PC laminated plate and manufacturing process thereof

Abstract

A PC laminated slab comprises a prefabricated layer and a cast-in-place layer, the cast-in-place layer is located on the prefabricated layer, and the PC laminated slab is characterized in that the PC laminated slab further comprises a rear rib, the rear rib is in a folded shape, and the rear rib comprises a horizontal section and a lower folded section; a conical hole is reserved in the prefabricated layer, the upper portion of the conical hole is large, the lower portion of the conical hole is small, the top face of the conical hole is located on the top face of the prefabricated layer, the bottom face of the conical hole is located on the side face of the prefabricated layer, the horizontal section of the rear rib is located on the top face of the prefabricated layer, the lower folding section of the rear rib penetrates through the conical hole, and the conical hole is filled with grouting materials. The invention further provides a manufacturing process of the PC laminated plate. The construction efficiency and the structural safety are improved.

Description

Technical Field

[0001] The invention belongs to the field of prefabricated buildings and relates to a PC composite board and a manufacturing process thereof. Background Art

[0002] In the traditional construction of PC composite panels, the anchoring and binding of exposed reserved steel bars has always been a construction problem. Existing technologies usually use embedded steel bars, but this method has many inconveniences during construction, such as conflicts between reserved anchor steel bars and longitudinal steel bars on the beam surface, resulting in low construction efficiency and reduced structural safety. Summary of the invention

[0003] In order to overcome the deficiencies of the prior art, the present invention provides a PC laminated board and a manufacturing process thereof to improve construction efficiency and structural safety.

[0004] The technical solution adopted by the present invention to solve its technical problem is:

[0005] A PC composite board comprises a prefabricated layer and a cast-in-place layer, wherein the cast-in-place layer is located on the prefabricated layer, and is characterized in that the PC composite board also comprises post-positioned reinforcement, wherein the post-positioned reinforcement is in a folded shape, and the post-positioned reinforcement comprises a horizontal section and a lower folded section; a conical hole is reserved on the prefabricated layer, wherein the conical hole is larger at the top and smaller at the bottom, the top surface of the conical hole is located on the top surface of the prefabricated layer, the bottom surface of the conical hole is located on the side surface of the prefabricated layer, the horizontal section of the post-positioned reinforcement is located on the top surface of the prefabricated layer, the lower folded section of the post-positioned reinforcement passes through the conical hole, and the conical hole is filled with grouting material.

[0006] Furthermore, a rubber sealing ring is sleeved on the lower folded section of the post-positioned rib, and the rubber sealing ring blocks the bottom opening of the conical hole.

[0007] The outer diameter of the post-positioned rib is smaller than the bottom opening of the tapered hole, the outer diameter of the rubber sealing ring is larger than the bottom opening of the tapered hole, and the outer diameter of the rubber sealing ring is smaller than the top opening of the tapered hole.

[0008] Furthermore, the grouting material is a non-shrinkage grouting material.

[0009] A process for producing a PC laminated board comprises the following steps:

[0010] Step 1, making a prefabricated layer: making a prefabricated layer on a table mold, using a reserved conical hole technology to form a conical hole on the prefabricated layer, wherein the conical hole is larger at the top and smaller at the bottom, the top surface of the conical hole is located at the top surface of the prefabricated layer, and the bottom surface of the conical hole is located at the side surface of the prefabricated layer;

[0011] Step 2: making a post-positioned rib, wherein the post-positioned rib is in a folded shape and comprises a horizontal section and a lower folded section;

[0012] Step 3: Sealing and anchoring the post-reinforcement in the conical hole: insert the post-reinforcement into the conical hole, with the horizontal section of the post-reinforcement located on the top surface of the prefabricated layer, and the lower folded section of the post-reinforcement passes through the conical hole, and then the conical hole is grouted and sealed with grouting material;

[0013] Step 4: Pour the cast-in-place layer on the prefabricated layer.

[0014] Furthermore, in the step one, the conical sleeves are pre-installed to ensure that the position, size and shape of the conical holes meet the design requirements. Before the concrete of the precast layer is poured, the conical sleeves are fixed in the side molds of the pedestal to ensure that they maintain the correct position and angle during the pouring process; after the concrete solidifies, the conical sleeves are removed, leaving the designed conical holes, providing precise positioning for the post-placed reinforcement.

