Prefabricated building (wall) plate system constructed by full dry method

Abstract

The invention discloses a prefabricated building (wall) plate system constructed by a full dry method, which is used for a low-rise fabricated building and comprises a prefabricated concrete building (wall) plate component and a special-shaped connecting column component, and continuous vertical hole channels and transverse hole channels are formed in prefabricated concrete building (wall) plates and special-shaped connecting columns. The primary and secondary grooves are adopted between the adjacent components, prestressed steel strands penetrate through hole channels during field installation, tensioning operation is carried out, and an overall stress system is formed through the prestress effect. The building (wall) can meet the requirements of large span and large load, breaks through the limitation of a common concrete floor, is widely suitable for various low-rise house buildings including rural houses, overseas houses, emergency security houses and the like, and provides solutions for different building requirements.

Description

Technical Field

[0001] The present invention relates to the field of construction engineering, and particularly to a precast floor (wall) panel system with all-dry construction, which adopts post-tensioned prestress for production and installation. Background Art

[0002] As building industrialization has gradually become an important driving force for the transformation of the construction industry, especially in the field of low-rise buildings, such as rural areas, overseas, and emergency support buildings, the industrialized construction method has put forward more stringent requirements for shortening the construction period and controlling costs. In order to meet these demands, building industrialization technology is developing towards a higher level of industrialization and greenness. Therefore, it is particularly necessary to innovate and improve the existing mainstream precast concrete structure technology to meet the growing market demand and environmental protection needs.

[0003] Currently, the construction industry is actively introducing modular construction technology, which can achieve rapid on-site assembly and disassembly, thus significantly shortening the construction period and improving construction efficiency. At the same time, by improving the production process of precast components, material waste can be effectively reduced, and the material utilization efficiency can be improved, thereby controlling costs. The application of digital technologies, such as BIM technology, also plays an important role in design and construction management. It can improve the accuracy of design and construction efficiency, reduce errors and rework, and further reduce costs.

[0004] In terms of greenness, building industrialization technology can better control the production environment through factory production, reducing the negative impact of on-site construction on the environment. The use of efficient thermal insulation materials and energy-saving equipment can improve the energy efficiency of buildings and reduce energy consumption. Promoting the use of renewable materials and recycling construction waste are also important measures to achieve the greenness of building industrialization. These measures not only help protect the environment but also improve the comfort and living quality of buildings.

[0005] Generally speaking, the application of building industrialization in the field of low-rise buildings not only improves the building quality and construction efficiency but also promotes the green and sustainable development of the construction industry. With the continuous progress and optimization of technology, building industrialization is expected to become a key force in promoting the transformation and upgrading of the construction industry, leading the industry towards a more efficient, environmentally friendly, and intelligent direction.

[0006] However, the existing mainstream precast structure systems have the following deficiencies:

[0007] 1) The connection of the PC shear wall system has cast-in-place

[0008] Although the current mainstream prefabricated structural system effectively reduces the use of support systems and formwork in the prefabrication stage, there are still local cast-in-place operations in the node area, which makes it difficult to completely eliminate wet operations, thereby causing hidden dangers in construction quality control and restricting the overall progress of the project. Secondly, the rebar-swinging structural characteristics commonly set up in this system have significant process operation and management difficulties in the actual production process. Furthermore, the maintenance procedures required for cast-in-place operations not only form complex working conditions with multiple types of work, but also easily lead to nonlinear growth in construction costs. What is particularly critical is that the construction quality of the node cast-in-place area is directly related to the load transfer performance and full-life durability of the overall structure, which puts forward more stringent requirements on the professional and technical qualifications and engineering experience of construction personnel, and objectively raises the industry entry threshold.

[0009] 2) Problems with existing dry connection methods

[0010] In the current prefabricated structural system, the traditional dry connection process mainly adopts technical means such as bolt connection and welding. However, this kind of process has several significant technical defects. First, the installation of embedded parts must strictly follow the positioning accuracy and verticality standards. This process places high demands on construction accuracy control and the professional qualifications of operators. Secondly, the complexity of the embedded system not only requires the configuration of special positioning molds and calibration devices for component production, but also restricts the standardization process of component production process. Finally, factors such as the purchase of special equipment, amortization of high-precision molds and the cost of skilled technicians involved in traditional processes have significantly increased the comprehensive cost of the project. It can be seen that the development of new connection technologies with convenient construction, efficient production and excellent economy has become a key issue in promoting the industrialization of prefabricated buildings. Such technological innovations will effectively simplify on-site operation processes, reduce dependence on professional technologies, and optimize the cost control of the entire life cycle of the project through a standardized production system.

