Prefabricated laminated wallboard, forming mold and forming process of prefabricated laminated wallboard

Abstract

The invention relates to the technical field of laminated slabs, provides a prefabricated laminated wallboard, a forming mold and a forming process thereof, and solves the problems of long production period and high production cost of the existing prefabricated laminated wallboard. The concrete slab comprises a concrete slab body, a reinforcing mesh and a supporting frame, the reinforcing mesh is arranged in the concrete slab body, and the reinforcing mesh comprises transverse bars and longitudinal bars which are arranged in a crossed mode; the bottom of the supporting frame stretches into the concrete slab body and is arranged in the longitudinal bar direction. The supporting frame comprises a supporting rod and wavy supporting pieces arranged on the two sides of the supporting rod. The wave troughs of the supporting pieces are far away from each other and are provided with bending sections which form an inclination angle of 15-30 degrees with the horizontal plane, the longitudinal bars are lapped above the bending sections, and the transverse bars are lapped below the bending sections; the wave crests of the supporting pieces draw close to each other and are provided with clamping sections used for fixing the supporting rods. And by adopting the wavy supporting pieces, the mode different from the mode that a truss is welded in a traditional prefabricated slab is adopted, the preparation process can be shortened, and the cost is saved.

Description

Technical Field

[0001] The present invention relates to the technical field of laminated plates, and particularly to a precast laminated wall panel, a forming mold and a forming process thereof. Background Art

[0002] In the field of prefabricated buildings, precast laminated plates have become the mainstream choice for floor systems due to their construction convenience. Traditional precast plates usually use welded steel bar trusses as the support structure, that is, longitudinal bars, transverse bars and diagonal web members are welded to form a space truss in the factory, and then integrally poured into the concrete slab. For example, a prefabricated laminated plate strengthening structure and reinforcement method disclosed in Chinese Patent Publication No. CN118422818A, by sleeving a bearing collar on the main bar, and then continuing to twist and adjust the bearing collar, and making the limit card slot of one of the fixing bodies on the bearing collar be stuck on the bottom stabilizing frame body, and then positioning the bearing collar through a positioning screw. At the same time, the upper stabilizing frame body is stuck in the limit card slot of the other fixing body on the bearing collar, and then the checking and stabilizing top block is placed, and then the reinforcing rod body is inserted, and finally the internal thread tightening rings are screwed tightly at both ends of the reinforcing rod body. And the assembly connecting piece in this scheme is a welded truss. Although this process can ensure the positioning accuracy of the steel bars, it has obvious defects: the preparation process is long, and the welding process requires multiple processes such as cutting, positioning, multi-point welding, and cooling correction, resulting in a long production cycle for single plates, and the welding energy consumption increases the production cost. Summary of the Invention

[0003] Therefore, in view of the above problems, the present invention provides a precast laminated wall panel, a forming mold and a forming process thereof, which solve the problems of long production cycle and high production cost of the existing precast laminated wall panels.

[0004] To achieve the above object, the present invention is realized through the following technical solutions: A precast laminated wall panel includes a concrete slab, a steel bar mesh and a support frame. The steel bar mesh is arranged in the concrete slab, and the steel bar mesh includes transverse bars and longitudinal bars arranged crosswise; The bottom of the support frame extends into the concrete slab and is arranged along the direction of the longitudinal bars. It includes a support rod and wavy support members arranged on both sides of the support rod; The troughs of the support members are far away from each other and are provided with bending sections with an inclination angle of 15° - 30° with the horizontal plane. The longitudinal bars are lapped above the bending sections, and the transverse bars are lapped below the bending sections; The crests of the support members are close to each other and are provided with clamping sections for fixing the support rod.

[0005] Further, each of the clamping sections is arranged vertically, and each of the clamping sections is provided with a fixing groove.

