Prefabricated stair and mounting process thereof

Abstract

The invention discloses a prefabricated stair and a manufacturing and mounting process thereof. The prefabricated stair comprises a stair body, interlayer plates, stair beams and bracket beams. The stair beams and the bracket beams are fixed to a wall where the stair body is installed. And step surfaces matched with the top of the stair main body are arranged on the stair beams. And embedded parts are arranged on the step surfaces and are used for realizing the fixation between the stair main body and the stair beams. The interlayer plates are fixed to the stair beams and the bracket beams to form an interlayer platform between the upper stair body section and the lower stair body section. The positioning bolts are fixed on the step surfaces of the ladder beams. And a first mounting hole and a second mounting hole which are matched with the positioning screw rod are respectively formed in the top of the stair main body and the interlayer plate. The positioning screw rods sequentially penetrate through the first mounting holes and the second mounting holes, and the top surface platform and the interlayer plates are fixed through nuts, so that quick mounting of the prefabricated stair main body and the interlayer plates is realized, and meanwhile, damage to the joint of the interlayer plates and the prefabricated stair caused by pouring and form stripping is avoided.

Description

Technical Field

[0001] The present invention belongs to the technical field of prefabricated buildings, and in particular relates to a prefabricated staircase and an installation process thereof. Background Art

[0002] Currently, stairs are essential components for vertical transportation between floors in buildings. They are primarily manufactured using two methods: cast-in-place and prefabricated. Cast-in-place stairs fully utilize the plasticity of reinforced concrete, offer excellent structural integrity, and are widely applicable. However, they suffer from disadvantages such as difficult formwork, complex construction processes, and a long construction period. To address these difficulties and time constraints of traditional cast-in-place stairs, prefabricated stairs have been developed. Prefabricated stairs are manufactured and then transported to the construction site for installation.

[0003] In the related art, the mounting platforms at both ends of the prefabricated stairs in the length direction are fixed on the upper beam and the lower beam respectively. After the prefabricated stairs are installed, the interlayer platform between the two adjacent sections of prefabricated stairs is cast, which has the advantages of simple construction, low cost and short construction period.

[0004] Regarding the aforementioned related technologies, the inventors believe that the inter-level landings between two adjacent staircases require separate wooden formwork to be cast in advance, which inevitably affects the construction period and wastes resources. Furthermore, when removing the inter-level landings from the molds, they are typically removed by prying. Because the staircase and inter-level landings are connected separately, prying and removal can easily damage the connection between the inter-level landings and the precast staircase, thereby affecting the quality of the precast staircase. Summary of the Invention

[0005] In order to make up for the shortcomings of the existing technology, the present invention provides a prefabricated staircase and its installation process to solve technical problems such as low construction efficiency of the inter-layer platform and easy damage to the connection between the inter-layer platform and the prefabricated staircase during molding and demoulding.

[0006] To achieve the above purpose, the specific technical solutions of the present invention are as follows: In a first aspect, a prefabricated staircase includes a staircase body, a floor plate, a stair beam, and a corbel beam.

[0007] The ladder beam and the corbel are both fixed to the wall on which the stair main body is mounted. The ladder beam is provided with a step surface that matches the top of the stair main body. The step surface is provided with embedded parts for fixing the stair main body to the ladder beam.

[0008] The interlayer plate is fixed on the ladder beam and the corbel beam to form an interlayer platform between the upper and lower sections of the stair main body.

[0009] Furthermore, the embedded component is embedded and fixed within the stair beam. A connecting sleeve is sleeved on the top of the embedded component. A positioning screw is threadedly connected to the top of the connecting sleeve. A first mounting hole and a second mounting hole are respectively formed on the top of the stair main body and the inter-level plate, which mate with the positioning screw. The positioning screw passes through the first and second mounting holes in sequence and is secured to the top platform and the inter-level plate via a nut.

[0010] Furthermore, a second limiting bolt is embedded and fixed on the corbel beam. A fixing hole corresponding to the second limiting bolt is opened at the inner end of the interlayer plate. The second limiting bolt passes through the fixing hole on the interlayer plate and is locked by a nut.

[0011] Furthermore, a plurality of positioning holes are formed at the bottom of the staircase body. First limiting bolts matching the positioning holes are pre-buried on the ground where the staircase body is installed. The first limiting bolts are inserted into the positioning holes and fixed with nuts.

[0012] Furthermore, the staircase body has multiple sections. The ladder beams are provided in multiple pieces for carrying two staircase bodies.

[0013] Furthermore, the embedded part has an L-shaped structure.

[0014] In a second aspect, a manufacturing and installation process of a prefabricated staircase as described in the first aspect includes the following specific steps: S1. Prefabricate the main body of the stairs. Assemble the staircase mold components used to cast the main body of the stairs and pour concrete.

