A fully decorated prefabricated large modular building and construction method

Abstract

This invention discloses a fully furnished prefabricated modular building and its construction method, comprising an upper prefabricated module and a lower prefabricated module. The upper and lower prefabricated modules have identical structures, each including a top slab and several exterior walls with decorative surfaces connected to the bottom of the top slab. A suspended ceiling is provided at the bottom of the top slab, and prefabricated wall panels are provided on the inner side of the exterior walls. A raised floor is provided between the bottom ends of the prefabricated wall panels, and the raised floor is laid on top of the top slab of the lower prefabricated module. The upper prefabricated module is positioned on top of the top slab of the lower prefabricated module via the bottom of its exterior walls. A first reinforcing bar is provided at the edge of the exterior wall of the upper prefabricated module, and a second reinforcing bar is provided on the top of the top slab of the lower prefabricated module, which cooperates with and is staggered with the first reinforcing bar. The first and second reinforcing bars are staggered and interlocked to form a concrete pouring area. A joint sealing device is provided between the upper and lower prefabricated modules to seal the concrete pouring area.

Description

Technical Field

[0001] This invention relates to the field of building construction technology, and specifically to a fully furnished prefabricated large modular building and its construction method. Background Technology

[0002] Large-module concrete construction is a building construction technique that involves dividing the horizontal structure of a building into several large modular structures. These modules are installed and connected on-site to form complete single-story structures. These single-story structures are then connected vertically, layer by layer, to form the complete building. This structure is characterized by its large modular division, high degree of prefabrication, and minimal assembly work. The modules are prefabricated on-site in a nomadic manner and then assembled at the building construction site, significantly shortening the construction cycle. It also reduces high-altitude work and improves construction safety.

[0003] For large modular buildings, it is necessary to easily connect the upper and lower modules on-site, thus requiring the design of an easy-to-construct connection method. Furthermore, to further reduce on-site workload, the finishing of large modular buildings needs to be completed in the factory. However, since the connection of upper and lower concrete sections requires a certain amount of wet work, such as pouring concrete, the existing wet work practices in large modular buildings will impact the finishing work completed in the factory beforehand. Summary of the Invention

[0004] To address the aforementioned technical problems of existing large modular buildings, the present invention aims to provide a fully furnished prefabricated large modular building and its construction method. Firstly, the structure and decoration of the large modular building are designed as an integrated whole, ensuring full synergy between the two. A connection method between the upper and lower structural layers and the decoration layer is invented to ensure the continuity of the upper and lower structural layers and the decoration. Simultaneously, a method is invented in which the decoration layer also serves as the internal formwork for concrete pouring, preventing contamination of the interior decoration during concrete pouring and reducing the workload of on-site assembly of upper and lower modules, thereby enabling rapid and high-quality on-site construction of large modular buildings.

[0005] To achieve the above objectives, the present invention provides a fully furnished prefabricated modular building, comprising an upper prefabricated module and a lower prefabricated module. The upper and lower prefabricated modules have the same structure, each including a top slab and several exterior walls with decorative surfaces connected to the bottom of the top slab. The bottom of the top slab is provided with a suspended ceiling, and the inner side of the exterior walls is provided with prefabricated wall panels. A raised floor is provided between the bottom ends of the prefabricated wall panels. The raised floor is laid on top of the top slab in the lower prefabricated module. Gaps are provided between the suspended ceiling and the top slab, between the prefabricated wall panels and the exterior walls, and between the raised floor and the top slab in the lower prefabricated module.

[0006] The upper prefabricated large module is set on the top of the top plate of the lower prefabricated large module through the bottom of the outer wall. The edge area of ​​the outer wall of the upper prefabricated large module is provided with a first steel bar. The top of the top plate of the lower prefabricated large module is provided with a second steel bar that cooperates with the first steel bar and is staggered. The first steel bar and the second steel bar are staggered and inserted to form a concrete pouring area that can be used for concrete pouring.

