Environment-friendly light-weight high-strength steel bar truss floor support plate and construction method thereof

Abstract

The invention relates to the technical field of steel bar truss floor support plates, in particular to an environment-friendly light-weight high-strength steel bar truss floor support plate which comprises an upper chord steel bar, a first web member steel bar, a second web member steel bar and a lower chord steel bar. Second web member steel bars corresponding to the first web member steel bars in a one-to-one mode are welded to the right side of the upper chord steel bar, each first web member steel bar comprises a web member steel bar straight part, and the upper end of each web member steel bar straight part is fixedly connected with a web member steel bar bent part. A lower chord steel bar is welded between the first web member steel bar and the second web member steel bar and close to one end of the web member steel bar bending part; the inverted-T-shaped single-group truss is composed of the upper chord steel bars, the first double-web-member steel bars, the second double-web-member steel bars and the lower chord steel bars, traditional bottom die steel bars and stabilizing bars are omitted, the load transmission path is simplified, the adjacent trusses are welded through inflection points of the straight portions of the web members to form rhombic grids, and unification of light weight, high strength and fast construction is achieved.

Description

Technical Field

[0001] The present invention relates to the technical field of steel bar truss floor decking, and in particular to an environmentally friendly, lightweight, high-strength steel bar truss floor decking and a construction method thereof. Background Art

[0002] Floor decking, also known as steel decking, composite floor slab, etc., is a plate made of galvanized steel plate by roller cold bending. It is mainly used as a permanent formwork for concrete floor slabs. It is also the lower load-bearing steel bar of the floor slab, participating in the force calculation of the floor slab, working together with concrete to form a composite floor slab, providing a firm working platform in a short time, and can adopt multiple floors to lay corrugated steel plates, and cast concrete slabs in layers in a continuous construction. During the use stage, the floor decking serves as the tensile reinforcement of the concrete floor slab, which improves the rigidity of the floor slab and saves the amount of steel bars and concrete. The embossing on its surface maximizes the bonding force between the floor decking and the concrete, making the two form a whole. Equipped with stiffening ribs, the floor decking system has high bearing capacity. When the floor decking is combined with the steel truss, a steel truss floor deck is formed.

[0003] The reinforced truss structure in traditional cast-in-place concrete floor slabs is mostly composed of upper chord steel bars, web steel bars, lower chord steel bars, bottom formwork steel bars and stabilizing bars. The load transfer path is redundant, and the multiple formwork steel bars and stabilizing bars result in high steel consumption, excessive deadweight, and many welding nodes, which greatly increases construction costs. It will also generate a large amount of construction waste during demolition, which violates the concept of green building.

[0004] Therefore, in order to address the problems of high steel consumption, insufficient environmental friendliness, and difficulty in achieving both lightweight and high strength in traditional steel trusses, an environmentally friendly, lightweight, high-strength micro-supported steel truss floor deck and its installation method can be designed. Summary of the Invention

[0005] In order to overcome the problems of traditional steel trusses such as high steel consumption, insufficient environmental protection, and difficulty in achieving both lightness and high strength.

[0006] The technical solution of the present invention is: an environmentally friendly lightweight high-strength steel truss floor deck, including an upper chord steel bar, a first web steel bar, a second web steel bar and a lower chord steel bar. The first web steel bar is welded to the left side of the upper chord steel bar, and the second web steel bar is welded to the right side of the upper chord steel bar and is arranged in a one-to-one correspondence with the first web steel bar. The first web steel bar includes a straight portion of the web steel bar, the upper end of the straight portion of the web steel bar is fixedly connected to a bent portion of the web steel bar, and the lower chord steel bar is welded between the first web steel bar and the second web steel bar and close to one end of the straight portion of the web steel bar.

[0007] Furthermore, the first web member steel bars, the second web member steel bars and the bottom chord steel bars are connected by resistance spot welding to form a single set of steel bar trusses, and the cross section of the single set of steel bar trusses is an inverted T-shaped structure.

[0008] Furthermore, the first web reinforcement and the second web reinforcement are both continuously bent reinforcements and are arranged at equal intervals along the extension direction of the upper chord reinforcement. The first web reinforcement and the second web reinforcement have the same structure.

