setting Treatment: The pouring plane of the concrete must be flush with the top surfaces of the two stair section retaining formworks, and ensure that no steel bars are exposed; use a trowel to level the surface of the concrete; after leveling, wait for 20 minutes for the concrete to reach the initial setting state and then remove the positioning pins.

[0023] S11. Curing: After completing S10, stand still for more than twelve hours for film curing. During curing, the curing personnel should check in time to prevent cracks on the concrete surface due to untimely curing.

[0024] S12. Demoulding: Demould the component mold according to the mold assembly sequence in S2 and S6. First, disassemble the bottom end formwork, bottom flat formwork, top end formwork, and top flat formwork in sequence, and then disassemble the outer retaining formwork of the convex platform and the inner retaining formwork of the convex platform in sequence to complete the demoulding of the precast component.

[0025] As a further supplementary description of the above technical solution, in S5, the embedded part is any one of a demoulding lifting nail, a turning lifting nail, and a hoisting lifting nail.

[0026] As a further supplementary description of the above technical solution, in S10, when screeding, the surface flatness of the concrete is controlled within 3 mm and there are no scratches.

[0027] As a further supplementary description of the above technical solution, in S11, the normal temperature curing time shall not be less than seven days, and the special curing time shall not be less than fourteen days.

[0028] A mirror staircase, including a staircase cast by using the use method of a precast staircase straight section left-right universal mold in the above solution, which is integrally cast by a staircase section, a lower straight section of the staircase, and an upper straight section of the staircase. The left-running staircase is cast by using a left-running staircase mold, that is, the convex platform is located on the right side of the lower straight section of the staircase, and the right-running staircase is cast by using a right-running staircase mold, that is, the convex platform is located on the left side of the lower straight section of the staircase. Sliding hinge end positioning holes and fixed hinge end positioning holes are respectively arranged on the lower straight section of the staircase and the upper straight section of the staircase. The sliding hinge end positioning holes and the fixed hinge end positioning holes are used to position the staircase through bolts and fillers, so as to play a shear resistance role during geological disasters and reduce the damage of the staircase.

[0029] Compared with many existing staircase molds, the present invention has the following advantages:

[0030] 1. In the design of the side mold of the present invention, aiming at the change of the convex platform position of the straight section of the staircase, it is designed in a combined manner. One group is the overall mold of the outer baffle template of the convex platform, and the other group is the combined inner baffle template of the convex platform formed by the triangular template and the convex platform mold. During the mold assembly process, by increasing or decreasing the convex platform mold parts in the inner baffle templates of the convex platforms on both sides, the position of the convex platform on the lower straight section of the staircase is adjusted, thus completely solving the problem that two sets of molds are required for mirror staircases due to different staircase running positions in the same building, and thereby reducing the amortization cost of the casting mold for mirror staircases.

[0031] 2. The present invention selects a reasonable method during mold assembly and disassembly and a scientific casting and demoulding process, which can reduce additional labor consumption and hoisting machinery work shifts; at the same time, the optimized structure of the mold can effectively reduce the number of molds, thereby improving the casting production efficiency.

[0032] 3. The present invention designs the inner baffle template of the convex platform into a triangular template and a convex platform template. During the demoulding process, by changing the removal sequence, the contact surface between the mold and the concrete is reduced, preventing the left-running staircase and the right-running staircase produced by casting from having chipping and corner breakage defects, and thus not affecting the appearance and quality of the precast staircase.

[0033] 4. In the present invention, a bolt connection method is adopted at the connection between the two side molds and the bottom support. During demolding, it only requires loosening the bolts and pulling the side molds upward without connecting them to the cast member to complete demolding. The safety and operability are greatly improved. Compared with most existing stair molds, it does not require mechanical (hoisting system) assistance, further reducing the additional expenditure on the cast member and simplifying the casting production process.

