Prefabricated composite board with detachable template and construction method thereof

Abstract

The present invention belongs to the technical field of prefabricated buildings, and specifically relates to a prefabricated composite panel with a detachable formwork, including a composite panel, wherein the composite panel includes a plurality of spliced ​​composite panel units, wherein a plurality of transverse steel bars are embedded in the composite panel units along the long span direction, and the two ends of the transverse steel bars are exposed from the composite panel units; a groove is provided at the top of the composite panel in the short span direction, and the bottom of the composite panel is bolted to a formwork assembly; and adjacent formwork assemblies are connected by a zipper assembly. The present invention omits the traditional steel bar truss, and there is no need to manually weld the steel bar truss to the prefabricated composite panel in the factory, thereby simplifying the production process and saving unnecessary steel bar waste.

Description

Technical Field

[0001] The invention belongs to the technical field of assembled buildings, and in particular relates to a prefabricated composite board with a detachable template and a construction method thereof. Background Art

[0002] In recent years, with the development of construction technology, building developers have not only made requirements for building structural safety and construction safety, but also began to pay attention to saving economic costs. Against this background, my country's prefabricated buildings have developed rapidly. Prefabricated composite panels, as an important structural component of prefabricated buildings, are used frequently in prefabricated buildings. In order to meet the mechanical requirements of the building structure for the floor slab, the thickness of the prefabricated composite panels has certain requirements to ensure its structural safety and stability.

[0003] In order to facilitate transportation and hoisting, the current prefabricated composite panels can only be made with smaller widths. The reality is that we often need to use floor slabs with larger length and width in design. Under normal circumstances, we will make unit prefabricated composite panels in the factory (the length is equal to the width of the larger floor slab, and the width is equal to several equal parts of the length of the larger floor slab). During construction, we need to lay the unit prefabricated composite panels in sequence along the length direction of the floor slab (the long span of the unit composite panel is placed in the width direction of the floor slab, and the short span of the unit composite panel is placed in the length direction of the floor slab in sequence), and splice them on site into composite panels with larger length and width. In order to ensure the integrity of the spliced ​​composite panels and the ability of the unit prefabricated composite panels to work together and resist deformation due to external forces, the workers will lay through steel bars on the surface of the spliced ​​composite panels along the length direction of the floor slab, connect all the unit prefabricated composite panels in series, and then cast the post-cast concrete composite layer. As a tensile element, steel bars can only fully resist tension if they are placed at a certain distance below the neutral axis of the floor slab. Assuming that the thickness of the precast composite slab is 60mm, in order to give full play to the tensile properties of the through-steel material, the thickness of the post-cast concrete composite layer should be at least 90mm, which not only fails to give full play to the material properties but also results in unnecessary waste. The steel bars placed at the junction of the composite layers cannot effectively exert their material properties, and will also reduce the shear resistance of the precast composite layer and the post-cast concrete composite layer, increase the risk of relative slip at the interface, and thus reduce the bearing capacity of the floor slab. Since through-steel bars must be placed on the surface of the precast composite slab before pouring concrete, it is impossible to install steel trusses on the upper part of the precast composite slab, which also greatly increases the risk of damage to the precast composite slab during transportation. Since the function of the truss is only to increase the bending stiffness of the precast composite slab before pouring and prevent the precast composite slab from cracking during transportation, hoisting and construction, the steel truss will no longer work after the pouring is completed to form the floor slab, which also causes a large amount of steel waste every year. The installation and disassembly of on-site scaffolding and formwork is also extremely time-consuming and labor-intensive work. A post-cast joint of no less than 200mm needs to be reserved between prefabricated composite slabs. Before pouring concrete, formwork must be laid under the post-cast joint. This not only takes time to lay additional formwork and scaffolding, increasing economic expenditure, but also may cause leakage or bulging due to improper formwork erection. Summary of the invention

[0004] The technical solution of the present invention to solve the technical problem is:

[0005] On the one hand, the technical solution proposes a prefabricated composite panel with a detachable formwork, including a composite panel, which includes a plurality of spliced ​​composite panel units; a plurality of transverse steel bars are embedded inside the composite panel units along the long span direction, and the composite panel units are exposed at both ends of the transverse steel bars; a groove is opened at the top of the composite panel in the short span direction, and the bottom of the composite panel is bolted to the formwork assembly; adjacent composite panel units are connected by a zipper assembly.