[0009] Furthermore, the straight portion of the web reinforcement and the bent portion of the web reinforcement are an integrally formed structure, the vertical height from the lower edge of the straight portion of the web reinforcement to the upper edge of the bent portion of the web reinforcement is 110 mm, and the horizontal spacing between the two end points of the straight portion of the web reinforcement parallel to the upper chord reinforcement is 200 mm.

[0010] Furthermore, two adjacent groups of steel bar trusses are connected via the inflection points of the straight portions of the web bars away from the bottom chord bars, and the adjacent straight portions of the web bars are welded in pairs to form a diamond-shaped steel bar grid.

[0011] Furthermore, the bent portion of the web reinforcement is an inverted V-shaped structure and the center distance between every two adjacent top nodes should be less than or equal to 200 mm.

[0012] Furthermore, the upper chord steel bars and the lower chord steel bars are both continuous straight steel bars and are parallel to each other. The distance between the upper surface of the upper chord steel bars and the lower surface of the lower chord steel bars should be controlled within the range of 60mm-170mm, and preferably with a module of 10mm.

[0013] The construction method of the environmentally friendly lightweight high-strength steel truss floor deck comprises the environmentally friendly lightweight high-strength steel truss floor deck as described above, and the steps are as follows:

[0014] The first step is on-site acceptance and positioning and setting out. The appearance quality, dimensional deviation and material certification documents of the steel truss floor decking are checked. The layout and positioning are carried out according to the design drawings. The edge line of the non-removal bottom formwork, the installation axis of the steel truss and the end anchor position line are accurately marked on the steel beam to mark the truss installation axis.

[0015] The second step is to set up scaffolding and support. Set up scaffolding and temporary support according to the construction plan.

[0016] The third step is to lay the bottom formwork. The non-removable bottom formwork is laid on the steel structure beam. The bottom formwork joints are fixed to the steel beam by welding or bolts to ensure that the joints are tight and there is no risk of leakage.

[0017] The fourth step is to install the side formwork. According to the shape and size of the floor slab edge, install the appropriate side formwork. The side formwork should be firmly fixed to prevent leakage when pouring concrete.

[0018] Step 5: Lay the first layer of alkali-resistant glass fiber mesh cloth on the non-removable bottom formwork, that is, on the concrete contact side. The overlap width of adjacent mesh cloths should be ≥100-150mm. Use special adhesive or U-shaped nails to fix the overlap on the bottom formwork, covering the entire range of the bottom formwork and extending to the inside of the side formwork.

[0019] The sixth step is concrete pouring. Evenly pour high-strength fiber concrete slurry on the mesh. During the pouring process, the concrete should be vibrated with a vibrator and leveled with a scraper to ensure density and flatness, providing a good foundation for subsequent truss placement.

[0020] The seventh step is to hoist and install the floor deck. Use special hoisting equipment to hoist the steel truss floor deck onto the wet concrete slurry according to the design drawings and the layout position. Make sure that the straight part of the truss web reinforcement is downward, that is, toward the bottom formwork, and the bent part of the web reinforcement and the upper chord reinforcement are upward. Use the inverted V-shaped structure of the bent part of the web reinforcement to engage with the concrete and ensure that it is completely embedded in the bottom concrete slurry and well bonded with the first layer of alkali-resistant glass fiber mesh. During the hoisting process, the panels should be hoisted in the order of numbering to ensure that each panel can be accurately installed.

[0021] Step 8: Lay the second layer of mesh cloth. Cover the top of the installed and positioned steel trusses with the second layer of mesh cloth, and lay it staggered with the bottom layer of mesh cloth. Lay it flat and tighten it to eliminate wrinkles. The overlap area covers the upper chord steel bars and the bent part of the web bars of the truss. The overlap width of adjacent mesh cloths should also be ≥100-150mm to avoid concrete shrinkage and cracking.

[0022] The ninth step is to pour the surface concrete. On the second layer of mesh cloth, pour the surface concrete of the designed strength. Use a vibrator to vibrate carefully and use a scraper, trowel, etc. to level, compact, and finish the surface to control the flatness.

