A super-large-area heavy-load floor non-cutting joint composite construction method

Abstract

The application discloses a kind of super-large area heavy load floor no-cut composite construction method, and it is different to carry out construction in sub-compartment joint, comprising: logistics channel area and door sub-compartment joint are handled using metal armoured joint;Other areas are handled using S-shaped force transmission rod construction joint.This application is different to carry out construction in sub-compartment joint in sub-region, realizes force transmission and deformation coordination, ensures that different sub-regions adjacent floor board whole force transmission error prevention platform, while allowing horizontal expansion and coordinating deformation, reduce crack to ensure that floor long-term stability.Metal armoured joint is connected with concrete by shear-resistant anchoring bolt, and S-shaped force transmission rod construction joint is connected with concrete by force transmission rod, to ensure that device does not displace during concrete pouring;Due to the setting of elastic pad, cement slurry leakage during concrete pouring can be effectively prevented, which affects the performance of the device and the flatness of the floor, and further sealing treatment is not needed, which can effectively save construction period.

Description

Technical Field

[0001] This invention relates to the field of industrial building and large-scale infrastructure construction, and in particular to a seamless composite construction method for ultra-large area heavy-duty flooring. Background Technology

[0002] With the continuous expansion of the scale of logistics warehousing, heavy industrial plants and other projects, the demand for ultra-large area flooring is growing. At the same time, heavy industrial bases involving high-precision production environments, such as semiconductor manufacturing equipment and integrated circuit manufacturing, have also put forward new requirements for the construction of ultra-large area flooring. They not only require one-time pouring, but also impose strict standards on its mechanical properties, crack resistance, wear resistance and other aspects, and require high flatness, light effect and extremely low dust generation.

[0003] Currently, the main technical challenges in constructing ultra-large area floor slabs include the following three aspects:

[0004] (1) High difficulty in forming: The one-time pouring of large-area floor requires strict control of flatness, light effect and construction quality. Traditional concrete materials are inherently brittle and easy to crack, which makes large-area construction difficult and prone to cracks and uneven quality.

[0005] (2) High precision requirements: Semiconductor manufacturing processes have very high requirements for clean environment and precision equipment. They have extremely high standards for the flatness, light sensitivity and dust-free nature of the floor. Any tiny cracks and uneven surfaces may affect the production of products and the normal operation of equipment.

[0006] (3) Crack control is difficult: Cracks have always been a difficult point in the construction of concrete floors. Especially in extreme environments, the expansion of cracks will directly affect the stability and durability of the structure, resulting in high repair and maintenance costs.

[0007] (4) Joint cutting is required: Traditional floor construction requires joint cutting, but joint cutting has problems such as poor integrity, easy cracking, and high maintenance costs.

[0008] Therefore, traditional concrete flooring materials can no longer meet the high-precision and high-performance requirements of high-precision industries for ultra-large area flooring, especially in terms of crack control, flatness, and construction difficulty, which pose huge technical challenges. The process of large-area construction flooring urgently needs to be optimized and innovated. Summary of the Invention

[0009] The technical problem to be solved by the present invention is to address the shortcomings of the prior art by providing a seamless composite construction method for ultra-large area heavy-duty flooring. This seamless composite construction method for ultra-large area heavy-duty flooring involves differentiated construction of the joints between different sections, achieving coordination of force transmission and deformation, ensuring the overall force transmission of adjacent floor slabs in different zones to prevent misalignment, while allowing horizontal expansion and contraction and coordinating deformation, reducing cracks to ensure the long-term stability of the flooring.

[0010] To solve the above-mentioned technical problems, the technical solution adopted by the present invention is as follows:

[0011] A method for seamless composite construction of ultra-large area heavy-duty flooring includes:

[0012] Differentiated construction methods for compartment joints include:

[0013] The logistics channel area and the entrance compartment joints are treated with metal armored joints: the metal armored joint consists of two symmetrically arranged steel plates connected by plastic easy-break bolts; each steel plate is formed by welding an upper load-bearing flat steel bar and a lower floor compartment joint steel plate, with an elastic pad sandwiched between the steel plates; each upper load-bearing flat steel bar is welded with shear anchor bolts at equal intervals, and the shear anchor bolts are inclined downwards at a certain angle; the area of ​​the elastic pad is less than or equal to the area of ​​the steel plate, and the height of the upper load-bearing flat steel bar is 1 / 4 to 1 / 3 of the height of the lower floor compartment joint steel plate; multiple high-strength plate pins are arranged at equal intervals through the lower floor compartment joint steel plate, and one side of the high-strength plate pin has a plastic sleeve pin nested at its end, which is fixed to the side wall of the steel plate on that side.

[0014] Other areas are treated with S-shaped dowel joints: The S-shaped dowel joint consists of two identical S-shaped steel plates connected by plastic easy-break bolts; an elastic pad is sandwiched between the two S-shaped steel plates, the size of which is less than or equal to the size of the S-shaped steel plates; each S-shaped steel plate is welded with a dowel bar at intervals along the concave part, and the dowel bar is inclined downward at a certain angle.

[0015] Furthermore, it also includes foundation load-bearing treatment:

[0016] Grassroots cleanup;

[0017] Layered backfilling: Use 5-40mm continuous graded crushed stone for layered backfilling. The graded crushed stone should have <15% needle-shaped and flaky particles, <20% crushing value, and <5% mud content. The thickness of each layer should be controlled at 200-300mm. Backfilling should start from the lowest point of the site and proceed from one end to the other to ensure uniform backfilling.

[0018] Layered compaction: Each layer of crushed stone is compacted using graded crushed stone compaction equipment;

[0019] Quality inspection: After each layer is compacted, the compaction coefficient is tested using the ring cutter method or sand filling method to ensure that the compaction coefficient reaches 0.94 or above; the acceptance requirement is to send samples for testing every 500m³.

[0020] Furthermore, it also includes column base treatment: a metal frame column sleeve is installed at the column base, the size of the metal frame column sleeve is larger than the size of the column base; during installation, the four corners of the metal frame column sleeve are all formed into an arc shape, and multiple additional rivets are evenly installed on both sides of each side of the metal frame column sleeve. The multiple additional rivets are all installed in the upper middle part of the side of the metal frame column sleeve, and the rivets on both sides of each side are staggered and arranged in a figure-eight shape.

