Fully-assembled hollow plate type building structure and mounting method thereof

Abstract

The invention discloses a fully-assembled hollow plate type building structure and a mounting method thereof, belongs to the technical field of building industrialization assembly type structures, and aims to solve the problems that the existing plate type assembly building connection node is large in field wet construction amount, needs welding or bolt connection, is complex in construction and is large in self weight. According to the fully-assembled hollow slab type building structure, a prefabricated hollow floor slab internally provided with a two-way through long bottom bar and a two-way support surface bar, a prefabricated hollow wall plate with a double-layer two-way reinforcing mesh, a wall plate connecting piece and a wall plate connecting piece with a toothed plate are pre-welded and formed in a factory; on site, toothed plates are meshed at the corners to form closed rectangular steel tube-shaped cavities, concrete is poured to form rectangular steel tube concrete columns, and upper and lower layers of prefabricated hollow wallboards are connected by arranging wallboard vertical lap joint ribs and post-pouring connection filling components in second hollow hole channels. Zero welding, bolt-free connection and less wet operation in full-assembly construction are achieved, and the overall stress performance of a building is guaranteed through a unique joint structure.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of building industrialization. More particularly, the present application relates to a full-assembled hollow slab building structure and a method for installing the same. BACKGROUND

[0002] Fabricated building is the development direction of the building industry, which has the advantages of fast construction speed, high engineering quality, and less environmental pollution. However, the existing slab-type fabricated building still has many problems in the connection node processing: some nodes need to be supported on site, tied with reinforcement and poured with a large amount of concrete, which has a large amount of wet work and low construction efficiency; some use bolt or welding connection mode, which has high requirements for construction precision, complex on-site operation and difficult quality control; in addition, the traditional solid prefabricated component has a large self-weight, which increases the difficulty of transportation and hoisting, and also affects the overall economy of the structure. Therefore, there is an urgent need in the art for a full-assembled slab building system which has simple connection node structure, less wet work on site, no need for welding and bolt connection, light self-weight and good overall performance. SUMMARY

[0003] An object of the present application is to solve at least the above problems and to provide at least the advantages to be described later.

[0004] Another object of the present application is to provide a full-assembled hollow slab building and a method for installing the same, which overcomes the defects of the existing fabricated slab building, such as complex connection node, large amount of wet work, need for welding or bolt connection, large self-weight of the component, and provides a new full-assembled hollow slab building and a method for installing the same. The system aims to realize "zero welding", "no bolt" and "less wet work" on site, and to ensure the overall stress performance of the building through a unique node structure.

[0005] In order to achieve these objects and other advantages in accordance with the present application, a full-assembled hollow slab building structure is provided, which comprises: a prefabricated hollow floor slab, which is internally laid with a bidirectional longitudinal bottom reinforcement and a bidirectional support surface reinforcement, and a first hollow channel is formed through the prefabricated hollow floor slab for reducing the self-weight of the building; a plurality of prefabricated hollow wall slabs, each of which is internally laid with a double-layer bidirectional steel mesh and a second hollow channel is formed through the vertical direction; a plurality of wall plate connectors, each of which is made of a channel-shaped steel plate and / or an L-shaped steel plate, and a tie bar, and each wall plate connector is fixed with a toothed plate; the horizontal reinforcement at the end of each prefabricated hollow wall slab is pre-welded and fixed with the corresponding wall plate connector to form a plurality of prefabricated integrated components; the plurality of intersecting prefabricated hollow wall slabs are mutually engaged through the toothed plates of the corresponding wall plate connectors at the corner area of the building to form a closed rectangular steel pipe-shaped cavity; The wallboard vertical lap joint is arranged in the second hollow channel of the upper and lower aligned prefabricated hollow wallboard, and the arrangement interval of the wallboard vertical lap joint in the second hollow channel is 150-250 mm. The prefabricated hollow wallboard is fixedly connected by the intersecting prefabricated hollow wallboard and the rectangular steel pipe concrete column formed by pouring concrete into the rectangular steel pipe-shaped cavity.

[0006] Preferably, the diameter of the wallboard vertical lap joint is 12-20 mm, and the length of the wallboard vertical lap joint is not less than 600 mm; the two ends of the wallboard vertical lap joint are provided with anchoring hooks with a bending angle of 90° and a bending length of 100-150 mm, which are used to form mechanical engagement with the double-layer bidirectional steel mesh inside the upper and lower prefabricated hollow wallboard; and the axis of the wallboard vertical lap joint coincides with the axis of the second hollow channel. After the pouring of the connecting filling member is completed, the anchoring hooks of the wallboard vertical lap joint are completely wrapped inside the connecting filling member, and the wallboard vertical lap joint and the double-layer bidirectional steel mesh of the upper and lower prefabricated hollow wallboard form a cooperative stress system through the connecting filling member.

[0007] Preferably, the overlap length of the prefabricated hollow floor slab on the top of the corresponding prefabricated hollow wallboard is 150-250 mm, and the bidirectional through-length bottom reinforcement of the prefabricated hollow floor slab extends to the top of the corresponding prefabricated hollow wallboard, and the extension length is consistent with the overlap length. A groove is provided on the top of the prefabricated hollow wallboard corresponding to the overlap area of the prefabricated hollow floor slab, the depth of the groove is 50-80 mm, the width matches the overlap length, the extended section of the bidirectional through-length bottom reinforcement is located in the groove, and the groove is poured with concrete and covers the extended section of the bidirectional through-length bottom reinforcement, forming an overlap anchoring structure of the floor slab and the wallboard.

[0008] Preferably, the concrete poured in the rectangular steel pipe-shaped cavity is high-strength micro-expansion concrete, the design strength grade of the high-strength micro-expansion concrete is not less than C40, and the free expansion rate is 0.03%-0.04%; the cross-sectional size of the rectangular steel pipe-shaped cavity matches the thickness of the intersecting prefabricated hollow wallboard, and the inner wall of the rectangular steel pipe-shaped cavity is provided with concave-convex texture, the depth of the concave-convex texture is 3-5 mm, and the interval is 20-30 mm.

[0009] Preferably, a horizontal shear key component is further arranged at the horizontal joint between the prefabricated hollow floor and the prefabricated hollow wall panel; the horizontal shear key component comprises a shear groove arranged at the top of the prefabricated hollow wall panel and a shear key arranged at the bottom of the prefabricated hollow floor, and the shear groove and the shear key are matched in shape; the depth of the shear groove is 20-40 mm, and the width is 50-100 mm; the shear key is embedded in the shear groove during hoisting of the floor, and the horizontal shear connecting component is formed by post-cast concrete at the joint.

[0010] Preferably, the tooth plate is integrally formed with the corresponding wall panel connector by stamping or welding.

[0011] Preferably, the bottom of the rectangular steel tubular cavity is provided with a detachable sealing formwork, and the sealing formwork is provided with a pouring hole and an exhaust hole communicated with the rectangular steel tubular cavity; the high-strength micro-expansion concrete is poured into the rectangular steel tubular cavity through the pouring hole by pressure grouting, and the pouring compactness is determined by observing the slurry overflowing from the exhaust hole.

