Concrete structure modular integrated building and production method

Abstract

The invention relates to a concrete structure modular integrated building and a production method, and belongs to the technical field of integrated building production. Comprising the following steps: designing and manufacturing a mold of the concrete modular integrated building; splicing an inner container mold of the concrete modular integrated building; prefabricated parts of the concrete modular integrated building are hoisted, and the concrete modular integrated building is subjected to form removal, hoisting and transferring; repairing the overall appearance of the concrete modular integrated building; and storing the concrete modular integrated building. The concrete modular integrated building has the beneficial effects that the building is split into a plurality of independent modules through standardized design, the modules are generally in a pentahedron or hexahedron structure form, the integrality is high, equipment pipelines and decoration can be integrated, complete factory production is achieved, and the building construction quality is improved. The assembly line production of the integrated module in a factory is not influenced by weather, the efficiency is also improved, and the comprehensive economic benefit can be remarkably improved especially for a large number of module projects.

Description

Technical Field

[0001] The invention relates to a modular integrated building with a concrete structure and a production method thereof, belonging to the technical field of integrated building production. Background Art

[0002] Modular integrated construction, as a method of prefabricated building construction, is centered around standardized prefabricated spatial modules. These prefabricated components, each consisting of a single room, are factory-fabricated to create a complete, integrated building (including finishes, mechanical and electrical components, fixtures, and interior amenities). These modules are then transported to the construction site and assembled into the building. Therefore, the majority of the building construction processes are already completed before the modules arrive on-site. Modular integrated construction significantly reduces on-site labor, streamlines on-site construction steps, and shortens construction time. Furthermore, it improves the working environment and site safety, enhances building quality, facilitates production and project schedule management, and reduces waste and pollution, making it more environmentally friendly. This aligns with the future development direction of my country's construction industry and holds promising prospects. Throughout its entire lifecycle, from design and production to construction and post-demolition recycling, modular integrated construction demonstrates advantages such as high efficiency, high digitalization, high quality, green and low-carbon development, and material and labor savings. It is a key tool for promoting the industrialization of new building systems, the low-carbon transformation and upgrading of the construction industry, and achieving high-quality development.

[0003] There is an urgent need for a modular integrated concrete structure building and a production method to solve the production problem of modular integrated concrete structure buildings. Summary of the Invention

[0004] In view of the above deficiencies in the existing technology, the technical problem to be solved by the present invention is: how to solve the problem of producing modular integrated buildings with concrete structures, adopt a pentahedron / hexahedron structure, simplify the installation and construction operation process, and be more conducive to strictly controlling the construction quality, and effectively controlling the installation control accuracy and construction progress of the modular box. To this end, a modular integrated building with concrete structures and a production method are provided.

[0005] The method for producing modular integrated concrete structures of the present invention is characterized by comprising the following steps: A1, Mould design and production of concrete modular integrated building; A2, assembly of liner molds for concrete modular integrated buildings; A3, hoisting of prefabricated components of concrete modular integrated buildings; A4, reinforcement binding and installation of cast-in-place parts of concrete modular integrated buildings; A5, mechanical, electrical, HVAC and other installations of cast-in-place parts of concrete modular integrated buildings; A6, concealed acceptance inspection of concrete modular integrated building mold installation, steel bar binding, electromechanical installation, etc.; A7, external mold closing of concrete modular integrated building; A8, concealed acceptance inspection before concrete placement of concrete modular integrated buildings; A9, concrete pouring for modular concrete integrated buildings; A10, finishing, roughening and maintenance of concrete modular integrated buildings; A11, demoulding, lifting and transportation of concrete modular integrated buildings; A12, overall exterior repair of concrete modular integrated buildings; A13, storage of concrete modular integrated buildings.

[0006] Solve the production problems of modular integrated buildings with concrete structures. The pentahedron / hexahedron structure is adopted to simplify the installation and construction operation process, which is more conducive to strictly controlling the construction quality and effectively controlling the installation accuracy and construction progress of the modular box.