[0021] The four sides of the metal frame column sleeve correspond one-to-one with the four sides of the column base and are installed in parallel, and the distance between each side of the metal frame column sleeve and the corresponding side of the column base is equal.

[0022] Furthermore, before the differentiated construction of the compartment joints, it also includes surveying and setting out, including setting benchmark control points and axis control networks, setting elevation control lines, and setting out the compartments; the compartment setting out uses finite element software to analyze the temperature field and stress field after concrete pouring to determine the compartment size; according to the compartment size and location, in accordance with the requirements of the skip-compartment construction method, the compartment boundary lines are marked on the foundation surface with ink lines.

[0023] Furthermore, after the differentiated construction of the compartment joints, the construction of the isolation joints is also included: determining the area where the floor needs to be isolated from the fixed structure; laying isolation material and sealing it in the area where it needs to be isolated from the fixed structure, with the laying height slightly higher than the floor elevation; the isolation material is a compressible extruded polystyrene board.

[0024] Furthermore, it also includes a composite reinforcement system of steel bar binding and galvanized steel fiber reinforced concrete:

[0025] Reinforcement binding: Bind a single-layer bidirectional steel mesh at the bottom of the foundation. Use a staggered binding method when binding the reinforcement. Use lap splicing or welding for the reinforcement joints, and stagger the joint positions.

[0026] Mix design of galvanized steel fiber waterproof concrete: Based on the usage per cubic meter, the ratio of cement: fine aggregate: coarse aggregate: mixing water: galvanized steel fiber: XYPEX admixture: high-efficiency water-reducing agent = 1:1.95:2.72:0.45:0.064:0.018:0.015.

[0027] Furthermore, the galvanized steel fiber reinforced concrete pouring process involves: using concrete mixer trucks to transport the galvanized steel fiber reinforced concrete, maintaining a uniform rotation speed of the mixing drum during transport; pouring the concrete in the floor compartments in sequence from one end to the other; and using a pumping method to deliver the concrete to the pouring area, controlling the pumping pressure and pouring speed during the pumping process.

[0028] Furthermore, this also includes laser screeding: before large-scale construction, the elevation of the ground is checked again to ensure accuracy before proceeding with large-scale construction; concrete must be laid continuously without cold joints; within the effective range of the laser screed's telescopic arm, manual spreading is carried out first to make the concrete roughly flat, and then the laser screed is used for vibration, compaction, and screeding; the laser screed's screed head is equipped with an integrated device of scraper, vibrator, and screed plate, with a vibration frequency of 4000 times / min, which can complete vibration, slurry lifting, and screeding work in the same period of time, ensuring the density and flatness of the concrete.

[0029] Furthermore, for areas outside the operating range of the laser screed, leveling is carried out manually in conjunction with a level, and a handheld vibrator is used to vibrate the corners to ensure the concrete is dense. During the pouring process, the dispersion of galvanized steel fibers is checked. If clumps of galvanized steel fibers are found, they should be torn apart and scattered or removed in time to avoid affecting the performance of the concrete.

[0030] Furthermore, it also includes smoothing and finishing the surface:

[0031] Timing for finishing: The finishing work should be carried out during the initial to final setting stage of galvanized steel fiber concrete. The timing of finishing should be determined according to the ambient temperature and the setting time of the concrete. Generally, it is advisable to press the concrete surface with a finger so that it leaves a slight mark but does not collapse.

[0032] Smoothing process: First, a ride-on double-disc grinder is used for slurry grinding. The grinder should grind perpendicular to the working path of the laser paver. After the first pass of grinding, the grinder is turned around and the operation is repeated in a straight line, covering 50% of the area of ​​the previous path. Then, the grinder is turned 90° and the operation is repeated, covering 50% of the area of ​​the previous path. Through multiple passes of grinding, the laitance on the concrete surface is fully removed, improving the density and smoothness of the surface. For areas such as corners that cannot be reached by machinery, a manual trowel is used for finishing.

[0033] Quality requirements: After the surface is smoothed and finished, the floor surface should be free of defects, have a uniform color, and the flatness should meet the design requirements.

[0034] The present invention has the following beneficial effects:

[0035] 1. This application employs differentiated construction methods for compartment joints in different zones to achieve coordinated force transmission and deformation. By implementing differentiated construction of compartment joints in different zones, it ensures overall force transmission and prevents misalignment between adjacent floor slabs in different zones, while allowing horizontal expansion and contraction and coordinating deformation, reducing cracks and ensuring long-term floor stability. The metal armored joints are connected to the concrete via shear anchor bolts, and the S-shaped dowel bar construction joints are connected to the concrete via dowel bars to ensure that the device does not shift during concrete pouring. The metal armored joints utilize high-strength plate pins and plastic sleeve pins to enhance the lower load-bearing capacity and ensure pouring quality. After the metal armored joints and S-shaped dowel bar construction joints are installed in different zones, the elastic padding effectively prevents cement slurry leakage during concrete pouring, which could affect the device's performance and the floor's flatness. Furthermore, no further sealing treatment is required, effectively saving construction time.

[0036] 2. The factory area has hidden ditches and ponds, and the foundation has a soft underlying soil layer of about 2m thick. Therefore, in view of this foundation condition, corresponding foundation heavy-load treatment is required. In addition, special treatment is needed for the column bases to avoid the risks to the floor caused by uneven foundation settlement. In order to avoid long-term and large-scale damage to the floor compartment joints caused by vehicles passing through the logistics passage area, the construction method of the compartment joints is differentiated. The compartment joints in the logistics passage area and the entrance are treated with metal armored joints; S-shaped dowel bar construction joints are arranged in other areas.

[0037] 3. Since the invention is applied to ultra-large area flooring, measurement and layout are essential steps. In addition to setting up benchmark control points, axis control networks and elevation control lines, it is also necessary to carry out section layout in order to ensure successful pouring in one go.