[0012] The application further provides a mounting method of the full-assembled hollow plate type building structure, which comprises the following steps: S1, hoisting the prefabricated hollow wall panel pre-welded with the wall panel connector to the designed position; S2, at the corner of the prefabricated hollow wall panel, the wall panel connectors of the adjacent prefabricated hollow wall panels are engaged with each other through the tooth plate to form a closed rectangular steel tubular cavity; S3, pouring the high-strength micro-expansion concrete into the rectangular steel tubular cavity by pressure grouting to form a rectangular steel tubular concrete column; S4, hoisting the prefabricated hollow floor to overlap the preset overlapping area at the top of the prefabricated hollow wall panel; S5, inserting the wall panel vertical overlapping rib into the second hollow hole of the upper and lower aligned prefabricated hollow wall panels; S6, pouring the concrete into the local area of the second hollow hole in which the wall panel vertical overlapping rib is inserted to form a connecting filling component.

[0013] Preferably, the step S4 specifically comprises the following steps: Pouring the concrete into the groove at the top of the prefabricated hollow wall panel to cover the two-way long bottom rib extension of the prefabricated hollow floor to form an overlapping anchoring structure.

[0014] The application at least has the following beneficial effects: High construction efficiency and easy quality control: all the connections of the prefabricated hollow wall panel and the prefabricated hollow floor are completed in the closed cavity (the corner cavity of the prefabricated hollow wall panel and the vertical hole) of the prefabricated component, without the need of site formwork and binding of steel bars, which greatly simplifies the construction process and reduces the difficulty of quality control.

[0015] Less field operation: the wet operation at the installation site is limited to the local area of the wallboard corner node and the wallboard vertical steel bar lap joint, the operation amount is greatly reduced, and the "less wet operation" is truly realized.

[0016] Superior connection performance: the corner of the wallboard where the stress is most concentrated adopts a rectangular steel pipe concrete structure enclosed by a connecting piece, which greatly enhances the integrity, stiffness and stress performance of the panel building, and the structure is safe and reliable.

[0017] High standardization and industrialization: all components (prefabricated hollow wallboard, prefabricated hollow floor, wallboard connecting piece) can be mass-produced in a factory, with stable quality and convenient industrialization application.

[0018] Convenient installation: the whole process of field installation is "zero welding" and "screwless", only needs hoisting, splicing and local pouring, simplifies the field work and reduces the dependence on the technical level of workers.

[0019] Economical and energy-saving: the hollow structure of the floor and the wallboard effectively reduces the self-weight of the component, reduces the material consumption, and reduces the transportation and hoisting cost, which meets the requirements of green building.

[0020] Other advantages, objects and features of the present application will be embodied in part by the following description, and part will be understood by those skilled in the art through research and practice of the present application. BRIEF DESCRIPTION OF DRAWINGS

[0021] Figure 1 is a three-dimensional explosion schematic diagram of a full-assembly hollow panel building structure in an embodiment of the present application; Figure 2 is a composition schematic diagram of a wallboard connecting piece in an embodiment of the present application; Figure 3 is a structure schematic diagram of a prefabricated hollow wallboard in an embodiment of the present application; Figure 4 is a structure schematic diagram of a prefabricated hollow floor in an embodiment of the present application; Figure 5 is a structure schematic diagram of a wallboard vertical lap bar and post-poured concrete in an embodiment of the present application; The figure mark: 1: prefabricated hollow wallboard, 11: second hollow hole, 2: prefabricated hollow floor, 21: first hollow hole, 22: bidirectional support surface bar, 23: bidirectional through-length bottom bar, 3: wallboard connecting piece, 31: groove-shaped steel plate, 32: L-shaped steel plate, 33: tension bar, 4: toothed plate, 5: rectangular steel pipe concrete column, 6: wallboard vertical lap bar, 7: connecting filling component. DETAILED DESCRIPTION

[0022] The application will be further described in detail below so that those skilled in the art can implement it according to the description.

[0023] It should be understood that the terms such as "have", "contain" and "include" used in the embodiments of the present application do not exclude the presence or addition of one or more other elements. All directional indications (such as up, down, left, right, front, back, etc.) in the embodiments of the present application are only used to explain the relative position relationship, movement condition, etc. between components in a certain posture, and if the posture changes, the directional indications also change accordingly. When an element is referred to as "fixed to" or "disposed on" another element, it can be directly on the other element or can have a middle element. When an element is referred to as "connected to" another element, it can be directly connected to the other element or indirectly connected to the other element through a middle element. The descriptions of "first", "second" and the like in the embodiments of the present application are only for the purpose of description and cannot be understood as indicating or implying the relative importance of the technical features indicated or implying the number of technical features indicated. Therefore, the features defined as "first", "second" can explicitly or implicitly include at least one of the features.

[0024] It should be noted that the experimental methods in the following embodiments are conventional methods, and the reagents and materials are commercially available unless otherwise specified.

[0025] It should be noted that the technical solutions of each embodiment of the present application can be combined with each other, but it must be based on the realization of a person skilled in the art, and when the combination of technical solutions appears contradictory or unachievable, it should be considered that the combination of technical solutions does not exist and is not within the protection scope claimed by the present application.

[0026] As shown in Figures 1-5 The present application provides a full-assembly hollow slab building structure, which comprises: A prefabricated hollow floor slab 2, which is internally laid with a bidirectional longitudinal bottom reinforcement 23 and a bidirectional support surface reinforcement 22, and a first hollow channel 21 for reducing the construction dead weight is vertically and internally provided in the prefabricated hollow floor slab 2; A plurality of prefabricated hollow wall slabs 1, each of which is internally laid with a double-layer bidirectional steel mesh and a second hollow channel 11 is vertically and internally provided in the prefabricated hollow wall slab 1; A plurality of wallboard connecting pieces 3, each wallboard connecting piece 3 is made of a channel steel plate 31 and / or an L-shaped steel plate 32, and a tie bar 33, and each wallboard connecting piece 3 is fixed with a tooth plate 4; the horizontal steel bars at the end of each prefabricated hollow wallboard 1 are pre-welded and fixed with the corresponding wallboard connecting piece 3 to form a plurality of prefabricated integrated components; a plurality of intersecting prefabricated hollow wallboards 1 are surrounded to form a closed rectangular steel pipe-shaped cavity through the tooth plates 4 of the corresponding wallboard connecting pieces 3. A wallboard vertical lap bar 6 is arranged in the second hollow channel of the upper and lower aligned prefabricated hollow wallboards 1, and the wallboard vertical lap bar 6 is arranged in the second hollow channel at an interval of 150-250 mm; Wherein, the rectangular steel pipe-shaped cavity is poured with concrete to form a rectangular steel pipe concrete column 5, and the rectangular steel pipe concrete column 5 fixes and connects the intersecting prefabricated hollow wallboards 1; the second hollow channel in which the wallboard vertical lap bar 6 is arranged is partially poured with concrete to form a connecting filling component 7, and the connecting filling component 7 forms the upper and lower aligned prefabricated hollow wallboards 1; the full-assembly hollow plate type building structure realizes the mechanical interlocking between the wallboards through the tooth plates 4 of the wallboard connecting pieces 3, and realizes the on-site installation zero-welding and non-bolt connection through the post-poured concrete in the closed cavity.