[0007] The present invention is suitable for civil construction projects such as public buildings or residences that need to be built quickly and have high requirements for functional use, as well as renovation projects of old urban residential areas. It is particularly suitable for the production and construction of modular integrated concrete structures for large low-rise, multi-story, and high-rise building projects with tight construction schedules, standardized designs, standardized apartment types, and a large number of units.

[0008] Preferably, the production process of the concrete modular integrated building prefabricated components includes: S1, Design and production of prefabricated component molds in concrete modular integrated buildings; S2, reinforcement binding and installation of prefabricated components in concrete modular integrated buildings; S3, installation of prefabricated component mold embedded parts in concrete modular integrated buildings; S4, installation of prefabricated mechanical, electrical, HVAC and other embedded parts in concrete modular integrated buildings; S5, prefabricated components adjusting iron, tying and lifting parts in concrete modular integrated buildings; S6, concealed inspection of prefabricated components, steel bars, mold embedded parts, electromechanical embedded parts, HVAC embedded parts, etc. in concrete modular integrated buildings; S7, concrete pouring of precast components in concrete modular integrated buildings; S8, finishing, roughening and curing of prefabricated components in concrete modular integrated buildings; S9, demoulding and lifting of prefabricated components in concrete modular integrated buildings; S10, overall appearance repair of prefabricated components in concrete modular integrated buildings; S10, Storage and standby of prefabricated components in concrete modular integrated buildings.

[0009] The present invention also discloses a modular integrated building with a concrete structure, which is characterized in that it is produced by utilizing the above-mentioned production method for the modular integrated building with a concrete structure.

[0010] The concrete structure modular integrated building is characterized by being a frame or frame shear wall system, having a pentahedron or hexahedron structure, including a retaining wall, a top plate, a beam form and a bottom plate. After the retaining wall is connected to the modular partition wall, the cross-section of the wall is "L" or "T".

[0011] Preferably, the retaining wall comprises a reinforced cage composite shear wall and a cast-in-situ shear wall assembled and connected to the reinforced cage composite shear wall, and the modular partition wall is vertically assembled and connected to the reinforced cage composite shear wall, and the three are combined to form a T".

[0012] Preferably, the retaining wall comprises a steel cage composite shear wall, the cross section of which is an "L" shape, and the modular partition wall is vertically assembled and connected to either side of the steel cage composite shear wall, and the two are combined to form a "T" shape, and embedded parts are connected between the steel cage composite shear wall and the modular partition wall.

[0013] Preferably, the retaining wall includes a steel cage composite shear wall and a cast-in-place shear wall vertically assembled and connected to the steel cage composite shear wall. The cast-in-place shear wall is assembled and connected to the modular partition wall, and the three are combined into a "T" shape. Embedded parts are connected between the steel cage composite shear wall and the modular partition wall.

[0014] Preferably, the retaining wall comprises a steel cage composite shear wall, and the steel cage composite shear wall is assembled and connected to the modular partition wall.

[0015] Preferably, the cast-in-place cavity of the beam formwork is filled with concrete to form a cast-in-place beam, the beam formwork is respectively assembled and connected to the top plate and the module partition wall, the steel cage composite shear wall is assembled and connected to the top plate, and the top plate includes the module top composite plate and the cast-in-place floor slab.

[0016] Compared with the prior art, the present invention has the following beneficial effects: The modular, integrated concrete building and production method described in this invention utilizes standardized design to separate the building into several independent modules. These modules typically have pentahedral or hexahedral structures, resulting in high integrity and the integration of equipment, pipelines, and finishes. This allows for fully factory-based production, significantly improving the quality of construction. The integrated modules are manufactured on factory lines, unaffected by weather, and offer improved efficiency. This is particularly true for projects with large numbers of modules, where large-scale production can significantly enhance overall economic returns.