[0023] The tenth step is concrete curing. Curing is to cure the poured concrete according to the curing plan, keeping the concrete surface moist to prevent early cracking. It is forbidden to walk on it or apply loads before the concrete reaches the specified strength.

[0024] The eleventh step is support removal. Only after the concrete strength reaches the design requirements can the temporary supports and scaffolding be removed in an orderly manner.

[0025] Furthermore, the distance between the lower surface of the lower chord steel bar and the upper surface of the non-removal bottom formwork should be greater than or equal to 5 mm.

[0026] Furthermore, the non-disassembly bottom mold is made of magnesium oxysulfide material, the thickness of the non-disassembly bottom mold is 20 mm and its width should be controlled within 600 mm-1200 mm.

[0027] Beneficial effects of the present invention:

[0028] This environmentally friendly, lightweight, high-strength steel truss floor deck and its construction method use upper chord steel bars, first and second double web bars, and lower chord steel bars to form an inverted T-shaped single truss, eliminating traditional bottom formwork steel bars and stabilizing bars, simplifying the load transfer path. The web bars are formed into one piece through continuous bending, reducing welding nodes. Adjacent trusses are welded at the inflection points of the straight parts of the web bars to form a diamond grid, realizing a self-stabilizing system and avoiding redundant steel bars. Compared with traditional trusses, the weight is reduced by more than 30%, significantly reducing material costs and transportation energy consumption. In addition, during construction, a double-layer alkali-resistant glass fiber mesh cloth is used to replace part of the load-bearing steel. Rebars suppress concrete shrinkage cracks while reducing steel consumption. The trusses are pre-welded and formed, and then hoisted and embedded on site, which greatly improves the construction speed and effectively shortens the construction period. There is no template removal process during the construction process, which reduces noise and dust pollution and meets the green building standards. This technology is centered on "simplified structure - green materials - efficient process", and overcomes the pain points of traditional steel trusses such as heavy weight, complex nodes and high pollution, achieving the unity of lightweight, high strength and fast construction. It is suitable for scenarios such as prefabricated buildings and large-span floor slabs, and has significant economic and social benefits. BRIEF DESCRIPTION OF THE DRAWINGS

[0029] Figure 1 This is a schematic diagram of the first three-dimensional structure of the entire steel truss floor deck of the present invention;

[0030] Figure 2 A second three-dimensional structural diagram of the entire steel truss floor deck of the present invention;

[0031] Figure 3 This is a schematic diagram of a first three-dimensional structure of a single set of steel bar trusses according to the present invention;

[0032] Figure 4 This is a schematic diagram of a second three-dimensional structure of a single set of steel bar trusses according to the present invention;

[0033] Figure 5 This is a schematic diagram of the split structure of a single set of steel bar trusses of the present invention;

[0034] Figure 6 It is a schematic diagram of the three-dimensional structure of the first web member reinforcement of the present invention.

[0035] Explanation of the accompanying reference numerals: 1. upper chord reinforcement; 2. first web reinforcement; 3. second web reinforcement; 4. lower chord reinforcement; 201. straight portion of the web reinforcement; 202. bent portion of the web reinforcement. DETAILED DESCRIPTION

[0036] The present invention will be further described below with reference to the accompanying drawings and examples.

[0037] See also Figures 1-6The present invention provides an embodiment: it includes an upper chord steel bar 1, a first web steel bar 2, a second web steel bar 3 and a lower chord steel bar 4, the first web steel bar 2 is welded to the left side of the upper chord steel bar 1, and the second web steel bar 3 arranged in a one-to-one correspondence with the first web steel bar 2 is welded to the right side of the upper chord steel bar 1, the first web steel bar 2 includes a web steel bar straight portion 201, the upper end of the web steel bar straight portion 201 is fixedly connected to the web steel bar bent portion 202, and the lower chord steel bar 4 is welded between the first web steel bar 2 and the second web steel bar 3 and close to one end of the web steel bar straight portion 201.