[0027] The full-assembly hollow plate type building structure provided by the above technical scheme of the application is characterized in that the combination of prefabricated components and post-poured concrete realizes the integrity of the structure and the efficiency of the construction. The prefabricated hollow floor 2 is pre-made in a factory, and is internally provided with bidirectional through-length bottom bars 23 and bidirectional support surface bars 22, and is provided with a first hollow channel 21 to reduce the self-weight. The prefabricated hollow wallboard 1 is also pre-made in a factory, and is internally provided with double-layer bidirectional steel mesh, and is vertically provided with a second hollow channel 11. The wallboard connecting piece 3 is composed of a channel steel plate 31 and an L-shaped steel plate 32, and is welded with a tooth plate 4. The horizontal steel bars at the end of the prefabricated hollow wallboard 1 are pre-welded with the wallboard connecting piece 3 to form an integrated component, and the welding seam needs to be subjected to penetration detection (PT) with a detection ratio of 100%, and the welding seam quality needs to meet the requirements of the II level in GB / T 3323-2005 “Metal Fusion Welding Welding Joint Radiography”. The allowable deviation of the flatness of the component is ≤3 mm / m, the allowable deviation of the perpendicularity of the wallboard connecting piece and the end of the wallboard is ≤1 mm / m, and the prefabricated component can be delivered only after passing the acceptance.

[0028] Two-way long bottom reinforcement 23: double-layer reinforcement arrangement is adopted in the length direction (longitudinal direction) and width direction (transverse direction) of the prefabricated hollow floor 2, the longitudinal reinforcement is 12 mm in diameter (HRB400 grade), and the spacing is 180 mm; the transverse reinforcement is 10 mm in diameter (HRB400 grade), and the spacing is 180 mm; the stirrup with a diameter of 8 mm is arranged between the upper and lower two layers of reinforcement, the stirrup spacing is 800 mm x 800 mm, the spacing between the two layers of reinforcement is not less than 50 mm, and the thickness of the reinforcement protection layer (from the bottom reinforcement to the bottom surface of the floor) is not less than 20 mm; Two-way support surface reinforcement 22: only arranged in the support area (consistent with the width and the length of the overlap, i.e. 200 mm) of the prefabricated hollow floor 2 overlapped on the top of the prefabricated hollow wall 1, double-layer reinforcement arrangement is adopted in the length direction (longitudinal direction) and width direction (transverse direction) of the prefabricated hollow floor, the longitudinal reinforcement is 12 mm in diameter (HRB400 grade), and the spacing is 120 mm; the transverse reinforcement is 10 mm in diameter (HRB400 grade), and the spacing is 120 mm; the stirrup with a diameter of 8 mm is arranged between the upper and lower two layers of reinforcement, the stirrup spacing is 800 mm x 800 mm, the spacing between the two layers of reinforcement is not less than 50 mm, and the thickness of the reinforcement protection layer (from the two-way support surface reinforcement 22 to the bottom surface of the prefabricated hollow floor 2) is not less than 20 mm; Coordination with the hole: all the reinforcement needs to avoid the first hollow hole 21, the distance between the center of the reinforcement and the edge of the first hollow hole 21 is not less than 30 mm, the center distance between adjacent first hollow holes 21 is uniformly 250 mm, and the rib width of the concrete between the first hollow holes 21 is not less than 80 mm, so as to ensure sufficient space for the arrangement of the reinforcement and avoid the conflict between the reinforcement and the first hollow hole 21 affecting the molding of the first hollow hole 21.

[0029] Reinforcement connection: at the intersection of the two-way long bottom reinforcement 23 and the two-way support surface reinforcement 22, binding connection is adopted (the binding wire is 22 gauge galvanized iron wire), the binding point spacing is not greater than 200 mm, and each intersection needs to be bound; the intersection points around the edge of the prefabricated hollow floor 2 and the first hollow hole 21 are fixed by spot welding (spot welding current is 120 A-150 A), the welding point diameter is not less than 6 mm, to prevent the displacement of the reinforcement; Coordination with the hole: all the reinforcement needs to avoid the first hollow hole, the distance between the center of the reinforcement and the edge of the hole is not less than 30 mm, to avoid the conflict between the reinforcement and the hole affecting the molding of the hole.

[0030] The first hollow channel 21 is designed in a circular cross-section, which can reduce the interference of the first hollow channel 21 to the internal reinforcement arrangement of the prefabricated hollow floor 2, and reduce the risk of air bubble residue during concrete pouring. The specific parameter design is as follows: the diameter of the first hollow channel 21 is set to 120 mm (which can be adjusted according to the thickness of the prefabricated hollow floor 2, 100-120 mm for thickness of 200-250 mm, and 120-150 mm for thickness of 250-300 mm); the center distance between adjacent first hollow channels 21 is uniformly 250 mm (not less than 200 mm at the minimum, and not more than 300 mm at the maximum), and the distance design needs to ensure that the concrete rib width between the first hollow channels 21 is not less than 80 mm, so as to ensure the bending and shear bearing capacity of the floor.

[0031] The first hollow channel 21 is arranged in parallel along the length direction of the prefabricated hollow floor 2, and needs to avoid the intersection point of the two-way longitudinal bottom reinforcement 23 and the two-way support surface reinforcement 22 during arrangement, and the distance between the edge of the first hollow channel 21 and the edge of the prefabricated hollow floor 2 is strictly controlled within the range of 100-120 mm, so as to avoid edge cracking of the first hollow channel 21 during hoisting or use due to too small edge distance. During factory prefabrication, the first hollow channel 21 is formed by a rubber core mold in a special mold, the diameter of the core mold is consistent with the diameter of the first hollow channel 21, and after pouring concrete and curing to the design strength, the core mold is extracted to ensure that the inner wall of the channel is smooth, without leakage or damage.