[0006] Preferably, the formwork assembly includes an interlocking thin plate, the two sides of which are longer than the short span of the composite plate unit, and the bottom of the interlocking thin plate is connected to two parallel formwork beams; the bottoms of the two sides of the interlocking thin plate are fixedly connected to a slide groove along the long span direction; the zipper assembly includes a zipper, the bottom of the zipper is fixedly connected to a connecting plate, the two ends of the connecting plate are connected to a fixed slider, and the fixed slider can slide in the slide groove; the two ends of the connecting plate are also rotatably connected to a rotating rod, one end of the rotating rod is installed with a power wedge head, and the other end is installed with a transmission assembly.

[0007] Preferably, the transmission assembly includes a gear and a rack matched with the gear, the gear is installed at one end of the rotating rod, and the rack is correspondingly installed at the bottom of both sides of the bite thin plate.

[0008] Preferably, the zipper includes two centrally symmetrical bending structures, each bending structure includes an input wide mouth, a bite sheet bending channel and an output narrow mouth, the two bite sheets can be input from the input wide mouth, pass through the bite sheet bending channel and be bent, and then output from the output narrow mouth, and the edges of the two output bite sheets are bent together clockwise to form a bite.

[0009] Preferably, the interlocking thin plate bending channel is a spatial curved surface formed by sequentially iterating from the spiral line to the straight line from the inside to the outside; the outermost side of the interlocking thin plate bending channel is a straight line, and the innermost side is a spatial spiral line, and the formula is:

[0010]

[0011]

[0012]

[0013] In the formula, a, b, c, and R are all real constants, and t is a variable parameter.

[0014] Preferably, the end face of the groove is a right triangle, the right angle of the triangle faces the center of the unit board surface of the composite plate, and the corner tip of the bottom of the groove is arc-shaped; the top of the transverse steel bar is higher than the bottom of the groove.

[0015] Preferably, through steel bars are placed in the grooves of the composite plates, and the through steel bars are welded to the transverse steel bars.

[0016] Preferably, three bolts are arranged every two grooves for fixing the template assembly.

[0017] On the other hand, the technical solution also proposes a construction method of a prefabricated composite board with a detachable formwork, comprising the following steps:

[0018] S1. Prefabricated composite slab: Place transverse reinforcement on the mold of the composite slab unit and remove the mold after casting;

[0019] S2. Install the template assembly: install the template assembly to the bottom of the composite panel unit;

[0020] S3. Hoisting: transport the composite panel unit to the construction site and hoist it at the designated location;

[0021] S4. Fix adjacent laminated plate units: Install the zipper assembly between adjacent laminated plate units, place the edges and corners of adjacent occlusal sheets into the two wide input openings of the zipper, and manually rotate the power wedge to occlude adjacent occlusal sheets;

[0022] S5. Install the through steel bars: place the through steel bars in the grooves on the plate surface and weld the through steel bars to the transverse steel bars;

[0023] S6. Casting: Cast the concrete overlay layer after installation and perform concrete curing;

[0024] S7. Disassemble the formwork assembly: Reverse the power wedge to pull back the zipper assembly, and the edge feet of the interlocking thin plate will return to the flat state from the interlocking state. The two interlocking thin plates will be separated. Continue to reverse the power wedge to separate the zipper assembly from the formwork assembly, unscrew the bolts, and remove the formwork assembly.

[0025] Preferably, the formwork assembly is disassembled when the concrete laminate layer strength reaches 75%.

[0026] Compared with the prior art, the above technical solution has the following advantages or beneficial effects:

[0027] 1. The traditional steel truss is omitted, and there is no need to manually weld the steel truss to the prefabricated composite plate in the factory, which simplifies the production process, saves unnecessary waste of steel bars, and leaves space for further operations on the surface of the prefabricated composite plate.