[0038] 4. The continuous row of galvanized steel fibers has high tensile strength, greater than 1070 MPa, which increases the concrete's resistance to punching and shearing. The hooks at both ends ensure optimal anchorage between the steel wire and the concrete, effectively transferring and distributing stress, controlling cracks. Furthermore, since the galvanized steel fibers are bonded together in rows using water-soluble adhesive, they dissolve quickly in water, ensuring that the galvanized steel fibers are evenly mixed and dispersed.

[0039] Galvanized steel fibers themselves have excellent corrosion resistance. At the same time, during the hydration process of cement particles, a lot of free calcium hydroxide is formed, making the pH value of concrete ≥12. Under this alkaline pH environment, a fine oxide film is formed on the surface of galvanized steel fibers. This oxide film has a passivating effect and can prevent steel from rusting.

[0040] 5. XYPEX admixture is an additive with unique crystallization properties. When added to cement mortar, it has the effects of preventing seepage, preventing corrosion, improving strength, and self-repairing.

[0041] 6. The steel bars bear the main bending and tensile forces, while the galvanized steel fibers resist cracking, toughen, and resist seepage, forming a "skeleton + network" system. The steel bars and galvanized steel fibers work together to comprehensively enhance the mechanical properties of the floor. Attached Figure Description

[0042] Figure 1 This is a schematic diagram illustrating the steps of a seamless composite construction method for ultra-large area heavy-duty flooring according to the present invention.

[0043] Figure 2 This is a schematic diagram of the column base treatment structure of a non-cutting composite construction method for ultra-large area heavy-duty flooring according to the present invention.

[0044] Figure 3 This is a schematic diagram of the metal armored joint structure of a non-cutting composite construction method for ultra-large area heavy-duty flooring according to the present invention.

[0045] Figure 4 This is a schematic diagram of the isolation joint construction structure of a non-cutting composite construction method for ultra-large area heavy-duty flooring according to the present invention.

[0046] Figure 5 This is a scanning electron microscope (SEM) comparison image (×10000) of concrete without XYPEX admixture treatment and concrete treated with XYPEX admixture in the present invention's method for seamless composite construction of ultra-large area heavy-duty flooring.

[0047] These include: 1. Upper load-bearing flat steel; 2. Shear anchor bolts; 3. Plastic pins; 4. Concrete; 5. High-strength plate pins; 6. Floor compartment joint steel plates; 7. Elastic padding layer. Detailed Implementation

[0048] The present invention will now be described in further detail with reference to the accompanying drawings and specific preferred embodiments.

[0049] In the description of this invention, it should be understood that the terms "left side," "right side," "upper part," "lower part," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. "First," "second," etc., do not indicate the importance of the components, and therefore should not be construed as a limitation of this invention. The specific dimensions used in this embodiment are only for illustrating the technical solution and do not limit the scope of protection of this invention.

[0050] like Figure 1As shown, a method for seamless composite construction of ultra-large area heavy-duty flooring includes the following steps: construction preparation, heavy-duty foundation treatment, column base treatment, surveying and setting out, differentiated construction of compartment joints, construction of isolation joints, reinforcement binding and mix design of galvanized steel fiber impermeable concrete, pouring of galvanized steel fiber impermeable concrete, laser leveling, surface finishing and concrete curing. The following detailed description, in conjunction with embodiments, further illustrates this application:

[0051] This project is based at the Jinni Automation Integrated Circuit Manufacturing High-Precision Control Equipment R&D Base in Wuhu Economic and Technological Development Zone. Covering an area of ​​62,600 square meters and a building area of ​​91,700 square meters, it is a large-scale comprehensive project integrating production, testing, and R&D. A large area of ​​the ground within the base, measuring 17,332 square meters, requires a single pour, demanding high precision, high strength, and crack resistance for this massive surface area.

[0052] S1. Construction Preparation

[0053] S1.1 Technical preparation: Organize technical personnel to study the design drawings, construction specifications and construction methods in depth, and prepare detailed construction plans and technical briefing documents; conduct stress calculations on the floor structure to determine the reinforcement configuration and the amount of galvanized steel fiber.

[0054] S1.2 Material Preparation: Strictly procure graded crushed stone, fine aggregate, reinforcing steel, galvanized steel fiber, cement, water-reducing agent, mixing agent, and other materials according to design requirements; before the crushed stone arrives on site, the mix proportion report must be checked, and acceptance should be carried out promptly after arrival to ensure that the performance of each material meets the established requirements; parameters such as the type, length, diameter, aspect ratio, and tensile strength of galvanized steel fiber must comply with the specifications; the selected reinforcing steel should have a factory certificate of conformity and a mechanical performance test report.

[0055] S1.3 Equipment preparation: Prepare graded crushed stone compaction equipment, steel bar processing equipment, concrete mixing and transportation equipment, laser leveling machine, power trowel, etc. Inspect and test all equipment to ensure their good performance. Table 1 is the main equipment usage table.

[0056] Table 1:

[0057]

[0058] S2, Foundation Heavy Loading Treatment

[0059] The project's foundation conditions are generally poor. The surface layer consists of approximately 3 meters of plain fill, which cannot serve as the bearing layer for the ground. The factory area has hidden ditches and ponds, and the foundation has a weak underlying soil layer of about 2 meters thick. Therefore, considering these foundation conditions and the recommendations in the geological survey report, appropriate foundation load-bearing treatment will be implemented. This foundation load-bearing treatment includes base layer cleaning, layered backfilling, layered compaction, and quality testing.

[0060] S2.1 Base cleaning: Remove unsuitable soil layers such as topsoil, silt, and debris from the ground surface to ensure that the foundation surface is flat and firm.

[0061] S2.2 Layered backfilling: Use 5-40mm continuous graded crushed stone for layered backfilling. The graded crushed stone has <15% needle-like and flaky particles, <20% crushing value, and <5% mud content. The thickness of each layer is controlled at 200-300mm. Backfilling should start from the lowest point of the site and proceed from one end to the other to ensure uniform backfilling.