[0011] 3) The existing wall panel connection has poor seismic performance and is difficult to meet strict seismic requirements

[0012] Most cities in my country are located in high-intensity earthquake zones, which objectively puts forward strict technical specifications for the seismic performance of building structures. Based on the basic principle of seismic design of "strong nodes and weak components", the current prefabricated wall panel connection technology system generally has difficulty meeting the standards in terms of node strength indicators. A large number of experimental studies and engineering practices have shown that under the action of seismic loads, wall connection nodes often show preferential damage characteristics compared with the main body of the wall panel. This type of node failure phenomenon directly leads to a significant weakening of the seismic performance of the overall structure, making it difficult to form an effective seismic bearing system. In order to ensure the safety performance of buildings under earthquakes, it is urgent to carry out systematic optimization research on wall panel connection technology, focusing on improving the seismic toughness of node connection parts, so that it can effectively maintain the integrity of the structure under seismic excitation and prevent the chain damage effect caused by node failure. Summary of the Invention

[0013] In view of the problems existing in the prior art, the present invention provides a precast floor (wall) panel system for all-dry construction, which breaks through the limitations of ordinary concrete floor slabs and is widely applicable to various low-rise building constructions.

[0014] The present invention is realized as follows. A precast floor (wall) panel system for all-dry construction, used for low-rise prefabricated buildings, includes precast concrete floor (wall) panel components and special-shaped connecting column components. Continuous vertical ducts and horizontal ducts are provided on both the precast concrete floor (wall) panels and the special-shaped connecting columns. Between adjacent components, male and female grooves are used, and prestressed steel strands are inserted into the ducts during on-site installation and tensioning operations are carried out, and an integral stress-bearing system is formed through the prestress effect.

[0015] The middle part of the precast concrete floor (wall) panel component is filled with lightweight thermal insulation materials, and a composite sandwich structure is formed by using the pre-assembly technology of a steel bar skeleton and a thermal insulation board.

[0016] For composite wall panels containing multiple layers of lightweight materials, the thermal insulation board and the steel bar skeleton are combined to form a semi-finished product with a thermal insulation interlayer, a positioning device and a pre-embedded round-hole corrugated pipe, and then the whole is placed into a vertical mold for integral concrete pouring.

[0017] A sealing connecting rubber pad is provided between adjacent components.

[0018] The vertical ducts and the horizontal ducts on the same component intersect, and the diameter of the ducts is at least more than 2 times the diameter of the prestressed steel strand.

[0019] The special-shaped connecting columns include cross-shaped, T-shaped, and L-shaped. The vertical ducts are arranged along the length direction of the special-shaped connecting columns, and vertical ducts are provided at the center of each stress-bearing surface and the intersection of adjacent stress-bearing surfaces of the special-shaped connecting columns.

[0020] The advantages and technical effects of the present invention are as follows:

[0021] (1) The construction period is significantly shortened.

[0022] Traditional in-situ building methods involve a large amount of wet work, which usually prolongs the construction period (generally 15 to 30 days). In low-rise prefabricated buildings, the foundation construction stage often occupies more than 70% of the total construction period. Although wet work is still required for the mainstream precast foundation or floor slab parts, the all-dry connection technology proposed by the present invention completely eliminates the need for wet work. This technology makes the production of components more convenient. For example, the vertical punching process of wall panels is extremely efficient, and the production of floors (walls) is also simpler. Therefore, the construction period is greatly shortened and the construction efficiency is significantly improved.

[0023] (2) The cost is effectively reduced.

[0024] Reducing wet operations not only means lowering labor costs and material waste, but also further reduces the costs of embedded components and related measures by adopting a post-tensioned prestressed connection method with a simple structure. In addition, the standardized mass production of components and the use of lightweight materials effectively reduce the building's self-weight. Combining these factors significantly reduces construction costs. In the field of low-rise housing, this method has particularly significant economic advantages.

[0025] (III) Improvement in Production Convenience

[0026] By adopting a structure without lapped bars and a vertical casting process, the production process of components is simplified. This not only facilitates automated production but also promotes standardized mass production. These improvements significantly enhance production efficiency, reduce production costs, and make it easier to control product quality.

[0027] (IV) Enhancement of Structural Performance

[0028] Excellent integrity: The post-tensioned prestressed technology transfers loads through friction, ensuring tight connections between components, thus endowing the structure with excellent integrity and connection reliability.