[0034] 5. In the present invention, different boss mold parts are respectively placed on the left or right side of the mold, thereby changing the position of the boss on the lower straight section of the stair, and thus casting a right-running stair or a left-running stair. At the same time, a sliding hinge end positioning hole is provided on the lower straight section of the stair, a fixed hinge end positioning hole is provided on the upper straight section of the stair, and the whole stair is positioned by bolts and fillers, playing a shear resistance role during geological disasters and reducing the damage to the stair. BRIEF DESCRIPTION OF THE DRAWINGS

[0035] Figure 1 is a three-dimensional schematic diagram of the present invention;

[0036] Figure 2 is an exploded structural schematic diagram of the present invention;

[0037] Figure 3 is a three-dimensional schematic diagram of the bottom support in the present invention;

[0038] Figure 4 is an exploded structural schematic diagram of the bottom support in the present invention;

[0039] Figure 5 is an assembly schematic diagram of the side retaining template and the outer boss retaining template and the inner boss retaining template in the present invention;

[0040] Figure 6 is a structural schematic diagram of the left-running stair mold in the present invention;

[0041] Figure 7 For use Figure 6 is a structural schematic diagram of the left-running stair cast by using the casting production in;

[0042] Figure 8 is a structural schematic diagram of the right-running stair mold in the present invention;

[0043] Figure 9 For use Figure 8 is a structural schematic diagram of the right-running stair cast by using the casting production in;

[0044] Figure 10 is a process flow chart of the usage method of the left and right running stair molds in the present invention;

[0045] Figure 11 is a physical diagram of the left-running stair cast by using the left-running stair mold in the present invention;

[0046] Figure 12 It is a physical diagram of a right-running staircase produced by pouring with the right-running staircase mold in the present invention.

[0047] In the figure: the bottom support is 1, the side formwork is 2, the outer formwork of the convex platform is 3, the top formwork is 4, the top flat formwork is 5, the bottom formwork is 6, the bottom flat formwork is 7, the inner formwork of the convex platform is 8, the first positioning hole is 9, the second positioning hole is 10, the left-running staircase mold is 11, and the right-running staircase mold is 12.

[0048] The bottom support includes: the bottom frame is 101, the connecting support feet are 102, the support plate is 103, and the bottom plate is 104; among them, the bottom frame includes: the longitudinal beam is 1011 and the cross beam is 1012.

[0049] The support plate includes: the staircase section support plate is 1031, the upper straight section support plate is 1032, and the lower straight section support plate is 1033.

[0050] The bottom plate includes: the staircase tread plate is 1041, the upper straight panel is 1042, and the lower straight panel is 1043.

[0051] The side formwork includes: the staircase section formwork is 201, the upper straight section formwork is 202, the lower straight section formwork is 203, and the rib plate is 204.

[0052] The inner formwork of the convex platform includes: the triangular formwork is 801 and the convex platform formwork is 802.

[0053] The structures of the left and right running staircases include: the staircase section is 100, the lower straight section of the staircase is 200, the upper straight section of the staircase is 300, the convex platform is 400, the sliding hinge end positioning hole is 500, and the fixed hinge end positioning hole is 600. Specific embodiments

[0054] In order to further elaborate the technical solution of the present invention, the following combines the attached Figures 1 to 10 , according to the on-site pouring process, we further illustrate the present invention through the optimal embodiment.

[0055] As shown in the attached Figure 1 and 2As shown in the figure, a precast staircase straight section left-right universal mold consists of eight template parts, including a bottom support 1, two side formwork 2, a convex platform outer formwork 3, a top template 4, a top flat template 5, a bottom template 6, a bottom flat template 7, and a convex platform inner formwork 8. Among them, two first positioning holes 9 are provided on the top flat template 5, and two second positioning holes 10 are provided on the bottom flat template 7. It should be noted that both the first positioning hole 9 and the second positioning hole 10 mentioned in this embodiment are used to insert a tooling (i.e., a positioning pin) before pouring and remove the tooling after initial setting, so as to form a fixed hinge end positioning hole and a sliding hinge end positioning hole on the demolded precast staircase. For the specific usage process and design purpose, refer to the following usage method of the precast staircase straight section left-right universal mold and the introduction of the mirror staircase.

