Modular building and construction method thereof

Abstract

According to the modular building and the construction method thereof, prefabricated parts in module units are produced in a factory, and adjacent module units on the same layer form a whole through post-cast module laminated columns, first module laminated beams, second module laminated beams or module shear walls or post-cast laminated layers of top plates; the upper-layer module and the lower-layer module are connected through penetrating load-bearing steel bars in module composite columns, vertical holes are reserved, and then concrete is poured to form a whole. The modular building is of a frame structure or a frame-shear wall structure formed by splicing different module units. Compared with the prior art, the modular units can be spliced to form a frame-shear wall structure, the lateral stiffness of a modular building is remarkably improved, and the applicable height and the anti-seismic property of the modular building are effectively improved; the upper-layer module and the lower-layer module are reliably connected through connection of through load-bearing steel bars in module composite columns and post-pouring of reserved vertical holes, the node connecting structure is optimized, force transmission is reliable, the path is clear, the structure is simple, and construction is convenient and fast.

Description

Technical Field

[0001] The invention belongs to the technical field of construction, and in particular relates to a modular building and a construction method thereof. Background Art

[0002] Modular buildings use factory-prefabricated modules and assemble them efficiently on site, providing an industrialized, green, and standardized construction method. Its core advantage is that factory prefabrication reduces on-site wet work, thereby greatly improving construction efficiency and shortening construction periods, while reducing on-site environmental pollution and carbon emissions, which is in line with the development trend of green and low-carbon buildings. With the increase in market demand, modular buildings have broad application prospects, especially in rapid construction and low-carbon economy.

[0003] There are some urgent problems to be solved in the application of existing modular buildings, mainly concentrated in the aspects of structural performance and construction technology. First, the overall lateral stiffness of existing modular buildings is low and the seismic performance is poor, which limits its applicable height and makes it difficult to meet the needs of high-rise buildings and high seismic fortification intensity areas. Secondly, the connection node design of existing modular buildings is relatively complex, and the technical precision requirements during the construction process are high, which increases the difficulty of construction and affects the efficiency and quality of on-site assembly. More importantly, the stiffness, bearing capacity, force transmission path and force transmission efficiency of the core area of ​​the existing modular building nodes are unclear, which leads to poor integrity and seismic performance of the overall structure. In order to improve the promotion and application level of modular buildings, it is urgent to develop a modular building and its construction method to solve the problems of low lateral stiffness, poor seismic performance, unclear force transmission path, complex node connection, difficulty in on-site construction, and limited applicable height of existing modular buildings. Summary of the invention

[0004] In order to overcome the shortcomings of the prior art, the purpose of the present invention is to provide a modular building and a construction method thereof to solve the problems of low lateral stiffness, poor seismic performance, unclear force transmission path, complex node connection, difficulty in on-site construction, limited applicable height, etc. of the existing modular buildings.

[0005] To achieve the above purpose, the present invention adopts the following technical scheme.

[0006] A modular building is composed of any one, two or three combinations of three types of modular units, wherein the modular units include several types of modular composite columns, modular composite beams 1, modular composite beams 2 and modular shear walls, wherein the length of the modular composite beams 1 is along the X direction, and the lengths of the modular composite beams 2 and the modular shear walls are along the Y direction; wherein the modular unit 1 is composed of four modular composite columns, two modular composite beams 1, two modular composite beams 2 and a top plate; the modular unit 2 is composed of four modular composite columns, two modular composite beams 1, one modular composite beam 2, one modular shear wall and a top plate; and the modular unit 3 is composed of four modular composite columns, two modular composite beams 1, two modular shear walls and a top plate.

[0007] In one embodiment, the module composite column includes a prefabricated column body, load-bearing longitudinal reinforcements and a reinforcement joint; a vertical hole is provided in the prefabricated column body, the load-bearing reinforcement is penetrated and arranged in the vertical hole and extends out of the top of the vertical hole, and the upper and lower layers of the load-bearing longitudinal reinforcements are reliably connected through the reinforcement joint, wherein the top extension lengths of the load-bearing reinforcements are different; the vertical hole is composed of an outer vertical hole adjacent to the module composite beam one and an inner vertical hole away from the module composite beam one; the load-bearing reinforcement includes main load-bearing reinforcements and structural load-bearing reinforcements, the main load-bearing reinforcements are arranged in the outer vertical hole, and the structural load-bearing reinforcements are arranged in the inner vertical hole.

[0008] In one embodiment, a groove is provided in the node core area of ​​the modular composite column, and the grooves of the adjacent modular composite columns on the same layer are connected to each other and then poured with concrete or grouting material to form a whole.