[0029] Lightweight and versatile: The use of lightweight materials not only reduces the building's self-weight but also endows the building with additional functions such as heat insulation and sound insulation, significantly enhancing the building's comprehensive performance.

[0030] Durability and disaster resistance advantages: The rubber strips at the edges of components ensure watertightness and impermeability, while the carefully designed connection nodes enable the building to effectively dissipate energy and reduce deformation during disasters such as earthquakes, and are also convenient for repair and recycling, thus significantly extending the building's service life.

[0031] (V) Expansion of Application Scenarios

[0032] The floor (wall) can meet the requirements of large spans and large loads, breaking through the limitations of ordinary concrete floor slabs, and is widely applicable to various low-rise housing buildings, including rural houses, overseas houses, emergency shelter houses, etc., providing solutions for different construction needs. Description of the Drawings

[0033] Figure 1 is the overall view of the precast floor (wall) slab system for the all-dry construction of the present invention.

[0034] Figure 2 is the post-tensioned prestressed connection diagram of the precast components of the present invention.

[0035] Figure 3 Cross-shaped corner column diagram of the precast components of the present invention.

[0036] Figure 4 T-shaped corner column diagram of the precast components of the present invention.

[0037] Figure 5 Precast component L-shaped corner column diagram of the present invention.

[0038] Figure 6 Floor slab (foundation base slab) splicing diagram of the present invention.

[0039] Figure 7 Diagram showing the addition of rubber strips at the splicing endpoints of the floor slab splicing of the present invention. Detailed implementation manners

[0040] In order to make the objectives, technical solutions and advantages of the present invention clearer and more understandable, the present invention will be further described in detail below with reference to the accompanying drawings. It should be understood that the specific implementation manners described herein are only used to explain the present invention and are not used to limit the present invention.

[0041] In the description of the present invention, it should be noted that the orientation or positional relationships indicated by the terms "upper", "middle", "lower", "inner", "outer", "both sides", etc. are based on the orientation or positional relationships shown in the accompanying drawings, and are only for the convenience of simplifying the description of the present invention, rather than indicating or implying that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and therefore should not be construed as a limitation to the present invention.

[0042] In the description of the present invention, it should be noted that unless otherwise clearly specified and defined, the terms "installation", "provided with", "connection", etc. should be understood in a broad sense. For example, "connection" can be a fixed connection, a detachable connection, or an integral connection; it can be a mechanical connection or an electrical connection; it can be directly connected or indirectly connected through an intermediate medium, and can be the communication inside two elements. For those of ordinary skill in the art, the specific meanings of the above terms in the present invention can be understood according to specific circumstances.

[0043] As Figure 1-7 shown, the precast floor (wall) slab system with all-dry construction of the present invention is used for low-rise prefabricated buildings, and includes precast concrete floor (wall) slab components and special-shaped connecting column components. Continuous vertical channels and horizontal channels are provided on both the precast concrete floor (wall) slabs and the special-shaped connecting columns. When installing on-site, the mother and son grooves are used between adjacent components, and prestressed steel strands are inserted into the channels and tensioning operations are carried out, so as to form an integral stress system through the prestress effect.

[0044] The middle part of the precast concrete floor (wall) slab component is filled with lightweight thermal insulation materials, and a composite sandwich structure is formed by using the pre-assembly technology of the steel bar skeleton and the thermal insulation board.

[0045] For a composite wall panel containing multiple layers of lightweight materials, a semi-finished product with a thermal insulation layer, a positioning device, and a pre-embedded round-hole corrugated pipe is formed by combining a thermal insulation board and a steel bar framework, and then the whole is placed into a vertical mold for concrete pouring.

[0046] An elastic sealing strip is arranged between the adjacent components.

[0047] The vertical ducts and the horizontal ducts on the same component intersect, and the diameter of the ducts is at least twice the diameter of the prestressed steel strand.

[0048] The special-shaped connecting columns include cross-shaped, T-shaped, and L-shaped ones. The vertical ducts are arranged along the length direction of the special-shaped connecting columns, and vertical ducts are arranged at the center of each stress surface and the intersection of adjacent stress surfaces of the special-shaped connecting columns.

[0049] The present invention innovatively solves the following problems:

[0050] (1) Breaking through the technical bottlenecks of the current prefabricated structural system

[0051] Aiming at the problems existing in the traditional prefabricated structural system, such as many wet operation processes, great difficulty in quality control, extended construction period, and the unfavorable construction of the component's protruding bars for industrial production, the present invention constructs a fully dry connection system. By completely eliminating the negative impacts of wet operations on the project quality and construction progress, and synchronously optimizing the structural form of the components, the industrial production efficiency and the adaptability of automated manufacturing are significantly improved.