[0062] In one embodiment, the lowest point of the site is backfilled with a first layer of graded crushed stone, with a particle size of 30-40mm and a thickness of 300mm. A second layer of graded crushed stone, with a particle size of 20-30mm and a thickness of 250mm, is laid on top of the first layer. A third layer of graded crushed stone, with a particle size of 10-20mm and a thickness of 250mm, is laid on top of the second layer. A fourth layer of graded crushed stone, with a particle size of 5-10mm and a thickness of 250mm, is laid on top of the third layer. By backfilling with four layers of 5-40mm continuous graded crushed stone, the foundation is subjected to heavy load treatment, thereby ensuring the effectiveness of the bearing layer.

[0063] S2.3 Layered compaction: Use graded crushed stone compaction equipment to compact each layer of crushed stone. During the compaction process, the driving speed should be controlled to avoid under-compaction or over-compaction.

[0064] S2.4 Quality Inspection: After each layer is compacted, the compaction coefficient shall be tested using the ring cutter method or sand cone method to ensure that the compaction coefficient reaches 0.94 or above. Any unqualified parts shall be promptly compacted or reworked. The acceptance requirement is to send samples for testing every 500m³. In addition to testing the compaction coefficient, the gradation and mud content shall also be tested.

[0065] The heavy-duty foundation treatment process involves backfilling the entire heavy-duty floor foundation with graded crushed stone. The particle size of the crushed stone is strictly controlled between 5-40mm. After the graded crushed stone is backfilled and compacted in layers, the particles are interlocked to form a stable skeleton. It resists deformation by means of interlocking force and internal friction, and has good permeability to drain water and prevent the bearing capacity from decreasing. It provides stable support for the floor and significantly improves the bearing capacity of the foundation.

[0066] S3, column base treatment

[0067] Due to the uneven soil layers in the project's foundation, the presence of hidden ditches and ponds within the factory area, and the existence of weak underlying soil layers, there is a risk of uneven ground settlement. Therefore, special treatment of the column bases is required to mitigate the risks to the floor slab caused by uneven foundation settlement. For example... Figure 2 As shown, the column base treatment includes: installing a metal frame column sleeve at the column base, the size of which is larger than the size of the column base.

[0068] During installation, the four corners of the metal frame column sleeve are all formed into an arc shape. Multiple additional rivets are evenly installed on both sides of each side of the metal frame column sleeve. The multiple additional rivets are installed in the upper middle part of the side of the metal frame column sleeve. The rivets on both sides of each side are installed in an alternating manner, forming a figure-eight shape in pairs.

[0069] The four sides of the metal frame column sleeve correspond one-to-one with the four sides of the column base and are installed in parallel, and the distance between each side of the metal frame column sleeve and the corresponding side of the column base is equal.

[0070] The rounded corners of the metal frame column sleeve allow for a smoother transition during casting. The additional rivets along the edges of the metal frame column sleeve further control cracking in localized areas.

[0071] S4. Measurement and Setting Out

[0072] Because this project involves a very large area of ​​ground, in addition to setting up benchmark control points, axis control networks, and elevation control lines, it is also necessary to carry out section-by-section layout in order to ensure successful pouring in one go.

[0073] S4.1 Setting up benchmark control points and axis control network: Based on the design drawings and coordinate control points of the construction site, use a total station to set up benchmark control points and axis control network for the ground construction.

[0074] Among them, the benchmark control points should be arranged in a location that is not affected by construction and is easy to preserve, and the number should be no less than 3.

[0075] S4.2 Setting of elevation control lines: Set 50mm elevation control lines on fixed structures such as steel columns and walls at the construction site as elevation control benchmarks; use these elevation control lines as the elevation control benchmarks for basic processes such as layered backfilling, rebar tying, and concrete pouring.

[0076] Furthermore, the elevation control line is clearly marked with red paint, and this elevation control line serves as the elevation control benchmark for basic processes such as foundation backfilling, rebar tying, and concrete pouring.

[0077] S4.3, Compartment Layout: Finite element analysis software is used to analyze the temperature and stress fields after concrete pouring to determine the compartment dimensions. Based on the compartment dimensions and locations, and in accordance with the requirements of the skip-compartment construction method, ink lines are used to mark the compartment boundary lines on the foundation surface. The location of the compartment joints should avoid special areas such as equipment foundations and column bases to ensure reasonable compartmentation.

[0078] S5, Differentiated Construction of Compartment Joints

[0079] Based on the layout of the compartments, installation grooves are reserved at the compartment joints. Since the project includes a production workshop with many logistics passage areas, to avoid long-term and extensive damage to the floor compartment joints caused by vehicles passing through the logistics passage areas, differentiated construction methods are adopted for these compartment joints. Metal armored joints are used for the compartment joints in the logistics passage area and at the entrance, while S-shaped dowel bar construction joints are arranged in other areas.

[0080] S5.1 The seams of the logistics channel area and the entrance to the warehouse shall be treated with metal armor seams.

[0081] The metal armor seam in this application comprises two symmetrically arranged steel plates connected by plastic breakable bolts.

[0082] Furthermore, each steel plate is formed by welding an upper force-transmitting flat steel 1 and a lower floor compartment joint steel plate 6, with an elastic pad 7 sandwiched between the steel plates; each upper force-transmitting flat steel is welded with shear anchor bolts 2 at equal intervals, and the shear anchor bolts are inclined downward at a certain angle; the metal armor joint is connected to the concrete 4 through the shear anchor bolts to ensure that the device does not shift during the concrete pouring process, and the elastic pad sandwiched in the middle can provide redundant space for the expansion and contraction of the concrete on both sides.

[0083] Furthermore, the area of ​​the elastic padding layer is less than or equal to the area of ​​the steel plate, and the height of the upper force-transmitting flat steel is 1 / 4 to 1 / 3 of the height of the lower floor compartment joint steel plate.

[0084] Furthermore, multiple high-strength plate pins 5 are evenly spaced through the steel plates of the lower floor compartment joints. One side of the high-strength plate pin has a plastic sleeve pin 3 nested at its end, which is fixed to the side wall of the steel plate on that side. The metal armor joint enhances the load-bearing capacity of the lower part through the high-strength plate pins and plastic sleeve pins, ensuring the quality of the pouring.

[0085] S5.2 Other areas are treated with S-shaped dowel bar construction joints.

[0086] The S-shaped dowel joint in this application comprises two identical S-shaped steel plates connected by plastic breakable bolts.

