Universal stair prefabricated template, device and prefabricated method

Abstract

The application discloses a universal stair prefabricated template, device and prefabricated method. The template comprises a bottom template in the middle, and a set of step side templates on each side, which are composed of step plates, head end modules and tail end modules. The bottom template is detachably connected with the step plates and the head end modules, and is fixedly connected or movably connected with the tail end modules. The step plates are closely spliced by selecting step modules from a module set comprising 1 to N step modules according to the length of the stair. Adjacent step modules are mutually clamped and mutually tightened on the vertical surface when connected to the bottom template. The universal stair prefabricated device clamps the head end modules, step module groups and tail end modules in sequence, and then mutually tightens and fixes them on the horizontal plane and the vertical surface. The whole template is assembled by mutually adaptive multiple modules, has strong universality, can adapt to diversified size requirements, has small weight, is convenient to disassemble and assemble, improves the space utilization rate, and ensures the stability of module connection and the overall rigidity of the system.

Description

Technical Field

[0001] This invention relates to the field of prefabricated building production, specifically to a universal stair prefabrication template, a universal stair prefabrication device, and a universal stair prefabrication method. Background Technology

[0002] With the continuous advancement of industrialization in the construction industry, prefabricated construction has emerged as a revolutionary construction model. Its core lies in the standardized, mass-produced prefabrication of certain building components in factories, followed by transportation to the construction site. Construction is then completed through precise hoisting and connection processes, achieving a leap from traditional "construction" to modern "manufacturing" in building production. This construction method is figuratively described as "building with blocks," involving a wide variety of prefabricated components, including exterior wall panels, interior wall panels, composite slabs, balconies, stairs, prefabricated beams, and prefabricated columns. Prefabricated concrete (PC) structures, with their superior performance and wide applicability, have become the most widely used type in the market, and have been extensively applied in numerous construction fields such as residential buildings, office buildings, educational buildings, and hospital buildings.

[0003] Compared to traditional on-site construction methods, prefabricated buildings exhibit several significant advantages. In the design phase, they enable a higher level of precision and collaborative work, effectively improving design quality and the overall building quality. Precast components, produced in a standardized environment, possess precision far exceeding that of temporary on-site cast-in-place components. This high precision not only extends to the precast components themselves but also drives a simultaneous improvement in the precision of the on-site cast-in-place concrete. Furthermore, the quality control of precast components in concrete pouring, vibration, and curing is significantly superior to on-site casting, ensuring product quality stability. Regarding material resource utilization, prefabricated buildings, through optimized design and production processes, can effectively reduce mold material consumption, particularly significantly reducing the use of wooden molds. On the construction site, this significantly reduces construction waste generation, lowers the amount of cast-in-place concrete, and consequently reduces the amount of water used for on-site curing and wastewater discharge from washing concrete mixer trucks. From a construction efficiency perspective, prefabricated building formwork operations significantly reduce reliance on manual labor; the molds used in workshops have a high reusability rate, and the labor required for mold assembly and disassembly is far lower than that for on-site cast-in-place concrete construction; furthermore, prefabricated buildings effectively reduce on-site wet work, achieving integrated construction of the external envelope and the main structure. Based on these numerous advantages, prefabricated buildings have received strong promotion and support from both the national policy level and the industry development level. In recent years, new materials and innovative processes have continuously emerged, with the widespread application of prefabricated stairs being a typical example.

[0004] With the booming development of prefabricated construction, prefabricated stairs are increasingly widely used in residential and public buildings. However, the current state of casting formwork technology in the production process of prefabricated stair components faces many challenges. Currently, the casting formwork used in the prefabricated construction industry is relatively simple, mainly using wooden or steel formwork. Wooden formwork, limited by its own material properties, requires significant manpower in its production and installation, and it is difficult to guarantee the quality of the formwork, while also wasting timber resources. Traditional prefabricated steel stair formwork mostly uses a welded shaping method. This type of formwork lacks adjustability and has a very limited range of applications. Different stair specifications require separate design and production, resulting in high initial investment costs and low utilization efficiency during actual use.

[0005] Furthermore, the current common production method for precast stair components typically involves welding stair casting molds together to form a single unit, based on different stair sizes. This method results in poor mold versatility, low turnover efficiency, and high production costs. While steel molds offer advantages in stair forming quality and process convenience, they also have significant drawbacks. These molds usually consist of a lower mold and an upper mold, forming a casting cavity between them for rebar tying and concrete pouring. However, monolithic steel molds are heavy and inconvenient to install; their applicability is limited, as the formed dimensions cannot be adjusted, only meeting the production needs of a single stair size. If stair sizes change or diverse requirements arise, new molds must be manufactured, significantly increasing overall production costs. Moreover, these steel molds have low turnover rates; after completing the production of one stair size, they are difficult to directly apply to the precast production of other stair sizes, lacking versatility.

[0006] For example, Chinese patent application number 202322623427.4 divides stair formwork into general-purpose step molds and general-purpose flat molds, creating a stair pouring space between the upper and lower casting molds. This method occupies a large space and can only cast staircases of a single size. Chinese patent application number 201620088829.6, on the other hand, uses steel plates and profiles to weld and fabricate a standardized steel frame formwork based on stair step design parameters, specifically for producing staircases of one size.

[0007] Therefore, there are key common problems in the current precast staircase production technology field. First, the dimensions of precast staircases produced by existing technologies are fixed, and special templates are required for staircases of different lengths. This not only increases the design and manufacturing costs of the templates but also reduces production flexibility. Second, most precast staircase templates adopt an integrated structural design, resulting in excessive weight of the templates, making operation difficult during the assembly and disassembly process and affecting construction efficiency. Third, the production capacity of existing precast staircase templates is limited, usually only one staircase can be precast at a time, resulting in low space utilization and difficulty in meeting the needs of large-scale production.

[0008] In view of this, the purpose of this invention is to provide a new prefabricated staircase technology solution, which aims to effectively overcome the above-mentioned technical difficulties, improve the production efficiency of prefabricated staircases, reduce production costs, enhance the versatility of templates and space utilization, so as to promote the development of prefabricated staircase production technology. Summary of the Invention

[0009] To address the aforementioned shortcomings of traditional prefabricated stair technology, this invention provides a universal prefabricated stair template, a universal prefabricated stair device, and a universal prefabricated stair method based on the device, all of which are highly versatile, easy to assemble and disassemble, and easy to operate.

[0010] The technical solution of the present invention is as follows: Firstly, a universal precast stair template is provided, characterized in that it comprises: a bottom template for forming the sloping bottom surface of the staircase, a tread for forming the stair steps, and a front end module and a rear end module for sealing the concrete and respectively constructing the front and rear ends of the staircase. The bottom template is detachably connected to the step plate and the first end module, respectively, and the tail end module is fixedly connected to the bottom template. The bottom formwork includes two longitudinal bottom formwork tubes arranged at both ends, and multiple horizontal bottom formwork tubes that are perpendicularly fixed to the longitudinal bottom formwork tubes and placed horizontally. On each of the two sides of the frame formed by the longitudinal bottom formwork tubes and the horizontal bottom formwork tubes, a bottom formwork steel plate is welded. In the 1 to N step modules constructed according to the module N, the step plate is formed by selecting multiple step modules and assembling them sequentially according to the required length of the staircase; each step module includes a step mold vertical plate and a step mold horizontal plate, and adjacent step modules are interlocked and detachably connected, so that the step mold vertical plate of the previous step module is in close contact with the step mold horizontal plate of the next step module. The first-end module has a vertical strip-shaped first-end mold protrusion that interlocks with the adjacent step module, and a first-end mold wall panel with the first-end mold protrusion as its edge. The space enclosed by the first-end mold wall panel, the adjacent step module, and the bottom mold formwork constitutes the first step of the prefabricated staircase. The tail end module has a strip-shaped tail end mold protrusion connected to one side of the tail end mold longitudinal tube to limit the adjacent step module. On the other side of the tail end mold longitudinal tube, there is a tail wall plate parallel to the step mold horizontal plate of the adjacent step module. The space enclosed by the tail wall plate and the adjacent step module forms the tail step of the prefabricated staircase.

[0011] Preferably, the step module further includes step mold longitudinal tubes and step mold horizontal tubes. The step mold longitudinal tubes are perpendicular to the horizontal plane and their length is greater than the horizontal width of the prefabricated stair treads. The step mold horizontal tubes form mutually perpendicular horizontal tube segments on the horizontal plane corresponding to the step height and step width of the prefabricated stair treads. Multiple horizontal tube segments on different horizontal planes are welded to multiple step mold longitudinal tubes to form a step module frame with a corresponding number of 7-shaped segments. A steel plate is welded to the side of the step module frame opposite to the bottom template to form the step mold vertical plate and the step mold horizontal plate.

[0012] Preferably, a strip-shaped wall plate extends from one end of the step module's vertical / horizontal step plate to form a step mold protrusion. The frame-shaped cavity formed by the strip-shaped wall plate and the edge of the vertical / horizontal step plate at its location is used to accommodate the edges of the horizontal / vertical step plates at opposite ends of adjacent step modules, so that the horizontal / vertical step plates at opposite ends of adjacent step modules are in close contact with the extended strip-shaped wall plate to form an approximately right-angled edge.

[0013] Preferably, the strip wall panel is a single-sided rectangular wall panel, and the frame cavity is a right-angled semi-enclosed cavity; or, the strip wall panel is a right-angled long strip wall panel with two sides, and the frame cavity is a topless rectangular frame cavity with three sides, and the opening of the frame cavity faces the edge of the step mold horizontal plate / step mold vertical plate of the adjacent step module it accommodates.

[0014] Preferably, the surfaces of the strip wall panel and the cavity that are in contact with the strip wall panel have corresponding spherical protrusions and spherical concave holes, and the spherical protrusions and spherical concave holes form an interference fit.

[0015] Preferably, the module N is 4, and the step modules of the step board include 1, 2 or 3 right-angled step module frames of the number 7; the step height corresponding to the step vertical plate is between 15 and 18 cm, the step width (i.e., depth) corresponding to the step horizontal plate is between 25 and 30 cm, and the horizontal width of the step corresponding to the step vertical plate and the step horizontal plate is between 125 and 150 cm.

[0016] Preferably, the first end module has three vertical first end mold tubes perpendicular to the horizontal plane and not on the same straight line, and multiple sets of first end mold horizontal tubes. Each set of first end mold horizontal tubes includes three horizontally placed first end mold horizontal tubes. Each set of first end mold horizontal tubes is welded at different height positions of the first end mold vertical tubes, and each end of the first end mold horizontal tube parallel to the bottom template is provided with a corner wedge, so that the outer edge of each set of first end mold horizontal tubes forms a triangle. The first first end mold horizontal tube adjacent to the step module has the first end mold protrusion fixed to its outer side. The first first end mold horizontal tube has a steel plate welded to its outer side between the first end mold protrusion and the first end mold vertical tube adjacent to the bottom template to form the first end mold wall plate.