[0006] Further, the side surface of the concrete slab body is provided with concave and convex blocks, the height of the concave and convex blocks is ≥ 3 cm, and the covered area of the concave and convex blocks is not less than 80% of the side surface of the concrete slab body.

[0007] Further, a mating block and a mating groove are integrally formed on the side wall of the concrete slab body. A fixing block with a threaded hole is embedded on the mating block, and the fixing block is connected to the transverse reinforcement or the longitudinal reinforcement.

[0008] Further, a wax block with a melting point of 60 - 70 °C is arranged in the threaded hole of the fixing block, and the filling depth of the wax block is 100% of the length of the threaded hole.

[0009] A precast composite wallboard forming mold for forming the above-mentioned precast composite wallboard includes four side templates connected end to end in sequence. A card slot for placing the transverse reinforcement or longitudinal reinforcement is arranged at the top of each side template. A concave and convex groove for forming the concave and convex blocks is arranged on the inner side of the side template. Adjacent side templates are connected by bolts and nuts to fix each side template and prevent leakage of materials at the connection of adjacent side templates.

[0010] Further, the concave and convex groove is a curved strip shape, and the cross-section of the concave and convex groove is semi-elliptical or triangular.

[0011] A precast composite wallboard production process using the above-mentioned precast composite wallboard forming mold includes the following steps: S1: Assemble the mold, insert bolts into the connection holes at the ends of each side template, and lock them with nuts. S2: Spray a release agent inside the assembled mold. S3: Set up a steel bar mesh and a support frame. Place the transverse reinforcement at the corresponding position inside the mold. Place the bent sections at the trough positions of the two support members above the transverse reinforcement. Place the support rod between the clamping sections of the two support members. Fix the support rod and the support member with wire. Pass the longitudinal reinforcement through between the bent sections and the transverse reinforcement, and place both ends of the longitudinal reinforcement in the card slots of the side templates. S4: Pour concrete in layers, each layer ≤ 50 mm. After vibration, draw a 3-mm deep grid on the top of the poured concrete slurry, and let the concrete solidify naturally to form a primary setting slab body. S5: Demold and trim. After taking out the primary setting slab body from the mold, first trim the edge of the primary setting slab body with a shovel, and then pour hot water at least 80 °C on the wax block on the slab body to melt the wax block to expose the threaded hole on the fixing block. S6: Drill fixing holes in the primary setting slab body. After the mating block of the slab body extends into the mating groove of the adjacent slab body, bolts can be passed through the fixing holes to connect with the fixing block. S7: Component curing. Wrap the primary setting slab body with a wet geotextile after drilling the fixing holes, and place it in a cool and ventilated place. Let it stand for more than 72 h to obtain a concrete slab body.

[0012] Further, in step S7, the ambient temperature is controlled at 30 ± 5°C, and the initial-set slab is sprayed every 1 h.

[0013] Further, when the ambient temperature is lower than 5°C, it is necessary to heat and keep the initial-set slab warm, stand still for more than 120 h, and no spraying is allowed during the curing process.

[0014] Compared with the prior art, the beneficial effects of the present invention are as follows: 1. The present invention adopts a wavy support member, which is different from the form of using welded trusses in traditional precast slabs. It can shorten the preparation process, save costs, generate bending sections and clamping sections simultaneously while preparing the support member, cancel the use of stirrup supports without affecting the limitation of horizontal bars and longitudinal bars, and reduce the layout time of the steel cage.

[0015] 2. The present invention sets mating blocks and mating grooves on the side walls of the concrete slab, so that when the composite slab is used in long-span projects, there is a strong connection force between adjacent slabs. When casting in situ, the leakage rate of joints is reduced. After pouring, the in-situ layer above the composite slab is not easy to crack, improving the building strength. BRIEF DESCRIPTION OF THE DRAWINGS

[0016] Figure 1 It is a schematic structural diagram of a concrete slab in Embodiment 1 of the present invention; Figure 2 It is a schematic partial structural diagram of a support frame in Embodiment 1 of the present invention; Figure 3 It is a schematic side structural diagram of a concrete slab in Embodiment 1 of the present invention; Figure 4 It is a schematic structural diagram of a side formwork in Embodiment 2 of the present invention; Figure 5 It is a schematic inner side structural diagram of a side formwork in Embodiment 2 of the present invention.