[0015] S2. According to the size data of the installed staircase body, a first limiting bolt is embedded in the ground to limit and fix the bottom of the first section of the staircase body.

[0016] S3. Build the wall formwork and pour the plain concrete to form the shear wall for fixing the main body of the staircase.

[0017] S4. Build wooden formwork on the shear wall for the corbel beam and two ladder beams, and begin casting. During the casting process, embed fixed embedded parts and second limit bolts in the ladder beam and corbel beam.

[0018] S5. After the ladder beam and corbel are cast and formed, remove the wooden formwork on the outer ring of the ladder beam and corbel. At the same time, install the positioning screw on the connecting sleeve.

[0019] S6. The prefabricated staircase body is hoisted and the end of the staircase body is placed on the step surface of the ladder beam.

[0020] S7. Move the interlayer board onto the ladder beam and corbel. Insert the positioning screw on the ladder beam and the second limiting bolt on the corbel into the second mounting hole and the fixing hole of the interlayer board, respectively, and secure them with nuts. This secures the interlayer board and simultaneously compresses and secures the ends of the stair main body.

[0021] Furthermore, the stair mold assembly in step S1 includes a step mold, a back mold, and a side mold made of steel molds, which together form a casting chamber with an open top.

[0022] Furthermore, the rough side of the staircase body formed in step S1 is directly opposite the shear wall, leaving a gap of 1 cm. After the staircase body is hoisted, structural adhesive is injected into the gap between the side of the staircase body and the shear wall.

[0023] Compared with the prior art, the present invention has the following advantages: 1. The present invention secures positioning bolts to the stepped surface of the stair beam. First and second mounting holes, corresponding to the positioning bolts, are provided on the top of the stair main body and the inter-level plate, respectively. The positioning bolts pass through the first and second mounting holes, and are secured to the top platform and inter-level plate by nuts. This allows for rapid installation of the prefabricated stair main body and inter-level plate, while preventing damage to the junction between the inter-level plate and the prefabricated staircase caused by casting and demolding.

[0024] 2. The present invention adopts prefabricated interlayer plates in combination with ladder beams and corbel beams, so that the interlayer plates can be constructed in an assembled manner. At the same time, through the positioning and locking of the positioning screws and the second limit bolts, the interlayer plates and the ladder beams and corbel beams can be quickly installed, thereby improving construction efficiency. BRIEF DESCRIPTION OF THE DRAWINGS

[0025] Figure 1 It is a schematic diagram of the overall structure of the present invention; Figure 2 Schematic diagram of the structure between the bottom platform and the ground in the present invention ( Figure 1 Partial enlarged view of part A); Figure 3 Schematic diagram of the structure between the middle layer plate and the ladder beam of the present invention ( Figure 1 Partial enlarged view of part B); Figure 4 It is a structural schematic diagram of the ladder beam and the two-section stair main body in the present invention.

[0026] Figure numerals: 1. Stair main body; 1-1. Bottom platform; 1-2. Top platform; 2. Interlayer plate; 3. Ladder beam; 4. Corbel beam; 5. First limiting bolt; 6. Embedded part; 7. Connecting sleeve; 8. Positioning screw; 9. Second limiting bolt. DETAILED DESCRIPTION

[0027] In the description of the present invention, it should be understood that the terms "one end", "the other end", "outside", "upper", "inside", "horizontal", "coaxial", "center", "end", "length", "outer end", etc., indicating the orientation or position relationship, are based on the orientation or position relationship shown in the accompanying drawings, and are 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 operate in a specific orientation, and therefore cannot be understood as limiting the present invention.

[0028] The present invention will be further described below with reference to the accompanying drawings.

[0029] like Figure 1 and 4 As shown, a prefabricated staircase comprises a staircase structure 1, a floor plate 2, a ladder beam 3, and a corbel 4. The ladder beam 3 and corbel 4 are fixed to the wall on which the staircase structure 1 is mounted. The ladder beam 3 is provided with a stepped surface that mates with the top of the staircase structure 1. This stepped surface is provided with embedded parts 6 for securing the staircase structure 1 to the ladder beam 3. The floor plate 2 is fixed to the ladder beam 3 and corbel 4, forming an inter-level platform between the upper and lower sections of the staircase structure 1.

[0030] In this embodiment, the staircase structure 1 comprises an inclined step structure, as well as a bottom platform 1-1 and a top platform 1-2 located at each end of the staircase structure. Corbels 4 and ladder beams 3 are both fixed to the wall on which the staircase structure 1 is mounted, with the top surfaces of ladder beams 3 and 4 aligned horizontally. The ladder beams 3 are provided with a stepped surface that mates with the top platforms 1-2. The top platform 1-2 at the top of the staircase structure 1 is fixed to the stepped surface. An inter-level plate 2 is fixed to the corbels 4 and the ladder beams 3 located below, forming an inter-level platform.