[0087] Furthermore, an elastic pad is sandwiched between the two S-shaped steel plates, the size of which is less than or equal to the size of the S-shaped steel plates; each S-shaped steel plate is welded with a dowel bar at intervals along the concave section, the dowel bar being inclined downwards at a certain angle. The S-shaped dowel bar construction joint is connected to the concrete through the dowel bar to ensure that the device does not shift during concrete pouring; the elastic pad sandwiched in the middle provides redundant space for the expansion and contraction of the concrete on both sides.

[0088] Based on the location and elevation of the compartment joints, the metal armor joints and S-shaped dowel bar construction joints are installed in the reserved grooves in sections; the positioning of the devices should be accurately measured using a level and a total station to ensure that the elevation error does not exceed ±3mm and the axis deviation does not exceed ±5mm.

[0089] After the metal armor joints and S-shaped dowel bar construction joints are installed in sections, the elastic padding layer can effectively prevent cement slurry leakage during concrete pouring, which would affect the performance of the device and the flatness of the floor. Furthermore, no further sealing treatment is required, which can effectively save construction time.

[0090] This application employs differentiated construction methods for compartment joints in different areas to achieve coordination between force transmission and deformation. By differentiating the construction of compartment joints in different areas, it ensures the overall force transmission and prevents misalignment of adjacent floor slabs in different zones. At the same time, it allows for horizontal expansion and contraction and coordinates deformation, reducing cracks to ensure the long-term stability of the floor.

[0091] S6. Construction of isolation joints

[0092] In order to isolate the floor slab from fixed structures such as walls, and to allow the floor to contract freely in the horizontal direction without being affected by the fixed structures, isolation joints are constructed at the points where the floor slab contacts these fixed structures.

[0093] Furthermore, the construction of the isolation joint includes the following steps:

[0094] Determine the areas where the floor needs to be isolated from fixed structures;

[0095] Apply and seal the isolation material in areas that need to be isolated from fixed structures. The material should be applied slightly above the floor level so that it penetrates the entire thickness of the floor slab to prevent grout from entering the gap between the floor and the adjacent fixed structures.

[0096] Furthermore, the insulating material is preferably a compressible extruded polystyrene board, with a preferred thickness of 10 mm.

[0097] S7. Reinforcement system combining steel reinforcement binding and galvanized steel fiber reinforced concrete.

[0098] S7.1 Reinforcement binding: According to the design drawings, bind the bottom single-layer bidirectional steel mesh on the foundation. When binding the reinforcement, use a quincunx binding method to ensure the integrity and stability of the steel mesh. The reinforcement joints are bound by lap splicing or welding, and the joint positions are staggered to avoid areas with greater stress.

[0099] Preferably, the reinforcing mesh can also be double-layered bidirectional reinforcing bars to enhance the strength of the skeleton.

[0100] S7.2, Mix Design of Galvanized Steel Fiber Optic Impermeable Concrete

[0101] Table 2 shows the mix proportions (per cubic meter) for galvanized steel fiber impermeable concrete.

[0102] Table 2:

[0103]

[0104] Cement: Use ordinary Portland cement of grade 42.5 or above to ensure the strength and stability of the cement.

[0105] Aggregates: including fine aggregates and coarse aggregates.

[0106] The fine aggregate should be clean natural medium sand, with a fineness modulus controlled between 2.3 and 3.0, a mud content not exceeding 3%, and a clay lump content not exceeding 1%.

[0107] The coarse aggregate is made of hard and durable crushed stone with a particle size controlled at 20-25mm. It adopts continuous gradation, with a mud content of no more than 1% and a needle-like or flaky particle content of no more than 15%.

[0108] Galvanized steel fiber: It is made of cut steel wire with a length of 60mm, a diameter of 0.75mm, and an aspect ratio of 80. The galvanized steel fiber is bonded into rows with water-soluble glue to form continuous rows of galvanized steel fiber with hooks at both ends. The content of continuous rows of galvanized steel fiber is 25kg / m³.

[0109] The continuous row of galvanized steel fibers has high tensile strength, greater than 1070 MPa, which increases the concrete's resistance to punching and shearing. The hooks at both ends ensure optimal anchorage between the steel wire and the concrete, effectively transferring and distributing stress, controlling cracks. Furthermore, since the galvanized steel fibers are bonded together in rows using water-soluble adhesive, they dissolve quickly in water, ensuring that the galvanized steel fibers are evenly mixed and dispersed.

[0110] Galvanized steel fibers themselves have excellent corrosion resistance. At the same time, during the hydration process of cement particles, a lot of free calcium hydroxide is formed, making the pH value of concrete ≥12. Under this alkaline pH environment, a fine oxide film is formed on the surface of galvanized steel fibers. This oxide film has a passivating effect and can prevent steel from rusting.

[0111] Mixing water: Use pure water sources such as drinking water. It is strictly forbidden to use untreated industrial wastewater, domestic sewage, or water containing harmful impurities.

[0112] The water-cement ratio should be controlled between 0.45 and 0.50 to ensure that the concrete has enough slurry to cover the galvanized steel fibers.

[0113] High-efficiency water-reducing agent: The high-efficiency water-reducing agent used in steel fiber reinforced concrete is a polycarboxylate-based high-performance water-reducing agent (20% solid content). It has good compatibility with cement and steel fibers. The type and dosage of the agent must be determined through testing. Water-reducing agents that can corrode steel fibers are strictly prohibited. By adding polycarboxylate-based high-performance water-reducing agent, the workability of the concrete is adjusted to ensure that the slump of the concrete meets the pumping requirements. During pumping, the slump is 140-180mm, and during non-pumping (upon arrival at the site), it is 120-140mm.

[0114] Preferably, the high-efficiency water-reducing agent used in steel fiber reinforced concrete can also be a naphthalene-based water-reducing agent.

[0115] XYPEX admixture: XYPEX admixture is an additive with unique crystallization properties. When added to cement mortar during the mixing process, it has the effects of preventing seepage, preventing corrosion, improving strength, and self-repairing.