[0017] Explanation of the reference numerals in the drawings: Concrete slab 1; Concave-convex block 11; Mating block 12; Mating groove 13; Fixed block 14; Fixed hole 15; Steel mesh 2; Horizontal bar 21; Longitudinal bar 22; Support frame 3; Support rod 31; Support member 32; Bending section 321; Clamping section 322; Fixed groove 323; Side formwork 4; Card slot 41; Concave-convex groove 42; Connection hole 43. DETAILED DESCRIPTION OF THE EMBODIMENTS

[0018] The following will specifically describe the embodiments of the present invention in detail, so as to fully understand how the present invention uses technical means to solve technical problems and achieve the realization process of technical effects and implement accordingly.

[0019] Example 1: As Figures 1 to 3 shown, a precast composite wall panel includes a concrete slab 1, a steel mesh 2 and a support frame 3. The steel mesh 2 is arranged in the concrete slab 1 and adopts an orthogonal grid structure. The steel mesh 2 includes a horizontal bar 21 and a longitudinal bar 22 which are cross - arranged; The bottom of the support frame 3 extends into the concrete slab 1 and is arranged along the direction of the longitudinal bar 22. It includes a support rod 31 and wavy support members 32 arranged on both sides of the support rod 31; The troughs of the support members 32 are far away from each other and are provided with bending segments 321 with an inclination angle of 15° - 30° with the horizontal plane. The longitudinal bar 22 is lapped above the bending segment 321, and the horizontal bar 21 is lapped below the bending segment 321; The crests of the support members 32 are close to each other and are provided with clamping segments 322 for fixing the support rod 31.

[0020] In this embodiment, the two - side support members 32 are bent upward at an inclination angle of 30° at the troughs to form the bending segments 321. The horizontal bar 21 is clamped below the bending segment 321, and the longitudinal bar 22 passes through between the horizontal bar 21 and the bending segment 321 to achieve two - way limiting.

[0021] The crests are bent outward to form vertical clamping segments 322. Semi - circular fixing grooves 323 are arranged on the inner sides of the clamping segments 322 to prevent the sliding of the support rod 31. After the concrete slab 1 is poured and solidified, the support rod 31 can be firmly clamped without welding. The diagonal web members and connection nodes in the traditional welded truss are cancelled. The support members 32 are formed by continuous roll - pressing in one step, reducing the production time. The trough bending segments 321 replace the stirrup bars, saving the amount of steel used and improving the construction efficiency.

[0022] In other preferred embodiments, the bending segments 321 of the two - side support members 32 at the troughs are at an angle of 15° with the horizontal plane.

[0023] The side surface of the concrete slab 1 is provided with convex and concave blocks 11. The height of the convex and concave blocks ≥ 3 cm, and the coverage area of the convex and concave blocks 11 is not less than 80% of the side surface of the concrete slab 1.

[0024] In this embodiment, the coverage area of the convex and concave blocks 11 not less than 80% of the side surface of the concrete slab 1 can enhance the structural strength of the joint, and the height of the convex and concave blocks 11 ≥ 3 cm can improve the interlocking ability of the cast - in - place material.

[0025] Among them, the convex and concave blocks 11 are curved strips, and their cross - section is semi - elliptical.

[0026] The side wall of the concrete slab 1 is integrally formed with a matching block 12 and a matching groove 13 . A fixing block 14 with a threaded hole is embedded in the matching block 12 . The fixing block 14 is connected to the transverse reinforcement 21 .