[0031] Specific structure such as Figure 2 As shown, the bottom platform 1-1 is provided with multiple positioning holes. First stop bolts 5, corresponding to each of the positioning holes, are pre-buried in the ground where the staircase body 1 is to be installed. During installation, the first stop bolts 5 determine the installation position of the staircase body 1. The staircase body 1 is hoisted above the location of the first stop bolts 5 and gradually lowered. The first stop bolts 5 are inserted into the positioning holes and secured with nuts, thereby securing the bottom of the staircase body 1 in position.

[0032] like Figure 3As shown, the embedded part 6 is an L-shaped structure, and a connecting sleeve 7 is sleeved on the top. The support of the embedded part 6 prevents the position of the connecting sleeve 7 from being offset during the casting process of the ladder beam 3. The top of the connecting sleeve 7 is threadedly connected to a positioning screw 8. The top platform 1-2 and the interlayer plate 2 are respectively provided with a first mounting hole and a second mounting hole that match the positioning screw 8. During installation, the top platform 1-2 and the interlayer plate 2 are sequentially installed on the step surface of the ladder beam 3. The positioning screw 8 passes through the first mounting hole and the second mounting hole in turn and is fixed by a nut.

[0033] Furthermore, a second limiting bolt 9 is pre-embedded and fixed on the corbel beam 4. A fixing hole corresponding to the second limiting bolt 9 is opened at the inner end of the interlayer plate 2. When the interlayer plate 2 is installed, the second limiting bolt 9 passes through the fixing hole on the interlayer plate 2 and is locked by a nut.

[0034] In this embodiment, the staircase 1 comprises two sections: a first section at the bottom and a second section at the top. Multiple ladder beams 3 are provided to support and secure the top platforms 1-2 on the first and second sections. The bottom platform 1-1 of the second section is supported by the lower ladder beams 3.

[0035] The manufacturing and installation process of the above-mentioned prefabricated stairs has the following specific process steps: S1. Prefabricate the staircase structure 1. Assemble the staircase mold assembly for casting the staircase structure 1 and pour concrete. The staircase mold assembly includes a step formwork, a back formwork, and side forms. These formworks together form a casting chamber with an open top.

[0036] When the staircase body 1 is poured, steel formwork is used to form the step formwork, back formwork, and side formwork, so that the step surface, back surface, and side surface of the staircase body 1 are flat, ensuring the smoothness of the stair surface. A rough step side surface is formed at the open top of the pouring chamber.

[0037] S2. According to the size data of the installed staircase body 1, a first limiting bolt 5 is embedded in the ground to limit and fix the bottom of the installed staircase body 1.

[0038] S3. Build a wall formwork and pour plain concrete to form a shear wall for fixing the staircase body 1.

[0039] S4. Build wooden formwork on the shear wall for casting the ladder beam 3 and corbel beam 4. After the wooden formwork for the ladder beam 3 is completed, the embedded parts 6 are welded to the steel bars in the wooden formwork. Connecting sleeves 7 are secured to the ends of the embedded parts 6. Plastic sheeting is tied to the connecting sleeves 7 to ensure that the top surface of the connecting sleeves 7 is exposed to the outside world after the ladder beam 3 is cast. Simultaneously, a second stopper bolt 9 is embedded in the completed wooden formwork for the corbel beam 4.

[0040] S5. After the ladder beam 3 and the corbel beam 4 are cast and formed, the wooden formwork of the outer ring of the ladder beam 3 and the corbel beam 4 is removed. At the same time, the positioning screw 8 is installed on the connecting sleeve 7.

[0041] S6. Hoist the prefabricated upper and lower stair main bodies 1. The bottom platform 1-1 and the top platform 1-2 at both ends of the stair main body 1 are respectively connected and fixed with the first limit bolt 5 and the positioning screw 8. The rough step side of the stair main body 1 is facing the shear wall, and a gap of 1 cm is left to adapt to the uneven step side. After the hoisting of the stair main body 1 is completed, structural glue is injected into the gap between the step side of the stair main body 1 and the shear wall. At the same time, polystyrene is filled in the gap between the top platform 1-2 and the ladder beam 3 to ensure the flatness of the junction of the top platform 1-2 and the ladder beam 3.

[0042] S7, move the interlayer plate 2 to the ladder beam 3 and the corbel beam 4. The positioning screw 8 on the ladder beam 3 and the second limiting bolt 9 on the corbel beam 4 are sequentially inserted into the second mounting hole and the fixing hole on the interlayer plate 2 and fixed with nuts.

[0043] S8. Build the floor formwork of the higher floor, and after the construction is completed, carry out concrete pouring construction, pour the staircase body 1 located above and the floor of the higher floor into one, and complete the installation and fixation of the upper and lower staircase bodies 1.