[0015] Preferably, the conical sleeve is detachably connected to the prefabricated pedestal side mold, for example, by bolts.

[0016] The conical sleeve is made of durable materials such as high-density polyethylene or steel to ensure durability and high turnover.

[0017] Furthermore, in the step three, a rubber sealing ring is sleeved on the lower folded section of the post-positioned rib, and after the post-positioned rib is inserted into the conical hole, the rubber sealing ring blocks the bottom opening of the conical hole.

[0018] The beneficial effects of the present invention are mainly manifested in: improving construction efficiency and structural safety. BRIEF DESCRIPTION OF THE DRAWINGS

[0019] Figure 1 It is a structural schematic diagram of the PC laminated board of the present invention. DETAILED DESCRIPTION

[0020] The present invention will be further described below in conjunction with the accompanying drawings.

[0021] Reference Figure 1 A PC composite board comprises a prefabricated layer 1 and a cast-in-place layer 2, wherein the cast-in-place layer 2 is located on the prefabricated layer 1, and the PC composite board further comprises a post-positioned reinforcement 11, wherein the post-positioned reinforcement 11 is in a folded shape and comprises a horizontal section and a lower folded section; a conical hole 12 is reserved on the prefabricated layer 1, wherein the conical hole 12 is larger at the top and smaller at the bottom, the top surface of the conical hole 12 is located at the top surface of the prefabricated layer 1, and the bottom surface of the conical hole 12 is located at the side surface of the prefabricated layer 1, the horizontal section of the post-positioned reinforcement 11 is located at the top surface of the prefabricated layer, the lower folded section of the post-positioned reinforcement 11 passes through the conical hole 12, and the conical hole 12 is filled with grouting material 13.

[0022] Furthermore, a rubber sealing ring 14 is sleeved on the lower folded section of the rear rib 11 , and the rubber sealing ring 14 blocks the bottom opening of the tapered hole 12 .

[0023] The outer diameter of the post-rib 11 is smaller than the bottom opening of the tapered hole 12 , the outer diameter of the rubber sealing ring 14 is larger than the bottom opening of the tapered hole 12 , and the outer diameter of the rubber sealing ring 14 is smaller than the top opening of the tapered hole 12 .

[0024] Furthermore, the grouting material 13 is a non-shrinkage grouting material.

[0025] A process for producing a PC laminated board comprises the following steps:

[0026] Step 1, making a prefabricated layer 1: making a prefabricated layer 1 on a table mold, using a reserved conical hole technology to form a conical hole 12 on the prefabricated layer, wherein the conical hole 12 is larger at the top and smaller at the bottom, the top surface of the conical hole 12 is located at the top surface of the prefabricated layer 1, and the bottom surface of the conical hole 12 is located at the side surface of the prefabricated layer 1;

[0027] In the step 1, the position, size and shape of the tapered hole are ensured to meet the design requirements by pre-installing the tapered sleeve. Before pouring the concrete of the precast layer, the tapered sleeve is fixed in the formwork to ensure that they maintain the correct position and angle during the pouring process. After the concrete solidifies, the tapered sleeve is removed, leaving the designed tapered hole 12, providing precise positioning for the post-placed reinforcement.

[0028] Preferably, the conical sleeve is detachably connected to the prefabricated pedestal side mold, for example, by bolts.

[0029] The conical sleeve is made of durable materials such as high-density polyethylene or steel to ensure durability and high turnover.

[0030] Step 2: making a rear rib 11, wherein the rear rib 11 is in a folded shape and comprises a horizontal section and a lower folded section;

[0031] Step 3: Sealing and anchoring the tapered hole post-reinforcement: the post-reinforcement 11 is inserted into the tapered hole 12, the horizontal section of the post-reinforcement 11 is located on the top surface of the prefabricated layer 1, the lower folded section of the post-reinforcement 11 passes through the tapered hole 12, and the tapered hole 12 is then grouted and sealed with the grouting material 13;

[0032] In the step three, a rubber sealing ring 14 is sleeved on the lower folded section of the rear rib 11 , and after the rear rib 11 is inserted into the tapered hole 12 , the rubber sealing ring 14 blocks the bottom opening of the tapered hole 12 .

[0033] Step 4: Cast the cast-in-place layer 2 on the prefabricated layer 1. The production process of the cast-in-place layer 2 is realized by using the existing technology. The cast-in-place layer 2 can be cast and formed at the same time as the cast-in-place beam 3.