[0017] The concrete structure modular integrated building and production method described in the present invention adopts the concept of "install first and then embed" in the concrete modular integrated building technology, which transfers the labor-intensive processes and most of the decoration projects in traditional buildings to the factory. Through standardized design, factory production, and assembly construction, it reduces on-site construction processes, saves on-site construction manpower, shortens the on-site operation period and the overall construction period, thereby improving construction efficiency and resource utilization, enhancing building quality and construction safety, and promoting sustainable development.

[0018] The concrete structure modular integrated building and production method described in the present invention, compared with traditional construction and installation processes, moves the production method to the factory, meets environmental protection and energy-saving requirements, reduces noise pollution and the generation of construction waste, and provides a good living environment for residents near the project.

[0019] The modular, integrated concrete building and production method described in this invention can be designed and constructed as permanent structures, while also better meeting the requirements of temporary structures and aligning with the concept of green, energy-efficient architecture. Compared to traditional architecture, modular, integrated buildings not only promote ecological and environmental protection but also help cities accelerate the development of industrialized products and production methods, improving the level of green urban development. They are more in line with the national concept of intelligent, digital, industrialized, and information-based building development, bringing greater social benefits. BRIEF DESCRIPTION OF THE DRAWINGS

[0020] To more clearly illustrate the specific embodiments of the present invention or the technical solutions in the prior art, the following briefly describes the drawings required for the specific embodiments or the description of the prior art. Similar elements or parts are generally identified by similar reference numerals throughout the drawings. Elements or parts in the drawings are not necessarily drawn to scale.

[0021] Figure 1 To provide modular integrated building production process for concrete structures; Figure 2 Connection node between reinforced cage composite shear wall and cast-in-place shear wall Figure 1 ; Figure 3 Connection node between reinforced cage composite shear wall and cast-in-place shear wall Figure 2 ; Figure 4 Connection node between reinforced cage composite shear wall and cast-in-place shear wall Figure 3 ; Figure 5 Connection node between reinforced cage composite shear wall and cast-in-place shear wall Figure 4 ; Figure 6 This is the blind hole connection method diagram at the bottom of the prefabricated wall panel;

[0022] Figure 7 This is the structural diagram of the embedded parts; Figure 8 This is the node diagram of the beam-slab connection at the top of the spliced ​​module; Figure 9 The connection node diagram of the top wall panel of the spliced ​​module; Figure 10 This is the connection node diagram between beam formwork, wall and top plate; Figure 11 This is the connection node diagram between the shear wall blade and the top plate; Figure 12 Connection node between modular shear wall and beam formwork Figure 1 ; Figure 13 Connection node between modular shear wall and beam formwork Figure 2 ; Figure 14 This is the connection node diagram of the edge support of the composite plate; Figure 15 This is the connection node diagram of the middle support of the composite slab; Figure 16 This is the connection node diagram between the bottom plate and the partition wall at the bathroom drop-down area; Figure 17 Connection joint between modular shear wall and partition wall Figure 1 ; Figure 18 Connection nodes between modular shear walls and partition walls Figure 2 ; Figure 19 Connection nodes between modular shear walls and partition walls Figure 3 ; Figure 20 Connection nodes between modular shear walls and partition walls Figure 4 ; Figure 21 Modular integrated building structure for concrete structures Figure 1 ; Figure 22 Modular integrated building structure for concrete structures Figure 2 ; Figure 23 for Figure 22 Internal diagram.

[0023] In the figure: 1. Reinforcement cage composite shear wall 2. Cast-in-place shear wall 3. Modular partition wall 4. Beam formwork 4.1. Cast-in-place beam 5. Top plate 5.1. Modular top composite plate 5.2. Cast-in-place floor slab 6. Embedded parts. DETAILED DESCRIPTION

[0024] The present invention will be further described below with reference to the accompanying drawings: The present invention will be further illustrated below through specific embodiments, but the present invention is not limited thereto. Any modifications, equivalent substitutions, improvements, etc. made within the spirit and principles of the present invention should be included in the scope of protection of the present invention.