[0017] Preferably, two of the three horizontally placed end mold horizontal tubes are rectangular steel tubes arranged at right angles, and the other is placed at the hypotenuse with its two sides cut at an angle to form a triangular connection structure with the two mutually perpendicular end mold vertical tubes.

[0018] Preferably, the tail end module has two tail end mold vertical tubes perpendicular to the horizontal plane and not on the same straight line, and multiple sets of tail end mold horizontal tubes. Each set of tail end mold horizontal tubes includes two horizontally placed tail end mold horizontal tubes. Each set of tail end mold horizontal tubes is welded at different height positions on the tail end mold vertical tubes. A steel plate is welded to the outside of the first tail end mold horizontal tube adjacent to the step module to form the tail wall plate. The first tail end mold vertical tube connected to the first and second tail end mold horizontal tubes extends from the interface between the first tail end mold vertical tube and the second tail end mold horizontal tube to form a tail end mold clip protrusion composed of two strip wall plates. The tail end mold clip protrusion and the outer wall of the first tail end mold vertical tube form a rectangular frame cavity surrounded on three sides, and the opening of the frame cavity faces the edge of the step mold vertical plate of the adjacent step module it accommodates. The end of the first tail end mold horizontal tube opposite to the first tail end mold vertical tube is cut at an angle so that its cut surface is parallel to the bottom template, and the cut surface is in contact with the bottom template.

[0019] Preferably, the cut surface is welded to the bottom template. Preferably, the other tail end mold longitudinal tube, i.e., the second tail end mold longitudinal tube, is the edge bottom mold longitudinal tube of the bottom template, or it can be a separate vertical steel pipe that is attached to the edge bottom mold longitudinal tube of the bottom template.

[0020] Preferably, the fixed connection between the tail end module and the bottom template is replaced by a flexible connection where the tail end module can move along the extension direction of the bottom template; the tail end module includes three tail end mold longitudinal tubes located on the vertical surface; bolts or threaded tie rods are pre-embedded at at least two different height positions on the side edge of the bottom template, and one of the tail end mold longitudinal tubes has pre-embedded through holes at two corresponding height positions, with the pre-embedded bolts or threaded tie rods passing through the through holes and fixed with nuts; the tail end mold longitudinal tubes are respectively erected at three corners, and multiple high-strength tail end modules are included in the tail end module. At each position, a set of three tail-end mold horizontal tubes are fixedly connected vertically to the three tail-end mold vertical tubes. Each set of tail-end mold horizontal tubes includes three horizontally placed tail-end mold horizontal tubes. A steel plate is welded to the outside of the first tail-end mold horizontal tube adjacent to the step module to form the tail wall plate. The tail-end module extends from the side edge away from the bottom template to form a tail-end mold locking protrusion composed of a strip wall plate. The tail-end mold locking protrusion and the outer wall of the side edge form a groove-shaped right-angle frame cavity with three sides surrounding one side to accommodate and limit the adjacent step module.

[0021] Preferably, in the step module, the first end module, and the last end module, the extended strip wall plate used to limit the adjacent modules is one side of an angle steel or two sides of a three-section, one-section C-shaped steel pipe, while the other side of the angle steel or the other side of the C-shaped steel pipe is welded to the edge of the module.

[0022] Preferably, when the edges of the module are directly made of the angle steel or C-shaped steel pipe, the edges are directly welded to the horizontal pipe and the vertical plate / horizontal plate of the step mold; wherein, one side wall of the angle steel or C-shaped steel pipe is connected by welding.

[0023] Preferably, at the connection between the first end module and the adjacent step module, the first end module can be replaced by a first end module protrusion made of a strip wall plate extending out of the first end module to limit the adjacent edges of the step module.

[0024] Preferably, the top bottom mold horizontal tube of the bottom template has multiple bottom mold clamps on its upper surface; the top step mold horizontal tube of each step module in the step plate has a step mold horizontal clamp on its upper surface, and the step mold horizontal clamp is connected to a bottom mold clamp by an adjustable bolt; the top end mold horizontal tube of the first end module has a first end mold clamp on its upper surface, and the first end mold clamp is connected to a bottom mold clamp by an adjustable bolt; the adjustable bolt includes, in sequence, a pull ring, a first screw section, a threaded cylinder, a second screw section, and a pull hook, wherein the first screw section and the second screw section are connected by a threaded cylinder with threads on its inner wall, and the threads connecting the first screw section and the second screw section to the threaded cylinder are threads in opposite directions; so that when the threaded cylinder is rotated in one direction, the first screw section and the second screw section move towards each other, and when the threaded cylinder is rotated in the other direction, they move away from each other.

[0025] Preferably, the bottom mold clamp is made of steel bars and formed into a rounded door frame shape.

[0026] Preferably, the bottom mold clamp, the step mold horizontal clamp, and the head mold clamp all adopt a three-sided enclosed gate-shaped structure, and the adjustable bolt is a bolt; the bottom mold clamp adopts a bottom mold clamping block, which includes a door corner seat and a door surface groove longitudinally cut from a rectangular short steel pipe. The door corner seat has an opening on one side and a slot for the bolt thread to pass through on the other side wall, which is the door surface groove, in a direction perpendicular to the two side walls; the step mold horizontal clamp adopts a step mold horizontal clamping block, and the step… The mold horizontal clamping block includes a portal-shaped base, a wedge-shaped block, and a wedge-shaped groove. The portal-shaped base consists of two opposing angle steel blocks. A wedge-shaped block is provided at the top of the portal-shaped base, where the two angle steel blocks are connected. The wedge-shaped block is a triangular block added to one side of the rectangular block, such that after the step mold horizontal clamping block is fixed to the upper surface of the top step mold horizontal tube of the step module, one end face of the triangular block is approximately parallel to the slotted sidewall of the bottom mold clamping block. The wedge-shaped groove is a through groove opened along a direction perpendicular to the end face.

[0027] Preferably, the first end mold clamp also adopts a step mold horizontal clamping block. The bolt passes through the wedge groove and the door surface groove, and the side with the nut is clamped on the outer wall of one of the slots on the step mold horizontal clamping block or the bottom mold clamping block, while the other side of the bolt is fixed to the inner wall of the other slot by a nut. Optionally, the step mold horizontal clamping block is cast or stamped.

[0028] Preferably, the bottom of the door panel groove is arc-shaped or rectangular. Preferably, the bottom mold clamp is a double bottom mold clamp, which differs from the bottom mold clamp in that two slots are opened in parallel on one side wall of the groove, so that two bolts can be used to connect the step mold horizontal clamps on both sides respectively.

[0029] Preferably, two adjacent step modules that interlock with each other are provided with a step mold horizontal clamp on the top of the step mold horizontal tube on both sides of the interlocking position, and each of the two step mold horizontal clamps is connected to the same bottom mold clamp by an adjustable bolt.

[0030] Preferably, two adjacent step modules that interlock with each other have a step mold stud respectively provided on the adjacent step mold longitudinal tubes on both sides outside the interlocking position, and the two opposing step mold studs are connected by the adjustable bolt.

[0031] Preferably, the two step mold studs can be set at different heights, such as a pair at each of the two heights. A stud is also set on the outer longitudinal tube of the first-end module, and is connected and fixed to the adjacent step module by an adjustable bolt.

[0032] Preferably, on the outward-facing longitudinal tube of the step module in the step plate, a step module vertical clamp facing outward is also provided at the same height. The step module vertical clamp is made of steel bars in the shape of a rounded door frame, and each step module vertical clamp is connected by a reinforcing steel pipe.

[0033] Secondly, the present invention also provides a universal prefabricated staircase device, characterized in that it includes a combination of components in the aforementioned universal prefabricated staircase template, and: a side sealing template for sealing concrete and constructing one side end of a stair tread, and a triangular support assembly for supporting the universal prefabricated staircase template; the combination of components in the universal prefabricated staircase template includes an intermediate bottom template, and two modules arranged symmetrically on both sides and facing each other, each consisting of a tread plate, a first end module, and a last end module; the side sealing template includes a side sealing template bottom plate with a side sealing template horizontal tube along the direction of the prefabricated staircase and a side sealing template vertical tube perpendicular to it as a frame; multiple side sealing template vertical tubes are symmetrically fixed to both sides of the side sealing template horizontal tube; the universal prefabricated staircase template is arranged in the middle of the side sealing template bottom plate; the triangular supports are arranged in two rows, wherein each triangular support is composed of a right angle steel and an inclined tube connecting the two sides of the angle steel; the bottom steel pipe of the right angle steel inside the triangular support is fixed to the side sealing template vertical tube.

[0034] Preferably, the side sealing mold base plate is made of concrete slabs covered with steel plates, and the covered steel plates are welded and fixed to the side sealing mold horizontal pipes and side sealing mold vertical pipes in the frame to form a straight whole.

[0035] Preferably, four lifting lugs are symmetrically provided on the side of the side sealing mold horizontal tube to facilitate the movement of the side sealing mold.

[0036] Preferably, a rectangular steel pipe is installed at the bottom and top of the triangular bracket where it connects to the universal stair prefabricated template, as a reinforcing bolt, to regulate the arrangement of the step modules in the step plate.

[0037] Thirdly, the present invention also provides a universal prefabrication method for stairs, characterized by comprising the following steps: S1. Initialize the structural design and manufacture the general-purpose prefabricated staircase device as described in claim 11, as well as the staircase steel mesh, wherein multiple step modules are selected according to the target length of the staircase to combine the first step plate and the second step plate. S2. Perform preliminary cleaning on the surface of the side sealing mold bottom plate in the side sealing mold, the bottom mold of the staircase pouring cavity in the precast mold, the vertical plate of the step mold in the step plate, the horizontal plate of the step mold, the first end mold wall plate in the first end module, and the tail wall plate in the tail end module. S3. On one side of the middle position of the side sealing mold base plate, arrange the step modules in the first step plate in sequence. After placing the first end module, snap the step mold protrusion formed by the strip wall plate on the first step module adjacent to it with the first end module. Snap the step mold protrusions on one side of the other step modules with the opposite edge of the previous step module in sequence. Simultaneously, use adjustable bolts to initially fix the adjacent modules in the first end module and step modules on the vertical surface. S4. Snap the bottom template and the tail module with the last step module in the direction of the opening of the receiving cavity formed by the tail end mold protrusion on the tail end module. S5. Using adjustable bolts, connect the bottom mold clamp on the bottom template to the step mold cross clamp on the step module and the first end mold clamp on the first end module respectively; when screwing the threaded cylinder on the adjustable bolt in the direction of tightening the two modules connected by the adjustable bolt, the first screw section and the second screw section on the adjustable bolt move towards each other until they are initially tightened. S6. On the other side of the middle position of the side sealing mold base plate, arrange each step module in the second step plate in sequence, and snap the bottom template and the tail module with the last step module according to the opening direction of the accommodating cavity formed by the tail end mold protrusion on the tail end module. S7. Sequentially, fasten the step mold protrusions formed by the strip wall panels on one side of the other step modules in the second step plate to the opposite edge of the next step module; place and adjust the position of the first end module so that the first end mold protrusion is fastened by the step mold protrusion on the first step module adjacent to it; simultaneously, use adjustable bolts to initially fix the first end module and adjacent modules in the step modules on the vertical surface. S8. Using adjustable bolts, connect the bottom mold clamps on the same bottom template in the middle to the step mold horizontal clamps on the step module in the second step plate and the first end mold clamps on the first end module respectively; initially tighten each adjustable bolt; S9. Fine-tune the position of each module, and insert a rectangular steel pipe reinforcing bolt between the bottom of the triangular bracket and the first step plate and the second step plate respectively; then, insert another rectangular steel pipe reinforcing bolt through each step mold vertical clamp of the first step plate and the second step plate respectively. S10. Tighten all adjustable bolts on the horizontal and vertical surfaces to complete the installation of the general-purpose prefabricated staircase device. S11. After cleaning the surfaces of the side sealing mold bottom plate, bottom mold steel plates on both sides of the bottom template, step mold vertical plate and step mold horizontal plate in the stair tread, first end mold wall plate in the first end module and tail wall plate in the tail end module, apply release agent to their surfaces. S12. Arrange the tied steel mesh in the casting cavity and fix the embedded parts according to the design position; S13. Pour concrete into the casting cavity and vibrate it at intervals until the concrete height reaches the elevation according to the horizontal width of the stair treads. S14. Vibrate the concrete, let it stand, and then smooth and polish the surface; then cure it. S15. After curing is completed, disassemble each module in the reverse order of installation; after removing the formwork, hoist the staircase to the storage location.