[0032] The groove-shaped steel plate 31 and the L-shaped steel plate 32 of the wallboard connecting piece 3 are made of Q355 grade low-alloy high-strength structural steel, which has higher strength than the conventional Q235 steel, so that the thickness of the steel plate can be reduced while ensuring the overall bearing capacity of the connecting piece. The specific thickness parameters are determined according to the thickness of the prefabricated hollow wallboard 1: when the thickness of the prefabricated hollow wallboard 1 is 180 mm-200 mm, the web thickness of the groove-shaped steel plate 31 is 10 mm, the flange thickness is 12 mm, the slot width of the groove-shaped steel plate 31 is 5 mm-8 mm smaller than the thickness of the prefabricated hollow wallboard 1, so that the end of the prefabricated hollow wallboard 1 can be embedded in the slot and tightly fit with the groove-shaped steel plate; the thickness of the two right angle edges of the L-shaped steel plate 32 is 10 mm, and the length of the right angle edge is 30 mm-50 mm larger than the thickness of the prefabricated hollow wallboard 1, so as to facilitate welding with the groove-shaped steel plate 31 and subsequent fixation of the tooth plate. The reinforcing bar 33 is made of Q355 grade steel and is shaped into a rectangle with a section of 20 mm x 10 mm, and the length is determined according to the distance between the groove-shaped steel plate 31 and the L-shaped steel plate 32 (usually 80 mm-100 mm, to ensure a 60°-70° angle with the two plates after installation). The surface is sandblasted and rusted (rusting level Sa2.5). The core function of the reinforcing bar 33 is to enhance the lateral bending and torsional stiffness of the single wallboard connecting piece 3: during the engagement of the tooth plate 4 and the subsequent concrete pouring process, the "T" shaped structure of the wallboard connecting piece 3 will bear horizontal extrusion force and concrete lateral pressure, which is easy to cause the connection between the groove-shaped steel plate 31 and the L-shaped steel plate 32 to warp or deform; the triangular support formed by the reinforcing bar 33 inside the connecting piece can effectively disperse the above-mentioned force to the overall structure of the groove-shaped steel plate 31 and the L-shaped steel plate 32, avoiding local stress concentration and excessive deformation of the connecting piece itself; at the same time, during the subsequent pouring of the cavity concrete, the reinforcing bar 33 can enhance the ability of the single wallboard connecting piece 3 to resist the lateral pressure of the concrete, ensuring that it does not deform under pressure, so as to ensure the stability of the rectangular steel pipe-shaped cavity cross-section formed by them (deviation not more than ±3 mm), meeting the concrete density requirements. The reinforcing bar 33 is independently arranged in the wallboard connecting piece 3, and is connected between different wallboard connecting pieces.

[0033] The processing of the groove-shaped steel plate 31 and the L-shaped steel plate 32 adopts numerical control cutting process, ensuring that the edges of the steel plates are flat and the size deviation is not more than ±1 mm; when welding, carbon dioxide gas shielded welding is used, the weld height is not less than 1.2 times the minimum thickness of the steel plate, and the weld needs to be detected by penetration, without cracks, pores and other defects. After welding, the surface of the wallboard connecting piece is subjected to hot galvanizing treatment, and the thickness of the galvanized layer is not less than 80 μm, which improves the anti-corrosion ability of the connecting piece and meets the long-term use requirements of buildings.

[0034] The wallboard connecting piece 3 is formed by combining a channel steel plate 31 (specifications: slot width 180-200 mm, web height 150 mm, web thickness 10 mm, flange thickness 12 mm) and / or an L-shaped steel plate 32 (specifications: right angle side length 150 mm, thickness 10 mm), and a reinforcing bar 33. The specific combination is as follows: As shown in Figure 2 , Figure 2 The left and right sides in the figure are different embodiments of the wallboard connecting piece 3. Figure 2 The wallboard connecting piece 3 on the left side in the figure is composed of two channel steel plates of different sizes and the reinforcing bar 33. Figure 2 The wallboard connecting piece 3 on the right side in the figure is composed of one channel steel plate 31 and two L-shaped steel plates 32, and a reinforcing bar.

[0035] Positioning: Place the channel steel plate 31 flat with the slot facing upwards, and the web in the vertical plane. Place one of the right angle sides (long side) of the L-shaped steel plate 32 horizontally and perpendicularly to the web of the channel steel plate. The abutting position is the intersection of the vertical midline of the web of the channel steel plate and the horizontal midline of the right angle side of the L-shaped steel plate, to ensure that the combined connecting piece as a whole has a “T” shaped stress structure. Temporarily fix the abutting position by spot welding (welding spot diameter 8 mm, spacing 50 mm). Reinforcing bar 33 installation: The reinforcing bar 33, as a stiffening rib, is arranged between the web of the channel steel plate 31 and the long side (flange) of the L-shaped steel plate 32. When installing, the two ends of the reinforcing bar 33 are tightly attached to the inner side of the web of the channel steel plate 31 and the inner side of the long side of the L-shaped steel plate 32, respectively, and the three form a stable triangular support system inside the connecting piece.

[0036] Full welding is performed on the abutting edges of the reinforcing bar 33 and the channel steel plate 31 and the L-shaped steel plate 32 using carbon dioxide gas shielded welding, and the welds are required to be continuous and full. The core role of the reinforcing bar 33 is to significantly enhance the stiffness and stability of the “T” shaped or “L” shaped joint area composed of the channel steel plate 31 and the L-shaped steel plate 32, to prevent deformation under the action of the tooth plate engagement stress and the concrete lateral pressure.

[0037] Tooth plate welding: The reinforcing bar is welded with a tooth plate 4 (tooth plate height 60-70 mm, thickness 10 mm) on the outer surface of the short side of the L-shaped steel plate 32. The center line of the tooth plate 4 coincides with the center line of the short side of the L-shaped steel plate 32, and the welds are arranged along the four sides of the tooth plate. The weld height is 8 mm, and the reinforcing bar 33 forms a cooperative stress system.

[0038] Size control: After the combination is completed, the outer edge of the flange of the channel steel plate 31 and the outer edge of the L-shaped steel plate 32 need to be flush, with a deviation of not more than ±1 mm. The overall height of the wallboard connecting piece 3 is consistent with the height of the prefabricated hollow wallboard 1, to ensure that the wallboard connecting piece 3 can be completely attached to the end of the prefabricated hollow wallboard 1 during installation.

[0039] The tooth plate 4 is a core component of the wall plate connector 3, and the size design needs to consider the reliability of the engagement and the processing convenience. The specific parameters are as follows: the height of the tooth plate 4 is determined according to the thickness of the prefabricated hollow wall plate 1. When the thickness of the prefabricated hollow wall plate 1 is 180-200 mm, the height of the tooth plate 4 is 60-70 mm, which ensures that the engagement depth of the tooth plate 4 is not less than 30 mm, avoiding the loosening of the joint due to insufficient depth after engagement; the thickness of the tooth plate 4 is consistent with the thickness of the channel steel plate 31 and the L-shaped steel plate 32 of the wall plate connector 3 (10 mm), which ensures that the stress is evenly distributed after the tooth plate 4 is welded with the wall plate connector 3, and there is no stress concentration.

[0040] The tooth pitch of the tooth plate 4 is set to 40 mm, the tooth top width of a single tooth is 12 mm, the tooth root width is 22 mm, and the tooth surface inclination angle is 50°. This angle design can reduce the friction during engagement, facilitate rapid docking on site, and form reliable mechanical interlocking after engagement to resist horizontal shear force. The tooth plate 4 is integrally formed by stamping process (thickness ≤10 mm) or numerical control milling (thickness >10 mm). The tooth plate 4 formed by stamping needs to ensure that the tooth edge has no burrs, and the surface roughness of the tooth plate 4 formed by milling is not greater than Ra6.3 μm. When the tooth plate 4 is welded with the wall plate connector 3, full welding is adopted, the weld is arranged along the four sides of the tooth plate 4, the weld height is consistent with the thickness of the tooth plate 4, and the tooth tip is polished after welding to prevent scratching the operator or damaging the wall plate during hoisting.