[0025] Example 1, as Figure 1 As shown, the method for producing a modular integrated building with a concrete structure comprises the following steps: A1, Mould design and production of concrete modular integrated building; A2, assembly of liner molds for concrete modular integrated buildings; A3, hoisting of prefabricated components of concrete modular integrated buildings; A4, reinforcement binding and installation of cast-in-place parts of concrete modular integrated buildings; A5, mechanical, electrical, HVAC and other installations of cast-in-place parts of concrete modular integrated buildings; A6, concealed acceptance inspection of concrete modular integrated building mold installation, steel bar binding, electromechanical installation, etc.; A7, external mold closing of concrete modular integrated building; A8, concealed acceptance inspection before concrete placement of concrete modular integrated buildings; A9, concrete pouring for modular concrete integrated buildings; A10, finishing, roughening and maintenance of concrete modular integrated buildings; A11, demoulding, lifting and transportation of concrete modular integrated buildings; A12, overall exterior repair of concrete modular integrated buildings; A13, storage of concrete modular integrated buildings.

[0026] Solve the production problems of modular integrated buildings with concrete structures. The pentahedron / hexahedron structure is adopted to simplify the installation and construction operation process, which is more conducive to strictly controlling the construction quality and effectively controlling the installation accuracy and construction progress of the modular box.

[0027] The present invention is suitable for civil construction projects such as public buildings or residences that need to be built quickly and have high requirements for functional use, as well as renovation projects of old urban residential areas. It is particularly suitable for the production and construction of modular integrated concrete structures for large low-rise, multi-story, and high-rise building projects with tight construction schedules, standardized designs, standardized apartment types, and a large number of units.

[0028] Furthermore, the production process of concrete modular integrated building prefabricated components includes: S1, Design and production of prefabricated component molds in concrete modular integrated buildings; S2, reinforcement binding and installation of prefabricated components in concrete modular integrated buildings; S3, installation of prefabricated component mold embedded parts in concrete modular integrated buildings; S4, installation of prefabricated mechanical, electrical, HVAC and other embedded parts in concrete modular integrated buildings; S5, prefabricated components adjusting iron, tying and lifting parts in concrete modular integrated buildings; S6, concealed inspection of prefabricated components, steel bars, mold embedded parts, electromechanical embedded parts, HVAC embedded parts, etc. in concrete modular integrated buildings; S7, concrete pouring of precast components in concrete modular integrated buildings; S8, finishing, roughening and curing of prefabricated components in concrete modular integrated buildings; S9, demoulding and lifting of prefabricated components in concrete modular integrated buildings; S10, overall appearance repair of prefabricated components in concrete modular integrated buildings; S10, Storage and standby of prefabricated components in concrete modular integrated buildings.

[0029] Example 2, reference Figure 2-20 The concrete structure modular integrated building is produced using the above-mentioned concrete structure modular integrated building production method.

[0030] Example 3, reference Figure 2-21 The concrete structure modular integrated building includes a frame or frame shear wall system, a pentahedron or hexahedron structure, including a retaining wall, a top plate and a bottom plate. After the retaining wall is connected to the module partition wall 3, the cross-section of the wall is "L" or "T".

[0031] Furthermore, the retaining wall includes a steel cage composite shear wall 1 and a cast-in-situ shear wall 2 assembled and connected to the steel cage composite shear wall 1, and the modular partition wall 3 is vertically assembled and connected to the steel cage composite shear wall 1, and the three are combined into a T".

[0032] Furthermore, the retaining wall includes a steel cage composite shear wall 1, whose cross section is an "L" shape. The modular partition wall 3 is vertically assembled and connected to any side of the steel cage composite shear wall 1, and the two are combined into a "T" shape. Embedded parts 6 are connected between the steel cage composite shear wall 1 and the modular partition wall 3.

[0033] Furthermore, the retaining wall includes a steel cage composite shear wall 1 and a cast-in-place shear wall 2 vertically assembled and connected to the steel cage composite shear wall 1. The cast-in-place shear wall 2 is assembled and connected to the modular partition wall 3. The three are combined into a T-shape. Embedded parts 6 are connected between the steel cage composite shear wall 1 and the modular partition wall 3.