[0028] 2. A formwork assembly is added to the bottom of the prefabricated composite board, which increases the bending stiffness of the prefabricated composite board and prevents the prefabricated composite board from cracking and damage during transportation. Compared with traditional technology, this technology can provide greater bending stiffness for prefabricated composite boards. There is no need to set up supporting scaffolding during construction. After pouring, when the cast concrete superposition layer reaches 75% strength, the formwork system can be removed from the bottom of the prefabricated composite board. The removed formwork system can be recycled, which makes this technology more environmentally friendly and economical.

[0029] 3. The formwork assembly is designed with a zipper assembly between adjacent composite plates, which can realize the mutual engagement between adjacent interlocking thin plates by rotating the power wedge head. In this way, there is no need to set up additional lower formwork for the post-casting strips between the prefabricated composite plates, and the adjacent formworks are tightly engaged with each other without concrete leakage, which can ensure better integrity of the concrete and prefabricated composite plates after pouring.

[0030] 4. A right-angled triangular groove is reserved on the surface of the composite slab unit, which is convenient for workers to weld through steel bars on the composite slab unit, thereby enhancing the overall stiffness of the floor slab, improving the bearing capacity of the floor slab, and saving a large amount of building materials at the same time; a right-angled triangular groove is reserved on the surface of the composite slab unit, which increases the overall roughness of the surface of the composite slab unit, and the interface between the composite slab unit and the post-cast concrete composite layer is more complex, and the integrity of the composite slab unit and the post-cast concrete composite layer is stronger; the groove is right-angled toward the mid-span of the prefabricated composite slab, which can avoid relative slippage between the composite slab unit and the post-cast concrete composite layer, and improve the bearing capacity of the unit floor slab; the arc-shaped design at the bottom of the groove can also effectively prevent stress concentration from causing concrete cracking. BRIEF DESCRIPTION OF THE DRAWINGS

[0031] The accompanying drawings in the specification, which constitute a part of the present invention, are used to provide a further understanding of the present invention. The exemplary embodiments of the present invention and their descriptions are used to explain the present invention and do not constitute improper limitations on the present invention.

[0032] Figure 1 It is a schematic diagram of the overall structure of the present invention;

[0033] Figure 2 It is a front view of the overall structure of the present invention;

[0034] Figure 3 It is a top view of the overall structure of the present invention;

[0035] Figure 4 It is a right view of the overall structure of the present invention;

[0036] Figure 5 It is a bottom view of the overall structure of the present invention;

[0037] Figure 6 This is a partial enlarged view of the groove where the steel bar is welded;

[0038] Figure 7 It is a schematic diagram of the overall structure of the zipper assembly;

[0039] Figure 8 is a front view of the zipper assembly;

[0040] Fig. 9 It is a right side view of the zipper assembly;

[0041] Fig.10 is a top view of the zipper assembly;

[0042] Fig.11 is a bottom view of the zipper assembly;

[0043] Fig.12 is an overall schematic diagram of a zipper;

[0044] Fig.13is a front view of the zipper;

[0045] Fig.14 is a rear view of the zipper;

[0046] Fig.15 It is the right side view of the zipper;

[0047] Fig.16 is a top view of the zipper;

[0048] Fig.17 Schematic diagram of the spatial surface of the interlocking thin plate bending channel.

[0049] Description of reference numerals:

[0050] 1. Composite plate unit; 2. Transverse reinforcement; 3. Groove; 4. Interlocking sheet; 5. Formwork beam; 6. Bolt; 7. Zipper assembly; 8. Rack; 9. Fixed slider; 10. Connecting plate; 11. Gear; 12 Slide; 13. Rotating rod; 14. Power wedge; 15. Zipper; 151. Wide input opening; 152. Interlocking sheet bending channel; 153. Narrow output opening; 16. Through reinforcement. DETAILED DESCRIPTION