[0009] In one embodiment, the modular composite beam 1 includes a prefabricated beam body 1, a post-cast composite layer 2 and a top reinforcement 1, wherein the top reinforcement 1 penetrates the post-cast composite layer 2 of the adjacent modular composite beam 1 on the same layer and the post-cast composite layer 1 of the adjacent modular composite column on the same layer;

[0010] The second modular composite beam comprises a second prefabricated beam body, a third post-cast composite layer and a second top reinforcement. The second top reinforcement runs through the second modular composite beam along the length direction of the second modular composite beam, and the end of the second top reinforcement extends into the first post-cast composite layer of the adjacent modular composite column of the same layer.

[0011] The wall thickness of the modular shear wall is less than that of an ordinary shear wall, and its longitudinal reinforcement adopts structural reinforcement. The longitudinal reinforcements of the modular shear walls of adjacent modular units in the upper and lower layers are not connected.

[0012] In one embodiment, the modular building further comprises a filling wall, which is arranged below the second module composite beam.

[0013] In one embodiment, the modular shear wall is arranged between two adjacent modular composite columns in a modular unit, perpendicular to the connection direction of the modular composite columns of adjacent modular units on the same floor, and the modular composite columns also serve as edge hidden columns connected to the modular shear walls; the modular composite beam 1 is parallel to the connection direction of the modular composite columns of adjacent modular units on the same floor; the modular composite beam 2 is perpendicular to the connection direction of the modular composite columns of adjacent modular units on the same floor.

[0014] In one embodiment, different module units are assembled to form a frame structure or a frame-shear wall structure:

[0015] Only the module unit 1 is used to form a frame structure;

[0016] Only the module unit 3 is used to form a frame-shear wall structure;

[0017] A frame-shear wall structure is formed by using several of the module units one and several of the module units two, or several of the module units one and several of the module units three, or several of the module units two and several of the module units three, or several of the module units one, several of the module units two and several of the module units three.

[0018] The present invention also provides a construction method of the modular building, the steps of which are as follows:

[0019] Step 1: Factory prefabrication

[0020] According to different module units, the production of the prefabricated column of the module composite column, the prefabricated beam body 1 of the module composite beam 1, the prefabricated beam body 2 of the module composite beam 2 and the corresponding parts of the prefabricated shear wall of the module shear wall is completed in the factory;

[0021] Step 2: Assembly of modular units on the same floor

[0022] The module units on the same floor are hoisted in place at the construction site, and the top reinforcement 1 of the module composite beam 1 passes through the post-cast composite layer 2 of the adjacent module composite beam 1 on the same floor and the post-cast composite layer 1 of the adjacent module composite column on the same floor; after the assembly is completed, the post-cast composite layer of the module units on the same floor is integrally cast to form a whole module unit on the same floor;

[0023] Step 3: Assemble the upper and lower module units

[0024] The upper module unit is hoisted into place at the construction site, the load-bearing longitudinal reinforcements of the upper and lower module composite columns are connected by steel bar joints, and the vertical holes of the module composite columns are cast to form the upper and lower module units as a whole.

[0025] In one embodiment, when setting up the filling wall, in step 2, the filling wall is set below the second module composite beam.

[0026] In one embodiment, when a prefabricated composite slab is used to set the top plate, the prefabricated top plate in step 1 is produced together with other components of the module unit in the factory, and in step 2, the post-cast composite layer of the top plate is cast and formed integrally with other post-cast composite layers; when the top plate is produced on-site, the top plate in step 2 is cast and formed integrally with other post-cast composite layers.

[0027] Compared with the prior art, the present invention has the following beneficial effects:

[0028] 1) The modular units of the present invention can be assembled to form a frame-shear wall structure, which significantly improves the lateral stiffness of the modular building and effectively improves the applicable height and seismic performance of the modular building.

[0029] 2) The upper and lower modules of the present invention are reliably connected by connecting the load-bearing steel bars through the module superimposed columns and reserving vertical holes for post-casting, thereby optimizing the node connection structure, ensuring reliable force transmission and clear paths, simple structure, and convenient construction.

[0030] 3) The modular composite columns of the present invention also serve as edge concealed columns of the connected modular shear walls. Therefore, the longitudinal reinforcements in the adjacent modular shear walls of the upper and lower layers may not be connected. At the same time, the thickness of the modular shear wall may be less than that of the ordinary shear wall. Under the premise of ensuring the stress-bearing performance of the module, the shear wall end connection structure can be simplified, materials can be saved, indoor space can be increased, construction costs can be reduced, and construction difficulty can be reduced. BRIEF DESCRIPTION OF THE DRAWINGS

[0031] In order to more clearly illustrate the technical solutions of the embodiments of the present invention, the drawings required for use in the embodiments are briefly introduced below. It should be understood that the following drawings only show certain embodiments of the present invention and therefore should not be regarded as limiting the scope. For ordinary technicians in this field, other related drawings can be obtained based on these drawings without creative work.