[0038] See also Figure 2-Figure 4 In this embodiment, the first web steel bar 2, the second web steel bar 3 and the bottom chord steel bar 4 are connected by resistance spot welding to form a single steel bar truss, and the cross section of the single steel bar truss is an inverted T-shaped structure.

[0039] See also Figure 1-Figure 4 The first web reinforcement 2 and the second web reinforcement 3 are both continuously bent reinforcements and are arranged at equal intervals along the extension direction of the upper chord reinforcement 1. The first web reinforcement 2 and the second web reinforcement 3 have the same structure.

[0040] See also Figure 3-Figure 6 The straight portion 201 of the web reinforcement and the bent portion 202 of the web reinforcement are an integrally formed structure. The vertical height from the lower edge of the straight portion 201 of the web reinforcement to the upper edge of the bent portion 202 of the web reinforcement is 110 mm. The horizontal spacing between the two end points of the straight portion 201 of the web reinforcement parallel to the upper chord reinforcement 1 is 200 mm. The two adjacent groups of steel trusses are connected through the inflection point of the straight portion 201 of the web reinforcement away from the lower chord reinforcement 4, and the adjacent straight portions 201 of the web reinforcement are welded in pairs to form a diamond steel grid. The bent portion 202 of the web reinforcement is an inverted V-shaped structure and the center spacing between every two adjacent top nodes should be less than or equal to 200 mm.

[0041] See also Figure 2-Figure 4 In this embodiment, the upper chord steel bar 1 and the lower chord steel bar 4 are both continuous straight steel bars and are parallel to each other. The distance between the upper surface of the upper chord steel bar 1 and the lower surface of the lower chord steel bar 4 should be controlled within the range of 60mm-170mm, and preferably with a module of 10mm.

[0042] The construction method of the environmentally friendly lightweight high-strength steel truss floor deck comprises the environmentally friendly lightweight high-strength steel truss floor deck as described above, and the steps are as follows:

[0043] The first step is on-site acceptance and positioning and setting out. The appearance quality, dimensional deviation and material certification documents of the steel truss floor decking are checked. The layout and positioning are carried out according to the design drawings. The edge line of the non-removal bottom formwork, the installation axis of the steel truss and the end anchor position line are accurately marked on the steel beam to mark the truss installation axis.

[0044] The second step is to set up scaffolding and support. Set up scaffolding and temporary support according to the construction plan.

[0045] The third step is to lay the bottom formwork. The non-removable bottom formwork is laid on the steel structure beam. The bottom formwork joints are fixed to the steel beam by welding or bolts to ensure that the joints are tight and there is no risk of leakage.

[0046] The fourth step is to install the side formwork. According to the shape and size of the floor slab edge, install the appropriate side formwork. The side formwork should be firmly fixed to prevent leakage when pouring concrete.

[0047] Step 5: Lay the first layer of alkali-resistant glass fiber mesh cloth on the non-removable bottom formwork, that is, on the concrete contact side. The overlap width of adjacent mesh cloths should be ≥100-150mm. Use special adhesive or U-shaped nails to fix the overlap on the bottom formwork, covering the entire range of the bottom formwork and extending to the inside of the side formwork.

[0048] The sixth step is concrete pouring. Evenly pour high-strength fiber concrete slurry on the mesh. During the pouring process, the concrete should be vibrated with a vibrator and leveled with a scraper to ensure density and flatness, providing a good foundation for subsequent truss placement.

[0049] Step 7: Hoisting and installation of floor decking. Use dedicated hoisting equipment to hoist the steel truss floor decking onto the wet concrete slurry according to the design drawings and the layout position. Ensure that the straight part 201 of the truss web reinforcement is downward, that is, facing the bottom formwork, and the bent part 202 of the web reinforcement and the upper chord reinforcement 1 are upward. Use the inverted V-shaped structure of the bent part 202 of the web reinforcement to engage with the concrete and position it. Ensure that it is completely embedded in the bottom concrete slurry and well bonded with the first layer of alkali-resistant glass fiber mesh. During the hoisting process, it should be hoisted in the order of numbering to ensure that each board can be accurately installed in place.