[0038] Preferably, in step S2, mechanical or manual cleaning is used to remove cement slurry and concrete residue, followed by polishing to ensure that each panel is smooth and free of rust. In step S3, adjacent end modules and step modules are simultaneously connected to the facade by adjustable bolts, with the bolts on their side edges being secured.

[0039] In step S11, when automatically or manually applying the release agent, it should be applied evenly in strips to prevent accumulation and missed areas. In step S12, the reinforcing mesh is lifted from multiple points to prevent twisting, bending, and skew deformation, and the embedded parts are securely fixed. In step S13, concrete is applied evenly in layers of 20 to 30 centimeters.

[0040] In step S14, each vibration lasts for 20 to 30 seconds, until the concrete stops settling, the surface becomes smooth, and no more air bubbles appear. Vibration can be performed manually with a vibrator or by using a vibrator attached to the formwork. After the concrete is poured, let it stand for one hour, then smooth the surface. After that, cover it with a curing shed and let it stand for about two hours before heating and curing, with the maximum temperature not exceeding 70°C.

[0041] Preferably, the sequential installation order of the first end module, step module to the last end module in steps S3 to S5 is replaced by the sequential installation order of the last end module, step module to the first end module in steps S6 to S7.

[0042] When the tail module is detachably connected, the first step plate and the second step plate can be connected and installed using a similar method, and steps S3 to S8 are replaced by: S32. On one side of the middle position of the side sealing mold base plate, arrange the step modules in the first step plate in sequence. After placing the first end module, snap the step mold protrusion formed by the strip wall plate on the first step module adjacent to it with the first end module. Snap the step mold protrusion on one side of the other step modules with the opposite edge of the previous step module in sequence. Simultaneously, use adjustable bolts to initially fix the adjacent modules in the first end module and step modules on the vertical surface. S42. After snapping the tail end module and the step module at the tail end into place according to the direction of the opening of the accommodating cavity formed by the tail end module clip protrusion, connect the tail end module to the bottom template. S52. Using adjustable bolts, connect the bottom mold clamp on the bottom template to the step mold cross clamp on the step module and the first end mold clamp on the first end module respectively; when screwing the threaded cylinder on the adjustable bolt in the direction of tightening the two modules connected by the adjustable bolt, the first screw section and the second screw section on the adjustable bolt move towards each other until they are initially tightened. S62. On the other side of the middle position of the side sealing mold base plate, according to steps S3 to S5, connect each step module of the second step plate, as well as the first end module and the last end module on that side.

[0043] Fourthly, the present invention also provides a method for installing a universal prefabricated staircase device, characterized in that it includes steps S3 to S10.

[0044] Fifthly, the present invention also provides a method for dismantling and assembling a universal prefabricated staircase device used in step S15, comprising: T1. On the sides of the first step plate and the second step plate, remove the rectangular steel pipe reinforcing bolts that run through the vertical clamps of the step mold and the rectangular steel pipe reinforcing bolts between them and the bottom of the triangular bracket. T2. Tighten the adjustable bolts between the rotating bottom mold clamp and the step mold horizontal clamp on the step module and the first end mold clamp on the first end module, so that the first screw section and the second screw section on the adjustable bolt move in opposite directions until the hook disengages; simultaneously loosen the adjustable bolts on the adjacent modules on the facade; T3. On both sides of the first step plate and the second step plate, respectively: move the first end module outward along the direction parallel to the bottom template to release the limit of the step module adjacent to the first end module; then move each step module in the step plate outward in the horizontal direction in sequence; then, move the last step module that is locked and limited by the tail end mold protrusion outward along the strip wall direction of the rectangular cavity formed by the tail end mold protrusion. T4. Gently tap the bottom formwork and slowly lift the staircase outward and upward at a slight angle to the vertical direction, separating it from the bottom formwork and the side sealing formwork.

[0045] As a preferred method, the demolding of the general-purpose prefabricated staircase device includes the following steps: the step mold protrusion adopts a straight notch protrusion, which is composed of parallel double-sided strip wall panels to form a three-sided enclosed, topless rectangular frame cavity; during demolding, the first end module can be moved out along the vertical surface upward to release the limiting position of the step module adjacent to the first end module; then, each step module in the step plate can be moved out in sequence along the notch direction of the side notch protrusion.

[0046] Alternatively, the demolding method of the general-purpose prefabricated staircase device adopted is used, including: if the tail end module is movably connected to the bottom formwork, and the step module adjacent to the head end module adopts a straight notch protrusion; when demolding it, the tail end module is first moved outward, and then the bottom formwork can also move a distance in the same direction to provide space for the movement of the head end module; the head end module moves along the two long side walls of the notch of the straight notch protrusion to release the restriction of the step module adjacent to the head end module, and then each step module in the step plate is removed in sequence along the notch of the strip wall until the second to last step module is removed, thus completing the demolding of the formwork.

[0047] Optionally, after the tail module is moved outward, the step module in the step plate adjacent to the tail module can be moved outward in the direction of the limiting strip wall notch, and the step modules at its front end can be moved one after another until the frontmost step module is moved out, so as to complete the disassembly of the template.

[0048] Compared with existing technologies, the present invention offers the following advantages: The prefabricated stair template is constructed separately for the two ends and the middle steps. The middle steps are further modularly combined using modules of different lengths, allowing for on-site prefabrication of step modules according to different stair lengths. This significantly reduces the number of dedicated template sets, fundamentally improving the versatility and multi-size adaptability of the stair template, while also reducing design and manufacturing costs. The flexible selection of step modules also improves template turnover efficiency and reduces overall equipment costs. The prefabricated stair template is composed of multiple modules, making it much lighter than a monolithic steel template. This facilitates easy assembly and disassembly, reducing reliance on large machinery and safety hazards. Compared to monolithic templates, this invention allows for modular assembly and disassembly, eliminating the need for overall hoisting or bending over to clean the internal walls of the pouring cavity. The stair modules at both ends and in the middle of the staircase are mutually restrained and fixed in multiple horizontal and vertical directions, effectively improving module connection stability and the overall rigidity of the template system, thus ensuring the final shape of the prefabricated staircase. The present invention provides a staircase prefabrication equipment in which two sets of step templates share a single staircase bottom template on one machine, enabling the prefabrication of two staircases at once. This improves the utilization rate of three-dimensional space, saves workshop land, and thus meets the needs of larger-scale production within the same floor area.

[0049] It should be understood that all combinations of the foregoing concepts and the additional concepts discussed in more detail below (provided that such concepts are not inconsistent with each other) can be contemplated as part of the inventive subject matter disclosed herein. In particular, all combinations of the claimed subject matter appearing in this disclosure can be contemplated as part of the inventive subject matter disclosed herein. Attached Figure Description

[0050] The present invention will be further described below with reference to the accompanying drawings and embodiments: Figure 1 This is a structural schematic diagram of a universal prefabricated stair template according to the present invention; Figure 2 Three-view diagram of the structural components of a general-purpose prefabricated staircase template; Figure 3 This is an exploded structural diagram of a general-purpose prefabricated staircase formwork. Figure 4 A schematic diagram of the tread structure in a general-purpose precast staircase formwork; Figure 5 This is a schematic diagram of the module structure at both ends in a general-purpose precast staircase formwork. Figure 6 This is an exploded view of the structure of a general-purpose prefabricated staircase assembly. Figure 7 A top view of a general-purpose prefabricated staircase assembly; Figure 8A , Figure 8B These are schematic diagrams of the three-dimensional structure of the treads and end modules of a general-purpose precast staircase template. Figure 9 This is a schematic diagram of the connecting module; Figure 10A , Figure 10B and Figure 10C These are schematic diagrams of another type of connection module; Figure 11A , Figure 11B These are schematic diagrams of another type of step assembly structure; Figure 12 A schematic diagram showing the assembly and disassembly of a general-purpose prefabricated staircase formwork; Figure 13 This is a schematic diagram of another structure for the tail module; Figure 14A , Figure 14B These are schematic diagrams showing the installation of a prefabricated staircase using the method of this invention.