[0027] In this embodiment, the concrete slab 1 is rectangular, and matching blocks 12 and matching grooves 13 are provided on both side walls of the long sides of the concrete slab 1 .

[0028] In other preferred embodiments, the concrete slab 1 is square, and the side walls of the concrete slab 1 are all provided with matching blocks 12 and matching grooves 13 .

[0029] In a specific implementation process, when installing two adjacent concrete slabs 1, the matching blocks 12 and matching grooves 13 on the adjacent slabs are first plugged into each other and then locked with bolts.

[0030] A wax block with a melting point of 70° C. is provided in the threaded hole of the fixing block 14 , and the wax block is filled to a depth of 100% of the threaded hole length. The wax block is provided to prevent the concrete slurry splashed during the pouring process from clogging the threaded hole.

[0031] Example 2: Figures 4 to 5 As shown, a prefabricated composite wall panel forming mold is used to form the above-mentioned prefabricated composite wall panel, including four side templates 4 connected end to end in sequence, each side template 4 is provided with a slot 41 for placing the longitudinal reinforcement 22 on the top, and the inner side of the side template 4 is provided with a concave-convex groove 42 for forming the concave-convex block 11. The adjacent side templates 4 are connected by bolts and nuts to fix each side template 4 to prevent material leakage at the connection between adjacent side templates.

[0032] The concave-convex groove 42 is in the shape of a curved strip, and the cross section of the concave-convex groove 42 is in the shape of a semi-ellipse.

[0033] Example 3: A process for producing prefabricated composite wall panels, using the above-mentioned prefabricated composite wall panel forming mold, comprising the following steps: S1: Assemble the mold, insert the bolts into the connection holes 43 at the ends of the templates 4 on each side, and tighten them with nuts; S2: Spraying release agent into the assembled mold; S3: Set up the steel mesh 2 and the support frame 3, place the transverse reinforcement 21 at the corresponding position in the mold, place the bent sections 321 at the trough position of the two support members 32 above the transverse reinforcement 21, place the support rod 31 between the clamping sections 322 of the two support members 32, fix the support rod 31 and the support members 32 with wire, pass the longitudinal reinforcement between the bent section 321 and the transverse reinforcement 21, and set the two ends of the longitudinal reinforcement 22 in the slots 41 of the side template 4; S4: Pour the concrete in layers, with each layer ≤ 50 mm. After vibration, draw a 3-mm deep grid on the top of the poured concrete slurry, and let the concrete solidify naturally to form an initial-set slab body. S5: Demold and trim. After taking out the initial-set slab body from the mold, first trim the edge of the initial-set slab body with a shovel, and then pour hot water at least 80 °C over the wax blocks on the slab body to melt the wax blocks to expose the threaded holes on the fixing blocks. S6: Drill fixing holes 15 in the initial-set slab body. After the mating blocks 12 of the slab body penetrate into the mating grooves 13 of the adjacent slab body, bolts can be passed through the fixing holes 15 to connect with the fixing blocks 14. S7: Component curing. Wrap the initial-set slab body with a wet geotextile after drilling the fixing holes 15, and place it in a cool and ventilated place. Let it stand for more than 72 h to obtain the concrete slab body 1.

[0034] In step S7, the ambient temperature is controlled at 30 ± 5 °C, and the initial-set slab body is sprayed every 1 h.

[0035] When the ambient temperature is lower than 5 °C, it is necessary to heat and insulate the initial-set slab body, let it stand for more than 120 h, and no spraying is allowed during the curing process.

[0036] Although the present invention is specifically shown and described in combination with the preferred embodiments, those skilled in the art should understand that various changes can be made to the present invention in terms of form and details without departing from the spirit and scope of the present invention defined by the appended claims, and all of them are within the protection scope of the present invention.