[0034] In this embodiment, the reserved conical hole technology is used. The PC laminate factory uses the reserved conical hole technology on the table form to form a standard and neat conical hole. This technology embeds a conical sleeve on the table form and removes it after concrete pouring, which can form a precise conical hole and provide accurate positioning for the post-reinforcement.

[0035] The reserved conical hole technology of this embodiment ensures that the position, size and shape of the reserved hole meet the design requirements through the pre-installed conical sleeve. The key advantage of this technology is that it can provide precise positioning, which is crucial to the stability and safety of the subsequent structure. The embedded sleeves are usually made of durable materials such as high-density polyethylene or steel to ensure durability and high turnover. Before the concrete is poured, these conical sleeves are fixed in the formwork to ensure that they maintain the correct position and angle during the pouring process. After the concrete solidifies, the conical sleeves are removed, leaving the designed conical holes to provide precise positioning for the post-placed reinforcement. This method not only improves construction efficiency and quality control, but also reduces material waste and construction costs.

[0036] This embodiment ensures the construction quality and improves the construction efficiency by post-positioning the reinforcement. This method can reduce the occurrence of quality defects such as bending of the reserved reinforcement and concrete damage caused by bending during the hoisting of the assembled PC prefabricated panels.

[0037] The present invention uses the post-reinforcement method, which ensures the quality of the project and improves the construction efficiency through a carefully designed post-reinforcement layout. The core of this method lies in the non-traditional staggered post-reinforcement arrangement. The application of the staggered post-reinforcement method not only optimizes the construction process, but also improves the flexibility and safety of the operation by reducing interference and conflicts during construction. In addition, this technology helps to shorten the project cycle and improve construction efficiency by reducing the amount of on-site work, while ensuring the stability and durability of the building structure.

[0038] The conical hole of this embodiment is designed in a trumpet shape, and the socket of the steel bar is designed as a conical hole (trumpet shape), with a large opening on the top and a small opening on the bottom. A rubber sealing ring is put on the rear reinforcement to block the bottom side with a small opening. After the rear reinforcement is installed, the conical hole is grouted and sealed with M60 grouting material. The present invention uses a conical hole (trumpet shape) design for the insertion of additional steel bars and the fixing of the rubber sealing ring on the steel bars to improve the overall strength of the structure. This design not only simplifies the construction process, but also improves the durability and safety of the structure. It is an innovative technology with great application value in assembled PC prefabricated panels.

[0039] The embodiments of the present invention are:

[0040] 1) Reserve conical holes: During the prefabrication stage of the PC laminate, a conical mold is accurately reserved in the table formwork according to the requirements of the design drawings, and a conical hole is formed after the concrete is poured. This step is the key to realizing the post-reinforcement process, because the design of the conical hole directly affects the installation of the post-reinforcement and the overall performance of the structure. The diameter, quantity and required mechanical properties of the steel bars must be considered during the design to ensure that the hole can accommodate steel bars of different diameters and lengths. To this end, a mold that matches the conical hole design is made, and the mold material must have sufficient strength and rigidity to maintain its shape and facilitate connection and removal with the table formwork. Before pouring concrete, place the mold in the correct position and ensure that the mold is firmly fixed to prevent displacement during the pouring process.

[0041] 2) Post-reinforcement insertion: After the concrete reaches a certain strength, the post-reinforcement is inserted. This step requires precise operation to ensure that the post-reinforcement is correctly placed in the tapered hole. Prepare steel bars of corresponding diameter and length as post-reinforcement according to design requirements, clean and derust the surface of the post-reinforcement, and use special tools or equipment to insert the post-reinforcement into the reserved tapered hole to ensure that the insertion depth and position of the post-reinforcement meet the design requirements.

[0042] 3) Fixing of post-reinforcement: Spray water to moisten the conical hole, and set a rubber sealing ring on the lower folded section of the post-reinforcement. After the post-reinforcement is inserted into the conical hole, the rubber sealing ring blocks the bottom opening of the conical hole. After the post-reinforcement is inserted, the position of the post-reinforcement is finally checked and adjusted to ensure that it meets the design requirements. The conical hole is then grouted and sealed with grouting material, and watered for maintenance.