[0051] In order to clearly illustrate the technical features of the present solution, the present invention is described in detail below through specific implementation methods and in combination with the accompanying drawings. The disclosure below provides many different embodiments or examples for realizing different structures of the present invention. In order to simplify the disclosure of the present invention, the components and settings of specific examples are described below. In addition, the present invention may repeat reference numbers and / or letters in different examples. This repetition is for the purpose of simplification and clarity, and does not itself indicate the relationship between the various embodiments and / or settings discussed. It should be noted that the components illustrated in the accompanying drawings are not necessarily drawn to scale. The present invention omits the description of known components and processing technologies and processes to avoid unnecessary limitations on the present invention. The orientation or position relationship indicated by the terms "center", "upper", "lower", "left", "right", "vertical", "horizontal", "inside", "outside", etc. is based on the orientation or position relationship shown in the accompanying drawings, which is only for the convenience of describing the present invention and simplifying the description, rather than indicating or implying that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and therefore cannot be understood as a limitation on the present invention. In addition, the terms "first", "second", and "third" are used only for descriptive purposes and cannot be understood as indicating or implying relative importance. In the description of the present invention, it should be noted that, unless otherwise clearly specified and limited, the terms "installed", "connected", and "connected" should be understood in a broad sense, for example, it can be a fixed connection, a detachable connection, or an integral connection; it can be a mechanical connection or an electrical connection; it can be a direct connection, or it can be indirectly connected through an intermediate medium, or it can be the internal communication of two components. For ordinary technicians in this field, the specific meanings of the above terms in the present invention can be understood according to specific circumstances.

[0052] like Figure 1-Figure 6 This embodiment provides a prefabricated composite panel with a detachable formwork, which abandons the steel truss on the upper part of the traditional prefabricated composite panel, including a composite panel, the composite panel includes a plurality of spliced ​​composite panel units 1, and grooves 3 are added at the position where the through steel bars 16 need to be placed on the panel surface of the composite panel unit 1. With the middle of the long span as the center line, the grooves 3 are symmetrically arranged on the upper surface of the composite panel unit 1, and penetrate the short span direction of the composite panel unit 1. The depth of the groove 3 can make the upper surface of the transverse steel bars 2 of the composite panel unit 1 completely exposed. The shape of the groove 3 is similar to a right triangle when viewed from the short span direction of the composite panel unit 1, the smallest angle of the right triangle faces the outside of the composite panel unit 1, the right angle of the right triangle faces the middle of the span of the composite panel unit 1, the third angle of the right triangle faces downward, and the corner tip is replaced by an arc.

[0053] A formwork assembly is added at the bottom of the composite plate unit 1, and no formwork is added on both sides of the composite plate unit 1. The formwork assembly leaves space for resting on the beam at both ends of the composite plate unit 1 in the long span direction. The formwork assembly includes an interlocking sheet 4, the width of which is greater than the short span width of the composite plate unit 1, and two parallel formwork beams 5 are connected to the bottom of the interlocking sheet 4. The formwork beams 5 are fixedly connected to the interlocking sheet 4 by welding, and the midpoint of the beam width of the formwork beam 5 is aligned with one quarter of the span of the width of the interlocking sheet 4. Racks 8 are fixedly connected to both sides of the interlocking sheet 4, and the toothed end of the rack 8 faces outward, and a slide groove 12 is provided at the bottom of the rack 8.

[0054] The composite plate unit 1 is connected to the formwork assembly by bolts 6. The bolts 6 are arranged to avoid the grooves 3 of the composite plate unit 1. The center of the bolts 6 is at least 30 mm away from the edge of the groove 3. At most, a row of at least three bolts 6 are arranged every two grooves 3.

[0055] like Figure 7-Figure 16 The laminated plate units 1 are connected and separated by a zipper assembly 7. The zipper assembly 7 includes a zipper 15. The bottom of the zipper 15 is fixedly connected to the connecting plate 10. The two ends of the connecting plate 10 are connected to fixed sliders 9. The fixed sliders 9 can slide in the slide grooves 12. The two ends of the connecting plate 10 are also rotatably connected to the rotating rods 13. One end of the rotating rod 13 is installed with a gear 11 that matches the rack 8, and the other end of the rotating rod 13 is installed with a power wedge 14. Among them, the zipper 15 includes two centrally symmetrical bending structures, each of which includes an input wide mouth 151, a bite sheet bending channel 152 and an output narrow mouth 153. The two bite sheets 4 can be input from the input wide mouth 151, pass through the bite sheet bending channel 152, and then be output from the output narrow mouth 153. The edges of the two output bite sheets 4 are bent together clockwise to form a bite. The interlocking thin plate bending channel 152 is a spatial curved surface formed by iteratively sequentially from the spiral line to the straight line from the inside to the outside; the outermost side of the interlocking thin plate bending channel 152 is a straight line, and the innermost side is a spatial spiral line, and the formula is:

[0056]

[0057]

[0058]

[0059] In the formula, a, b, c, and R are all real constants, and t is a variable parameter.