[0044] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, rather than to limit it. Although the present invention has been described in detail with reference to the above embodiments, those skilled in the art should understand that they can still modify the technical solutions described in the above embodiments, or replace some or all of the technical features therein with equivalents. However, these modifications or replacements do not cause the essence of the corresponding technical solutions to deviate from the scope of the technical solutions of the embodiments of the present invention.

Claims

1. A prefabricated staircase, comprising a staircase body (1), characterized in that: It also includes an interlayer plate (2), a ladder beam (3) and a corbel beam (4); The ladder beam (3) and the corbel beam (4) are both fixed to the wall on which the staircase body (1) is installed; the ladder beam (3) is provided with a step surface that matches the top of the staircase body (1); the step surface is provided with an embedded part (6) for fixing the staircase body (1) and the ladder beam (3); The interlayer plate (2) is fixed on the stair beam (3) and the corbel beam (4) to form an interlayer platform of the staircase body (1).

2. A prefabricated staircase according to claim 1, characterized in that: The embedded part (6) is embedded and fixed in the ladder beam (3); a connecting sleeve (7) is sleeved on the top of the embedded part (6); a positioning screw (8) is threadedly connected to the top of the connecting sleeve (7); a first mounting hole and a second mounting hole matching the positioning screw (8) are respectively provided on the top of the staircase body (1) and the interlayer plate (2); the positioning screw (8) passes through the first mounting hole and the second mounting hole in sequence, and is fixed to the top surface platform (1-2) and the interlayer plate (2) by a nut.

3. A prefabricated staircase according to claim 2, characterized in that: A second limiting bolt (9) is pre-embedded and fixed on the corbel beam (4); a fixing hole corresponding to the second limiting bolt (9) is opened at the inner end of the interlayer plate (2); the second limiting bolt (9) passes through the fixing hole on the interlayer plate (2) and is locked by a nut.

4. The prefabricated staircase according to claim 3, characterized in that: A plurality of positioning holes are provided at the bottom of the staircase body (1); first limiting bolts (5) matching the positioning holes are pre-buried on the ground corresponding to the installation of the staircase body (1); the first limiting bolts (5) are inserted into the positioning holes and fixed by nuts.

5. The prefabricated staircase according to claim 1, characterized in that: The staircase body (1) has a total of multiple sections; the staircase beams (3) are provided in a total of multiple pieces for carrying each section of the staircase body (1).

6. The prefabricated staircase according to claim 1, characterized in that: The embedded part (6) has an L-shaped structure.

7. The manufacturing and installation process of a prefabricated staircase according to claim 4, characterized in that: The following steps are involved: S1, prefabrication of the staircase main body (1), assembling staircase mold components for casting the staircase main body (1), and pouring concrete; S2. According to the size data of the installed staircase body (1), a first limiting bolt (5) is embedded in the ground to achieve limiting fixation at the bottom of the corresponding staircase body (1); S3, constructing a wall formwork and pouring plain concrete to form a shear wall for fixing the staircase body (1); S4, constructing a wooden formwork for casting the corbel beam (4) and the ladder beam (3) on the shear wall, and casting; during the casting process, embedding the second limit bolt (9) and the embedded part (6) in the corbel beam (4) and the ladder beam (3) respectively; S5. After the ladder beam (3) and the corbel beam (4) are cast and formed, the wooden formwork of the outer ring of the ladder beam (3) and the corbel beam (4) is removed; at the same time, a positioning screw (8) is installed on the connecting sleeve (7) at the top of the embedded part (6); S6, hoisting the prefabricated staircase main body (1); the end of the staircase main body (1) is placed on the step surface of the ladder beam (3); S7, move the interlayer plate (2) onto the ladder beam (3) and the corbel beam (4); insert the positioning screw (8) on the ladder beam (3) and the second limit bolt (9) on the corbel beam (4) into the second mounting hole and the fixing hole on the interlayer plate (2) in sequence, and fix them with nuts, thereby achieving the fixation of the interlayer plate (2) and completing the compression and fixation of the end of the stair body (1) at the same time.

8. The manufacturing and installation process of a prefabricated staircase according to claim 7, characterized in that: The staircase mold assembly in step S1 includes a step mold, a back mold and a side mold made of steel molds; the step mold, the back mold and the side molds are combined to form a casting chamber with an open top.

9. The manufacturing and installation process of a prefabricated staircase according to claim 7, characterized in that: In the step S6, the rough step side of the staircase main body (1) hoisted is directly opposite to the shear wall, and a gap of 1 cm is left; after the hoisting of the staircase main body (1) is completed, structural glue is injected into the gap between the step side of the staircase main body (1) and the shear wall.

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