[0056] As shown in the attached Figure 3 and 4 As shown in the figure, the bottom support 1 includes a bottom frame 101 and a plurality of connecting feet 102. The plurality of connecting feet 102 are symmetrically and equidistantly arranged in two groups on both sides of the bottom frame 101 along the center line of the bottom frame 101. Specific connection method: The bottom frame 101 is welded by two longitudinal beams 1011 and a plurality of cross beams 1012, and the plurality of cross beams 1012 are equidistantly distributed between the two longitudinal beams 1011. The plurality of connecting feet 102 are evenly welded in two groups on the outer sides of the two longitudinal beams 1011. And a screw hole is provided on each connecting foot 102 for bolt connection with the side formwork 2. A plurality of support plates 103 are vertically and fixedly connected to the bottom frame 101, and the bottom plate 104 is fixedly connected to the bottom frame 101 through the plurality of support plates 103. The support plates 103 are divided into three parts: a staircase section support plate 1031, an upper straight section support plate 1032, and a lower straight section support plate 1033. The bottom plate 104 is divided into three parts: a staircase tread plate 1041, an upper straight panel 1042, and a lower straight panel 1043, and their shapes respectively correspond to the staircase section support plate 1031, the upper straight section support plate 1032, and the lower straight section support plate 1033.

[0057] As shown in the attached Figure 5 As shown in the figure, the two side formworks 2 have the same shape and their structures are mirror images of each other. They are mainly divided into three parts: a staircase section formwork 201, an upper straight section formwork 202, and a lower straight section formwork 203. The cross-section of the staircase section formwork 201 is rectangular. The upper straight section formwork 202 includes a right-angled surface, a large inclined surface, and a small inclined surface. The cross-section of the lower straight section formwork 203 is a right-angled trapezoid. At the same time, the positions of the staircase section support plate 1031, the upper straight section support plate 1032, and the lower straight section support plate 1033 in the above-mentioned support plates 103 respectively correspond to the staircase section formwork 201, the upper straight section formwork 202, and the lower straight section formwork 203.

[0058] As shown in the attached Figure 2and 5 As shown in the figure, the outer baffle template 3 of the boss is integrally formed, and its shape is the same as that of the inner baffle template 8 of the boss. The shapes of the two inner baffle templates 8 of the boss are the same and their structures are mirror-symmetrical to each other. The shape of the inner baffle template 8 of the boss is a right trapezoid, which is composed of a triangular template 801 and a boss template 802. After mold assembly, the bottom surface of each outer baffle template 3 of the boss is in contact with the inclined surface of the lower straight-section baffle template 203 through bolt connection, and the inclined surface of the outer baffle template 3 of the boss is flush with the top surface of the stair-section baffle template 201.

[0059] Mold assembly method: As shown in the appendix Figures 1 to 5 As shown in the figure, first, we install the two side baffle templates 2 on the connecting feet 102 on both sides of the chassis 101 through bolt connection; then, a bottom-end template 6 is bolt-connected between the two outer baffle templates 3 of the boss, where the bottom-end template 6 is located on the right-angle side of the two outer baffle templates 3 of the boss. At the same time, a bottom-flat template 7 is bolt-connected between the two outer baffle templates 3 of the boss, and the bottom-flat template 7 is located on the top surface side of the two outer baffle templates 3 of the boss. A top-end template 4 is bolt-connected between the small inclined surfaces of the two upper straight-section baffle templates 202, and a top-flat template 5 is bolt-connected to the large inclined surfaces of the two upper straight-section baffle templates 202, and the top surface of the top-flat template 5 is in contact with the side surface of the top-end template 4, completing the assembly of the general-purpose mold.