[0007] A joint sealing device is installed between the upper precast module and the lower precast module to seal the concrete pouring area.

[0008] Furthermore, the area at the bottom of the outer wall of the upper prefabricated large module, excluding the first reinforcing bar section, is connected to the area on the top plate of the lower prefabricated large module, excluding the second reinforcing bar section, by means of grouting.

[0009] Furthermore, a skirting board is installed between the raised floor and the prefabricated wall for covering.

[0010] Furthermore, the joint sealing device consists of an inner template, a lower sealing block, a positioning pin, flexible material, an upper sealing block, and an outer template;

[0011] The internal template is L-shaped and is set inside the upper precast module and located inside the concrete pouring area. One end of the internal template is fixed to the top plate in the lower precast module, and the other end is fixed to the raised floor in the upper precast module.

[0012] The lower sealing block is fixed to the top of the inner template, and the positioning pin and flexible material are attached to the top of the lower sealing block;

[0013] The upper sealing block is fixed to the outer wall of the upper prefabricated large module and corresponds to the lower sealing block. The upper sealing block has a groove at the position of the corresponding positioning pin. When the first steel bar and the second steel bar are staggered and inserted, the upper sealing block and the lower sealing block can be inserted at the same time, so that the positioning pin can be inserted into the groove. The groove presses the flexible material, so that the upper sealing block and the lower sealing block are sealed and the inner side of the concrete pouring area is sealed.

[0014] The external template is set outside the concrete pouring area, and the external template is connected to the outer side of the outer wall of the upper precast module and the outer side of the outer wall of the lower precast module respectively, so as to seal the outside of the concrete pouring area.

[0015] To achieve the above objectives, the present invention provides a construction method for a fully furnished prefabricated large modular building, used in any of the above-mentioned applications, wherein the construction method includes:

[0016] S1: Concrete module fabrication. In the prefabrication yard, molds are prepared according to design requirements, including cleaning and inspection of the bottom mold, outer mold, and various inner molds. The first and second reinforcing bars and connectors are pre-embedded according to the design positions to ensure that the position and length of the staggered connecting reinforcing bars of the upper and lower prefabricated modules meet the requirements. Pipeline holes and decoration connection interfaces are accurately reserved to prepare for subsequent decoration construction. Concrete is poured according to the mix ratio requirements and cured to ensure that the concrete reaches the design strength.

[0017] S2: Exterior finishing construction, including base treatment of the exterior wall, including cleaning, leveling and waterproofing layer construction, spraying of exterior wall finish or installation of decorative surface layer according to design requirements, and protection of the completed exterior finish to avoid damage during subsequent construction.

[0018] S3: Interior decoration construction. First, the raised floor is installed. The leveling layer is constructed, and the adjustment brackets and keel system are installed. Finally, the surface panels are laid to complete the installation of the raised floor. Then, the prefabricated wall construction is carried out. First, the wall frame system is installed, then the internal pipes are laid out, and finally the wall panels are installed to complete the installation of the raised floor. For the ceiling installation, first, the main and secondary keels are set up, then the pipes are laid out, and finally the ceiling panels are installed to complete the ceiling installation.

[0019] S4: Joint sealing device installation: Fix the internal template to the top plate in the lower precast large module and the raised floor in the upper precast large module; install the lower sealing block on the internal template; install positioning pins and flexible materials on the lower sealing block; and fix the upper sealing block on the outer wall in the upper precast large module.

[0020] S5: Finished product protection and transportation. Comprehensive protection is provided for prefabricated walls, raised floors, ceilings, and other parts. Specialized transportation equipment is used for overall transportation, and support points are set up reasonably to avoid deformation during transportation.

[0021] S6: On-site installation and connection, measurement and layout, determination of module installation position, hoisting and positioning using professional equipment, adjustment of module position to ensure vertical alignment, alignment and insertion of upper and lower sealing blocks, and then checking the insertion of positioning pins and the compression of flexible materials;

[0022] S7: Structural connection construction, check the fixation of the internal formwork, set up the external formwork to form a pouring space, pour high-performance concrete and vibrate it to compact it, and cure the concrete to the design strength.