[0032] Figure 1 It is a three-dimensional schematic diagram of a structure of a module unit of the present invention.

[0033] Figure 2 It is a three-dimensional schematic diagram of the structure of the second module unit of the present invention.

[0034] Figure 3 It is a three-dimensional schematic diagram of the three structures of the module unit of the present invention.

[0035] Figure 4 3D schematic diagram of modular frame structure in an embodiment of the present invention (only module unit 1 is used)

[0036] Figure 5A three-dimensional schematic diagram of a modular frame-shear wall structure in an embodiment of the present invention (only module unit three is used).

[0037] Figure 6 A three-dimensional schematic diagram of a modular frame-shear wall structure in an embodiment of the present invention (including module unit 2).

[0038] Figure 7 It is a three-dimensional schematic diagram of a modular composite column in an embodiment of the present invention.

[0039] Figure 8 It is a top view of the modular composite column in an embodiment of the present invention.

[0040] Fig. 9 It is a three-dimensional schematic diagram of the core area of ​​the module composite column node in an embodiment of the present invention.

[0041] Fig.10 It is a three-dimensional schematic diagram of a modular composite beam 1 in an embodiment of the present invention.

[0042] Fig.11 It is a three-dimensional schematic diagram of the second modular composite beam in an embodiment of the present invention.

[0043] Fig.12 It is a three-dimensional schematic diagram of a fully prefabricated shear wall in an embodiment of the present invention.

[0044] Fig.13 It is a three-dimensional schematic diagram of a prefabricated composite hollow shear wall in an embodiment of the present invention.

[0045] In the figure:

[0046] 1-module composite column; 11-vertical hole; 111-outer vertical hole; 112-inner vertical hole; 12-stressed longitudinal reinforcement; 121-main stress-bearing steel bar; 122-structural stress-bearing steel bar; 13-steel bar joint; 14-groove; 15-precast column; 16-post-cast composite layer one; 2-module composite beam one; 21-top reinforcement; 22-post-cast composite layer two; 23-precast beam one; 3-module composite beam two; 31-precast beam two; 32-post-cast composite layer three; 4-module shear wall; 41-longitudinal reinforcement; 42-precast shear wall; 43-post-cast composite layer four; 44-fully precast shear wall; 45-precast composite hollow shear wall; 5-module unit one; 6-module unit two; 7-module unit three; 8-filling wall; 9-top plate. DETAILED DESCRIPTION

[0047] The embodiments of the present invention are described in detail below with reference to the accompanying drawings and examples.

[0048] In order to make the purpose, technical solutions and advantages of the embodiments of the present invention clearer, the technical solutions in the embodiments of the present invention will be clearly and completely described below in conjunction with the drawings in the embodiments of the present invention. Obviously, the described embodiments are part of the embodiments of the present invention, not all of the embodiments. Generally, the components of the embodiments of the present invention described and shown in the drawings here can be arranged and designed in various different configurations.

[0049] Therefore, the following detailed description of the embodiments of the present invention provided in the accompanying drawings is not intended to limit the scope of the invention claimed for protection, but merely represents selected embodiments of the present invention. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0050] It should be noted that similar reference numerals and letters denote similar items in the following drawings, and therefore, once an item is defined in one drawing, further definition and explanation thereof is not required in subsequent drawings.

[0051] In the description of the present invention, it should be noted that if the terms "upper", "lower", "inside", "outside", etc. appear to indicate an orientation or position relationship, they are based on the orientation or position relationship shown in the accompanying drawings, or are the orientation or position relationship in which the product of the invention is usually placed when used. They are only for the convenience of describing the present invention and simplifying the description, and do not indicate or imply 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.

[0052] In addition, the terms “first”, “second”, etc., if used, are merely used to distinguish between the descriptions and should not be understood as indicating or implying relative importance.

[0053] It should be noted that, in the absence of conflict, the features in the embodiments of the present invention may be combined with each other.

[0054] The current modular buildings still need to be improved in terms of overall lateral stiffness, seismic performance, applicable height, construction difficulty, etc. Based on this, the present invention provides a modular building, which is composed of any one, two or three of the three types of module units.