[0060] We can choose to use the left-running stair mold or the right-running stair mold according to the type of precast component. (1) When assembling into the left-running stair mold 11, on the basis of the above general-purpose mold, we respectively install a triangular template 801 and a boss template 802 on the inner side of the outer baffle template 3 of the boss on the left side of the mold, and install a triangular template 801 on the inner side of the outer baffle template 3 of the boss on the right side of the mold, then the final mold assembly operation can be completed (refer to the appendix Figure 6 ); (2) When it is necessary to assemble into the right-running stair mold 12, on the basis of the above general-purpose mold, we install a triangular template 801 on the inner side of the outer baffle template 3 of the boss on the left side of the mold, and respectively install a triangular template 801 and a boss template 802 on the inner side of the outer baffle template 3 of the boss on the right side of the mold, then the final mold assembly operation can be completed (refer to the appendix Figure 8 ).

[0061] As a further implementation method of this embodiment, a plurality of rib plates 204 are fixedly connected in the back groove of the stair-section baffle template 201. The rib plates 204 are used to increase the shear strength of the side baffle template 2 and prevent deformation caused by stress concentration.

[0062] In this embodiment, for all the connecting screw holes on all the mold parts such as the bottom support, side formwork, outer formwork of the boss, top formwork, top flat formwork, bottom formwork, bottom flat formwork, and the inner formwork of the boss composed of triangular formwork and boss formwork, those skilled in the art can infer according to the bolt connection method, and since the bolt connection method belongs to the conventional design, the inventor will not elaborate here.

[0063] As shown in the appendix Figure 10 shown, a method for using a left-right universal mold for a precast staircase straight section, including the left-right universal mold for a precast staircase straight section in the above embodiment, comprises the following steps:

[0064] S1. Clean the mold: Clean the residual concrete slag and joint glue on all surfaces and joints of the staircase tread plate 1041 of the bottom support 1, side formwork 2, outer formwork 3 of the boss, top formwork 4, top flat formwork 5, bottom formwork 6, bottom flat formwork 7, and inner formwork 8 of the boss, ensuring that all mold surfaces in contact with the concrete are clean and free of any residues that may affect the appearance of the component;

[0065] S2. Install the side mold group according to the component requirements: Confirm the type of precast staircase component, that is, the position of the boss 400 on the lower straight section 200 of the precast staircase; S2.1, if the boss 400 is on the left side of the lower straight section 200 of the staircase, first bolt and fix the two side formworks 2 on the two connecting feet 102 on both sides of the bottom support 1, then bolt and fix the left outer formwork 3 of the boss to the left side formwork 2, respectively bolt and fix the two triangular formworks 801 on the inner sides of the outer formworks 3 of the boss on both sides, and at the same time bolt and fix the right boss formwork 802 on the inner side of the right outer formwork 3 of the boss, thus assembling the left-running staircase mold 11; S2.2, if the boss 400 is on the right side of the lower straight section 200 of the staircase, with other operations remaining unchanged, only bolt and fix the left boss formwork 802 on the inner side of the left outer formwork 3 of the boss, and at the same time remove the right boss formwork 802, thus assembling the right-running staircase mold 12;

[0066] S3. Apply release agent: After confirming that the inner surface of the mold is clean and free of debris, use a sponge brush to evenly apply the release agent on the inner surfaces of each mold component in the order of side formwork 2, outer formwork 3 of the boss, inner formwork 8 of the boss, bottom support 1, top formwork 4, top flat formwork 5, bottom formwork 6, bottom flat formwork 7, and keep the direction of the gesture consistent when applying the release agent;

[0067] S4. Lift and place the steel reinforcement cage: According to the requirements of the steel reinforcement dimensions on the drawing, place the steel reinforcement cage of the corresponding specification into the assembled mold, and use concrete pads to lift the bottom steel bars of the steel reinforcement cage and steel stool made of steel reinforcement material to support the upper steel bars of the steel reinforcement cage, so as to ensure the protection layer thickness of the cast staircase;

[0068] S5. Embedded Binding: Fix the positioning pins to be embedded in the precast stairs respectively through the first positioning holes 9 and the second positioning holes 10. At the same time, determine the positions of the embedded parts required for the railing handrail on the mold and fix them. The embedded parts are any one of the demolding lifting pins, flipping lifting pins, and hoisting lifting pins.