[0023] S8: Finishing repair and finished product acceptance, remove external formwork, repair the exterior wall finish, check the integrity of the interior decoration, clean the construction site and protect the finished products.

[0024] This invention provides a fully furnished prefabricated large modular building and its construction method. Firstly, the structure and decoration of the large modular building are designed as a single unit, ensuring full synergy between the two. A connection method between upper and lower modules is invented, using interlocking steel reinforcement to ensure the continuity of the upper and lower structures and decoration. Simultaneously, a joint sealing device 600 is installed in the interlocking steel reinforcement area to prevent concrete contamination of the interior decoration during pouring and to reduce the workload of on-site assembly of upper and lower modules, thereby achieving rapid and high-quality on-site construction of the large modular building. Attached Figure Description

[0025] The present invention will be further described below with reference to the accompanying drawings and specific embodiments.

[0026] Figure 1 This is a structural schematic diagram of the upper prefabricated large module in the fully furnished prefabricated large modular building provided by the present invention;

[0027] Figure 2 A cross-sectional view of the upper prefabricated large module in the fully furnished prefabricated large modular building provided by the present invention;

[0028] Figure 3 The side view of the upper prefabricated large module in the fully furnished prefabricated large modular building provided by the present invention;

[0029] Figure 4 This is a schematic diagram of the joint sealing device for fully furnished prefabricated large modular buildings provided by the present invention.

[0030] Upper precast large module 100, lower precast large module 200, first steel reinforcement section 300, second steel reinforcement section 400, concrete pouring area 500, joint sealing device 600, grout connection 700.

[0031] Top slab 110, exterior wall 120, suspended ceiling 130, prefabricated wall panel 140, raised floor 150, skirting board 160, internal formwork 610, lower sealing block 620, positioning pin 630, flexible material 640, upper sealing block 650, external formwork 660. Detailed Implementation

[0032] To make the technical means, creative features, objectives and effects of this invention easier to understand, the invention will be further described below with reference to specific illustrations.

[0033] See Figures 1-3 The diagram shown is a structural schematic of the fully furnished prefabricated large modular building provided by the present invention.

[0034] As shown in the figure, the fully furnished prefabricated modular building provided by the present invention includes two components: an upper prefabricated modular module 100 and a lower prefabricated modular module 200.

[0035] The upper prefabricated large module 100 and the lower prefabricated large module 200 have the same structure, both including a top plate 110 and several exterior walls 120 with decorative surfaces connected to the bottom of the top plate 110. The bottom of the top plate 110 is provided with a suspended ceiling 130, the inner side of the exterior wall 120 is provided with a prefabricated wall panel 140, and a raised floor 150 is provided between the bottom ends of the prefabricated wall panels 140. The raised floor 150 is laid on the top of the top plate 110 in the lower prefabricated large module 200. There are gaps between the suspended ceiling 110 and the top plate 110, between the prefabricated wall panel 140 and the exterior wall 120, and between the raised floor 150 and the top plate 110 in the lower prefabricated large module 200.

[0036] The upper precast large module 100 is set on the top of the top plate 110 of the lower precast large module 200 through the bottom of the outer wall 120. The edge area of ​​the outer wall 120 of the upper precast large module 100 is provided with a first steel bar 300. The top of the top plate 110 of the lower precast large module 200 is provided with a second steel bar 400 that cooperates with the first steel bar 300 and is staggered. The first steel bar 300 and the second steel bar 400 are staggered and inserted to form a concrete pouring area 500 that can be used for concrete pouring.

[0037] A joint sealing device 600 is installed between the upper precast large module 100 and the lower precast large module 200, which can seal the concrete pouring area 500.