[0041] The connection between the tooth plate 4 and the channel steel plate 31 and the L-shaped steel plate 32 is provided with a preset positioning scale line. The positioning scale line is arranged at intervals of 20 mm along the length direction of the tooth plate 4, and the engagement surface of the tooth plate 4 of the adjacent wall plate connector 3 is provided with matching positioning convex points and positioning grooves (the diameter of the positioning convex point is 5 mm, and the height is 2 mm; the depth of the positioning groove is 2 mm, and the inner diameter is 5 mm). When the tooth plate 4 is engaged, the positioning convex points are embedded in the positioning grooves, and the positioning scale lines of the adjacent wall plate connectors 3 are aligned, realizing the engagement precision control of the tooth plate 4 and ensuring that the deviation of the sectional size of the enclosed rectangular steel pipe-shaped cavity is not more than ±3 mm.

[0042] The tooth plate 4 is integrally formed with the corresponding wall plate connector by stamping or welding. During the forming process, a positioning scale line is laser engraved on the connecting edge of the tooth plate 4 and the channel steel plate 31 and the L-shaped steel plate 32. The scale line is evenly distributed along the length direction of the tooth plate, the distance between adjacent scale lines is 20 mm, and the color of the scale line is red, which is convenient for visual identification on site. At the same time, positioning protrusions and positioning grooves are processed on the occlusal surface of the tooth plate 4: the positioning protrusions are arranged at the middle position of the occlusal surface of the tooth plate 4, and each tooth plate 4 is provided with two positioning protrusions, the diameter of the positioning protrusion is 5 mm, and the height is 2 mm; the positioning groove is arranged on the occlusal surface of the adjacent tooth plate 4, and the positioning groove position corresponds to the positioning protrusion one by one, the depth of the positioning groove is 2 mm, and the inner diameter is 5 mm, so that when the tooth plates 4 of the adjacent wall plate connectors 3 are occluded, the positioning protrusions can be accurately embedded into the positioning grooves, and the occlusion accuracy can be judged by observing whether the positioning scale lines are aligned (the alignment deviation of the scale lines needs to be controlled within 1 mm), so that the sectional size deviation of the enclosed rectangular steel pipe-shaped cavity is not more than ±3 mm, which meets the sealing requirement of the cavity for subsequent concrete pouring.

[0043] Occlusion process: occlusion prerequisite: accurate hoisting of wall plate: first hoist the prefabricated hollow wall plate 1 with the wall plate connector 3 pre-welded to the designed position, correct the wall plate axis (deviation ≤±3 mm) and perpendicularity (deviation ≤0.5‰H, H is the height of the wall plate) by using a total station instrument, and fix it with temporary supports. Ensure that the intersecting prefabricated hollow wall plates (such as 2-3 wall plates at the corner) form a preset joint angle (such as 90° right angle, 135° oblique angle) in the corner area.

[0044] Occlusion operation: mechanical embedding of tooth plate: adjust the relative positions of adjacent prefabricated hollow wall plates 1 to make the tooth plates 4 on the wall plate connectors 3 of each wall plate close to each other. Use the 50° inclined tooth surface of the tooth plate to guide the "tooth tip" of one tooth plate to be embedded into the "tooth groove" of another tooth plate until the positioning protrusions are completely embedded into the positioning grooves, and the positioning scale lines are aligned (alignment deviation ≤1 mm). The tooth plates 4 of multiple intersecting wall plates are enclosed to form a closed rectangular steel pipe-shaped cavity at the building corner by the above embedding method. For example, after the tooth plates of the wall plate connectors of two wall plates at a right-angle corner are occluded, the channel steel plate 31 and the L-shaped steel plate 32 jointly form four side walls of the rectangular cavity, and the sectional size of the cavity matches the thickness of the wall plate (such as when the thickness of the wall plate is 200 mm, the sectional size of the cavity is 200 mm x 200 mm).

[0045] The upper and lower ends of the second hollow channel 11 of the precast hollow wall panel 1 are provided with annular positioning marks (the ring marks are 10 mm wide and yellow in color). The bottom of the upper precast hollow wall panel 1 is provided with a positioning pin (the positioning pin is 15 mm in diameter and 80 mm in length) corresponding to the position of the second hollow channel 11. The top of the lower precast hollow wall panel 11 is provided with a positioning hole (the positioning hole is 15.5 mm in diameter and 80 mm in depth) corresponding to the position of the second hollow channel 11. When the upper and lower precast hollow wall panels 1 are hoisted, the positioning pin is inserted into the positioning hole, and the second hollow channel is aligned by visually aligning with the annular positioning marks to ensure that the deviation of the channel axis does not exceed ±2 mm.

[0046] During on-site installation, the precast hollow wall panels 1, pre-welded with wall panel connectors 3, are hoisted to the designed position. In the corner area of ​​the building, the wall panel connectors 3 of adjacent precast hollow wall panels 1 interlock with each other through toothed plates 4, forming a closed rectangular steel tube cavity. High-strength micro-expansion concrete (with a mix ratio (mass ratio) of cement:sand:stone:water:expansion agent:water-reducing agent = 1:1.8:2.5:0.45:0.08:0.015, wherein the cement is P.O42.5R ordinary Portland cement, the sand is medium sand (fineness modulus 2.3-3.0), the stone is 5 mm-20 mm continuously graded crushed stone, the expansion agent is ettringite type, and the water-reducing agent is high-efficiency water-reducing agent (water reduction rate ≥25%)) is poured into the rectangular steel tube concrete column 5, realizing the rigid connection between the wall panels.

[0047] Vertical lap reinforcement bars 6 are inserted into the second hollow ducts 11 of the upper and lower aligned precast hollow wall panels 1, with a spacing of 150-250 mm. Concrete is pressure-poured into a localized area of ​​the second hollow duct 11 to form a connecting infill component 7, linking the upper and lower wall panels into a single unit. This structure, through a combination of mechanical interlocking and post-poured concrete, achieves weld-free and bolt-free connections between the precast hollow wall panels 1, significantly reducing on-site wet work and improving construction efficiency and quality.

[0048] The existing technology is a traditional prefabricated panel structure, in which the wall panels are mostly connected by on-site welding or bolts. The joint treatment is complicated, the construction accuracy requirements are high, the amount of wet work is large, and the components are mostly solid, heavy, and difficult to transport and hoist.