[0051] In the diagram: 1000 General-purpose prefabrication device for stairs; 100 General-purpose prefabrication template for stairs; 10 Precast stairs; 20 Stair beams; 30 High-end slabs; 40 Bottom slabs; 50 Stair beam connectors; 101 Step wall; 102 Step plan; 103 First step; 104 Last step; 105 Embedded parts; 106 Steel mesh; 201 Stair beam reinforcement; 1031 Platform type first step; 110 Step tread; 120 Bottom template; 130 First end module; 140 Last end module; 150 Adjustable tie rod; 160 Side sealing template; 170 Triangular bracket; 180 Reinforcing bolt; 111 Vertical plate of step mold; 112 Horizontal plate of step mold; 113 Longitudinal tube of step mold; 114 Horizontal tube of step mold; 115 Vertical clamp of step mold; 116 Horizontal clamp of step mold; 117 Protruding part of step mold; 118 Stud of step mold; 119 Vibrator attached; 1101 Single-step module; 1102 Double-step module; 1103 Triple-step module; 1161 Step mold horizontal locking block; 1162 Gate-shaped base; 1163 Wedge groove; 1164 Wedge block; 1171 Straight notch protrusion; 1172 Lateral notch protrusion; 1173 Spherical crown protrusion; 1174 Spherical crown concave hole; 121 Bottom mold steel plate; 122 Bottom mold horizontal tube; 123 Bottom mold longitudinal tube; 124 Bottom mold clamp; 1241 Bottom mold locking block; 1242 Bottom mold double locking block; 1243 Door face groove; 1244 Door corner seat; 131 First end mold protrusion; 132 Corner wedge; 133 First end mold longitudinal tube; 134 First end mold horizontal tube; 135 First end mold clamp; 136 First end mold wall plate; 141 Tail end mold protrusion; 142 Tail wall plate; 143 Tail end mold longitudinal tube; 144 Tail end mold transverse tube; 151 Pull ring; 152 First screw section; 153 Threaded cylinder; 154 Second screw section; 155 Pull hook; 1501 Threaded pull rod; 1502 Nut; 161 Side sealing mold base plate; 162 Side sealing mold horizontal tube; 163 Side sealing mold vertical tube; 171 Angle steel; 172 Diagonal brace. Detailed Implementation

[0052] The preferred embodiments of the present invention are described in detail below with reference to the accompanying drawings, but the present invention is not limited to these embodiments. The present invention covers any substitutions, modifications, equivalent methods, and solutions made within the spirit and scope of the present invention.

[0053] To provide the public with a thorough understanding of the present invention, specific details are described in detail in the following preferred embodiments of the invention, but those skilled in the art can fully understand the invention without these details.

[0054] The invention is described in more detail below by way of example with reference to the accompanying drawings. It should be noted that the drawings are in a simplified form and use non-precise proportions, and are only used to facilitate and clarify the illustration of the embodiments of the invention.

[0055] In particular, terms such as vertical, horizontal, elevation, and perpendicular are described from the perspective of observation described in the context. Their orientation will switch when viewed from different angles. Such understanding should be included within the protection scope of the technical solutions disclosed in this invention. Example

[0056] To address the shortcomings of existing precast stair formwork, such as poor versatility, heavy weight, low assembly and disassembly efficiency, and insufficient space utilization, this invention provides a modular and adjustable precast stair formwork system, namely a stair prefabrication method. Through structural optimization, it achieves multi-size adaptation, rapid assembly and disassembly, and mass production, thereby reducing overall costs and improving construction efficiency and resource utilization.

[0057] like Figure 1 , Figure 2 , Figure 3 and Figure 4 As shown, the present invention provides a universal precast stair template 100, which includes: a bottom template 120 for forming the sloping bottom surface of the staircase, a tread plate 110 for forming the stair treads, and a first end module 130 and a last end module 140 for sealing the concrete and respectively constructing the front end of the staircase (i.e., the first tread 103) and the rear end of the staircase (i.e., the last tread 104). The bottom template 120 is detachably connected to the tread plate 110 and the first end module 130, respectively, and the last end module 140 is fixedly connected to the bottom template 120.

[0058] like Figure 2 As shown in the figure below, the bottom formwork 120 includes two bottom formwork longitudinal tubes 123 arranged at both ends, and multiple bottom formwork horizontal tubes 122 that are perpendicularly fixed to the bottom formwork longitudinal tubes 123 and placed horizontally. On each of the two sides of the frame formed by the bottom formwork longitudinal tubes 123 and bottom formwork horizontal tubes 122, a bottom formwork steel plate 121 is welded. The figure shows the longitudinal section structure of the bottom formwork.

[0059] To accommodate the prefabrication of staircases of varying lengths, this invention constructs the treads using modular assembly. See also... Figure 3 As shown, where Figure 3 The upper middle image is Figure 2 The structure after removing the bottom template 120 in the image above. Figure 3 The lower half of the diagram shows the structure after the step plate is disassembled. Specifically, step modules consisting of 1 to N steps are constructed according to the module N. Without loss of generality, if the module N is 4, the step module includes 1, 2, 3, or 4 right-angled step module frames of the number 7. When N is 4, the combination of step plates is more flexible; while when N is a smaller value of 3, the number of types of step modules can be reduced and the weight of the largest step module can be limited, facilitating disassembly and assembly.

[0060] See Figure 3As shown in the lower figure, the treads in the figure use one single-step module 1101, one double-step module 1102 and three triple-step modules 1103 respectively; when the staircase is prefabricated, the same length can also be composed of four triple-step modules 1103, which can further reduce the types and number of tread modules.

[0061] Each stair tread includes the tread surface and the elevation, see [link / reference]. Figure 14A , Figure 14B As shown, the prefabricated staircase 10 manufactured using this invention includes a step wall 101 and a step plane 102 in each step. (Combined) Figure 2 As shown in the upper middle figure, in order to prefabricate the steps of the staircase, in each step module of the step plate, a step mold vertical plate 111 and a step mold horizontal plate 112 are set to construct the step wall 101 and the step plane 102 respectively.

[0062] Combined Figure 1 , Figure 2 As shown in the middle figure, this invention employs a frame structure to construct the support for the vertical plate 111 and horizontal plate 112 of the stair tread mold, thereby reducing the weight of the stair treads while effectively ensuring the structural strength. Specifically, a three-dimensional frame structure is formed using mutually perpendicular vertical tubes 113 and horizontal tubes 114 of the stair tread mold. The vertical tubes 113 are perpendicular to the horizontal plane, i.e., located on the vertical surface; the horizontal tubes 114, on the horizontal plane, form mutually perpendicular horizontal tube segments corresponding to the step height, depth, and width of the prefabricated stair treads. Multiple horizontal tube segments at different horizontal heights are welded to multiple vertical tubes 113 to form a corresponding module, i.e., 1 to N right-angled (7-shaped) stair tread module frames. Figure 4 As shown, the single-step module 1101 includes two step mold vertical tubes 113 and two step mold horizontal tubes 114, the double-step module 1102 includes four step mold vertical tubes 113 and four step mold horizontal tubes 114, and the triple-step module 1103 has six step mold vertical tubes 113 and six step mold horizontal tubes 114.

[0063] Combination Figure 1 , Figure 2 , Figure 4 As shown, on the side of the step module frame formed by the longitudinal tube 113 and the horizontal tube 114 of the step mold, opposite to the bottom formwork 120, steel plates are welded to form the vertical plate 111 and the horizontal plate 112 of the step mold, respectively. Based on the volume of concrete required for the precast staircase, the stress requirements of the bottom formwork steel plate and the vertical and horizontal plates of the step mold can be calculated; preferably, the thickness of the two steel plates can be selected as 3 to 4 mm. Correspondingly, the wall thickness of the rectangular steel pipes used for the longitudinal and horizontal tubes can be selected as 4 to 5 mm.

[0064] The design of stair tread dimensions needs to comprehensively consider factors such as safety, comfort, and architectural space. Based on experience, the tread depth is generally between 25 and 30 centimeters; in residential buildings, a common value is 26 to 28 centimeters; public buildings, due to the larger number of users, require better accessibility and safety, so the tread depth is generally larger, typically between 28 and 30 centimeters. The tread height is generally between 15 and 18 centimeters; residential stair tread heights are often 16 to 17.5 centimeters; public building tread heights are mostly 15 to 16 centimeters. This height allows people to ascend and descend stairs comfortably and conforms to ergonomic principles, reducing fatigue. Therefore, in this invention, the tread height corresponding to the vertical plate of the tread mold is between 15 and 18 centimeters, and the tread width (depth) corresponding to the horizontal plate of the tread mold is between 25 and 30 centimeters.

[0065] Furthermore, the horizontal length of the treads depends on the width of the intended staircase. The width of ordinary residential staircases is typically between 80 and 120 centimeters to accommodate single or double passage; the width of staircases in public buildings is designed based on factors such as the number of users and evacuation requirements, and is generally wider, commonly ranging from 120 to 200 centimeters or even wider. Preferably, the horizontal width of the treads corresponding to the vertical and horizontal plates of the tread mold is between 125 and 150 centimeters. Correspondingly, the length of the longitudinal tube 113 of the tread mold is greater than the horizontal width of the prefabricated stair treads, and a conventional value can be 160 centimeters.

[0066] To achieve a reliable and stable connection between the modular components of the prefabricated staircase formwork, a nested structure between adjacent modules was designed. For example... Figure 3 , Figure 4 As shown, the first end module, the last end module, and the adjacent step modules are also interlocked and mutually positioned. Adjacent step modules within the step plate are also interlocked and detachably connected. Specifically, the first end module 130 has a vertical strip-shaped first end mold protrusion 131 that interlocks with the right-angled step mold protrusion of the adjacent step module to form a positioning and fixing mechanism; the last end module 140 has an angle steel strip-shaped last end mold protrusion 141 connected to one side of the longitudinal tube of the last end mold to limit the edges of the adjacent step modules.

[0067] Combination Figure 2 , Figure 3 , Figure 5 and Figure 8BAs shown, the space enclosed by the first end module 130, the adjacent step module 110, and the bottom template 120 is used to construct the first step 103 of the prefabricated staircase. The first end module 130 includes three first end mold vertical tubes 133 that are perpendicular to the horizontal plane and not on the same straight line, and multiple sets of first end mold horizontal tubes. Each set of first end mold horizontal tubes includes three horizontally placed first end mold horizontal tubes 134. Each set of first end mold horizontal tubes 134 is welded at different height positions of the first end mold vertical tubes 133, and each end of the first end mold horizontal tube 134 parallel to the bottom template 120 is provided with a corner wedge 132 so that the outer edge of each set of first end mold horizontal tubes 134 forms a triangle.

[0068] To form the first tread of the staircase with its end parallel to the vertical wall of the tread, the first end module 130 is provided with a first end mold wall plate 136, with the first end mold protrusion 131 as its edge. The plane of the wall plate is parallel to the vertical template of the tread. Accordingly, see Figure 2 upper and middle images Figure 14A As shown, when prefabricating stairs, an embedded part 105 can be set in the concrete injection cavity outside the first end formwork panel 136 to serve as the installation part for the first step.

[0069] In the triangular structure formed by the first end mold horizontal tube, the first end mold protrusion 131 is fixed to the outside of the first end mold horizontal tube 134 adjacent to the step module. The first end mold horizontal tube 134 welds a steel plate to the outer side of the first end mold protrusion 131 and the first end mold vertical tube adjacent to the bottom template, i.e., the outer side of the first end mold protrusion 131 facing the bottom template in the triangular structure, to form the first end mold wall plate 136 parallel to the step mold vertical plate.

[0070] As a preferred option, see Figure 8B As shown, in each set of first-end mold horizontal tubes, two of the three horizontal tubes are rectangular steel tubes arranged at right angles, and the other is placed at the hypotenuse parallel to the bottom template with its two sides cut at an angle to form a triangular connection structure with the two perpendicular tubes through the first-end mold vertical tube.

[0071] Similarly combined Figure 2 , Figure 3 , Figure 5 and Figure 8B As shown, the space enclosed by the tail module 140, the adjacent step module 110, and the bottom template 120 is used to construct the tail step 104 of the prefabricated staircase.