Claims

1. A precast composite wall panel, comprising a concrete slab, a steel mesh and a support frame, characterized in that: The steel mesh is arranged in the concrete slab, and the steel mesh includes horizontal bars and vertical bars arranged crosswise; The bottom of the support frame extends into the concrete slab and is arranged along the direction of the vertical bars. The support frame includes a support rod and wavy support members arranged on both sides of the support rod; The troughs of the support members are far away from each other and are provided with bending sections with an inclination angle of 15°-30° to the horizontal plane. The vertical bars are lapped above the bending sections, and the horizontal bars are lapped below the bending sections; The peaks of the support members are close to each other and are provided with clamping sections for fixing the support rod.

2. A precast composite wall panel according to claim 1, characterized in that: Each of the clamping sections is arranged vertically, and each of the clamping sections is provided with a fixing groove.

3. The precast composite wall panel according to claim 2, characterized in that: The side surface of the concrete slab is provided with convex and concave blocks, the height of the convex and concave blocks ≥ 3 cm, and the coverage area of the convex and concave blocks is not less than 80% of the side surface of the concrete slab.

4. A precast composite wall panel according to claim 3, characterized in that: A fitting block and a fitting groove are integrally formed on the side wall of the concrete slab. A fixing block with a threaded hole is embedded in the fitting block, and the fixing block is connected to the horizontal bar or the vertical bar.

5. A precast composite wall panel according to claim 4, characterized in that: A wax block with a melting point of 60-70 °C is arranged in the threaded hole of the fixing block, and the filling depth of the wax block is 100% of the length of the threaded hole.

6. A precast composite wallboard forming mold for forming the precast composite wallboard according to claim 5, characterized in that: It includes four side templates connected end to end in sequence. Each side template is provided with a card slot for placing the horizontal bar or the vertical bar at the top. An uneven groove for forming the convex and concave blocks is arranged inside the side template. Adjacent side templates are connected by bolts and nuts to fix each side template and prevent leakage of materials at the connection of adjacent side templates.

7. A precast composite wall panel forming mold according to claim 6, characterized in that: The uneven groove is a curved strip, and the cross section of the uneven groove is semi-elliptical or triangular.

8. A production process for precast composite wall panels, using the precast composite wall panel forming mold described in claim 7, characterized in that, It includes steps: S1: Assemble the mold, insert bolts into the connection holes at the ends of each side template, and lock them with nuts; S2: Spray a release agent in the assembled mold; S3: Set up the steel mesh and the support frame. Place the horizontal bar at the corresponding position in the mold. Place the bending sections at the trough positions of the two support members above the horizontal bar. Place the support rod between the clamping sections of the two support members. Fix the support rod and the support members with iron wire. Pass the vertical bar through between the bending section and the horizontal bar, and lap both ends of the vertical bar in the card slots of the side template; S4: Pour concrete in layers, each layer ≤ 50 mm. After vibration, draw a 3-mm deep grid on the top of the poured concrete slurry, and let the concrete solidify naturally to form a primary setting slab; S5: Demold and trim. After taking out the primary setting slab from the mold, first trim the edge of the primary setting slab with a spatula, and then pour hot water at least 80 °C on the wax block on the slab to melt the wax block to expose the threaded hole on the fixing block; S6: Drill fixing holes on the primary setting slab. After the fitting block of the slab extends into the fitting groove of the adjacent slab, the bolt can pass through the fixing hole and be connected to the fixing block; S7: Component curing. Wrap the primary setting slab with drilled fixing holes with a wet geotextile and place it in a cool and ventilated place. Let it stand for more than 72 h to obtain a concrete slab.

9. A production process of a precast composite wall panel according to claim 8, characterized in that: In step S7, the ambient temperature is controlled at 30 ± 5 °C, and the primary setting slab is sprayed every 1 h.

10. A production process of a precast composite wall panel according to claim 9, characterized in that: When the ambient temperature is lower than 5°C, it is necessary to heat and insulate the initial-set slab, let it stand for more than 120 hours, and no spraying is allowed during the curing process.

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