[0049] The present invention overcomes the above problems in the following ways: Innovative connection method: The mechanical interlocking of the wall panel connector 3 and the toothed plate 4 replaces welding or bolt connection, simplifying on-site operation and improving installation efficiency; Post-cast concrete integration: Post-cast concrete is poured into the cavity formed by interlocking to form a rectangular steel tube concrete column 5, which enhances the joint stiffness and integrity. Vertical connection optimization: reliable connection of upper and lower wallboards is realized through wallboard vertical lap joint 6 and post-cast connection filling component 7, and on-site binding of steel bars is avoided; Component lightening: the design of prefabricated hollow slab significantly reduces the self weight of the component, and reduces transportation and hoisting cost; Low construction precision requirement: the interlocking connection method has stronger tolerance to installation error, and reduces construction difficulty.

[0050] Therefore, the above technical scheme of the present application realizes efficient, light and green construction while maintaining the integrity of the structure, and has strong practicability and popularization value.

[0051] In another technical scheme, the diameter of the wallboard vertical lap joint 6 is 12 mm-20 mm, and the length of the wallboard vertical lap joint 6 is not less than 600 mm; the two ends of the wallboard vertical lap joint 6 are provided with anchor hooks with a bending angle of 90° and a bending length of 100 mm-150 mm, the anchor hooks are used to form mechanical interlocking with the double-layer and double-direction steel mesh inside the upper and lower prefabricated hollow wallboards 1; and the axis of the wallboard vertical lap joint 6 coincides with the axis of the second hollow channel 11. Wherein, after the pouring of the connection filling component 7 is completed, the anchor hook of the wallboard vertical lap joint 6 is completely wrapped inside the connection filling component 7, and the wallboard vertical lap joint 6 and the double-layer and double-direction steel mesh of the upper and lower prefabricated hollow wallboards 1 form a cooperative stress system through the connection filling component 7.

[0052] In the above technical scheme, the wallboard vertical lap joint 6 adopts HRB400 grade steel bar with a diameter of 16 mm, and the single length is set to 700 mm. The wallboard vertical lap joint 6 is provided with 90° hooks at both ends, and the hook length is 120 mm, so as to ensure effective mechanical interlocking with the double-layer and double-direction steel mesh inside the upper and lower prefabricated hollow wallboards 1. The wallboard vertical lap joint 6 is prefabricated in the factory before hoisting, and the axis is strictly centered with the axis of the second hollow channel 11 of the prefabricated hollow wallboard 1, so as to avoid installation deviation.

[0053] During construction, the lower prefabricated hollow wall plate 1 is first hoisted into position and corrected, and then the upper prefabricated hollow wall plate 1 is hoisted, ensuring that the second hollow channel 11 is accurately aligned with the channel of the lower wall plate. Then, the wall plate vertical lap joint 6 is inserted into the aligned second hollow channel 11 from above until the lower end of the hook is anchored into the double-layer double-direction steel mesh of the lower prefabricated hollow wall plate 1, and the upper end of the hook is located at the predetermined elevation position of the upper prefabricated hollow wall plate 1. Then, a high-pressure electric grouting pump (such as model UBJ3.0) is used to grout C40 fine stone concrete to the local area of the second hollow channel 11 to form the connecting filler member 7. During the concrete grouting process, it is ensured that the concrete is dense and completely wraps the wall plate vertical lap joint 6 and its hook, and after the concrete hardens, the upper and lower prefabricated hollow wall plates 1 are rigidly connected through the wall plate vertical lap joint 6 and the connecting filler member 7 to jointly bear vertical loads and horizontal forces.

[0054] In traditional fabricated buildings, the vertical connection of upper and lower wall plates is usually achieved by welding connecting steel bars on site or pre-bonding and post-grouting concrete, which has the problems of large welding workload, high steel positioning accuracy requirement, large wet work area, and difficult quality control. The present application realizes rapid steel bar insertion and pressure grouting through the cooperation of the prefabricated wall plate vertical lap joint 6 and the standardized channel, without the need for on-site welding or binding, greatly reducing the wet work area and improving the construction efficiency and connection reliability. At the same time, the hook design enhances the mechanical anchoring effect, and after the concrete is grouted, an integral stress system is formed, with better structural performance than the traditional lap joint method.

[0055] In another technical solution, the lap joint length of the prefabricated hollow floor 2 on the top of the corresponding prefabricated hollow wall plate 1 is 150 mm-250 mm, and the double-direction long bottom steel bar 23 of the prefabricated hollow floor 2 extends to the top of the corresponding prefabricated hollow wall plate 1, with the same extension length as the lap joint length. A groove is provided on the top of the prefabricated hollow wall plate 1 corresponding to the lap joint area of the prefabricated hollow floor 2, with a depth of 50 mm-80 mm and a width matching the lap joint length. The extension segment of the double-direction long bottom steel bar 23 is located in the groove, and concrete is grouted in the groove and covers the extension segment of the double-direction long bottom steel bar 23, forming a lap joint anchoring structure of the prefabricated hollow floor 2 and the prefabricated hollow wall plate 1.

[0056] The design lap joint length of the prefabricated hollow floor 2 on the top of the prefabricated hollow wall plate 1 is 200 mm. The double-direction long bottom steel bar 23 inside the prefabricated hollow floor 2 extends 200 mm in the direction of the prefabricated hollow wall plate 1, forming a reliable stress transmission path.

[0057] During construction, the top lap area of the prefabricated hollow wall panel 1 that has been installed, positioned and corrected is first cleaned to ensure that the preset groove is clean and free of debris. The groove depth is 60 mm, and the width matches the 200 mm lap length, providing sufficient space for subsequent steel anchoring and concrete pouring.

[0058] Subsequently, the hoisting operation of the prefabricated hollow floor slab 2 is carried out, and it is smoothly lowered to accurately lap the end of the prefabricated hollow floor slab 2 on the preset area on the top of the prefabricated hollow wall panel 1. At this time, the extension segment of the two-way through-length bottom reinforcement 23 of the prefabricated hollow floor slab 2 is precisely embedded in the groove on the top of the prefabricated hollow wall panel 1.

[0059] Finally, a pneumatic grouting device (such as model: PJ-50 type) is used to pressure pour C40 fine stone concrete into the groove, so that the concrete completely fills the groove space and covers and wraps the extension segment of the two-way through-length bottom reinforcement 23. After the concrete hardens, a solid lap anchoring structure is formed, connecting the prefabricated hollow floor slab 2 and the prefabricated hollow wall panel 1 into a whole.

[0060] The connection between the floor slab and the wall panel of the traditional fabricated building is mostly simple lap placement, or a large number of steel bars are bound on site, which has problems such as large amount of wet work in the joint area, waterproof performance depending on external sealing materials, and insufficient connection integrity. The present application realizes the combination of dry assembly and local efficient wet work through the prefabricated groove structure, precise extension positioning of the steel bar, and the dense joint formed by pressure pouring concrete. This greatly reduces the amount of formwork engineering and steel bar binding work on site, and significantly improves the waterproof reliability and connection integrity of the joint area through the self-dense nature of the concrete and the waterproof effect of the groove structure, making the construction more simple, fast and quality easier to control.