[0072] Combination Figure 1 , Figure 14A As shown, the bottom surface of the precast stair tread at the bottom should be parallel to the tread plane. To construct the final tread, its bottom surface is separated from the sloping bottom surface; see [reference needed]. Figure 8BAs shown, a tail wall panel 142 is provided in the tail module 140, which is parallel to the step mold cross plate of the adjacent step module. The tail wall panel 142 and the adjacent step module form a rectangular space to construct the tail step of the prefabricated staircase.

[0073] Specifically, the tail-end module 140 includes two vertical tail-end mold tubes 143 perpendicular to the horizontal plane and not on the same straight line, and multiple sets of tail-end mold horizontal tubes. Each set of tail-end mold horizontal tubes includes two horizontally placed tail-end mold horizontal tubes 144. Each set of tail-end mold horizontal tubes is welded at different height positions on the tail-end mold vertical tubes 143. A steel plate is welded to the outside of the first tail-end mold horizontal tube 144 adjacent to the step module to form the tail wall plate 142. Figure 3 , Figure 8B As shown, the first tail end mold vertical tube 143, which is connected to the first tail end mold horizontal tube and the other, namely the second tail end mold horizontal tube, is adjacent to the step module. An angle steel strip tail end mold clip protrusion 141, which is composed of two strip wall plates, extends from the interface between the first tail end mold vertical tube 143 and the second tail end mold horizontal tube. The tail end mold clip protrusion 141 and the outer wall of the first tail end mold vertical tube form a rectangular frame cavity surrounded on three sides. The opening of the frame cavity faces the edge of the step mold vertical plate of the adjacent step module, i.e., the step mold vertical tube.

[0074] As a preferred option, see Figure 2 As shown, the other tail-end mold longitudinal tube, namely the second tail-end mold longitudinal tube, is a bottom mold longitudinal tube on the edge of the bottom template; it can also be a separate vertical steel pipe that is attached to the bottom mold longitudinal tube on the edge of the bottom template. The end of the first tail-end mold horizontal tube away from the first tail-end mold longitudinal tube is cut at an angle so that its cut surface is parallel to the bottom template; the cut surface is attached to the bottom template, and the cut surface can be welded to the bottom template to form a fixed connection.

[0075] Combination Figure 3 , Figure 4 As shown, to achieve the interlocking connection between adjacent step modules, a strip-shaped wall plate extends from one end of the step module's vertical / horizontal step plate to form a step mold latching protrusion 117. The frame-shaped cavity formed by the strip-shaped wall plate and the edge of the vertical / horizontal step plate at its location accommodates the edges of the opposite ends of the adjacent step modules' horizontal / vertical step plates, ensuring that the opposite ends of the adjacent step modules' horizontal / vertical step plates are in close contact with the extended strip-shaped wall plate, forming an approximately right-angled edge. Figure 3 On the left side of the first three-step module, a strip-shaped wall plate extends from the left end of the horizontal plate of the step mold and engages with the edge of the vertical plate of the step mold on the right side of the single-step module 1101. See also Figure 4As shown, when the strip wall panel is a single-sided rectangular wall panel, the frame cavity is a right-angled semi-enclosed cavity. Preferably, the step mold protrusion 117 is made of angle steel, with one side wall extending out and the other side wall welded to the step mold horizontal tube 114.

[0076] See Figure 12 As shown, during demolding, the first end module 130 can be moved outward along a direction parallel to the bottom template, thereby releasing the limiting position of the step module adjacent to the first end module 130. Then, each step module in the step plate 110 can be removed in any direction along the horizontal outward direction or along any direction within the angle range of the two side walls of the accommodating cavity where one side edge of the step module is located. Finally, the last step module that is locked and limited by the tail end mold clip protrusion 141 is moved out along the strip wall direction of the rectangular frame cavity formed by the tail end mold clip protrusion 141, thereby realizing the disassembly of each template of the prefabricated staircase.

[0077] To achieve detachable connection between the bottom template, the step plate, and the first end module, such as Figure 8A , 8B As shown, multiple bottom mold clamps 124 are spaced apart on the upper surface of the top bottom mold horizontal tube in the bottom template. Simultaneously, a step mold horizontal clamp 116 is provided on the upper surface of the top step mold horizontal tube of each step module in the step plate. Each step mold horizontal clamp 116 is connected to a bottom mold clamp 116 via an adjustable bolt 150. Similarly, a first end mold clamp 135 is provided on the upper surface of the top first end mold horizontal tube of the first end module. The first end mold clamp 135 is also connected to a bottom mold clamp 124 via an adjustable bolt 150.

[0078] like Figure 9 As shown, the bottom formwork clamp, the step formwork horizontal clamp, and the first end formwork clamp can all be made of steel bars into a rounded door frame shape. The adjustable bolt 150 includes, in sequence, a pull ring 151, a first screw section 152, a threaded cylinder 153, a second screw section 154, and a hook 155. The first screw section 152 and the second screw section 154 are connected by a threaded cylinder 153 with threads on its inner wall. The threads connecting the first screw section 152 and the second screw section 154 to the threaded cylinder are threads in opposite directions. This is so that when the threaded cylinder is rotated in one direction, the first screw section 152 and the second screw section 154 move towards each other and move closer together, while when the threaded cylinder is rotated in the other direction, they move away from each other.

[0079] The interlocking mechanism between adjacent step modules in the stair tread achieves mutual restraint. Rigid connections between different steps within each module are achieved via horizontal and vertical steel pipes. To further ensure the rigidity of the connection between adjacent step modules, a tie rod is used at this location for further reinforcement. Figure 9As shown, two adjacent step modules that are interlocked have a step mold stud 118 facing each other on the two adjacent step mold longitudinal tubes outside the interlocking position, and the two opposing step mold studs 118 are connected by an adjustable bolt 150.

[0080] Combination Figure 3 , Figure 4 , Figure 8A and Figure 9 As shown, in two adjacent step modules, the step mold protrusion and side edge of one module abuts and limits the connection with the step mold longitudinal tube of the other module. On one hand, in the top horizontal direction, the step mold horizontal clamps of the two adjacent step modules are tightened by the bottom template through a bolt, and tend to rotate towards the bottom mold with the abutment position as the axis; on the other hand, on another horizontal plane, the step mold studs on the step mold longitudinal tubes of the two step modules are also tightened by a bolt, and tend to rotate away from the bottom mold with the abutment position as the axis. The two tension forces are balanced, thus achieving a rigid connection at the splicing position for the adjacent step modules through mutual interlocking and two detachable connections, ensuring the stability of the structure.

[0081] Preferably, the two studs of the step molds, which are arranged opposite each other, can be set at different heights, such as a pair at each of the two heights of adjacent step modules. Preferably, a stud is also set on the longitudinal tube of the outer end mold of the first end module, and is connected and fixed to the adjacent step module by an adjustable bolt.

[0082] See Figure 6 As shown, on one of the outward-facing longitudinal tubes of each step module in the stair tread, an outward-facing vertical clamp is also installed at the same height. This vertical clamp 115 is also made of steel reinforcement in a rounded-corner door frame shape, and each vertical clamp is reinforced by the same 180mm steel pipe. The modules of the precast stair template of this invention are subjected to tensile forces in the horizontal and vertical directions, as well as abutting forces from the vertical tubes in the vertical direction and the reinforcing bolts in the horizontal direction. Through these multi-directional horizontal and vertical fixations, the stability of the module connections and the overall rigidity of the template system are effectively improved, thereby ensuring the forming effect of the precast staircase.

[0083] This invention utilizes modular combinations of stair tread modules, enabling the production of staircases of various lengths through combinations of several modules. This improves the versatility of the modules and avoids the need to create custom prefabricated templates for new length requirements. Furthermore, the modular tread modules, which can be integrated into different staircase prefabricated templates, effectively increase turnover efficiency and reduce the overall cost of prefabricated templates. Simultaneously, the use of a frame structure rather than a solid construction, along with the different modular tread modules, offers advantages such as light weight, flexibility, and ease of operation. Example

[0084] Based on Example 1, combined with Figure 6 , Figure 7 As shown, this embodiment provides a universal prefabricated staircase device 1000, which includes a combination of components in the universal prefabricated staircase template as described above, and: a side sealing template 160 for sealing concrete and constructing one side end of a stair tread, and a triangular support group for supporting the universal prefabricated staircase template; the combination of components in the universal prefabricated staircase template includes an intermediate bottom template 120, and two modules arranged symmetrically on both sides and facing each other, each consisting of a tread plate 110, a first end module 130, and a last end module 140 respectively.

[0085] The side sealing formwork 160 includes a side sealing formwork horizontal pipe 162 running along the direction of the precast staircase, a side sealing formwork vertical pipe 163 perpendicular to the side sealing formwork horizontal pipe 162, and a side sealing formwork base plate 161 formed by the side sealing formwork horizontal pipe 162 and the side sealing formwork vertical pipe 163 as a frame and welded to the top surface of the frame. Multiple side sealing formwork vertical pipes 161 are symmetrically fixed to both sides of the side sealing formwork horizontal pipe 162. A general-purpose precast staircase formwork is arranged in the middle of the side sealing formwork base plate 161. When pouring the staircase concrete, the surface of the side sealing formwork base plate 161 forms one side end face of each of the two precast staircases on both sides of the base formwork; the other side end face of each of the two precast staircases is formed on the upward-facing side of the concrete in the space enclosed by the base formwork, the first end module, the tread, and the last end module.

[0086] like Figure 14A As shown, the prefabricated staircase 10 of this invention is fixed at one end to the high-end plate 30 and at the other end to the low-end plate 40 during installation. The high-end plate 30 and the low-end plate 40 are relative terms; the high-end plate 30 serves as the low-end plate of one prefabricated staircase and the low-end plate of another prefabricated staircase installed below it. The high-end and low-end plates can be floor slabs or intermediate rest platforms between floors.

[0087] Without loss of generality, such as Figure 14A As shown, the prefabricated staircase 10 has its first step base plate directly abutting against the stair beam 20 of the installation platform. In this type of prefabricated staircase 10, embedded parts 105 such as bolts or screws are set in the first step. The embedded parts correspond to the stair beam connecting parts 50 in the stair beam such as bolt holes. After the connection is made, the ends are fixed by nuts.

[0088] In the universal precast staircase device 1000, two rows of triangular brackets are arranged, each triangular bracket 170 consisting of a right-angle steel 171 and an inclined tube 172 connecting the two sides of the angle steel. The bottom steel pipe of the right-angle steel 171 in the triangular bracket 170 is welded to the sections of the side sealing formwork vertical tubes 161 at both ends and in the middle that extend beyond the side sealing formwork horizontal tubes 162. The triangular brackets 170 effectively restrain the tension force of the poured concrete on the step formwork during precast staircase construction. The vertical height of the triangular reinforcement brackets can generally be half the horizontal width of the stair step or half the length of the step formwork vertical tube, such as 70-80 cm.