[0050] Step 8: Lay the second layer of mesh cloth. Cover the top of the installed and positioned steel truss with the second layer of mesh cloth, and lay it staggered with the bottom layer of mesh cloth. Lay it flat and tighten it to eliminate wrinkles. The overlap area covers the truss upper chord steel bar 1 and the web steel bar bent portion 202. The overlap width of adjacent mesh cloths is also ≥100-150mm to prevent concrete shrinkage and cracking.

[0051] The ninth step is to pour the surface concrete. On the second layer of mesh cloth, pour the surface concrete of the designed strength. Use a vibrator to vibrate carefully and use a scraper, trowel, etc. to level, compact, and finish the surface to control the flatness.

[0052] The tenth step is concrete curing. Curing is to cure the poured concrete according to the curing plan, keeping the concrete surface moist to prevent early cracking. It is forbidden to walk on it or apply loads before the concrete reaches the specified strength.

[0053] The tenth step is to remove the supports. Only after the concrete strength reaches the design requirements can the temporary supports and scaffolding be removed in an orderly manner.

[0054] The distance between the lower surface of the lower chord steel bar 4 and the upper surface of the non-removal bottom formwork should be greater than or equal to 5 mm.

[0055] The non-disassembly bottom formwork is made of magnesium oxysulfide material. The thickness of the non-disassembly bottom formwork is 20mm and its width should be controlled within 600mm-1200mm.

[0056] The embodiments of the present invention are described in detail above with reference to the accompanying drawings. However, the present invention is not limited to the above embodiments. Various changes can be made within the scope of knowledge of those skilled in the art without departing from the spirit of the present invention.

Claims

1. An environmentally friendly, lightweight, high-strength steel truss floor deck, comprising an upper chord steel bar (1); characterized in that: The invention also includes a first web steel bar (2), a second web steel bar (3) and a lower chord steel bar (4); the first web steel bar (2) is welded to the left side of the upper chord steel bar (1); the second web steel bar (3) is welded to the right side of the upper chord steel bar (1) and is arranged in a one-to-one correspondence with the first web steel bar (2); the first web steel bar (2) includes a web steel bar straight portion (201); the upper end of the web steel bar straight portion (201) is fixedly connected to the web steel bar bent portion (202); the lower chord steel bar (4) is welded between the first web steel bar (2) and the second web steel bar (3) and close to one end of the web steel bar straight portion (201).

2. The environmentally friendly, lightweight, high-strength steel truss floor deck according to claim 1 is characterized by: The upper chord steel bars (1), the first web member steel bars (2), the second web member steel bars (3) and the lower chord steel bars (4) are connected by resistance spot welding to form a single set of steel bar trusses, and the cross section of the single set of steel bar trusses is an inverted T-shaped structure.

3. The environmentally friendly, lightweight, high-strength steel truss floor deck according to claim 2 is characterized by: The first web reinforcement (2) and the second web reinforcement (3) are both continuously bent reinforcements and are arranged at equal intervals along the extension direction of the upper chord reinforcement (1). The first web reinforcement (2) and the second web reinforcement (3) have the same structure.

4. The environmentally friendly, lightweight, high-strength steel truss floor deck according to claim 1 is characterized by: The web member steel bar straight portion (201) and the web member steel bar bent portion (202) are an integrally formed structure; the vertical height from the lower edge of the web member steel bar straight portion (201) to the upper edge of the web member steel bar bent portion (202) is 110 mm; and the horizontal spacing between the two end points of the web member steel bar straight portion (201) parallel to the upper chord steel bar (1) is 200 mm.

5. The environmentally friendly, lightweight, high-strength steel truss floor deck according to claim 1 is characterized by: Two adjacent groups of steel bar trusses are connected via the inflection points of the web bar straight portions (201) away from the lower chord steel bars (4), and the adjacent web bar straight portions (201) are welded in pairs to form a diamond-shaped steel bar grid.

6. The environmentally friendly, lightweight, high-strength steel truss floor deck according to claim 4, characterized in that: The web reinforcement bending portion (202) is an inverted V-shaped structure and the center distance between every two adjacent top nodes should be less than or equal to 200 mm.