[0061] In another technical solution, the concrete poured in the rectangular steel tubular cavity is high-strength micro-expansive concrete with a design strength grade not lower than C40 and a free expansion rate of 0.03%-0.04%; the cross-sectional size of the rectangular steel tubular cavity matches the thickness of the intersecting prefabricated hollow wall panel 1, and the inner wall of the rectangular steel tubular cavity is provided with concave-convex textures with a depth of 3 mm-5 mm and a pitch of 20 mm-30 mm.

[0062] In the above technical solution, the rectangular steel tubular cavity formed by the mutual engagement of the toothed plates 4 of the wall panel connectors 3 has high-strength micro-expansive concrete with a design strength grade of C45 poured inside. The concrete has a free expansion rate of 0.03% during the setting process, which can effectively compensate for the shrinkage of the concrete, ensuring that the concrete inside the cavity is densely filled and tightly contacts the inner wall of the cavity formed by the wall panel connectors 3 without shrinkage gaps.

[0063] The cross-sectional size of the rectangular steel tubular cavity is designed as a square cavity of 200 mm x 200 mm according to the thickness (for example, 200 mm) of the intersecting prefabricated hollow wall panel 1 to ensure the integrity and directness of force transmission of the structure. To further enhance the adhesion and mechanical interlocking force between the post-cast concrete and the steel wall panel connector 3, uniform concave-convex textures with a depth of 4 mm and a spacing of 25 mm are pre-processed on the inner side wall (i.e., the inner wall surface forming the cavity) of the wall panel connector 3 during prefabrication of the wall panel connector 3 in the factory.

[0064] During construction, after the wall panel connector 3 is engaged by the tooth plate 4 to form a closed rectangular steel tubular cavity, the mixed high-strength micro-expanding concrete is injected from the pouring hole at the top of the rectangular steel tubular cavity through a pressure grouting device (such as a HGB20 high-pressure grouting machine). The concrete fills every corner of the cavity under pressure, and its micro-expanding property generates a continuous compressive stress on the inner wall of the rectangular steel tubular cavity during the hardening process. The concave-convex textures on the inner wall greatly increase the contact surface area and mechanical interlocking action between the concrete and the steel, together forming an exceptionally strong rectangular steel tube concrete column 5.

[0065] Traditional fabricated buildings often use cast-in-place reinforced concrete columns at corner joints or rely on a large amount of on-site welding and bolting, which has the problems of large amount of wet work, long construction period, high technical requirements for operators, difficult control of welding quality, and weak joints. The present application forms a formwork-free closed cavity by quickly engaging the prefabricated wall panel connector 3 with the tooth plate 4, and fills it with high-strength concrete with micro-expanding properties, combined with the concave-convex texture design of the inner wall of the cavity, completely avoiding on-site formwork, formwork removal, and a large amount of welding work. This method not only greatly improves the construction speed, but also forms a rectangular steel tube concrete column 5 with much better overall performance, stiffness, and strength than traditional joints, significantly enhancing the seismic performance and overall stability of the panel building structure, and truly realizing the perfect combination of efficient assembly and structural performance.

[0066] In another technical solution, a horizontal shear key component is also provided at the horizontal joint between the prefabricated hollow floor slab 2 and the prefabricated hollow wall panel 1; the horizontal shear key component includes a shear groove provided on the top of the prefabricated hollow wall panel 1 and a shear key provided on the bottom of the prefabricated hollow floor slab 2, and the shape of the shear groove matches that of the shear key; wherein the depth of the shear groove is 20 mm-40 mm, and the width is 50 mm-100 mm; the shear key is embedded in the shear groove during hoisting of the floor slab, and the post-cast concrete at the joint forms a horizontal shear connection component.

[0067] In the above technical solution, in order to effectively transmit the horizontal shear force between the prefabricated hollow floor 2 and the prefabricated hollow wall 1, a horizontal shear key component is arranged at the horizontal joint between the two. This component is completed during the prefabrication stage in the factory: on the top surface of the prefabricated hollow wall 1, shear grooves with a depth of 30 mm and a width of 80 mm are milled at intervals along the length direction. At the same time, on the bottom of the prefabricated hollow floor 2, shear keys with a matching shape and size are prefabricated at the corresponding positions, with a protruding height of 30 mm and a width of 80 mm. The arrangement interval of the horizontal shear key component is determined according to the span of the prefabricated hollow floor 2: when the span is ≤4 m, the interval is ≤1500 mm; when the span is >4 m, the interval is ≤1200 mm; the shear keys are embedded in the shear grooves during the hoisting of the prefabricated hollow floor 2, and the post-cast concrete at the joint forms a horizontal shear connection component.

[0068] During on-site construction, after the hoisting, correction and corner rectangular steel pipe concrete column 5 pouring of the prefabricated hollow wall 1 are completed, the installation of the prefabricated hollow floor 2 is carried out. When hoisting the prefabricated hollow floor 2, the operator accurately positions it so that the shear keys at the bottom of the floor are accurately embedded in the shear grooves on the top of the prefabricated hollow wall 1. This embedding process not only provides preliminary positioning and support for the floor, but more importantly, it forms a mechanical interlocking that resists horizontal shear force.

[0069] Subsequently, post-cast concrete is poured at the horizontal joint between the prefabricated hollow floor 2 and the prefabricated hollow wall 1. The post-cast concrete wraps around the engagement area of the shear grooves and shear keys, and after hardening, it forms a solid and reliable horizontal shear connection component together with the mechanical action of the shear grooves, ensuring that the horizontal load of the floor can be effectively transmitted to the wall.

[0070] In traditional fabricated buildings, the horizontal shear connection between the floor and the wall is usually achieved by reserving post-cast strips on the top of the wall and binding a large number of U-shaped shear reinforcement on site, or by using pre-embedded parts for on-site welding. These methods have the disadvantages of large amount of on-site wet work, complicated steel binding, high requirements for worker skills and weather conditions, low construction efficiency and unstable quality control. The present invention realizes dry and fast installation of shear connection through the precise matching of prefabricated shear grooves and shear keys in the factory, greatly reducing the amount of on-site steel work and welding. This combination of mechanical engagement and concrete wet joint not only facilitates construction, speeds up the process, but also ensures reliable shear performance and stable quality, significantly improving construction efficiency and the overall integrity of the structure connection.

[0071] In another technical solution, the tooth plate 4 is integrally formed with the corresponding wall plate connector 3 through stamping or welding.