[0116] Figure 5 This is a scanning electron microscope (SEM) comparison (×10000) of concrete without XYPEX admixture treatment and concrete treated with XYPEX admixture in the present invention's method for seamless composite construction of ultra-large area heavy-duty flooring. (Example: The image shows a 10000×× image of the concrete.) Figure 5 As shown, the left image is a scanning electron microscope (SEM) image of concrete without XYPEX admixture treatment, revealing cubic and rhombic hexahedral cementitious particles and microparticles of calcium hydroxide. The right image is a SEM image of concrete treated with XYPEX admixture. After 28 days, a dense and fully developed crystalline structure has formed in the capillaries of the concrete, thus enabling it to withstand strong water pressure and erosion from various liquids over a long period. Testing showed it has excellent penetration resistance to various liquids, with a permeability coefficient reaching 10⁻¹² cm / s. The performance indicators of the admixture are shown in Table 3.

[0117] Table 3:

[0118]

[0119] Large-area concrete floors are prone to cracking during pouring, curing, and use. This application uses XYPEX admixture and galvanized steel fibers with hooks at both ends to add to cement mortar, which improves the tensile strength, crack resistance, and impermeability of concrete.

[0120] Galvanized steel fibers are evenly dispersed in cement mortar, and their hooked ends form a three-dimensional reinforcement network within the mortar. This effectively prevents crack formation and propagation, reduces cracking caused by temperature changes and shrinkage, and significantly improves the tensile strength and crack resistance of concrete, meeting the requirements for high-strength and high-durability buildings. After mixing with cement mortar and other materials, XYPEX admixture forms dendritic crystals within the mortar through a catalytic process, filling capillary pores and making the mortar denser and more impermeable. This enhances concrete strength and durability, slows down carbonation, and prevents steel corrosion. Furthermore, it has the ability to self-repair cracks in concrete structures upon contact with water. If cracks appear, they can crystallize again and again upon contact with water, sealing the cracks, thus providing permanent impermeability.

[0121] Compared to traditional concrete, galvanized steel fiber impermeable concrete can better control the generation of cracks during large-area pouring, thus improving the overall efficiency and quality of construction.

[0122] In this step, the steel bars bear the main bending and tensile forces, while the galvanized steel fibers resist cracking, toughen, and resist water seepage, forming a "skeleton + network" system. The steel bars and galvanized steel fibers work together to comprehensively enhance the mechanical properties of the floor.

[0123] S7.3, Mixing steel fiber reinforced concrete

[0124] When mixing steel fiber reinforced concrete, first dry mix sand, stone, and cement evenly, then add continuous galvanized steel fibers, water, and XYPEX admixture and mix until the concrete has good workability. The total mixing time should be extended by 30-60 seconds compared to ordinary concrete to ensure that the continuous galvanized steel fibers dissolve quickly in water and are evenly distributed.

[0125] Slump: Depending on the construction process, the slump of steel fiber reinforced concrete should be controlled between 100-150mm, and the slump loss over time should not be too large to ensure smooth on-site pouring.

[0126] Furthermore, the slump is 120-140 mm when not pumped (upon arrival at the site), and 140-180 mm when pumped.

[0127] Air content: To improve the frost resistance and workability of concrete, the air content of steel fiber reinforced concrete should be controlled between 3% and 5%, which can be adjusted by adding an air-entraining agent.

[0128] The compressive strength of steel fiber reinforced concrete after 28 days of standard curing should not be lower than the design strength grade, and the flexural strength should meet the design requirements. Test blocks must be retained as specified for strength testing to ensure that its mechanical properties meet the standards. Simultaneously, measures should be taken to ensure the durability of the concrete, such as controlling alkali-aggregate reaction and providing rust protection for the steel fibers.

[0129] S8, Galvanized Steel Fiber Reinforced Concrete Pouring

[0130] When laying galvanized steel fiber reinforced concrete in this project, direct unloading by tanker trucks should be used. The slump should be set as required and the slump should be maintained continuously. The concrete should be 2-3 cm higher than the ground elevation when unloading to ensure sufficient concrete for the machine to level. Otherwise, manual replenishment is required. The laser leveling and paving direction should always be maintained from left to right.

[0131] S8.1 Preparations before pouring: Conduct concealed works inspections of column bases, reinforcing bars, compartment joints, and isolation joints to ensure they meet design requirements; protect fixed structures such as columns and walls by wrapping them with plastic film at least 1m above the ground and at least 0.15mm thick to prevent concrete contamination and collision damage; check whether the concrete transport route is unobstructed and whether the pouring equipment is operating normally.

[0132] S8.2 Concrete Transportation: Galvanized steel fiber reinforced concrete shall be transported using concrete mixer trucks. During transportation, the mixing drum shall be kept rotating at a constant speed to prevent concrete segregation. The transportation time shall be controlled within the initial setting time of the concrete. When the transportation distance is long, measures shall be taken to maintain the workability of the concrete.

[0133] S8.3 Concrete pouring: Concrete shall be poured in the floor compartments in the order from one end to the other; the concrete shall be transported to the pouring area by pumping. During the pumping process, attention shall be paid to controlling the pumping pressure and pouring speed to avoid segregation and bleeding of the concrete.

[0134] By pouring the concrete in sections and batches, each section can fully release thermal shrinkage stress, reduce the volume of a single section to reduce stress impact, and achieve seamless construction.

[0135] S9, Laser Leveling

[0136] Before large-scale construction, the elevation of the ground should be checked again to ensure it is accurate before proceeding with large-scale construction; concrete must be laid continuously without cold joints.

[0137] S9.1 Before laser leveling: Check the working status of the laser emitter, laser receiver, computer control system and other equipment to ensure that they are operating normally; set the working parameters of the laser leveling machine according to the design elevation and slope of the ground; set the laser emitter according to the given ground elevation and adjust the position of the laser receiver of the laser leveling machine.

[0138] S9.2 Laser leveling operation: Within the effective range of the telescopic arm of the laser leveling machine, manual paving is first carried out to make the concrete roughly flat. Then, the laser leveling machine is used for vibration, compaction and leveling. The leveling head of the laser leveling machine is equipped with an integrated device of scraper, vibrator and leveling plate. The vibration frequency is 4000 times / min, which can complete the vibration, slurry lifting and leveling work in the same period of time to ensure the density and flatness of the concrete.