[0052] (2) Innovating the dry connection technical solution

[0053] Aiming at the defects of the traditional dry construction methods such as bolt connection and welding, such as complex pre-embedded parts structure, cumbersome production process, and high measure cost, the present invention innovatively adopts the post-tensioned prestress connection technology. Only by presetting the ducts and the end anchor plates can three technical breakthroughs of structural simplification, pre-embedded system optimization, and construction cost control be achieved, and efficient and reliable assembly connection can be realized.

[0054] (3) Adapting to the special needs of low-rise building industrialization

[0055] Aiming at the strict requirements of low-rise building fields such as rural houses, overseas buildings, and emergency shelter houses for construction period control, cost-benefit, industrialization level, and green performance, this system realizes the dual optimization of construction period and cost through structural technology innovation and production process innovation, and promotes the development of building industrialization towards high efficiency, intensiveness, ecological protection.

[0056] 1. Constructing a system integrity guarantee mechanism

[0057] The coordinated force of the component system is realized through the post-tensioned prestress technology, and the integrity of the structure is strengthened by using the interface friction force transmission mechanism to ensure the reliability of the mechanical properties of the connection nodes.

[0058] 2. Achieve structural lightweight and functional integration

[0059] Adopt the sandwich structure technology, integrate thermal insulation materials or lightweight masonry in the structural panels, and realize the composite functions such as thermal insulation and sound insulation of the building envelope while reducing the self - weight.

[0060] 3. Strengthen the design of durability and maintainability

[0061] Build a continuous waterproof system through the connecting rubber pads 4, optimize the joint structure settings with both temporary fixing and energy - dissipating shock - absorbing functions, and ensure that the structure has excellent durability, reparability after earthquake and potential for material recycling during its whole life cycle.

[0062] (4) Optimization of the performance of the floor slab (wall) system

[0063] Aiming at the problems of traditional cast - in - place floor slabs (walls) such as large amount of wet work, excessive self - weight, limited span and insufficient bearing capacity, this solution provides a precast floor slab (wall) system that is cast - in - place without formwork support, has a low self - weight coefficient and large - span bearing capacity, significantly improving the engineering applicability and economic indicators of building foundation components.

[0064] Specifically, as Figure 1 shown, the post - tensioned prestressed connection system consists of precast wall panels and special - shaped connecting columns (the details of the cross - shaped, T - shaped, L - shaped, etc. structures are shown in Figures 3 to 5 ) to form the core components. Continuous ducts are preset inside the components, and prestressed steel strands 1 are inserted and tensioned during on - site installation, forming an integral stress system through the prestress effect (the structural schematic is shown in Figure 2 ). This system has excellent seismic performance and waterproof efficiency.

[0065] This system abandons the process of local steel bar lapping and casting in traditional prefabricated structures, and innovatively adopts the mother - son groove post - tensioned prestressed connection technology. Precise matching notch structures are set during the prefabrication of components, and an interface friction force transmission mechanism is formed through the tensioning of prestressed steel bars. This connection method is widely used in key joints such as between wall panels, between wall panels and floor slabs (foundations), realizing fully dry construction while ensuring the structural integrity.

[0066] Fill lightweight thermal insulation materials 2 in the middle of plate - type components such as floor slabs and wall panels. For wall panel components 3, adopt the pre - assembly technology of steel bar skeletons and thermal insulation boards to form a composite sandwich structure, and then carry out concrete pouring after positioning and fixing. The application of such lightweight materials not only effectively reduces the self - weight of the components, but also endows the structural system with good thermal insulation and sound insulation performance. In terms of process optimization, the production process is significantly simplified by canceling the traditional cast - off steel bar structure, creating favorable conditions for standardized mass production.

[0067] Efficient wall panel forming process: The vertical casting process is used to replace the conventional flat casting process, which significantly improves production efficiency. For composite wall panels containing multiple layers of lightweight materials, the vertical process can avoid the need for layered casting and the control measures for the floating of lightweight materials in the flat casting process, ensuring the density of the bottom of the component. During construction, the insulation board and the steel skeleton are first combined to form a semi-finished product with an insulation interlayer, a positioning device and a pre-buried circular corrugated pipe, and then placed in a vertical mold for integral casting.