[0069] S6. End Mold Installation: On the premise of completing S4 and S5, then install and fix the top flat template 5, bottom flat template 7, top end template 4, and bottom end template 6 to the bottom support 1, the side retaining templates 2 on both sides, and the outer retaining template 3 of the convex platform in sequence through bolts.

[0070] S7. Mold Size Inspection: Check the outer mold size with reference to the drawing, that is, the length and width of the component. Check that the side retaining templates 2 on both sides are not deformed or bent, and the deformation amount meets the technical standards.

[0071] S8. Steel Bar Inspection: Check that the varieties, grades, and specifications of the steel bars all meet the requirements of the document; the ends of the steel bars must be kept at a distance of 2 - 2.5 cm from the inner and outer sides, and this distance is the protective layer; the tying heads and steel bars are guaranteed to face down and not touch the bottom support 1, and face up and not be higher than the horizontal plane of the side retaining templates 2 on both sides; check whether the cushion blocks and stools are placed stably.

[0072] S9. Pouring and Vibrating: According to the mold size and structural characteristics, use a cloth - spreading route that is far - first and near - later, narrow - first and wide - later; after receiving the material, start moving the cloth - spreading trolley from one end, and open the discharge door according to the width of the material to be spread; according to the unloading speed of the concrete, adjust the speed of the cloth - spreading trolley to keep it at a constant speed, so as to meet the requirements of uniform and full spreading in one go for the cloth - spreading operation. After the cloth - spreading operation is completed, for the positions with corner shortages and leaks during the cloth - spreading process, on - site personnel evenly rake the concrete; after raking, select the corresponding vibration device to vibrate the precast stairs, so that the surface of the precast stairs presents a flat and bubble - free state.

[0073] S10. Surface and Initial Setting Treatment: The pouring plane of the concrete must be flush with the top surfaces of the two stair - section retaining templates 201, and ensure that no steel bars are exposed; use a trowel to level the surface of the concrete. When leveling, the surface flatness of the concrete is controlled within 3 mm and there are no scratches; after leveling, wait for 20 minutes for the concrete to reach the initial setting state and then remove the positioning pins.

[0074] S11. Curing: After completing S10, stand still for more than twelve hours for film - covering curing. During curing, the curing personnel should check in time to prevent cracks on the concrete surface due to untimely curing.

[0075] S12. Demold the mold: Demold the component mold according to the mold assembly sequence of S2 and S6. First, remove the bottom template 6, bottom flat template 7, top template 4, and top flat template 5 in sequence, and then remove the convex platform outer retaining template 3 and convex platform inner retaining template 8 in sequence to complete the demolding of the precast component.

[0076] In S11, the normal curing time shall not be less than seven days, and the special curing time shall not be less than fourteen days.

[0077] As shown in the appendix Figures 6 to 9 , a mirror staircase, including a staircase cast by using the above-mentioned general mold usage method. The staircase is integrally cast by a staircase section 100, a lower straight section 200 of the staircase, and an upper straight section 300 of the staircase. The left-running staircase is cast by using a left-running staircase mold 11, that is, the convex platform 400 is located on the right side of the lower straight section 200 of the staircase. The right-running staircase is cast by using a right-running staircase mold 12, that is, the convex platform 400 is located on the left side of the lower straight section 200 of the staircase. Sliding hinge end positioning holes 500 and fixed hinge end holes 600 are respectively arranged on the lower straight section 200 of the staircase and the upper straight section 300 of the staircase. The sliding hinge end positioning holes 500 and fixed hinge end holes 600 are used to position the staircase through bolts and fillers, playing a shear-resistant role in geological disasters and reducing the damage of the staircase.