[0055] refer to Figure 1 , Figure 2 and Figure 3As shown, the three types of modular units of the present invention are modular unit 1 5, modular unit 2 6 and modular unit 3 7. Each modular unit includes several of modular composite columns 1, modular composite beams 1 2, modular composite beams 2 3 and modular shear walls 4. For ease of description, the present invention defines modular composite beams 1 2 as beams with a length along the X direction, modular composite beams 2 3 as beams with a length along the Y direction, and modular shear walls 4 as walls with a length along the Y direction. The definition of the XY direction is Figure 1 , Figure 2 and Figure 3 There are hints in it.

[0056] Specifically, the module unit 1 5 is composed of four module composite columns 1, two module composite beams 1 2, two module composite beams 2 3 and a top plate 9. Figure 1 As shown, the module unit 1 5 does not have a module shear wall 4. The module unit 2 6 is composed of four module composite columns 1, two module composite beams 1 2, one module composite beam 2 3, one module shear wall 4 and one top plate 9, as shown in FIG. Figure 2 As shown, there is only one modular composite beam 2 3 and one modular shear wall 4 in the modular unit 2 6, and the modular shear wall 4 is arranged on the side without the modular composite beam 2 3. The modular unit 3 7 is composed of four modular composite columns 1, two modular composite beams 1 2, two modular shear walls 4 and a top plate 9, that is, the modular unit 3 7 does not have the modular composite beam 2 3.

[0057] The Y-direction lateral stiffness of various module units of the present invention is: module unit one 5 < module unit two 6 < module unit three 7.

[0058] According to the above-mentioned modular units, different modular units of the present invention can be assembled with each other to form a frame structure or a frame-shear wall structure. The typical combinations are as follows:

[0059] Combination 1, only using module unit 1 5, forming a frame structure, such as Figure 4 Compared with the conventional modular frame structure, the frame structure module composite column node of the present invention has a simple structure, a clear force transmission path, good integrity and convenient construction.

[0060] Combination 2, only module unit 3 7 is used to form a frame-shear wall structure, such as Figure 5 As shown. The frame-shear wall structure has good overall lateral stiffness and earthquake resistance, and its applicable height exceeds that of the existing modular frame structure. According to this combination, when each module unit is assembled along the X direction, the lateral stiffness in the Y direction is relatively weak, and by adding the modular shear wall 4 along the Y direction, the lateral stiffness in the Y direction can be increased, thereby effectively increasing the applicable height of the modular building.

[0061] The remaining combinations are to introduce module unit 2 6 and combine it with the remaining module units, such as Figure 6As shown. For example, a combination of several module units 1 5 and several module units 2 6, or a combination of several module units 1 5 and several module units 3 7, or a combination of several module units 2 6 and several module units 3 7, or a combination of several module units 1 5, several module units 2 6 and several module units 3 7 can be adopted. These combinations all form a frame-shear wall structure. In these combinations, the advantages of the aforementioned combination 1 and combination 2 are combined.

[0062] According to the combination of the present invention, the frame structure is suitable for multi-story buildings with low floor heights. When the shear walls are set, a frame-shear wall structure can be formed. The Y-axis stiffness of the modular building is increased, which is suitable for multi-story buildings with high floor heights, breaking through the limitation of floor height.

[0063] The prefabricated parts of the modular composite column 1, modular composite beam 1 2, modular composite beam 2 3 or modular shear wall 4 in each modular unit of the present invention are all produced in the factory; the top plate 9 is made of prefabricated composite panels or on-site. When prefabricated composite panels are used, the prefabricated parts of the prefabricated composite panels are also produced in the factory. Therefore, the on-site construction links are greatly reduced and the construction difficulty is reduced.

[0064] In a further embodiment of the present invention, reference Figure 1 , Figure 2 , Figure 3 and Figure 7 As shown, the modular composite column 1 includes a prefabricated column 15, a stressed longitudinal reinforcement 12 and a reinforcement joint 13. A vertical hole 11 is provided in the prefabricated column 15, and the vertical hole 11 includes but is not limited to a formed channel, and can be in the form of a weldable thin-walled metal pipe, a plastic pipe or a core-pulling hole. The stressed steel bar 12 is arranged through the vertical hole 11 and extends upward and outward from the top of the vertical hole 11, and is reliably connected to the stressed steel bar 12 of the modular composite column 1 of the upper layer of the module unit through the reinforcement joint 13. For example, at least two vertical holes 11 are provided, and preferably symmetrically arranged along the column axis, and the top extension lengths of the stressed steel bars 12 of different vertical holes 11 are preferably set to different lengths, so that the reinforcement joints 13 of the upper and lower layers of stressed longitudinal reinforcement 12 are not at the same height, which improves the connection performance, and at the same time can reduce the number of longitudinal reinforcements in position, simplify the construction process, and reduce the difficulty of construction.