[0068] Construction of standard small panel system: Based on the 1.2m module, a standard small panel system is constructed, supplemented by corner wall panels, opening wall panels and other special-shaped components to form a complete product series. While ensuring the advantages of standardized production, this system meets the diverse architectural layout and functional requirements through the flexible combination of standard and non-standard parts, and realizes the organic unity of industrialized production and personalized design.

[0069] Dual-node collaborative working mechanism: set up a dual system of temporary energy-consuming nodes and permanent prestressed nodes. During the construction phase, temporary nodes made of low-yield steel are used to achieve rapid positioning and provide a stable working surface for subsequent processes. Under the action of an earthquake, the prestressed system provides structural reset capability, and temporary nodes dissipate energy through plastic deformation (meeting the requirements of the "repairable in moderate earthquakes and not collapsing in major earthquakes" specification). After the earthquake, rapid repairs can be achieved by replacing energy-consuming components. Permanent nodes form the main bearing system after prestressing to ensure the long-term stability of the structure.

[0070] Floor (foundation) optimization: adopt post-tensioning prestressing connection technology without wet operation (see the construction for details) Figure 6 ), while improving construction efficiency and reducing environmental impact; the lightweight core material in the middle significantly reduces the weight of the floor slab and optimizes the transportation and installation process; the prestressed system design breaks through the thickness limit of traditional concrete floor slabs and realizes large-span and heavy-load application scenarios. The connection nodes adopt a concave-convex meshing structure (see details for details) Figure 7 ), combined with the setting of elastic sealing strips, a composite interface with both mechanical properties and waterproof function is formed.

[0071] The production and installation method of the present invention:

[0072] 1. Component production

[0073] The wall panels are prefabricated using a standardized production line: the preassembled insulation sandwich components are precisely positioned and placed in a vertical mold to complete the concrete pouring. The floor slab (foundation) components are prefabricated in the factory according to the design parameters, strictly ensuring the construction accuracy of key structures such as the post-tensioning prestressed duct.

[0074] 2. On-site installation

[0075] On-site assembly guided by BIM technology: Standard parts and non-standard components are combined according to the design sequence, and the overall connection is achieved through the post-tensioned prestressing system. The construction process strictly follows the technological sequence of "temporary fixation - prestress tensioning - permanent forming", and elastic sealing treatment is synchronously implemented at the joint parts to ensure that the overall watertightness and airtightness of the building meet the design requirements.

[0076] The above are only the preferred embodiments of the present invention and are not intended to limit the present invention. Any modifications, equivalent replacements, and improvements made within the spirit and principle of the present invention shall be included within the protection scope of the present invention.

Claims

1. A precast floor (wall) panel system for dry construction, which is used in low-rise prefabricated buildings, characterized in that, It includes precast concrete floor (wall) slab components and special-shaped connecting column components. Continuous vertical ducts and horizontal ducts are provided on both the precast concrete floor (wall) slabs and the special-shaped connecting columns. When installing on-site, the adjacent components are connected by male-female grooves, and prestressed steel strands are inserted into the ducts and tensioned, forming an integral stress-bearing system through the prestress effect.

2. The precast floor (wall) panel system for all-dry construction according to claim 1, wherein The middle part of the precast concrete floor (wall) slab component is filled with lightweight thermal insulation materials, and a composite sandwich structure is formed by using the pre-assembly technology of the steel bar skeleton and the thermal insulation board.

3. The precast floor (wall) slab system for all-dry construction according to claim 2, characterized in that, For the composite wallboard containing multiple layers of lightweight materials, the thermal insulation board and the steel bar skeleton are combined to form a semi-finished product with a thermal insulation interlayer, a positioning device and a pre-embedded round hole corrugated pipe, and then it is placed into a vertical mold for integral concrete pouring.

4. The precast floor (wall) slab system constructed by the all-dry method according to claim 1, characterized in that, A sealing connecting gasket is provided between the adjacent components.

5. The precast floor (wall) slab system for all-dry construction according to claim 1, characterized in that, The vertical ducts and the horizontal ducts on the same component intersect, and the diameter of the ducts is at least twice the diameter of the prestressed steel strand.

6. The precast floor (wall) slab system constructed by the all-dry method according to claim 1, characterized in that, The special-shaped connecting column includes a cross shape, a T shape, and an L shape. The vertical ducts are arranged along the length direction of the special-shaped connecting column, and vertical ducts are provided at the center of each stress-bearing surface and the intersection of adjacent stress-bearing surfaces of the special-shaped connecting column.

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