[0034] Furthermore, the enclosure wall comprises a reinforced cage composite shear wall 1, which is assembled and connected to the modular partition wall 3. Furthermore, the cast-in-situ cavity of the beam formwork 4 is filled with concrete to form a cast-in-situ beam 4.1, which is assembled and connected to the top plate 5 and the modular partition wall 3 respectively. The reinforced cage composite shear wall 1 is assembled and connected to the top plate 5, which comprises a modular top composite plate 5.1 and a cast-in-situ floor slab 5.2. Example 4, refer to Figure 22-23 The concrete structure modular integrated building includes concrete steel cage composite shear walls, composite top plates, prefabricated partition walls, prefabricated beam molds for cast-in-place beams, prefabricated column molds for cast-in-place columns and prefabricated toilets.

[0035] The vertical connection of the assembled integral steel cage composite shear wall is achieved by inserting rebar into the cavity and then pouring concrete into the cavity to connect the upper and lower walls into a single unit. This vertical connection method of the steel cage composite shear wall increases the joint surface and provides a reliable connection method.

[0036] The composite top slab is a concrete modular box modular top slab, which is the factory prefabricated composite part of the modular composite floor slab and can also serve as the formwork for the post-cast part of the composite floor slab.

[0037] The partition walls of the concrete module box are reinforced cage composite shear walls or prefabricated lightweight partition panels. The reinforced cage composite shear walls are vertically connected by configuring vertical steel bars; the internal walls of the module use prefabricated lightweight partition panels ALC walls.

[0038] The prefabricated beam formwork for cast-in-place beams adopts 30mm thick C60 concrete and is equipped with beam formwork connecting reinforcement as the structure. When the concrete module box is installed on site, the beam formwork is used permanently as a non-removal template for cast-in-place beams.

[0039] The prefabricated column formwork for cast-in-place columns uses 30mm thick C60 concrete and is equipped with column formwork connecting reinforcement as a structure. When the concrete module box is installed on site, the column formwork is used permanently as a non-removal formwork for the cast-in-place columns.

[0040] The prefabricated toilet part in the concrete module box adopts a hexahedron structure, a 220mm lowering plate, and a folded plate structure. This structure realizes the self-waterproof effect of the prefabricated toilet, avoids water leakage and seepage, and can realize factory-integrated decoration.

[0041] Project statistics show that using modular concrete integrated construction can shorten construction time by over 67% compared to reinforced concrete structures of the same scale. Furthermore, standardized design, factory-based production, and prefabricated construction reduce human resource input, effectively improving factory worker efficiency and significantly reducing on-site processes. The four projects saw a total reduction in construction time of nearly 30,000 people. Furthermore, the quality of the finished products remains stable, avoiding delays and financial losses caused by substandard products.

[0042] Compared with reinforced concrete structures of the same design, each concrete modular integrated building unit saves at least 54m2 of wooden formwork on average. 2 , saving nearly 10m of reinforced concrete 3 Therefore, the total reduction of wooden formwork is nearly 2970m 2 , save about 550m3 of concrete 3 Since there is basically no need to carry out wet work on site, more than 80% of construction waste, noise, wastewater and other pollution can be reduced.

[0043] The basic principles, main features, and advantages of the present invention are shown and described above. Those skilled in the art should understand that the present invention is not limited to the above embodiments. The above embodiments and descriptions are merely illustrative of the principles of the present invention. Various changes and modifications may be made to the present invention without departing from the spirit and scope of the present invention. Such changes and modifications are intended to fall within the scope of the present invention. The scope of protection claimed in the present invention is defined by the appended claims and their equivalents.

[0044] Any matters not described in detail in the present invention are well-known technologies to those skilled in the art.