[0065] For example, when the cross section of the modular composite column 1 is square, four vertical holes 11 can be set and defined as outer vertical holes 111 and inner vertical holes 112, wherein the vertical hole 11 adjacent to the modular composite beam 12 is defined as the outer vertical hole 111, and the vertical hole 11 away from the modular composite beam 12 is defined as the inner vertical hole 112. At the same time, the stress-bearing steel bars 12 are defined as two types: main stress-bearing steel bars 121 and structural stress-bearing steel bars 122, wherein the main stress-bearing steel bars 121 are set in the outer vertical holes 111, and the structural stress-bearing steel bars 122 are set in the inner vertical holes 112. At this time, the main stress-bearing steel bars 121 in the two adjacent modular composite columns 1 on the same layer bear the main load, and the diameter of the structural stress-bearing steel bars 122 can be reduced to achieve the purpose of saving materials and reducing construction costs.

[0066] In a further embodiment of the present invention, reference Figure 1 , Figure 2 , Figure 3 , Figure 7 , Figure 8 and Fig. 9 As shown, the node core area of ​​the modular composite column 1 is provided with a groove 14, which is a notch structure at the top of the prefabricated column 15. The grooves 14 of the adjacent modular composite columns 1 on the same layer are connected and then cast to form a whole. In this embodiment, by designing the groove 14 on the top of the prefabricated column 15, the node core area of ​​the adjacent module units on the same layer is cast as a whole, ensuring that the module node core area after assembly is subjected to force together, thereby improving the node force performance.

[0067] Further preferably, the gap between the grooves 14 of adjacent module composite columns 1 on the same floor is the same width as the installation gap of the module composite columns 1 of the adjacent module units, usually not exceeding 2 cm. Different materials can be selected for casting according to actual engineering needs, including ordinary concrete, ultra-high performance concrete or high-strength grouting materials, etc., to ensure the stress performance of the core area of ​​the node.

[0068] Further preferably, considering the transmission of shear force at the beam end in the core area of ​​the node, in order to enhance the interface shear bearing capacity between the post-cast composite layer 16 of the module composite column 1 and the prefabricated column 15, the interface where the post-cast composite layer 16 intersects with the side of the groove 14 is preferably a rough surface or a keyway, and a naturally formed surface may also be used.

[0069] In a further embodiment of the present invention, reference Figure 1 , Figure 2 , Figure 3 , Fig. 9 and Fig.10As shown, the modular composite beam 1 2 includes a prefabricated beam body 1 23, a post-cast composite layer 2 22 and a top reinforcement 21. The top reinforcement 21 runs through the post-cast composite layer 2 22 of the adjacent modular composite beam 1 2 on the same layer and the post-cast composite layer 1 16 of the adjacent modular composite column 1 on the same layer. It is easy to understand that the basic steel cage structure such as longitudinal reinforcement and stirrups can also be designed in the modular composite beam 1 2 as needed.

[0070] In a further embodiment of the present invention, reference Figure 1 , Figure 2 , Figure 3 and Fig.11 As shown, the modular composite beam 23 includes a prefabricated beam body 231, a post-cast composite layer 32 and a top reinforcement 233. The top reinforcement 233 runs through the modular composite beam 23 along the length direction of the modular composite beam 23, and its end extends into the post-cast composite layer 16 of the modular composite column. It is easy to understand that the basic steel cage structure such as longitudinal reinforcement and stirrups can also be designed in the modular composite beam 23 as needed. Furthermore, in order to enhance anchorage, an anchor plate can be set at the end of the top reinforcement 23 extending into the post-cast composite layer 16.

[0071] In a further embodiment of the present invention, the module shear wall 4 of the present invention includes but is not limited to a fully prefabricated shear wall 44, a prefabricated composite hollow shear wall 45, a prefabricated double-sided composite shear wall, a composite shear wall with a membrane shell on one side, etc. Appropriate shear walls can be selected according to local conditions, combining structural construction, vertical connection, overall weight of the module, etc.

[0072] Fig.12 The structure of a fully prefabricated shear wall 44 is shown, which includes a prefabricated shear wall body 42 and a post-cast composite layer four 43, and longitudinal steel bars 41 extend from the prefabricated shear wall body 42 into the post-cast composite layer four 43.