[0089] As a preferred option, the side sealing formwork horizontal pipe 162 and side sealing formwork vertical pipe 163 are welded into a grid-like frame in sections. Concrete is then poured into the frame grid, and steel plates are covered on one or both sides of the formed concrete slab. The steel plates are then welded flatly onto the frame steel pipes in sections to form a flat side sealing formwork base plate.

[0090] Four lifting lugs can be symmetrically installed on the sides of the side sealing formwork horizontal tubes to facilitate the movement of the side sealing formwork when necessary. Preferably, a rectangular steel pipe is also installed at the bottom and top of the triangular bracket where it connects to the universal stair precast formwork, serving as a reinforcing bolt 180. This acts as a medium for the triangular bracket to abut against the precast formwork, ensuring the orderly arrangement of the step modules when laying the treads and providing horizontal constraint to the vertical tubes of the step formwork. Simultaneously, the reinforcing bolt 180 provides operational and movement space for the installation and disassembly of the stair formwork.

[0091] See also Figure 7 As shown, this structure with the ends facing each other on both sides disperses the arrangement of the bottom mold clamps, so that the bottom mold clamps only need to tighten two adjacent step modules on one side at the same position, and stagger the bottom mold clamps that tighten the step modules on different sides, thereby making the bottom mold clamps more evenly distributed and balanced in tightening the step modules on both sides.

[0092] Accordingly, based on the aforementioned universal stair prefabrication device, the present invention provides a stair prefabrication method, characterized by comprising the following steps: S1. Initialize the structural design, manufacture the general-purpose prefabricated staircase device and the staircase steel mesh as described above, wherein multiple step modules are selected according to the target length of the staircase to combine the first step plate and the second step plate. S2. Perform preliminary cleaning on the surface of the side sealing mold bottom plate in the side sealing mold, the bottom mold of the staircase pouring cavity in the precast mold, the vertical plate of the step mold in the step plate, the horizontal plate of the step mold, the first end mold wall plate in the first end module, and the tail wall plate in the tail end module. S3. On one side of the middle position of the side sealing mold base plate, arrange the step modules in the first step plate in sequence. After placing the first end module, snap the step mold protrusion formed by the strip wall plate on the first step module adjacent to it with the first end module. Snap the step mold protrusions on one side of the other step modules with the opposite edge of the previous step module in sequence. Simultaneously, use adjustable bolts to initially fix the adjacent modules in the first end module and step modules on the vertical surface. S4. Snap the bottom template and the tail module with the last step module in the direction of the opening of the receiving cavity formed by the tail end mold protrusion on the tail end module. S5. Using adjustable bolts, connect the bottom mold clamp on the bottom template to the step mold cross clamp on the step module and the first end mold clamp on the first end module respectively; when screwing the threaded cylinder on the adjustable bolt in the direction of tightening the two modules connected by the adjustable bolt, the first screw section and the second screw section on the adjustable bolt move towards each other until they are initially tightened. S6. On the other side of the middle position of the side sealing mold base plate, arrange each step module in the second step plate in sequence, and snap the bottom template and the tail module with the last step module according to the opening direction of the accommodating cavity formed by the tail end mold protrusion on the tail end module. S7. Sequentially, fasten the step mold protrusions formed by the strip wall panels on one side of the other step modules in the second step plate to the opposite edge of the next step module; place and adjust the position of the first end module so that the first end mold protrusion is fastened by the step mold protrusion on the first step module adjacent to it; simultaneously, use adjustable bolts to initially fix the first end module and adjacent modules in the step modules on the vertical surface. S8. Using adjustable bolts, connect the bottom mold clamps on the same bottom template in the middle to the step mold horizontal clamps on the step module in the second step plate and the first end mold clamps on the first end module respectively; initially tighten each adjustable bolt; S9. Fine-tune the position of each module, and insert a rectangular steel pipe reinforcing bolt between the bottom of the triangular bracket and the first step plate and the second step plate respectively; then, insert another rectangular steel pipe reinforcing bolt through each step mold vertical clamp of the first step plate and the second step plate respectively. S10. Tighten all adjustable bolts on the horizontal and vertical surfaces to complete the installation of the general-purpose prefabricated staircase device. S11. After cleaning the surfaces of the side sealing mold bottom plate, bottom mold steel plates on both sides of the bottom template, step mold vertical plate and step mold horizontal plate in the stair tread, first end mold wall plate in the first end module and tail wall plate in the tail end module, apply release agent to their surfaces. S12. Arrange the tied steel mesh in the casting cavity and fix the embedded parts according to the design position; S13. Pour concrete into the casting cavity and vibrate it at intervals until the concrete height reaches the elevation according to the horizontal width of the stair treads. S14. Vibrate the concrete, let it stand, and then smooth and polish the surface; then cure it. S15. After curing is completed, disassemble each module in the reverse order of installation; after removing the formwork, hoist the staircase to the storage location.

[0093] Preferably, in step S3, adjacent head modules and step modules are simultaneously connected on the vertical surface by adjustable bolts, with the bolts on their side edges being connected.

[0094] Preferably, in step S2, mechanical or manual cleaning is used to remove cement slurry and concrete residue, and then polishing is performed to ensure that each panel is smooth and free of rust.

[0095] In step S11, when applying the release agent automatically or manually, it should be applied evenly in strips to prevent accumulation and missed areas. In step S12, the reinforcing bars should be lifted from multiple points to prevent twisting, bending, and skew deformation; the embedded parts should be securely fixed. In step S13, the concrete should be applied evenly in layers of 20 to 30 centimeters.

[0096] In step S14, each vibration lasts for 20 to 30 seconds, until the concrete stops settling, the surface becomes smooth, and no more air bubbles appear. Vibration can be performed manually with a vibrator or by using a vibrator attached to the formwork. After the concrete is poured, let it stand for one hour, then smooth the surface. After that, cover it with a curing shed and let it stand for about two hours before heating and curing, with the maximum temperature not exceeding 70°C.

[0097] Preferably, the sequential installation order of the first end module, step module to the last end module in steps S3 to S5 is replaced by the sequential installation order of the last end module, step module to the first end module in steps S6 to S7.

[0098] The present invention also provides a method for installing a universal prefabricated staircase device, characterized in that it includes steps S3 to S10.

[0099] In step S15, the demolding is performed using a general-purpose prefabricated staircase assembly and disassembly method, including: T1. On the sides of the first step plate and the second step plate, remove the rectangular steel pipe reinforcing bolts that run through the vertical clamps of the step mold and the rectangular steel pipe reinforcing bolts between them and the bottom of the triangular bracket. T2. Tighten the adjustable bolts between the rotating bottom mold clamp and the step mold horizontal clamp on the step module and the first end mold clamp on the first end module, so that the first screw section and the second screw section on the adjustable bolt move in opposite directions until the hook disengages; simultaneously loosen the adjustable bolts on the adjacent modules on the facade; T3. On both sides of the first step plate and the second step plate, respectively: move the first end module outward along the direction parallel to the bottom template to release the limit of the step module adjacent to the first end module; then move each step module in the step plate outward in the horizontal direction in sequence; then, move the last step module that is locked and limited by the tail end mold protrusion outward along the strip wall direction of the rectangular cavity formed by the tail end mold protrusion. T4. Gently tap the bottom formwork and slowly lift the staircase outward and upward at a slight angle to the vertical direction, separating it from the bottom formwork and the side sealing formwork.

[0100] This invention relates to a prefabrication device for stairs, which arranges two sets of step templates facing each other and inverted end to end on the same side sealing base plate. The two sets of step templates share a single bottom template for the stairs, allowing for the prefabrication of two stairs at once. The overall lateral width of the entire prefabrication device, including the support frame, is generally within 1.8 meters. Compared to traditional horizontal structures, this significantly saves floor space, improves the utilization rate of three-dimensional space, and enables larger-scale production within a limited area. Example

[0101] This embodiment optimizes the structure of the step mold protrusion at the end of the step module in the step plate. For example... Figure 11B As shown, the strip-shaped wall panel constituting the locking protrusion is a single-sided strip, i.e., a rectangular wall panel. The strip-shaped wall panel and the edge of the vertical / horizontal step mold plate at one end form a right-angled semi-enclosed cavity. The strip-shaped wall panel and the adjacent cavity have corresponding spherical protrusions and concave holes on their respective accommodating surfaces, forming an interference fit. This fit achieves initial locking between the two components, facilitating subsequent tightening operations.

[0102] In the second structure, see Figure 11A and combined Figure 3 , Figure 4 As shown, the strip wall panel constituting the step mold protrusion adopts a right-angled long strip wall panel with double sides. The frame cavity is a topless rectangular frame cavity surrounded on three sides, and the opening of the frame cavity faces the edge of the step mold horizontal plate / step mold vertical plate of the adjacent step module it accommodates.

[0103] Combination Figure 3 , Figure 11AAs shown in the left figure, on the first step module adjacent to the first end module, a straight notch protrusion 1171 for accommodating the first end mold protrusion 131 in the first end template 130 is composed of parallel double-sided strip wall panels to form a three-sided enclosed, topless rectangular frame cavity. Figure 11A As shown in the right figure, the side notch protrusion 1172 used to accommodate the edges of other step modules is composed of an extended angle steel wall plate, and together with the side edge wall of the extended part, it forms a three-sided enclosed topless rectangular frame cavity.

[0104] In the second structure, see Figure 12 As shown, during demolding, the first end module 130 can be moved out along the vertical surface upwards to release the restriction of the step module adjacent to the first end module 130. Then, each step module in the step plate 110 can be moved out along the notch direction of the side notch protrusion 1172 in sequence.

[0105] In addition, combined Figure 4 As shown, each step module can also be provided with a step mold longitudinal tube at one end of the step mold protrusion 117. Then, the single step module 1101, the double step module 1102 and the triple step module 1103 respectively include three, five and seven step mold longitudinal tubes 113.

[0106] This embodiment extends the design of the convex structure, making it easier to operate when assembling prefabricated templates. Example

[0107] This implementation includes another clamp and bolt structure to connect the bottom template to the step plate and adjacent step modules within the step plate.

[0108] Combination Figure 10A , Figure 10B , Figure 10C As shown, the bottom mold clamp, the step mold horizontal clamp, and the first end mold clamp all adopt a three-sided enclosed gate-shaped structure, and the adjustable tie bolts connecting the two end clamps are bolts and nuts.

[0109] like Figure 10C As shown, the bottom mold clamp uses a bottom mold clamping block 1241, which includes a door corner seat 1244 longitudinally cut from a rectangular short steel pipe and a door surface groove 1243 opened on its front. The door surface groove 1243 opened on the middle side wall of the two end door corner seats 1244 is used as a groove for bolts to pass through.