[0139] After the first layer of laser leveling is completed, the elevation needs to be re-measured using a handheld receiver pole to ensure the accuracy of the elevation position for subsequent leveling. If the measured value differs from the elevation, the laser receiver needs to be fine-tuned.

[0140] Furthermore, the paving width should be controlled at around 5 meters to avoid tires running over the concrete as much as possible; when using laser leveling, the extension and retraction speed of the leveling head should be controlled at a uniform speed. It is recommended that the extension and retraction time of the 6-meter arm be controlled at more than 30 seconds each time to ensure leveling accuracy and to ensure that the vibrator fully vibrates and compacts the concrete.

[0141] Furthermore, to ensure accuracy, the laser leveling machine scrapes twice per pass, and maintains a certain overlap between the front pass and the left side to improve flatness.

[0142] S9.3 For areas outside the operating range of the laser leveling machine, such as column bases and wall corners, leveling should be carried out manually in conjunction with a level. A handheld vibrator should be used to vibrate the edges and corners to ensure the concrete is dense. During the pouring process, a dedicated person should check the air content and dispersion of the galvanized steel fibers. If clumps of galvanized steel fibers are found, they should be torn apart and scattered or removed in time to avoid affecting the performance of the concrete.

[0143] The laser screed machine performs screeding operations according to the set parameters. Operators should closely monitor the equipment's operating status and screeding effect. During the screeding process, construction workers on both sides of the machine need to work together to remove mortar and replenish concrete in a timely manner to avoid low-lying areas. At the same time, exposed galvanized steel fibers should be treated to ensure that the concrete surface is flat and free of exposed fibers.

[0144] S9.4 Precision Control: After the leveling work is completed, use a level to check the flatness of the floor surface to ensure that the flatness error does not exceed ±4mm / 2m. Any areas that do not meet the requirements should be leveled and adjusted in a timely manner.

[0145] Preferably, the flatness error is ensured to be no more than ±3mm / 2m, so as to further control the flatness accuracy.

[0146] S10. Smooth and finish the surface.

[0147] When the surface of the steel fiber reinforced concrete floor is visually inspected and there is basically no bleeding, or when a 3-5mm deep mark is left by pressing with a finger, you can start to use a power trowel to smooth and level the surface, ensuring that the surface is dense and pressing the aggregate down. The speed should not be too fast to avoid carrying out the steel fibers. Once the concrete begins to set, start smoothing it multiple times.

[0148] The timing of finishing depends on the hardness of the ground. Pay attention to adjusting the speed and blade angle as needed. The edges and corners still need to be finished with a trowel. If any steel wires are exposed, they should be pulled out and smoothed immediately. After the final finishing, go up again to check the surface. If there are still a few steel wires exposed, they should be carefully trimmed with pliers.

[0149] S10.1 Timing of finishing: The finishing work is carried out during the initial to final setting stage of galvanized steel fiber concrete. The timing of finishing is determined according to the ambient temperature and the setting time of the concrete. Generally, it is advisable to press the concrete surface with a finger so that it leaves a slight mark but does not collapse.

[0150] S10.2 Polishing Process: First, a ride-on dual-disc grinder is used for slurry grinding. The grinder should grind perpendicular to the laser paver's working path. After the first pass, the grinder is turned around and the operation is repeated in a straight line, covering 50% of the previous path. Then, the grinder is turned 90° and the operation is repeated, covering 50% of the previous path. Through multiple passes of grinding, the laitance on the concrete surface is fully removed, improving the surface density and smoothness. For areas such as corners that cannot be reached by machinery, a manual trowel is used for finishing to ensure that the entire floor surface is flat and smooth.

[0151] S10.3 Quality Requirements: After the surface is smoothed and finished, the floor surface should be free of defects such as trowel marks, bubbles, and sand holes, with uniform color and flatness meeting design requirements.

[0152] S11, Concrete Curing

[0153] S11.1 Maintenance method: After the galvanized steel fiber concrete floor is poured, it should be maintained in time by covering with plastic film, geotextile or spraying curing agent to keep the floor surface moist.

[0154] S11.2 Curing time: The curing time shall not be less than 28 days. During the curing period, the surface of the floor shall be kept moist at all times. When the ambient temperature is below 5℃, insulation measures shall be taken to prevent the concrete from freezing.

[0155] S11.3 Load Control: During the curing period, it is strictly forbidden to pile heavy objects or drive vehicles on the floor to avoid cracking or deformation of the floor due to premature load. Heavy loads are strictly prohibited within 28 days to ensure that the concrete strength can fully develop.

[0156] The technical features of the above embodiments can be combined in any way. For the sake of brevity, not all possible combinations of the technical features in the above embodiments are described. However, as long as there is no contradiction in the combination of these technical features, they should be considered to be within the scope of this specification.

[0157] The preferred embodiments of the present invention have been described in detail above. However, the present invention is not limited to the specific details in the above embodiments. Within the scope of the technical concept of the present invention, various equivalent transformations can be made to the technical solutions of the present invention, and these equivalent transformations all fall within the protection scope of the present invention.

Claims

1. A method for seamless composite construction of ultra-large area heavy-duty flooring, characterized in that: Differentiated construction methods for compartment joints include: The logistics channel area and the entrance compartment joints are treated with metal armored joints: the metal armored joint consists of two symmetrically arranged steel plates connected by plastic easy-break bolts; each steel plate is formed by welding an upper load-bearing flat steel bar and a lower floor compartment joint steel plate, with an elastic pad sandwiched between the steel plates; each upper load-bearing flat steel bar is welded with shear anchor bolts at equal intervals, and the shear anchor bolts are inclined downwards at a certain angle; the area of ​​the elastic pad is less than or equal to the area of ​​the steel plate, and the height of the upper load-bearing flat steel bar is 1 / 4 to 1 / 3 of the height of the lower floor compartment joint steel plate; multiple high-strength plate pins are arranged at equal intervals through the lower floor compartment joint steel plate, and one side of the high-strength plate pin has a plastic sleeve pin nested at the end, which is fixed to the side wall of the steel plate on that side; Other areas are treated with S-shaped dowel joints: The S-shaped dowel joint consists of two identical S-shaped steel plates connected by plastic easy-break bolts; an elastic pad is sandwiched between the two S-shaped steel plates, the size of which is less than or equal to the size of the S-shaped steel plates; each S-shaped steel plate is welded with dowels at intervals along the concave part, and the dowels are inclined downward at a certain angle. It also includes column base treatment: install a metal frame column sleeve at the column base, the size of the metal frame column sleeve is larger than the size of the column base; during installation, the four corners of the metal frame column sleeve are all formed into an arc shape, and multiple additional rivets are evenly installed on both sides of each side of the metal frame column sleeve. The multiple additional rivets are all installed in the upper middle part of the side of the metal frame column sleeve, and the rivets on both sides of each side are staggered and arranged in a figure-eight shape. The four sides of the metal frame column sleeve correspond one-to-one with the four sides of the column base and are installed in parallel, and the distance between each side of the metal frame column sleeve and the corresponding side of the column base is equal.