[0073] Fig.13 The structure of the prefabricated composite hollow shear wall 45 is shown, which includes a prefabricated shear wall body 42 and a post-cast composite layer 43. The longitudinal steel bars 41 extend from the prefabricated shear wall body 42 into the post-cast composite layer 43, and vertical channels are arranged throughout the height. The construction of the horizontal joints of the upper and lower layers of the existing fully prefabricated wall is difficult, and the horizontal joints of the prefabricated composite hollow shear wall can be cast through its vertical channels.

[0074] refer to Figure 1 , Figure 2 , Figure 3 , Fig.12 and Fig.13As shown, various forms of modular shear walls 4 all include longitudinal reinforcement 41, and the longitudinal reinforcement 41 can be structurally reinforced. In a further embodiment of the present invention, the modular shear wall 4 is arranged between two adjacent modular composite columns 1 in a modular unit, perpendicular to the connection direction of the modular composite columns 1 of the adjacent modular units on the same layer, and the modular composite columns 1 also serve as the edge hidden columns of the connected modular shear walls 4, so the adjacent longitudinal reinforcements 41 of the upper and lower layers may not be connected, and at the same time, the thickness of the modular shear wall 4 may be less than the thickness of the ordinary shear wall, generally 100-120mm, and under the premise of ensuring the stress performance of the module, the shear wall end connection structure can be simplified, materials can be saved, the indoor space can be increased, the cost can be reduced, and the construction difficulty can be reduced. The modular composite beam 1 2 is parallel to the connection direction of the modular composite columns 1 of the adjacent modular units on the same layer; the modular composite beam 2 3 is perpendicular to the connection direction of the modular composite columns 1 of the adjacent modular units on the same layer. Among them, there are splicing seams between the adjacent module composite beams 23 on the same layer, the adjacent module composite beams 23 on the same layer and the module shear walls 4 or the adjacent module shear walls 4 on the same layer. The width of the splicing seams is usually not more than 2 cm. On the one hand, it can effectively prevent the leakage of cement slurry during pouring, simplify the construction process, reduce the time for adjustment and repair, ensure the pouring quality, improve the construction efficiency, and reduce the material and labor costs. On the other hand, it can also ensure the close connection between the modules and reduce the impact of the gap on the integrity of the structure.

[0075] In a further embodiment of the present invention, the modular building also includes a filling wall 8, which can be arranged below the module composite beam 2 3, including but not limited to autoclaved sand aerated concrete board, foamed cement board, foam particle concrete board, light steel keel, building blocks, etc.

[0076] According to the structure of the modular building of the present invention, the construction difficulty is greatly reduced. The main construction steps are as follows:

[0077] Step 1, divided into module unit one 5, module unit two 6, module unit three 7 to illustrate the module unit factory prefabrication steps.

[0078] Module unit 15, completes the production of prefabricated column 15 of module composite column 1, prefabricated beam 1 23 of two module composite beams 1 2, and prefabricated beam 2 31 of two module composite beams 2 3 in the factory;

[0079] Module unit 2 6, completes the production of precast column bodies 15 of four module composite columns 1, precast beam bodies 23 of two module composite beams 1 2, precast beam body 2 31 of one module composite beam 2 3, and precast shear wall body 42 of one module shear wall 4 in the factory;

[0080] Module unit three 7, completes the production of prefabricated column bodies 15 of four module composite columns 1, prefabricated beam bodies 23 of two module composite beams 2, and prefabricated shear wall bodies 42 of two module shear walls 4 in the factory.

[0081] Furthermore, the various types of module units of the present invention can be integrally processed and cast in a factory, or the wall panels, columns, beams, and top panels can be prefabricated separately and then assembled in a factory to form modules.

[0082] This step is the basis of the construction process. Before the binding operation is carried out, all steel materials must be strictly checked to see if they meet the design specifications, including the size, quantity, and strength grade of the steel bars. The surface of the steel bars must be kept clean to prevent rust and impurities to ensure the quality of the connection. The design of the steel cage must comprehensively consider its bearing capacity and seismic resistance to ensure that the concrete has sufficient strength and stability after pouring.

[0083] The core task of this step is to implement the pouring of prefabricated modules. During the construction process, the flow characteristics of the pouring need to be precisely controlled to prevent material separation and bubble generation. After the pouring is completed, the pouring needs to be vibrated with the help of vibration equipment to remove internal bubbles and enhance its compactness. After pouring, proper maintenance is required to maintain a suitable humidity environment to avoid cracks and ensure that its strength meets the standards.

[0084] Step 2: Assembling and constructing the module units on the same floor.