[0038] Compared to existing technologies, this solution firstly integrates the structure and decoration of large modular buildings, ensuring full synergy between the two. It also introduces a connection method between upper and lower modules, using interlocking steel reinforcement to guarantee the continuity of the upper and lower structures and decoration. Simultaneously, a joint sealing device 600 is installed in the interlocking steel reinforcement area to prevent concrete contamination of the interior decoration during pouring and to reduce the workload during on-site assembly of upper and lower modules, thereby enabling rapid and high-quality on-site construction of large modular buildings.

[0039] Specifically, in this design, the raised floor 150 is set up as a raised ground, there is a gap between the prefabricated wall 140 and the exterior wall 120, and the top is a suspended ceiling 130. With this decoration method, the pipelines can be freely arranged in the cavity formed by the decoration, which improves the applicability of the decoration under various conditions.

[0040] Furthermore, such as Figure 2 The area at the bottom of the outer wall 120 of the upper precast large module 100, excluding the first steel reinforcement 300, and the area at the top plate 110 of the lower precast large module 200, excluding the second steel reinforcement 400, are connected by grouting 700. Grouting connection is a common building construction technique, which will not be elaborated here.

[0041] Furthermore, such as Figure 3For the interior decoration, the area where the upper and lower sections meet is located at the junction of the raised floor 150 and the prefabricated wall 140. The gap between the raised floor 150 and the prefabricated wall 140 is set according to conventional decoration practices, and a skirting board 160 is installed between the raised floor 150 and the prefabricated wall 140 to cover them.

[0042] like Figure 4 The joint sealing device 600 consists of an inner template 610, a lower sealing block 620, a positioning pin 630, a flexible material 640, an upper sealing block 650, and an outer template 660.

[0043] The internal template 610 is L-shaped and is set inside the upper precast large module 100 and located inside the concrete pouring area 500. One end of the internal template 610 is fixed to the top plate 110 in the lower precast large module 200, and the other end is fixed to the raised floor 150 in the upper precast large module 100. Both sides are firmly fixed, so that the internal template 610 has sufficient rigidity.

[0044] The lower sealing block 620 is fixed to the top of the inner template 610, and the positioning pin 630 and flexible material 640 are attached to the top of the lower sealing block 620.

[0045] The upper sealing block 650 is fixed on the outer wall 120 in the upper prefabricated large module 100 and corresponds to the lower sealing block 620. The upper sealing block 650 has a groove at the position of the corresponding positioning pin 630. When the first steel bar 300 and the second steel bar 400 are staggered and inserted, the upper sealing block 650 and the lower sealing block 620 can be inserted at the same time, so that the positioning pin 630 can be inserted into the groove, and the groove presses the flexible material, so that the upper sealing block 650 and the lower sealing block 620 are sealed, and the inner side of the concrete pouring area 500 is sealed.

[0046] The external formwork 660 is set outside the concrete pouring area 500, and the external formwork 660 is connected to the outer side of the outer wall 120 of the upper precast large module 100 and the outer side of the outer wall 120 of the lower precast large module 200 respectively, so as to seal the outer side of the concrete pouring area 500.

[0047] The outer formwork 660 cooperates with the inner formwork 610 located on the inside, the lower sealing block 620, the positioning pin 630, the flexible material 640, and the upper sealing block 650 to seal the concrete pouring area 500.

[0048] Based on the above-described fully furnished prefabricated modular building, this plan also provides a construction method, the construction steps of which are as follows:

[0049] S1: Concrete module fabrication. In the prefabrication yard, molds are prepared according to design requirements, including cleaning and inspection of the bottom mold, outer mold, and various inner molds. The first reinforcing bar 300 and the second reinforcing bar 400 and connectors are pre-embedded according to the design position to ensure that the position and length of the staggered connecting reinforcing bars of the upper prefabricated module 100 and the lower prefabricated module 200 meet the requirements. Pipeline holes and decoration connection interfaces are accurately reserved to prepare for subsequent decoration construction. Concrete is poured according to the mix ratio requirements and cured to ensure that the concrete reaches the design strength.