[0110] The step mold horizontal clamp uses a step mold horizontal clamping block 1161, which includes a portal base 1162, a wedge block 1164, and a wedge groove 1163. The portal base 1162 consists of two opposing angle steel blocks, and a wedge block 1164 is provided at the top of the portal base, in the middle where the two angle steel blocks connect. Figure 10BAs shown, the wedge block 1164 is a triangular block added to one side of the top of the rectangular wall, such that after the step mold horizontal locking block 1161 is fixed to the upper surface of the step mold horizontal tube at the top of the step module, the top end face of the triangular block is approximately parallel to the wall surface of the slotted side wall of the bottom mold locking block, i.e., the side wall of the door face slot. This allows the inner wall of the nut of the bolt passing through the slot on the step mold horizontal locking block 1161 or the bottom mold locking block 1241 to abut against the top outer wall of the wedge-shaped slot 1163 of the bottom mold locking block, so that the bolt can fit snugly against the bottom mold locking block 1241. Generally, according to the angle between the bottom surface of the prefabricated staircase and the horizontal plane of the step, the angle between the slotted side wall and the top wall of the door-shaped seat is staggered to compensate for the angle difference between the horizontal step and the inclined bottom surface of the staircase, so that the bolt can fit into the slot. The wedge groove 1163 is a through groove opened along a direction perpendicular to the outer end face of the wedge block 1164. Similarly, the head mold clamp also adopts the structure of the step mold horizontal clamp block 1161.

[0111] Accordingly, the bolts of the threaded tie rod 1501 are inserted into the wedge groove and the door groove, and the side with the nut is locked on the outer / inner side wall of one of the slots on the step mold horizontal block or the bottom mold block, while the other side of the bolt is fixed to the inner / outer side wall of the other slot by the nut 1502.

[0112] Combination Figure 10A , Figure 10B As shown, the door corner seat of the bottom mold block and the door-shaped seat opening of the step mold horizontal block both face the bottom mold plate side; preferably, the two openings can be in opposite directions or face different directions to facilitate the tightening of nuts. Preferably, the step mold horizontal block can be formed by casting or stamping.

[0113] Generally, the bottom of the doorway groove is arc-shaped or rectangular. Preferably, the bottom mold clamp can be a bottom mold double clamping block 1242. The difference between the bottom mold double clamping block and the standard bottom mold clamping block is that two slots are opened in parallel on the front wall of the grooved side, for two bolts to connect to the step mold horizontal clamping blocks of the two side step plates respectively. Preferably, combined with... Figure 8A As shown, two adjacent step modules that interlock with each other are each provided with a step mold horizontal clamp on the top of the step mold horizontal tubes on both sides immediately adjacent to the interlocking position, and each of the two step mold horizontal clamps is connected to the same bottom mold clamp by an adjustable bolt. Preferably, a vibrator 119 is attached to the back of the step mold horizontal plate 112 of the step module for vibration after concrete pouring.

[0114] This embodiment uses bolts to fix the step plate and the first end module to the bottom template, providing another simple fixing operation method. Example

[0115] This embodiment includes another structure for the tail template, which is detachably and flexibly connected to the bottom template and can move along the extension direction of the bottom template; it also includes another design for the edge of the step plate module.

[0116] like Figure 13 As shown, in the tail module 140, there are three tail mold longitudinal tubes 143, which stand upright at the three corners. Each group of tail mold horizontal tubes at the same height includes three horizontally placed tail mold horizontal tubes 144. Similarly, a steel plate is welded to the outside of the first tail mold horizontal tube adjacent to the step module 110 to form the tail wall plate 142. The first tail mold longitudinal tube closest to the step module extends from the side away from the bottom template to form a tail mold locking protrusion 141 composed of a strip wall plate. The tail mold locking protrusion 141 and the outer wall of the first tail mold longitudinal tube form a semi-enclosed rectangular right-angled cavity to accommodate and limit the side edge of the adjacent step module, i.e., the step mold longitudinal tube 113.

[0117] Combination Figure 1 , Figure 8B As shown, correspondingly, bolts or threaded tie rods 1501 are pre-embedded at at least two different height positions on the side edge of the bottom template 120. After the adjacent step modules are initially positioned, when connecting the tail module 140 to the bottom template 120, the tail module 140 is pushed in along the extension direction of the bottom template so that the pre-embedded bolts pass through the pre-set through holes of the tail end mold longitudinal tube 143 on the tail module, and then fixed with nuts.

[0118] Combination Figure 11A , Figure 12 , Figure 13 As shown, for the structure where the tail module 140 is movably connected to the bottom template 120, when the step module adjacent to the head module 130 uses a straight notch protrusion 1171, during demolding, start from the other end and move the tail module 140 outwards first. Then, the bottom template can also move a distance in this direction to provide space for the movement of the head module 130. The head module 130 moves along the two long sidewalls of the notch of the straight notch protrusion 1171 to release the restriction of the step module adjacent to the head module 130, and then each step module in the step plate 110 is moved along... Figure 13 The strip wall, indicated by the dashed arrow, was dismantled until the penultimate step module was removed, completing the template dismantling process.

[0119] Alternatively, after the tail module 140 moves outward first, the movement can begin from the step module in the step plate 110 adjacent to the tail module, along... Figure 13 The strip wall, indicated by the solid arrow in the lower center, moves outwards, and the step modules at its front end are moved one after another until the frontmost step module is removed, thus completing the disassembly of the template.

[0120] See Figure 4, Figure 11A As shown, in the step module and the head module, the extended strip wall plate used to limit the movement of adjacent modules is one side of an angle steel or two sides of a C-shaped steel pipe with one side missing. The other side of the angle steel or the other side of the C-shaped steel pipe is welded to the edge of the module. Combined with... Figure 4 As shown, when the edges of the module are directly made of the angle steel or C-shaped steel pipe, the wide wall surface of the angle steel or C-shaped steel pipe is welded to the horizontal pipe and the vertical / horizontal plate of the step mold. And for... Figure 5 In the right figure, when the tail end module uses a vertical tube for its edge, the narrow side wall of the protruding angle steel, i.e. its edge strip, is welded to the vertical tube.

[0121] Preferably, at the connection between the first end module and the adjacent step module, the first end module can be replaced by a first end module protrusion made of a strip wall plate extending out of the first end module to limit the flat adjacent edges of the step module.

[0122] When the tail module is detachably connected, the first step plate and the second step plate can be installed using a similar connection method, and steps S3 to S8 are replaced by: S32. On one side of the middle position of the side sealing mold base plate, arrange the step modules in the first step plate in sequence. After placing the first end module, snap the step mold protrusion formed by the strip wall plate on the first step module adjacent to it with the first end module. Snap the step mold protrusion on one side of the other step modules with the opposite edge of the previous step module in sequence. Simultaneously, use adjustable bolts to initially fix the adjacent modules in the first end module and step modules on the vertical surface. S42. After snapping the tail end module and the step module at the tail end into place according to the opening direction of the accommodating cavity formed by the tail end module clip protrusion, connect the tail end module to the bottom template. S52. Using adjustable bolts, connect the bottom mold clamp on the bottom template to the step mold cross clamp on the step module and the first end mold clamp on the first end module respectively; when screwing the threaded cylinder on the adjustable bolt in the direction of tightening the two modules connected by the adjustable bolt, the first screw section and the second screw section on the adjustable bolt move towards each other until they are initially tightened. S62. On the other side of the middle position of the side sealing mold base plate, according to steps S3 to S5, connect each step module of the second step plate, as well as the first end module and the last end module on that side.

[0123] In this embodiment, the tail module can be detached from the base plate mold, thus providing a more flexible operation method for the assembly and disassembly of the template. Example

[0124] This embodiment presents a prefabricated template structure for a staircase with a platform-type first step.

[0125] like Figure 14BAs shown, different from Figure 14A The prefabricated staircase 10 features a platform-type first tread 1031 at its initial end. In this type of staircase, no embedded parts are required in the first tread; similar to the final tread, the platform-type first tread 1031 directly overlaps the stair beam 20. The stair beam 20 is cast using horizontal and vertical stair beam reinforcing bars 201. During prefabrication, a reinforcing mesh 106 is placed in the concrete space formed by the bottom formwork and the tread. The reinforcing mesh 106 is bent near the front wall of the platform-type first tread 1031.

[0126] Combination Figure 14B and Figure 5 As shown, to construct the platform-type first step 1031, its corresponding first end mold wall plate must extend beyond the bottom mold plate plane and, similar to the tail end module, construct a rectangular space. The first end mold wall plate includes three surfaces, with the innermost surface parallel to the step vertical mold plate; and a recessed pit is formed along the direction perpendicular to this surface, i.e., parallel to the step horizontal mold plate, to form the protruding platform portion.

[0127] This embodiment prefabricates an alternative staircase configuration, thus providing another method for staircase installation.

[0128] In addition, although the embodiments are described and illustrated separately above, some common technologies are involved, and those skilled in the art can replace and integrate them between the embodiments. If there is any content not explicitly described in one embodiment, then another embodiment that is described can be referred to.

[0129] The embodiments described above do not constitute a limitation on the scope of protection of this technical solution. Any modifications, equivalent substitutions, and improvements made within the spirit and principles of the above embodiments should be included within the scope of protection of this technical solution.

Claims

1. A universal prefabricated staircase template, characterized in that, include: The bottom formwork is used to form the sloping bottom surface of the staircase; the treads are used to form the stair steps; and the front and rear end modules are used to seal the concrete and construct the front and rear ends of the staircase, respectively. The bottom template is detachably connected to the step plate and the first end module, and the tail end module is fixedly connected to the bottom template. The bottom formwork includes two longitudinal bottom formwork tubes arranged at both ends, and multiple horizontal bottom formwork tubes that are perpendicularly fixed to the longitudinal bottom formwork tubes and placed horizontally. On each of the two sides of the frame formed by the longitudinal bottom formwork tubes and the horizontal bottom formwork tubes, a bottom formwork steel plate is welded. In the 1 to N step modules constructed according to the module N, the step plate is formed by selecting multiple step modules and assembling them sequentially according to the required length of the staircase. Each step module includes a step mold vertical plate and a step mold horizontal plate. Adjacent step modules are interlocked and detachably connected, so that the step mold vertical plate of the previous step module is in close contact with the step mold horizontal plate of the next step module. A strip-shaped wall plate extends from one end of the step mold vertical plate / step mold horizontal plate of the step module to form a step mold latching protrusion. The frame-shaped cavity formed by the strip-shaped wall plate and the edge of the step mold vertical plate / step mold horizontal plate at its respective end is used to accommodate the edges of the step mold horizontal plate / step mold vertical plate at opposite ends of the adjacent step module, so that the step mold horizontal plate / step mold vertical plate at opposite ends of the adjacent step module and the extended strip-shaped wall plate are in close contact with an approximately right-angled edge. The first-end module has a vertical strip-shaped first-end mold protrusion that interlocks with the adjacent step module, and a first-end mold wall panel with the first-end mold protrusion as its edge. The space enclosed by the first-end mold wall panel, the adjacent step module, and the bottom mold formwork constitutes the first step of the prefabricated staircase. The tail end module has a strip-shaped tail end mold protrusion connected to one side of the tail end mold longitudinal tube to limit the adjacent step module. On the other side of the tail end mold longitudinal tube, there is a tail wall plate parallel to the step mold horizontal plate of the adjacent step module. The space enclosed by the tail wall plate and the adjacent step module forms the tail step of the prefabricated staircase.