[0085] At the construction site, the module units on the same floor are hoisted in place, and the top reinforcement 21 of the module composite beam 1 2 is placed so that it can penetrate the post-cast composite layer 2 22 of the adjacent module composite beam 1 2 on the same floor and the post-cast composite layer 16 of the adjacent module composite column 1 on the same floor. By penetrating the top reinforcement 1 21, the reliability of the structural connection is ensured and the integrity of the structure is improved. This step can be performed after the assembly of the module units on the same floor is completed, and then the post-cast composite layer of the module on the same floor is cast in one piece to form a whole module unit on the same floor. After the casting is completed, sufficient maintenance is required to ensure the strength performance of the cast object and the overall stability of the structure.

[0086] When the filling wall 8 is set, it is also necessary to complete the construction of the filling wall 8 in this step. Specifically, the filling wall 8 is set below the second module composite beam 3 in this step.

[0087] Furthermore, this step requires sealing the joints between adjacent module units on the same layer, for example, using a caulking agent or a cover plate as a sealing material to prevent leakage of concrete slurry.

[0088] The core goal of this step is to achieve effective sealing of the joints. After the modules are connected, it is necessary to select appropriate caulking agents to fill the joints according to the width and design specifications, or to cover them with covers to prevent slurry leakage and water infiltration. The use of caulking agents must ensure that the joints are completely sealed to avoid water seepage or structural stability problems during subsequent construction or use.

[0089] Step 3: Assemble the upper and lower module units.

[0090] At the construction site, the adjacent upper module units are hoisted into place, the upper load-bearing longitudinal reinforcement 12 is connected with the load-bearing longitudinal reinforcement 12 in the lower module composite column 1 one by one through the steel bar joint 13, and the vertical holes 11 of the module composite column 1 are cast to form the upper and lower module units as a whole.

[0091] In this step, when hoisting the upper module unit, the position of the stressed longitudinal reinforcement 12 must be precisely controlled to prevent it from hindering the fall of the upper module unit. The height of the upper module unit from the horizontal joint of the lower module unit can be adjusted by leveling bolts, and the verticality of the upper module unit can be corrected. The stirrups in the bottom horizontal joint are lifted to the designed position and tied and fixed with the lower stressed longitudinal reinforcement 12. Then the bottom horizontal joint is closed, and the bottom horizontal joint and the post-casting in the vertical hole 11 are completed through the vertical hole 11; finally, maintenance is performed and the formwork is removed to complete the connection between the upper and lower module units, so that the upper and lower module composite columns 1, the stressed longitudinal reinforcement 12 in the vertical hole 11 and the post-casting form a whole and are stressed together.

[0092] Since the top plate 9 of the present invention can be a prefabricated composite plate, it can also be made on the construction site. Therefore, when it is a prefabricated composite plate, it can be produced in the factory with other prefabricated parts in step 1, and in step 2, the post-cast composite layer of the top plate 9 is cast and formed integrally with other post-cast composite layers; when the top plate 9 is made on the construction site, the top plate 9 is cast and formed integrally with other post-cast composite layers in step 2. For example, the formwork-free floor slab bottom plate or the floor slab formwork can be laid on site, and the floor concrete can be cast and formed afterwards.

Claims

1. Modular building, characterized by, The invention is composed of any one, two or three combinations of three types of module units, wherein the module units include several types of module composite columns (1), module composite beams one (2), module composite beams two (3) and module shear walls (4), wherein the length of the module composite beams one (2) is along the X direction, and the lengths of the module composite beams two (3) and the module shear walls (4) are along the Y direction; wherein the module unit one (5) is composed of four of the module composite columns (1), two of the module composite beams one (2), two of the module composite beams two (3) and a top plate (9); the module unit two (6) is composed of four of the module composite columns (1), two of the module composite beams one (2), one of the module composite beams two (3), one of the module shear walls (4) and a top plate (9); and the module unit three (7) is composed of four of the module composite columns (1), two of the module composite beams one (2), two of the module shear walls (4) and a top plate (9).

2. The modular building according to claim 1, characterized in that The modular composite column (1) comprises a prefabricated column body (15), a load-bearing longitudinal reinforcement (12) and a reinforcement joint (13); a vertical hole (11) is arranged in the prefabricated column body (15); the load-bearing reinforcement (12) is arranged through the vertical hole (11) and extends outward from the top of the vertical hole (11); the load-bearing longitudinal reinforcement (12) of the upper and lower layers is reliably connected through the reinforcement joint (13); the top extension lengths of the load-bearing reinforcement (12) are different; the vertical hole (11) is composed of an outer vertical hole (111) adjacent to the modular composite beam (2) and an inner vertical hole (112) away from the modular composite beam (2); the load-bearing reinforcement (12) comprises a main load-bearing reinforcement (121) and a structural load-bearing reinforcement (122); the main load-bearing reinforcement (121) is arranged in the outer vertical hole (111), and the structural load-bearing reinforcement (122) is arranged in the inner vertical hole (112).