[0060] Since the interlocking sheets 4 are metal sheets, their edge feet are easy to bend. When adjacent composite board units 1 need to be connected, it is only necessary to rotate the power wedge head 14 manually or by a motor to drive the gear 11 to rotate along the direction of the rack 8, thereby driving the zipper 15 to screw the edge feet of the two interlocking sheets 4 together to form a dense casting formwork that will not leak slurry. After the casting is completed, the power wedge head 14 is reversed to drive the zipper 15 to pull back, and the edge feet of the screwed interlocking sheets 4 are restored to their original state, and the adjacent formwork components can be separated.

[0061] The following are the detailed construction steps:

[0062] S1. Prefabricated composite slab: Place transverse reinforcement 2 on a special mold for manufacturing composite slab unit 1 according to the design drawing. After placement, pour concrete of a certain strength and cover the special mold. Use steam curing to make the concrete reach 75% strength. After curing, remove the mold.

[0063] S2. Install the template assembly: Use bolts 6 to install the template with template beam 5 and rack 8 on the composite plate unit 1. After the installation is completed, the overall structure is as follows Figure 1 shown.

[0064] S3. Hoisting: transport the composite panel unit 1 to the construction site and hoist it to the designated location.

[0065] S4. Fix the adjacent superimposed plate units 1: install the zipper assembly 7 between the adjacent superimposed plate units 1, put the edge corners of the adjacent interlocking sheets 4 into the two wide input openings 151 of the zipper 15, rotate the power wedge head 14 by a motor or manually, the power wedge head 14 rotates the gear 11 through the rotating rod 13 to drive the entire zipper assembly 7 to move, the interlocking sheets 4 will be input at the wide input opening 151, and output at the narrow output opening 153, the edges of the two interlocking sheets 4 will interlock, move the zipper assembly 7 to the other end to stop the movement, and retain the zipper 15 system on the template assembly.

[0066] S5. Install the through-steel 16: place the through-steel 16 in the groove 3 of the plate surface, and weld the through-steel 16 to the transverse steel bar 2.

[0067] S6. Casting: After the through steel bars 16 in the grooves 3 of all the composite plate units 1 are welded, the post-cast concrete composite layer is cast and the concrete is cured.

[0068] S7. Disassemble the formwork assembly: When the post-cast concrete superposition layer reaches 75% strength, reverse the power wedge head 14 to move the zipper assembly 7 back from the other end, and the bite sheet 4 will enter at the output narrow opening 153 and output at the input wide opening 151. The two bite sheets 4 are separated, and the zipper assembly 7 is moved to the initial end and the power wedge head 14 is continued to be rotated to separate it from the formwork assembly; unscrew the bolts 6 in sequence to remove the bite sheet 4 with the formwork beam 5, and then transport the bite sheet 4 with the formwork beam 5 back to the prefabrication factory for repeated use.

[0069] Finally, it should be noted that the above is only a preferred embodiment of the present invention and is not intended to limit the present invention. Although the present invention has been described in detail with reference to the aforementioned embodiments, those skilled in the art can still modify the technical solutions described in the aforementioned embodiments or replace some of the technical features therein by equivalents. Any modification, equivalent replacement, improvement, etc. made within the spirit and principle of the present invention shall be included in the protection scope of the present invention.

Claims

1. A prefabricated composite panel with a detachable formwork, comprising a composite panel, the composite panel comprising a plurality of spliced ​​composite panel units (1), characterized in that: A plurality of transverse steel bars (2) are embedded in the composite plate unit (1) along the long span direction, and both ends of the transverse steel bars (2) are exposed from the composite plate unit (1); a groove (3) is provided at the top of the composite plate unit (1) in the short span direction, and the bottom of the composite plate is bolted to a formwork assembly; adjacent formwork assemblies are connected by a zipper assembly (7); The end face of the groove (3) is in the shape of a right triangle, the right angle of the triangle faces the center of the plate surface of the composite plate unit (1), and the corner tip of the bottom of the groove (3) is in the shape of an arc; the top of the transverse steel bar (2) is higher than the bottom of the groove (3); A through steel bar (16) is placed in the groove (3) of the composite plate, and the through steel bar (16) and the transverse steel bar (2) are welded.