[0078] In the initial design of the general mold for the left and right straight sections of the precast staircase, in order to cope with the position change of the convex platform on the lower straight section of the mirror staircase, we split the mold at this place into two groups and made it into an assembled type. One group is the integral mold of the convex platform outer retaining template; the other group is the convex platform inner retaining template formed by combining the triangular template and the convex platform mold. During the mold assembly process, by increasing or decreasing the convex platform mold parts in the convex platform inner retaining templates on both sides, that is, adjusting the position of the staircase in the stairwell without changing the overall staircase mold. Therefore, no additional labor consumption and hoisting machine shifts are added during mold assembly and demolding, effectively reducing the number of molds and improving the casting production efficiency. At the same time, the left-running staircase (see Figure 11 ) and the right-running staircase (see Figure 12 ) cast and produced also have no edge collapse and corner chipping defects, which is sufficient to ensure the casting quality of the components.

[0079] The main features and advantages of the present invention have been shown and described above. For those skilled in the art, it is obvious that the specific implementation manners of the present invention are not limited to the details of the above exemplary embodiments, and without departing from the spirit or basic features of the present invention, the creative ideas and design concepts of the present invention can be implemented in other specific forms, which should be equally within the protection scope disclosed in the technical solution of the present invention. Therefore, from any point of view, the embodiments should be regarded as exemplary and non-limiting. The scope of the present invention is defined by the appended claims rather than the above description. Therefore, all changes falling within the meaning and scope of the equivalent elements of the claims are intended to be embraced within the present invention.

[0080] In addition, it should be understood that although this specification is described according to embodiments, not every embodiment only contains an independent technical solution. This narrative manner of the specification is only for clarity. Those skilled in the art should regard the specification as a whole, and the technical solutions in each embodiment can also be appropriately combined to form other embodiments that can be understood by those skilled in the art.

Claims

1. A precast staircase straight section left - right universal mold, including a bottom support (1), and side retaining templates (2) are respectively bolt - connected to the left and right sides of the bottom support (1), characterized in that: It also includes two convex inner retaining templates (8) with the same shape and mirror-image structures. The cross-section of the convex inner retaining template (8) is a right trapezoid, which is composed of a triangular template (801) and a convex platform template (802). The bottom support (1) includes a chassis (101) and a plurality of connecting feet (102). The plurality of connecting feet (102) are symmetrically and equidistantly arranged in two groups on both sides of the chassis (101) along the center line of the chassis (101), and screw holes are provided on each connecting foot (102) for bolt-connecting the side retaining templates (2). A plurality of support plates (103) are vertically and fixedly connected to the chassis (101), and the plurality of support plates (103) fixedly connect the bottom plate (104) to the chassis (101). The two side retaining templates (2) have the same shape and mirror-image structures, and both are divided into three parts: a staircase section retaining template (201), an upper straight section retaining template (202), and a lower straight section retaining template (203). The cross-section of the staircase section retaining template (201) is a rectangle. The upper straight section retaining template (202) includes a right-angled surface, a large inclined surface, and a small inclined surface. The cross-section of the lower straight section retaining template (203) is a right trapezoid. A convex outer retaining template (3) is bolt-connected to the inclined surface of each lower straight section retaining template (203). The convex outer retaining template (3) is integrally formed and has the same shape as the convex inner retaining template (8). The inclined surface of each convex outer retaining template (3) is flush with the top surface of the staircase section retaining template (201). A bottom end template (6) is bolt-connected between the two convex outer retaining templates (3). The bottom end template (6) is located on the right-angled surface side of the two convex outer retaining templates (3). A bottom flat template (7) is bolt-connected between the two convex outer retaining templates (3). The bottom flat template (7) is located on the top surface side of the two convex outer retaining templates (3). A top end template (4) is bolt-connected between the small inclined surfaces of the two upper straight section retaining templates (202). A top flat template (5) is bolt-connected to the large inclined surfaces of the two upper straight section retaining templates (202), and the top surface of the top flat template (5) is in contact with the side surface of the top end template (4). The two triangular templates (801) are respectively bolt-connected to the inner sides of the two convex outer retaining templates (3). One of the two convex platform templates (802) is bolt-connected to the inner side of the corresponding convex outer retaining template (3).