[0043] 4) Subsequent concrete pouring: After the fixing of the rear reinforcement is completed, the subsequent concrete pouring is carried out to complete the construction of the composite slab. Before pouring, the construction site is cleaned to ensure that there are no debris that affects the pouring quality of the concrete. Pour in accordance with the standard concrete construction process to ensure that the concrete is evenly filled and avoid voids and cracks. After pouring, the concrete is properly cured to ensure that it reaches the designed strength.

[0044] Through the above steps, the PC composite plate tapered hole post-reinforcement process of this embodiment not only improves the construction efficiency, but also enhances the safety and reliability of the structure. This process achieves a good combination between steel bars and concrete by optimizing the hole design and the construction method of post-reinforcement, thereby improving the overall performance of the structure. In addition, this process also uses fiber-reinforced materials and the strongest UHPC materials to further improve the mechanical properties and bending stiffness of the composite plate, bringing an innovative solution to the field of building structures.

[0045] The contents described in the embodiments of this specification are merely enumerations of implementation forms of the inventive concept and are for illustrative purposes only. The protection scope of the present invention should not be considered to be limited to the specific forms described in this embodiment, and the protection scope of the present invention also extends to equivalent technical means that can be thought of by ordinary technicians in this field based on the inventive concept.

Claims

1. A PC laminated board, comprising a prefabricated layer and a cast-in-place layer, wherein the cast-in-place layer is located on the prefabricated layer, characterized in that: The PC composite board also includes post-positioned reinforcement, which is in a folded shape and includes a horizontal section and a lower folded section; a conical hole is reserved on the prefabricated layer, the conical hole is larger at the top and smaller at the bottom, the top surface of the conical hole is located on the top surface of the prefabricated layer, the bottom surface of the conical hole is located on the side surface of the prefabricated layer, the horizontal section of the post-positioned reinforcement is located on the top surface of the prefabricated layer, the lower folded section of the post-positioned reinforcement passes through the conical hole, and the conical hole is filled with grouting material.

2. A PC laminated board as claimed in claim 1, characterized in that: The lower folded section of the rear rib is sleeved with a rubber sealing ring, and the rubber sealing ring blocks the bottom opening of the tapered hole. The outer diameter of the rear rib is smaller than the bottom opening of the tapered hole, the outer diameter of the rubber sealing ring is larger than the bottom opening of the tapered hole, and the outer diameter of the rubber sealing ring is smaller than the top opening of the tapered hole.

3. A PC laminated board as claimed in claim 1 or 2, characterized in that: The grouting material is a non-shrinkage grouting material.

4. A process for manufacturing a PC laminated board as claimed in claim 1, characterized in that: The following steps are involved: Step 1, making a prefabricated layer: making a prefabricated layer on a table mold, using a reserved conical hole technology to form a conical hole on the prefabricated layer, wherein the conical hole is larger at the top and smaller at the bottom, the top surface of the conical hole is located at the top surface of the prefabricated layer, and the bottom surface of the conical hole is located at the side surface of the prefabricated layer; Step 2: making a post-positioned rib, wherein the post-positioned rib is in a folded shape and comprises a horizontal section and a lower folded section; Step 3: Sealing and anchoring the post-reinforcement in the conical hole: insert the post-reinforcement into the conical hole, with the horizontal section of the post-reinforcement located on the top surface of the prefabricated layer, and the lower folded section of the post-reinforcement passes through the conical hole, and then the conical hole is grouted and sealed with grouting material; Step 4: Pour the cast-in-place layer on the prefabricated layer.

5. The manufacturing process according to claim 4, characterized in that: In the step 1, the conical sleeves are pre-installed to ensure that the position, size and shape of the conical holes meet the design requirements. Before the concrete of the precast layer is poured, the conical sleeves are fixed in the side molds of the pedestal to ensure that they maintain the correct position and angle during the pouring process; after the concrete solidifies, the conical sleeves are removed, leaving the designed conical holes, providing precise positioning for the post-placed reinforcement.

6. The manufacturing process according to claim 5, characterized in that: The conical sleeve is detachably connected to the prefabricated pedestal side mold.

7. The manufacturing process according to claim 5, characterized in that: The conical sleeve is made of high-density polyethylene or steel.

8. The manufacturing process according to any one of claims 4 to 7, characterized in that: In the step three, a rubber sealing ring is sleeved on the lower folded section of the rear reinforcement, and after the rear reinforcement is inserted into the conical hole, the rubber sealing ring blocks the bottom opening of the conical hole.

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