[0050] S2: Exterior finishing construction. This involves preparing the 120mm exterior wall surface, including cleaning, leveling, and waterproofing. The exterior 120mm surface is then sprayed with paint or a decorative finish is installed according to design requirements. The completed exterior surface is protected to prevent damage during subsequent construction.

[0051] S3: Interior decoration construction. First, the raised floor 150 is installed. The leveling layer is constructed, and the adjustment brackets and keel system are installed. Finally, the surface layer panels are laid to complete the installation of the raised floor 150. Then, the prefabricated wall 140 is constructed. First, the wall frame system is installed. Then, the internal pipes of the wall are arranged. Finally, the wall panels are installed to complete the installation of the raised floor 150. For the ceiling 130, the main and secondary keels are set up first. Then, the pipes are arranged. Finally, the ceiling panels are installed to complete the installation of the ceiling 130.

[0052] S4: The joint sealing device 600 is installed, the inner template 610 is fixed on the top plate 110 in the lower prefabricated large module 200 and the raised floor 150 in the upper prefabricated large module 100, the lower sealing block 620 is installed on the inner template 610, the positioning pin 630 and the flexible material 640 are installed on the lower sealing block 620, and the upper sealing block 650 is fixed on the outer wall 120 in the upper prefabricated large module 100.

[0053] S5: Finished product protection and transportation. Comprehensive protection is provided for prefabricated wall panels 140, raised floor 150, ceiling 130, etc. Special transportation equipment is used for overall transportation, and support points are reasonably set to avoid deformation during transportation.

[0054] S6: On-site installation and connection, measurement and layout, determination of module installation position, hoisting and positioning using professional equipment, adjustment of module position to ensure vertical alignment, alignment and insertion of upper sealing block 650 and lower sealing block 620, and then checking the insertion of positioning pin 630 and the compression of flexible material 640.

[0055] S7: Structural connection construction, check the fixation of the internal formwork 610, set up the external formwork 660 to form a pouring space, pour high-performance concrete and vibrate it to compact it, and cure the concrete to the design strength.

[0056] S8: Finishing repair and finished product acceptance, remove external formwork 660, repair the exterior finish of the exterior wall 120, check the integrity of the interior decoration, clean the construction site and protect the finished products.

[0057] The foregoing has shown and described the basic principles, main features, and advantages of the present invention. Those skilled in the art should understand that the present invention is not limited to the above embodiments. The embodiments and descriptions in the specification are merely illustrative of the principles of the invention. Various changes and modifications can be made to the invention without departing from its spirit and scope, and all such changes and modifications fall within the scope of the present invention as claimed. The scope of protection of this invention is defined by the appended claims and their equivalents.

Claims

1. A fully furnished prefabricated large modular building, characterized in that, It includes an upper prefabricated large module and a lower prefabricated large module. The upper and lower prefabricated large modules have the same structure, each including a top slab and several exterior walls with decorative surfaces connected to the bottom of the top slab. The bottom of the top slab is provided with a suspended ceiling, and the inner side of the exterior walls is provided with prefabricated wall panels. A raised floor is provided between the bottom ends of the prefabricated wall panels. The raised floor is laid on the top of the top slab in the lower prefabricated large module. There are gaps between the suspended ceiling and the top slab, between the prefabricated wall panels and the exterior walls, and between the raised floor and the top slab in the lower prefabricated large module. The upper prefabricated large module is set on the top of the top plate of the lower prefabricated large module through the bottom of the outer wall. The edge area of ​​the outer wall of the upper prefabricated large module is provided with a first steel bar. The top of the top plate of the lower prefabricated large module is provided with a second steel bar that cooperates with the first steel bar and is staggered. The first steel bar and the second steel bar are staggered and inserted to form a concrete pouring area that can be used for concrete pouring. A joint sealing device is provided between the upper prefabricated large module and the lower prefabricated large module, which can seal the concrete pouring area. The joint sealing device consists of an inner template, a lower sealing block, a positioning pin, flexible material, an upper sealing block, and an outer template. The internal template is L-shaped and is set inside the upper precast module and located inside the concrete pouring area. One end of the internal template is fixed to the top plate in the lower precast module, and the other end is fixed to the raised floor in the upper precast module. The lower sealing block is fixed to the top of the inner template, and the positioning pin and flexible material are attached to the top of the lower sealing block; The upper sealing block is fixed to the outer wall of the upper prefabricated large module and corresponds to the lower sealing block. The upper sealing block has a groove at the position of the corresponding positioning pin. When the first steel bar and the second steel bar are staggered and inserted, the upper sealing block and the lower sealing block can be inserted at the same time, so that the positioning pin can be inserted into the groove. The groove presses the flexible material, so that the upper sealing block and the lower sealing block are sealed and the inner side of the concrete pouring area is sealed. The external template is set outside the concrete pouring area, and the external template is connected to the outer side of the outer wall of the upper precast module and the outer side of the outer wall of the lower precast module respectively, so as to seal the outside of the concrete pouring area.