2. The universal left and right mold for the straight section of a precast staircase according to claim 1, characterized in that: Two first positioning holes (9) are provided in the top flat template (5), and two second positioning holes (10) are provided in the bottom flat template (7). The first positioning holes (9) and the second positioning holes (10) are both used for inserting tooling before pouring.

3. A universal left and right mold for the straight section of a precast staircase according to claim 2, characterized in that: The support plate (103) is divided into three parts: a stair-section support plate (1031), an upper straight-section support plate (1032), and a lower straight-section support plate (1033). Their positions respectively correspond to the stair-section formwork (201), the upper straight-section formwork (202), and the lower straight-section formwork (203). The bottom plate (104) is divided into three parts: a stair tread plate (1041), an upper straight plate (1042), and a lower straight plate (1043). Their shapes respectively correspond to the stair-section support plate (1031), the upper straight-section support plate (1032), and the lower straight-section support plate (1033).

4. A universal left and right mold for the straight section of a precast staircase according to claim 3, characterized in that: The chassis (101) is welded by two longitudinal beams (1011) and multiple cross beams (1012). The multiple cross beams (1012) are evenly distributed between the two longitudinal beams (1011). The multiple connecting feet (102) are evenly welded in two groups on the outer sides of the two longitudinal beams (1011).

5. A universal left and right mold for the straight section of a precast staircase according to claim 4, characterized in that: A plurality of rib plates (204) are fixedly connected in the back groove of the stair-section formwork (201). The rib plates (204) are used to increase the shear strength of the side formwork (2) and prevent deformation caused by stress concentration.

6. A method for using a left - and - right - universal mold for the straight section of a precast staircase, comprising the left - and - right - universal mold for the straight section of a precast staircase according to claim 5, characterized in that: It includes the following steps: S1. Clean the mold: Clean the residual concrete slag and joint glue on all surfaces and joints of the stair tread plate (1041), side formwork (2), outer formwork of the convex platform (3), top formwork (4), top flat formwork (5), bottom formwork (6), bottom flat formwork (7), and inner formwork of the convex platform (8) of the bottom support (1), ensuring that all surfaces of the mold in contact with the concrete are clean and there are no residues that affect the appearance of the component. S2. Install the side mold group according to the requirements of the component: Confirm the type of precast stair component, that is, the position of the convex platform (400) on the lower straight section (200) of the precast stair. S2.

1. If the convex platform (400) is on the left side of the lower straight section (200) of the stair, first bolt-fix the two side formworks (2) to the two connecting feet (102) on both sides of the bottom support (1), then bolt-connect and fix the left outer formwork of the convex platform (3) to the left side formwork (2). The two triangular formworks (801) are respectively bolt-fixed to the inner sides of the two outer formworks of the convex platform (3). At the same time, bolt-fix the right convex platform formwork (802) to the inner side of the right outer formwork of the convex platform (3), thus assembling the left-running stair mold (11). S2.