7. The environmentally friendly, lightweight, high-strength steel truss floor deck according to claim 2 is characterized by: The upper chord steel bars (1) and the lower chord steel bars (4) are both continuous straight steel bars and are parallel to each other. The distance between the upper surface of the upper chord steel bars (1) and the lower surface of the lower chord steel bars (4) should be controlled within the range of 60 mm to 170 mm, and preferably with a module of 10 mm.

8. The construction method of environmentally friendly lightweight high-strength steel truss floor deck is characterized by: The method comprises the following steps: The first step is on-site acceptance and positioning and setting out. The appearance quality, dimensional deviation and material certification documents of the steel truss floor decking are checked. The layout and positioning are carried out according to the design drawings. The edge line of the non-removal bottom formwork, the installation axis of the steel truss and the end anchor position line are accurately marked on the steel beam to mark the truss installation axis. The second step is to set up scaffolding and support, and set up scaffolding and temporary support according to the construction plan; The third step is to lay the bottom formwork. The non-removable bottom formwork is laid on the steel structure beam. The bottom formwork joints are fixed to the steel beam by welding or bolts to ensure that the joints are tight and there is no risk of leakage. The fourth step is to install the side formwork. According to the shape and size of the floor slab edge, install the appropriate side formwork. The side formwork should be firmly fixed to prevent leakage when pouring concrete. Step 5: Lay the first layer of alkali-resistant glass fiber mesh cloth on the non-removable bottom formwork, that is, on the concrete contact side. The overlap width of adjacent mesh cloths should be ≥100-150mm. Use special adhesive or U-shaped nails to fix the overlap on the bottom formwork, covering the entire range of the bottom formwork and extending to the inside of the side formwork. The sixth step is concrete pouring. Evenly pour high-strength fiber concrete slurry on the mesh. During the pouring process, the concrete should be vibrated with a vibrator and leveled with a scraper to ensure density and flatness, providing a good foundation for subsequent truss placement. The seventh step is to hoist and install the floor deck. According to the design drawings and the layout position, the steel truss floor deck is hoisted onto the wet concrete slurry using a dedicated hoisting device. Ensure that the straight portion (201) of the truss web reinforcement is downward, i.e., toward the bottom formwork, and the bent portion (202) of the web reinforcement and the upper chord reinforcement (1) are upward. The inverted V-shaped structure of the bent portion (202) of the web reinforcement is engaged with the concrete to ensure that it is completely embedded in the bottom concrete slurry and well bonded with the first layer of alkali-resistant glass fiber mesh cloth. During the hoisting process, the hoisting should be carried out in the order of numbering to ensure that each plate can be accurately installed in place. Step 8: Lay the second layer of mesh cloth. Cover the top of the installed and positioned steel truss with the second layer of mesh cloth and lay it staggered with the bottom layer of mesh cloth. Lay it flat and tighten it to eliminate wrinkles. The overlap area covers the upper chord steel bars (1) of the truss and the bent part of the web steel bars (202). The overlap width of adjacent mesh cloths is also ≥100-150mm to avoid concrete shrinkage and cracking. The ninth step is to pour the surface concrete. On the second layer of mesh cloth, pour the surface concrete of the designed strength. Use a vibrator to vibrate carefully and use a scraper, trowel, etc. to level, compact, and finish the surface to control the flatness. The tenth step is concrete curing. Curing is to cure the poured concrete according to the curing plan, keeping the concrete surface moist to prevent early cracking. It is forbidden to walk on it or apply loads before the concrete reaches the specified strength. The eleventh step is support removal. Only after the concrete strength reaches the design requirements can the temporary supports and scaffolding be removed in an orderly manner.

9. The construction method of the environmentally friendly lightweight high-strength steel bar truss floor deck according to claim 8, characterized in that: The distance between the lower surface of the lower chord steel bar (4) and the upper surface of the non-removal bottom formwork should be greater than or equal to 5 mm.

10. The construction method of the environmentally friendly lightweight high-strength steel bar truss floor deck according to claim 8, characterized in that: The non-disassembly bottom formwork is made of magnesium oxysulfide material. The thickness of the non-disassembly bottom formwork is 20mm and its width should be controlled within 600mm-1200mm.

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