2. The prefabricated composite panel with a detachable formwork according to claim 1, characterized in that: The template assembly comprises an interlocking thin plate (4), the two sides of the interlocking thin plate (4) being longer than the short span of the composite plate unit (1), the bottom of the interlocking thin plate (4) being connected to two parallel template beams (5); the bottoms of the two sides of the interlocking thin plate (4) being fixedly connected to a slide groove (12) along the long span direction; The zipper assembly (7) comprises a zipper (15), the bottom of the zipper (15) is fixedly connected to a connecting plate (10), both ends of the connecting plate (10) are connected to a fixed slider (9), and the fixed slider (9) can slide in a slide groove (12); both ends of the connecting plate (10) are also rotatably connected to a rotating rod (13), one end of the rotating rod (13) is installed with a power wedge head (14), and the other end is installed with a transmission assembly.

3. The prefabricated composite panel with a detachable formwork according to claim 2, characterized in that: The transmission assembly comprises a gear (11) and a rack (8) matched with the gear (11); the gear (11) is mounted on one end of the rotating rod (13), and the rack (8) is correspondingly mounted on the bottom of both sides of the bite thin plate (4).

4. The prefabricated composite panel with a detachable formwork according to claim 2, characterized in that: The zipper (15) comprises two centrally symmetrical bending structures, each bending structure comprising an input wide opening (151), an interlocking thin plate bending channel (152) and an output narrow opening (153), the two interlocking thin plates (4) can be input from the input wide opening (151), bend through the interlocking thin plate bending channel (152), and then be output from the output narrow opening (153), and the edges of the two output interlocking thin plates (4) are bent together clockwise to form an interlocking state.

5. The prefabricated composite panel with a detachable formwork according to claim 4, characterized in that: The interlocking thin plate bending channel (152) is a spatial curved surface formed by iteratively forming a spiral line and a straight line from the inside to the outside; the outermost side of the interlocking thin plate bending channel (152) is a straight line, and the innermost side is a spatial spiral line, and the formula is: In the formula, a, b, c, and R are all real constants, and t is a variable parameter.

6. A prefabricated composite panel with a detachable formwork according to any one of claims 1 to 5, characterized in that: Three bolts (6) are arranged every two grooves (3) to fix the template assembly.

7. A construction method for prefabricated composite panels using the detachable formwork according to claim 4, characterized in that The following steps are involved: S1. Prefabricated composite slab: placing transverse reinforcement (2) on the mold of the composite slab unit (1), and removing the mold after casting; S2. Installing the template assembly: installing the template assembly to the bottom of the laminated plate unit (1); S3. Hoisting: transport the composite panel unit (1) to the construction site and hoist it at a designated location; S4. Fixing adjacent laminated plate units (1): Installing a zipper assembly (7) between adjacent laminated plate units (1), placing the edges and corners of adjacent interlocking sheets (4) into the two input wide openings (151) of the zipper (15), and manually rotating the power wedge (14) to interlock the adjacent interlocking sheets (4); S5. Installing the through-steel (16): placing the through-steel (16) in the plate groove (3), and welding the through-steel (16) to the transverse steel bar (2); S6. Casting: Cast the concrete overlay layer after installation and perform concrete curing; S7. Disassemble the formwork assembly: reverse the power wedge head (14) to pull back the zipper assembly (7), restore the edge feet of the interlocking sheet (4) from the interlocking state to the flat state, separate the two interlocking sheets (4), continue to reverse the power wedge head (14), separate the zipper assembly (7) from the formwork assembly, unscrew the bolts (6), and disassemble the formwork assembly.

8. The construction method of the prefabricated composite board with a detachable formwork according to claim 7 is characterized in that: When the concrete superposition layer strength reaches 75%, the formwork assembly is removed.

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