2. The seamless composite construction method for ultra-large area heavy-duty flooring according to claim 1, characterized in that: This also includes foundation reloading treatment: Grassroots cleanup; Layered backfilling: Use 5-40mm continuous graded crushed stone for layered backfilling. The graded crushed stone should have <15% needle-shaped and flaky particles, <20% crushing value, and <5% mud content. The thickness of each layer should be controlled at 200-300mm. Backfilling should start from the lowest point of the site and proceed from one end to the other to ensure uniform backfilling. Layered compaction: Each layer of crushed stone is compacted using graded crushed stone compaction equipment; Quality inspection: After each layer is compacted, the compaction coefficient is tested using the ring cutter method or sand filling method to ensure that the compaction coefficient reaches 0.94 or above; the acceptance requirement is to send samples for testing every 500m³.

3. The seamless composite construction method for ultra-large area heavy-duty flooring according to claim 1, characterized in that: Before the differentiated construction of the compartment joints, the process also includes surveying and setting out, including setting benchmark control points and axis control networks, setting elevation control lines, and setting out the compartments. The compartment setting out uses finite element software to analyze the temperature field and stress field after concrete pouring to determine the compartment size. Based on the compartment size and location, and in accordance with the requirements of the skip-compartment construction method, the compartment boundary lines are marked on the foundation surface with ink lines.

4. The seamless composite construction method for ultra-large area heavy-duty flooring according to claim 1, characterized in that: Following the differentiated construction of compartment joints, the construction of isolation joints is also included: determining the areas where the floor needs to be isolated from fixed structures; laying isolation material and sealing it in the areas where isolation is required, with the laying height slightly higher than the floor elevation; compressible extruded polystyrene board is selected as the isolation material.

5. The seamless composite construction method for ultra-large area heavy-duty flooring according to claim 4, characterized in that: It also includes a composite reinforcement system of steel bar binding and galvanized steel fiber reinforced concrete: Reinforcement binding: Bind a single-layer bidirectional steel mesh at the bottom of the foundation. Use a staggered binding method when binding the reinforcement. Use lap splicing or welding for the reinforcement joints, and stagger the joint positions. Mix design of galvanized steel fiber waterproof concrete: Based on the usage per cubic meter, the ratio of cement: fine aggregate: coarse aggregate: mixing water: galvanized steel fiber: XYPEX admixture: high-efficiency water-reducing agent = 1:1.95:2.72:0.45:0.064:0.018:0.

015.

6. The seamless composite construction method for ultra-large area heavy-duty flooring according to claim 5, characterized in that: Galvanized steel fiber reinforced concrete pouring: Galvanized steel fiber reinforced concrete is transported by concrete mixer trucks, and the mixing drum is kept rotating at a constant speed during transportation; in the floor compartments, concrete is poured in sequence from one end to the other; concrete is delivered to the pouring area by pumping, and the pumping pressure and pouring speed are controlled during the pumping process.

7. The seamless composite construction method for ultra-large area heavy-duty flooring according to claim 6, characterized in that: This also includes laser leveling: before large-scale construction, the elevation of the ground must be checked again to ensure accuracy before proceeding with large-scale construction; concrete must be laid continuously without cold joints; within the effective range of the laser leveling machine's telescopic arm, manual spreading is carried out first to make the concrete roughly flat, and then the laser leveling machine is used for vibration, compaction, and leveling; the leveling head of the laser leveling machine is equipped with an integrated device of scraper, vibrator, and leveling plate, with a vibration frequency of 4000 times / min, which can complete vibration, slurry lifting, and leveling work in the same period of time, ensuring the density and flatness of the concrete.

8. The seamless composite construction method for ultra-large area heavy-duty flooring according to claim 7, characterized in that: For areas outside the operating range of the laser screed, leveling is carried out manually in conjunction with a level, and a handheld vibrator is used to vibrate the corners to ensure the concrete is dense. During the pouring process, the dispersion of galvanized steel fibers is checked. If clumps of galvanized steel fibers are found, they should be torn apart and scattered or removed in time to avoid affecting the performance of the concrete.

9. The seamless composite construction method for ultra-large area heavy-duty flooring according to claim 8, characterized in that: This also includes smoothing and finishing the surface: Timing for finishing: The finishing work should be carried out during the initial to final setting stage of galvanized steel fiber concrete. The timing of finishing should be determined according to the ambient temperature and the setting time of the concrete. Generally, it is advisable to press the concrete surface with a finger so that it leaves a slight mark but does not collapse. Smoothing process: First, a ride-on double-disc grinder is used for slurry grinding. The grinder should grind perpendicular to the working path of the laser paver. After the first pass of grinding, the grinder is turned around and the operation is repeated in a straight line, covering 50% of the area of ​​the previous path. Then, the grinder is turned 90° and the operation is repeated, covering 50% of the area of ​​the previous path. Through multiple passes of grinding, the laitance on the concrete surface is fully removed, improving the density and smoothness of the surface. For areas such as corners that cannot be reached by machinery, a manual trowel is used for finishing. Quality requirements: After the surface is smoothed and finished, the floor surface should be free of defects, have a uniform color, and the flatness should meet the design requirements.

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