2. If the convex platform (400) is on the right side of the lower straight section (200) of the stair, with other operations unchanged, only bolt-fix the left convex platform formwork (802) to the inner side of the left outer formwork of the convex platform (3), and at the same time remove the right convex platform formwork (802), thus assembling the right-running stair mold (12). S3. Apply release agent: After confirming that the inner surface of the mold is clean and free of debris, use a sponge brush to evenly apply the release agent on the inner surfaces of each mold component in the order of the side retaining template (2), the outer boss retaining template (3), the inner boss retaining template (8), the bottom support (1), the top template (4), the top flat template (5), the bottom template (6), and the bottom flat template (7). Keep the direction of the gesture consistent when applying the release agent. S4. Lift and install the steel reinforcement cage: According to the steel bar size requirements on the drawing, place the steel reinforcement cage of the corresponding specification into the assembled mold. Use concrete pads to lift the bottom layer of steel bars of the steel reinforcement cage and use steel bar stools made of the same steel material to support the upper layer of steel bars of the steel reinforcement cage, so as to ensure the thickness of the protective layer for pouring the staircase. S5. Embedded part binding: Fix the positioning pins to be embedded in the precast staircase respectively through the first positioning holes (9) and the second positioning holes (10). At the same time, determine the positions of the embedded parts required for the railing handrail on the mold and make them fixed. S6. End mold installation: On the premise of completing S4 and S5, then install and fix the top flat template (5), the bottom flat template (7), the top template (4), and the bottom template (6) to the bottom support (1), the side retaining templates (2) on both sides, and the outer boss retaining template (3) in sequence through bolts. S7. Mold size inspection: Check the outer mold size with reference to the drawing, that is, the length and width of the component. Check that the side retaining templates (2) on both sides are not deformed or bent, and the deformation amount meets the technical standards. S8. Steel bar inspection: Check that the variety, grade, and specification of the steel bars all meet the requirements of the document; the ends of the steel bars must be kept at a distance of 2 - 2.5 cm from the inner and outer edges, and this distance is the protective layer; the tied ends and the steel bars are ensured to face down and not touch the bottom support (1), and face up and not be higher than the horizontal plane of the side retaining templates (2) on both sides; check whether the pads and stools are placed stably. S9. Pouring and vibrating: According to the mold size and structural characteristics, use a pouring route that is first far then near and first narrow then wide; after receiving the material, start moving the pouring trolley from one end and open the discharge door according to the width of the material to be poured; adjust the speed of the pouring trolley according to the discharging speed of the concrete to keep it running at a constant speed, and perform the pouring operation to meet the requirements of uniform and full pouring in one go. After the pouring operation is completed, for the positions with corners and edges lacking or leaking during the pouring process, the on-site personnel evenly rake the concrete; after raking is completed, select the corresponding vibration device to vibrate the precast staircase, so that the surface of the precast staircase presents a flat and bubble-free state. S10. Surface and initial setting treatment: The pouring plane of the concrete must be flush with the top surfaces of the two staircase section retaining templates (201), and ensure that no steel bars are exposed; use a trowel to level the surface of the concrete; after leveling, wait for 20 minutes for the concrete to reach the initial setting state and then remove the positioning pins. S11. Curing: After completing S10, stand still for more than twelve hours for film curing. During curing, the curing personnel should check in time to prevent cracks on the concrete surface due to untimely curing. S12. Demoulding the mould: Demould the component mould according to the mould assembly sequence of S2 and S6. First, remove the bottom formwork (6), bottom flat formwork (7), top formwork (4), and top flat formwork (5) in sequence, and then remove the outer boss retaining formwork (3) and inner boss retaining formwork (8) in sequence to complete the demoulding of the precast component.

7. The usage method of a precast staircase straight section left-right universal mold according to claim 6, characterized in that: In S5, the embedded part is any one of the demoulding lifting nails, turning lifting nails, and hoisting lifting nails.

8. The usage method of a precast staircase straight section left-right universal mold according to claim 6, characterized in that: In S10, during troweling, the surface flatness of the concrete is controlled within 3 mm and there are no scratches.

9. The usage method of a precast staircase straight section left-right universal mold according to any one of claims 6 to 8, characterized in that: In S11, the normal curing time shall not be less than seven days, and the special curing time shall not be less than fourteen days.

10. A mirror staircase, comprising a staircase cast by using the method of using a precast staircase straight section left - right universal mold described in claim 9, which is integrally cast by a staircase section (100), a lower staircase straight section (200), and an upper staircase straight section (300), and is characterized in that: The left-running staircase is cast using the left-running staircase mould (11), that is, the boss (400) is located on the right side of the lower straight section (200) of the staircase. The right-running staircase is cast using the right-running staircase mould (12), that is, the boss (400) is located on the left side of the lower straight section (200) of the staircase. Sliding hinge end positioning holes (500) and fixed hinge end positioning holes (600) are respectively provided on the lower straight section (200) and the upper straight section (300) of the staircase. The sliding hinge end positioning holes (500) and the fixed hinge end positioning holes (600) are used to position the staircase through bolts and fillers, so as to play a shear resistance role during geological disasters and reduce the damage to the staircase.

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