Claims

1. A method for producing modular integrated concrete structures, characterized in that: The following steps are included: A1, Mould design and production of concrete modular integrated building; A2, assembly of liner molds for concrete modular integrated buildings; A3, hoisting of prefabricated components of concrete modular integrated buildings; A4, reinforcement binding and installation of cast-in-place parts of concrete modular integrated buildings; A5, mechanical, electrical, HVAC and other installations of cast-in-place parts of concrete modular integrated buildings; A6, concealed acceptance inspection of concrete modular integrated building mold installation, steel bar binding, electromechanical installation, etc.; A7, external mold closing of concrete modular integrated building; A8, concealed acceptance inspection before concrete placement of concrete modular integrated buildings; A9, concrete pouring for modular concrete integrated buildings; A10, finishing, roughening and maintenance of concrete modular integrated buildings; A11, demoulding, lifting and transportation of concrete modular integrated buildings; A12, overall exterior repair of concrete modular integrated buildings; A13, storage of concrete modular integrated buildings.

2. The method for producing modular integrated concrete structures according to claim 1, characterized in that: The production process of concrete modular integrated building prefabricated components includes: S1, Design and production of prefabricated component molds in concrete modular integrated buildings; S2, reinforcement binding and installation of prefabricated components in concrete modular integrated buildings; S3, installation of prefabricated component mold embedded parts in concrete modular integrated buildings; S4, installation of prefabricated mechanical, electrical, HVAC and other embedded parts in concrete modular integrated buildings; S5, prefabricated components adjusting iron, tying and lifting parts in concrete modular integrated buildings; S6, concealed inspection of prefabricated components, steel bars, mold embedded parts, electromechanical embedded parts, HVAC embedded parts, etc. in concrete modular integrated buildings; S7, concrete pouring of precast components in concrete modular integrated buildings; S8, finishing, roughening and curing of prefabricated components in concrete modular integrated buildings; S9, demoulding and lifting of prefabricated components in concrete modular integrated buildings; S10, overall appearance repair of prefabricated components in concrete modular integrated buildings; S10, Storage and standby of prefabricated components in concrete modular integrated buildings.

3. A modular integrated building with a concrete structure, characterized in that: The concrete structure modular integrated building is produced using the concrete structure modular integrated building production method according to claim 1 or 2.

4. The modular integrated concrete building according to claim 3, characterized in that: It is a frame or frame shear wall system with a pentahedron or hexahedron structure, including a retaining wall, a top plate, a beam form and a bottom plate. After the retaining wall is connected to the module partition wall, the cross-section of the wall is "L" or "T".

5. The integrated building according to claim 4, characterized in that: The retaining wall includes a reinforced cage composite shear wall and a cast-in-situ shear wall assembled and connected to the reinforced cage composite shear wall. The modular partition wall is vertically assembled and connected to the reinforced cage composite shear wall, and the three are combined to form a "T" shape.

6. The integrated building according to claim 4, characterized in that: The retaining wall includes a steel cage composite shear wall with an L-shaped cross section. The modular partition wall is vertically assembled and connected to either side of the steel cage composite shear wall, and the two are combined to form a T-shape. Embedded parts are connected between the steel cage composite shear wall and the modular partition wall.

7. The integrated building according to claim 4, characterized in that: The retaining wall includes a steel cage composite shear wall and a cast-in-place shear wall vertically assembled and connected to the steel cage composite shear wall. The cast-in-place shear wall is assembled and connected to the modular partition wall. The three are combined to form a "T" shape. Embedded parts are connected between the steel cage composite shear wall and the modular partition wall.

8. The integrated building according to claim 4, characterized in that: The enclosure wall comprises a steel cage composite shear wall, and the steel cage composite shear wall is assembled and connected to the module partition wall.

9. The integrated building according to claim 4, characterized in that: The cast-in-place cavity of the beam formwork is filled with concrete to form a cast-in-place beam. The beam formwork is respectively assembled and connected with the top plate and the module partition wall. The steel cage composite shear wall is assembled and connected with the top plate. The top plate includes the module top composite plate and the cast-in-place floor slab.

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