3. The modular building according to claim 1, characterized in that A groove (14) is provided in the node core area of ​​the modular composite column (1), and the grooves (14) of the adjacent modular composite columns (1) at the same layer are connected relative to each other and then cast to form a whole.

4. The modular building according to claim 1, characterized in that The modular composite beam (2) comprises a prefabricated beam body (23), a post-cast composite layer (22) and a top reinforcement (21), wherein the top reinforcement (21) penetrates the post-cast composite layer (22) of the adjacent modular composite beam (2) on the same layer and the post-cast composite layer (16) of the adjacent modular composite column (1) on the same layer; The modular composite beam 2 (3) comprises a prefabricated beam body 2 (31), a post-cast composite layer 3 (32) and a top reinforcement 2 (33), wherein the top reinforcement 2 (33) penetrates the modular composite beam 2 (3) along the length direction of the modular composite beam 2 (3), and the end of the top reinforcement 2 (33) extends into the post-cast composite layer 1 (16) of the adjacent modular composite column (1) at the same layer; The wall thickness of the modular shear wall (4) is smaller than that of an ordinary shear wall, and its longitudinal steel bars (41) adopt structural reinforcement. The longitudinal steel bars (41) of the modular shear walls (4) of adjacent modular units in upper and lower layers are not connected.

5. The modular building according to claim 1, characterized in that The modular building also includes a filling wall (8), which is arranged below the second modular composite beam (3).

6. The modular building according to claim 1, characterized in that The modular shear wall (4) is arranged between two adjacent modular composite columns (1) in a modular unit, perpendicular to the connection direction of the modular composite columns (1) of adjacent modular units on the same layer, and the modular composite columns (1) also serve as edge concealed columns connected to the modular shear wall (4); the modular composite beam 1 (2) is parallel to the connection direction of the modular composite columns (1) of adjacent modular units on the same layer; and the modular composite beam 2 (3) is perpendicular to the connection direction of the modular composite columns (1) of adjacent modular units on the same layer.

7. The modular building according to any one of claims 1 to 6, characterized in that: Different module units are assembled to form a frame structure or frame-shear wall structure: Only the module unit one (5) is used to form a frame structure; Only the module unit three (7) is used to form a frame-shear wall structure; A frame-shear wall structure is formed by using a plurality of the module units one (5) and a plurality of the module units two (6), or a plurality of the module units one (5) and a plurality of the module units three (7), or a plurality of the module units two (6) and a plurality of the module units three (7), or a plurality of the module units one (5), a plurality of the module units two (6) and a plurality of the module units three (7).

8. The construction method of a modular building according to any one of claims 1 to 7, characterized in that: Here are the steps: Step 1: Factory prefabrication According to different module units, the production of the corresponding parts of the prefabricated column body (15) of the module composite column (1), the prefabricated beam body 1 (23) of the module composite beam 1 (2), the prefabricated beam body 2 (31) of the module composite beam 2 (3) and the prefabricated shear wall body (42) of the module shear wall (4) is completed in the factory; Step 2: Assembly of modular units on the same floor The module units of the same layer are hoisted into place at the construction site, and the top reinforcement 1 (21) of the module composite beam 1 (2) passes through the post-cast composite layer 2 (22) of the adjacent module composite beam 1 (2) of the same layer and the post-cast composite layer 1 (16) of the adjacent module composite column (1) of the same layer; after the assembly is completed, the post-cast composite layer of the module units of the same layer is integrally cast to form a whole module unit of the same layer; Step 3: Assemble the upper and lower module units The upper module unit is hoisted into place at the construction site, the load-bearing longitudinal reinforcements (12) of the upper and lower module composite columns (1) are connected by a reinforcement joint (13), and the vertical holes (11) of the module composite columns (1) are cast so that the upper and lower module units form a whole.

9. The construction method of modular building according to claim 8, characterized in that: When setting the filling wall (8), in step 2, the filling wall (8) is set below the second module composite beam (3).

10. The construction method of modular building according to claim 8, characterized in that: When a prefabricated composite slab is used to set the top plate (9), the prefabricated top plate and other components of the module unit are produced together in the factory in step 1, and in step 2, the post-cast composite layer of the top plate (9) is cast and formed integrally with other post-cast composite layers; when the top plate (9) is produced on the construction site, the top plate (9) and other post-cast composite layers are cast and formed integrally in step 2.

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