2. The fully furnished prefabricated modular building according to claim 1, characterized in that, The area at the bottom of the outer wall of the upper precast module, excluding the first reinforcing bar section, is connected to the area on the top slab of the lower precast module, excluding the second reinforcing bar section, by means of grouting.

3. The fully furnished prefabricated modular building according to claim 1, characterized in that, A skirting board is installed between the raised floor and the prefabricated wall to cover the area.

4. A construction method for a fully furnished prefabricated large modular building according to any one of claims 1-3, characterized in that, include: S1: Concrete module fabrication. In the prefabrication yard, molds are prepared according to design requirements, including cleaning and inspection of the bottom mold, outer mold, and various inner molds. The first and second reinforcing bars and connectors are pre-embedded according to the design positions to ensure that the position and length of the staggered connecting reinforcing bars of the upper and lower prefabricated modules meet the requirements. Pipeline holes and decoration connection interfaces are accurately reserved to prepare for subsequent decoration construction. Concrete is poured according to the mix ratio requirements and cured to ensure that the concrete reaches the design strength. S2: Exterior finishing construction, including base treatment of the exterior wall, including cleaning, leveling and waterproofing layer construction, spraying of exterior wall finish or installation of decorative surface layer according to design requirements, and protection of the completed exterior finish to avoid damage during subsequent construction; S3: Interior decoration construction. First, the raised floor is installed. The leveling layer is constructed, and the adjustment brackets and keel system are installed. Finally, the surface panels are laid to complete the installation of the raised floor. Then, the prefabricated wall construction is carried out. First, the wall frame system is installed, then the internal pipes are laid out, and finally the wall panels are installed to complete the installation of the raised floor. For the ceiling installation, first, the main and secondary keels are set up, then the pipes are laid out, and finally the ceiling panels are installed to complete the ceiling installation. S4: Joint sealing device installation: Fix the internal template to the top plate in the lower precast large module and the raised floor in the upper precast large module; install the lower sealing block on the internal template; install positioning pins and flexible materials on the lower sealing block; and fix the upper sealing block on the outer wall in the upper precast large module. S5: Finished product protection and transportation. Comprehensive protection is provided for prefabricated walls, raised floors, ceilings, and other parts. Specialized transportation equipment is used for overall transportation, and support points are set up reasonably to avoid deformation during transportation. S6: On-site installation and connection, measurement and layout, determination of module installation position, hoisting and positioning using professional equipment, adjustment of module position to ensure vertical alignment, alignment and insertion of upper and lower sealing blocks, and then checking the insertion of positioning pins and the compression of flexible materials; S7: Structural connection construction, check the fixation of the internal formwork, set up the external formwork to form a pouring space, pour high-performance concrete and vibrate it to compact it, and cure the concrete to the design strength. S8: Finishing repair and finished product acceptance, remove external formwork, repair the exterior wall finish, check the integrity of the interior decoration, clean the construction site and protect the finished products.

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