2. The universal precast stair formwork according to claim 1, characterized in that, The step module also includes step mold longitudinal tubes and step mold horizontal tubes. The step mold longitudinal tubes are perpendicular to the horizontal plane and their length is greater than the horizontal width of the prefabricated stair treads. The step mold horizontal tubes form mutually perpendicular horizontal tube segments on the horizontal plane corresponding to the step height and step width of the prefabricated stair treads. Multiple horizontal tube segments on different horizontal planes are welded to multiple step mold longitudinal tubes to form a step module frame with a corresponding number of 7-shaped segments. A steel plate is welded to the side of the step module frame opposite to the bottom template to form the step mold vertical plate and the step mold horizontal plate.

3. A universal precast staircase formwork according to claim 1, characterized in that, The strip wall panel is a single-sided rectangular wall panel, and the frame cavity is a right-angled semi-enclosed cavity; or, the strip wall panel is a right-angled long strip wall panel with two sides, and the frame cavity is a topless rectangular frame cavity with three sides, and the opening of the frame cavity faces the edge of the step mold horizontal plate / step mold vertical plate of the adjacent step module it accommodates.

4. A universal precast stair formwork according to claim 1, characterized in that, The first end module has three first end mold vertical tubes that are perpendicular to the horizontal plane and not on the same straight line, and multiple sets of first end mold horizontal tubes. Each set of first end mold horizontal tubes includes three horizontally placed first end mold horizontal tubes. Each set of first end mold horizontal tubes is welded to different height positions of the first end mold vertical tubes. At each end of the first end mold horizontal tube that is parallel to the bottom template, a corner wedge is provided so that the outer edge of each set of first end mold horizontal tubes forms a triangle. The first end mold horizontal tube adjacent to the step module is fixed to the outside of the first end mold protrusion. A steel plate is welded to the outside of the first end mold horizontal tube between the first end mold protrusion and the first end mold vertical tube adjacent to the bottom template to form the first end mold wall plate.

5. A universal precast stair formwork according to claim 1, characterized in that, The tail end module has two tail end mold longitudinal tubes that are perpendicular to the horizontal plane and not on the same straight line, and multiple sets of tail end mold horizontal tubes. Each set of tail end mold horizontal tubes includes two horizontally placed tail end mold horizontal tubes. Each set of tail end mold horizontal tubes is welded at different height positions of the tail end mold longitudinal tubes. A steel plate is welded to the outside of the first tail end mold horizontal tube adjacent to the step module to form the tail wall plate. The first tail end mold vertical tube, which is connected to the first and second tail end mold horizontal tubes, extends from the interface between the first tail end mold vertical tube and the second tail end mold horizontal tube to form a tail end mold clip protrusion composed of two strip wall plates. The tail end mold clip protrusion and the outer wall of the first tail end mold vertical tube form a rectangular frame cavity surrounded on three sides, and the opening of the rectangular frame cavity faces the edge of the step mold vertical plate of the adjacent step module it accommodates. The end of the first tail end horizontal tube opposite to the first tail end vertical tube is cut at an angle and its cut surface is parallel to the bottom template, and the cut surface is in contact with the bottom template.

6. A universal precast staircase formwork according to claim 1, characterized in that, The top bottom mold horizontal tube of the bottom template has multiple bottom mold clamps on its upper surface; each step module in the step plate has a step mold horizontal clamp on its upper surface, and the step mold horizontal clamp is connected to a bottom mold clamp by an adjustable bolt; the top end mold horizontal tube of the first end module has a first end mold clamp on its upper surface, and the first end mold clamp is connected to a bottom mold clamp by an adjustable bolt. The adjustable bolt includes, in sequence, a pull ring, a first screw section, a threaded cylinder, a second screw section, and a pull hook. The first screw section and the second screw section are connected by a threaded cylinder with threads on its inner wall. The threads connecting the first screw section and the second screw section to the threaded cylinder are threads in opposite directions. This is so that when the threaded cylinder is rotated in one direction, the first screw section and the second screw section move towards each other, and when the threaded cylinder is rotated in the other direction, they move away from each other.

7. A universal precast stair formwork according to claim 1, characterized in that, The top end mold horizontal tube of the first end module has a first end mold clamp on its upper surface, and the top bottom mold horizontal tube of the bottom template has multiple bottom mold clamps on its upper surface; the top step mold horizontal tube of each step module in the step plate has a step mold horizontal clamp on its upper surface, and the first end mold clamp and the step mold horizontal clamp are all connected to a bottom mold clamp by an adjustable bolt; The bottom mold clamp, the step mold horizontal clamp, and the first end mold clamp all adopt a three-sided enclosed gate-shaped structure, and the adjustable pull bolt is a bolt; The bottom mold clamp adopts a bottom mold clamp block, which includes a door corner seat and a door surface groove cut longitudinally from a rectangular short steel pipe. The door corner seat has an opening on one side and a groove for bolts and screws to pass through on the other side wall in a direction perpendicular to the two side walls. Both the head mold clamp and the step mold horizontal clamp adopt step mold horizontal clamping blocks. The step mold horizontal clamping block includes a portal-shaped base, a wedge block, and a wedge groove. The portal-shaped base consists of two opposing angle steel blocks. A wedge block is provided in the middle of the connection between the two angle steel blocks. The wedge block is a triangular block added to one side of the rectangular block. After the step mold horizontal clamping block is fixed on the upper surface of the top step mold horizontal tube of the step module, one end face of the triangular block is approximately parallel to the slotted sidewall of the bottom mold clamping block. The wedge groove is a through groove opened in a direction perpendicular to the end face.

8. A universal precast staircase formwork according to claim 6, characterized in that, Two adjacent step modules that interlock with each other have a step mold stud respectively on the adjacent step mold longitudinal tubes on both sides outside the interlocking position, and the two opposing step mold studs are connected by the adjustable bolt.

9. A universal precast stair formwork according to claim 1, characterized in that, On the outward-facing longitudinal tube of the step module in the step plate, a step module vertical clamp facing outward is also set at the same height. The step module vertical clamp is made of steel bars in the shape of a rounded door frame, and each step module vertical clamp is connected by a reinforcing steel pipe.

10. A universal prefabricated staircase device, characterized in that, Includes a universal precast stair template as described in claim 6 or 8, and: a side sealing template for sealing concrete and constructing one side of a stair tread, and a triangular support assembly for supporting the universal precast stair template. The assembly of components in the general-purpose prefabricated staircase template includes a central bottom template and two modules arranged symmetrically on both sides and facing each other, each consisting of a tread, a first end module, and a last end module. The side sealing template includes a side sealing template base plate with a frame consisting of horizontal side sealing template tubes along the direction of the precast staircase and vertical side sealing template tubes perpendicular to them; multiple vertical side sealing template tubes are symmetrically fixed to both sides of the horizontal side sealing template tubes; the universal staircase precast template is arranged in the middle of the side sealing template base plate. The triangular brackets are arranged in two rows, each of which consists of a right-angled steel and an inclined tube connecting the two sides of the angled steel; the bottom steel tube of the right-angled steel inside the triangular bracket is fixed to the side sealing vertical tube.

11. A general method for prefabricating stairs, characterized in that, Includes the following steps: S1. Initialize the structural design and manufacture the general-purpose prefabricated staircase device as described in claim 10, as well as the staircase steel mesh, wherein multiple step modules are selected according to the target length of the staircase to combine the first step plate and the second step plate. S2. Perform preliminary cleaning on the surface of the side sealing mold bottom plate in the side sealing mold, the bottom mold of the staircase pouring cavity in the precast mold, the vertical plate of the step mold in the step plate, the horizontal plate of the step mold, the first end mold wall plate in the first end module, and the tail wall plate in the tail end module. S3. On one side of the middle position of the side sealing mold base plate, arrange the step modules in the first step plate in sequence. After placing the first end module, snap the step mold protrusion formed by the strip wall plate on the first step module adjacent to it with the first end module. Snap the step mold protrusions on one side of the other step modules with the opposite edge of the previous step module in sequence. Simultaneously, use adjustable bolts to initially fix the adjacent modules in the first end module and step modules on the vertical surface. S4. Snap the bottom template and the tail module with the last step module in the direction of the opening of the receiving cavity formed by the tail end mold protrusion on the tail end module. S5. Using adjustable bolts, connect the bottom mold clamp on the bottom template to the step mold cross clamp on the step module and the first end mold clamp on the first end module respectively; when screwing the threaded cylinder on the adjustable bolt in the direction of tightening the two modules connected by the adjustable bolt, the first screw section and the second screw section on the adjustable bolt move towards each other until they are initially tightened. S6. On the other side of the middle position of the side sealing mold base plate, arrange each step module in the second step plate in sequence, and snap the bottom template and the tail module with the last step module according to the opening direction of the accommodating cavity formed by the tail end mold protrusion on the tail end module. S7. Sequentially, fasten the step mold protrusions formed by the strip wall panels on one side of the other step modules in the second step plate to the opposite edge of the next step module; place and adjust the position of the first end module so that the first end mold protrusion is fastened by the step mold protrusion on the first step module adjacent to it; simultaneously, use adjustable bolts to initially fix the first end module and adjacent modules in the step modules on the vertical surface. S8. Using adjustable bolts, connect the bottom mold clamps on the same bottom template in the middle to the step mold horizontal clamps on the step module in the second step plate and the first end mold clamps on the first end module respectively; initially tighten each adjustable bolt; S9. Fine-tune the position of each module, and insert a rectangular steel pipe reinforcing bolt between the bottom of the triangular bracket and the first step plate and the second step plate respectively; then, insert another rectangular steel pipe reinforcing bolt through each step mold vertical clamp of the first step plate and the second step plate respectively. S10. Tighten all adjustable bolts on the horizontal and vertical surfaces to complete the installation of the general-purpose prefabricated staircase device. S11. After cleaning the surfaces of the side sealing mold bottom plate, bottom mold steel plates on both sides of the bottom template, step mold vertical plate and step mold horizontal plate in the stair tread, first end mold wall plate in the first end module and tail wall plate in the tail end module, apply release agent to their surfaces. S12. Arrange the tied steel mesh in the casting cavity and fix the embedded parts according to the design position; S13. Pour concrete into the casting cavity and vibrate it at intervals until the concrete height reaches the elevation according to the horizontal width of the stair treads. S14. Vibrate the concrete, let it stand, and then smooth and polish the surface; then cure it. S15. After the curing is completed, disassemble each module in the reverse order of installation. After removing the template, the stairs are hoisted to the storage location.

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