[0072] In the above technical solution, the integration of the toothed plate 4 and the wall plate connecting piece 3 is completed in the factory prefabrication stage by one of the two preferred processes. The first process is stamping forming: using a large-tonnage stamping equipment, the toothed plate 4 shape required by the design is directly stamped at a specific position of the steel plate (slot-shaped steel plate 31 or L-shaped steel plate 32) used for the wall plate connecting piece 3. This process makes the toothed plate 4 and the base plate of the wall plate connecting piece 3 a complete continuum without any connection interface, with consistent material and high structural strength. The second process is welding forming: first, a precise blanking equipment is used to separately manufacture the base plate (slot-shaped steel plate 31 or L-shaped steel plate 32) of the wall plate connecting piece 3 and an independent toothed plate blank, and the toothed plate blank needs to be preheated (preheating temperature 150-200°C, holding time 30 min) before welding; a robot automatic welding system is used to weld the toothed plate blank at the specified position of the base plate of the wall plate connecting piece 3 in a full-welding manner according to the sequence of "symmetrical welding from the middle to both ends", and the weld height is consistent with the thickness of the toothed plate 4; after welding, a mechanical correction method (using a special correction clamp) is used to correct the position of the toothed plate 4 to ensure that the flatness deviation of the toothed plate 4 is not more than 0.5 mm / m, the weld is full and defect-free, and the two are combined into a solid integral component.

[0073] The wall plate connecting piece 3 with the toothed plate 4 thus made is welded with the horizontal steel bars at the end of the prefabricated hollow wall plate 1 in the subsequent process, finally forming a prefabricated integrated component, which is transported to the construction site for use.

[0074] In the traditional method, complex node connecting components are often assembled and welded on site by multiple parts, or connected by mechanical connecting pieces such as bolts. This method not only increases the process and operation time of the site construction, but also puts very high requirements on the operation skills of the site workers, and the welding quality and bolt tightening torque are difficult to stabilize and control, which is prone to quality risks. The present application uses stamping or automatic welding process in the factory to pre-manufacture the key force transmission component-toothed plate 4 and wall plate connecting piece 3 into a high-precision and high-strength integrated unit, completely avoiding any assembly or welding operation of the toothed plate 4 on site. This greatly simplifies the on-site installation difficulty, ensures the consistency of the size and performance of each connecting piece, improves the reliability of the node connection and the construction quality of the overall structure, and is the key technical guarantee for realizing "zero welding" and "bolt-free" rapid installation on site.

[0075] In another technical solution, a detachable sealing formwork is arranged at the bottom of the rectangular steel pipe-shaped cavity, and a pouring hole and an exhaust hole communicating with the rectangular steel pipe-shaped cavity are arranged on the sealing formwork; wherein the high-strength micro-expansion concrete is poured by pressure grouting through the pouring hole, and the pouring compactness is judged by observing the slurry overflowing from the exhaust hole.

[0076] In the above technical solution, to ensure the bottom of the rectangular steel tubular cavity is sealed and to achieve high-quality concrete pouring, a detachable sealed template is installed at the bottom opening of the rectangular steel tubular cavity. This sealed template is made of high-strength steel plate, and its shape and size perfectly match the bottom opening of the rectangular steel tubular cavity. Two holes are pre-drilled precisely on the sealed template at the factory or on-site: one as a pouring hole and the other as a venting hole, both of which communicate with the interior of the rectangular steel tubular cavity.

[0077] The detachable sealed template (made of Q235 steel, 8 mm thick, with dimensions matching the cavity cross-section) is fixed using bolts. The specific steps are as follows: Prefabrication stage: M10 threaded holes (20 mm deep, 15 mm from the center of the threaded hole to the edge of the steel plate 32 and the channel steel plate 31 of the wall panel connector 3) are pre-set on the bottom edge of the wall panel connector 3. Four threaded holes are set on each wall panel connector 3 (evenly distributed at the four corners of the rectangular cavity). Template processing: The edges of the sealed template are bent upward to form a 20 mm wide and 5 mm thick flange. A 10 mm diameter through hole is made on the flange corresponding to the position of the threaded hole of the wall panel connector 3 (the center of the through hole is 5 mm away from the edge of the flange). The inside of the sealed template (the side in contact with the concrete) is coated with a release agent (water-based release agent, coating thickness 0.1 mm-0.2 mm). Sealing gasket installation: On the side where the flange of the sealed template contacts the wall panel connector, attach a 3mm thick nitrile rubber sealing gasket (15mm wide). The sealing gasket must completely cover the contact area between the flange and the wall panel connector 3, and avoid the bolt hole position to ensure the sealing effect. Bolt fixing: Place the sealed template at the bottom of the rectangular steel tube cavity, align the through hole of the sealed template flange with the threaded hole of the wall panel connector 3, insert a ×30mm high-strength bolt (strength grade 8.8), and tighten the bolt with a torque wrench to a torque of 30N・m-35N・m. One bolt corresponds to each threaded hole to ensure that the sealed template and the wall panel connector 3 fit tightly without gaps. Sealing Inspection: After fixing, inject a small amount of clean water (50mm high) into the cavity, let it stand for 10 minutes, and observe whether there is water seepage at the bottom and edges of the sealed template. If there is no water seepage, the seal is qualified and grouting can be carried out; if there is water seepage, the bolt torque needs to be readjusted or the sealing gasket needs to be replaced. The sealed template should be removed after the concrete in the rectangular steel tube cavity has been cured to 75% of the design strength (determined by strength test of test blocks cured under the same conditions; under standard curing conditions for C40 concrete, it usually takes 7-10 days). When removing, loosen the bolts in a diagonal sequence to avoid deformation of the sealed template. After removal, clean the surface of the sealed template in time for future reuse.

[0078] During on-site construction, after assembling the wall panel connectors 3 of adjacent precast hollow wall panels 1 using interlocking toothed plates 4 to form a rectangular steel tubular cavity, the construction workers first tightly install the sealed template at the bottom of the cavity to ensure a sealed interface and prevent grout leakage. During concrete pouring, the delivery pipe of the pressure grouting equipment is tightly connected to the pouring hole on the sealed template, and high-strength micro-expansion concrete is pumped into the rectangular steel tubular cavity from bottom to top under certain pressure. As the concrete slurry level rises, the air in the rectangular steel tubular cavity is gradually expelled from the vent holes located at higher positions. The construction workers continuously observe the condition of the vent holes. When they see uniformly viscous concrete slurry steadily overflowing from the vent holes, they can determine that the rectangular steel tubular cavity is completely filled with concrete without any voids or air bubbles, and then grouting is stopped.

[0079] Traditionally, when pouring concrete into vertical enclosed cavities (such as column cavities enclosed by formwork), a free-fall pouring method from the top opening is often used. This method is prone to concrete segregation and easily leads to voids or honeycomb-like pitting due to incomplete air expulsion, severely affecting the density and final strength of the component, resulting in high quality risks. This invention innovatively employs bottom pressure grouting technology by setting a perforated, detachable, sealed formwork at the bottom. Pressure is used to tightly fill the cavity with concrete, and the vent holes serve as observation points for a direct and reliable assessment of the filling density. This method not only thoroughly guarantees the pouring quality of the rectangular steel-concrete composite column 5, ensuring its internal density and defects, and guaranteeing strength, but also eliminates the need for a complex pouring platform at the top of the cavity, simplifying construction operations. It is a core technology for ensuring the performance of key nodes.

[0080] In another technical solution, the present invention also provides an installation method for a fully prefabricated hollow slab building structure, which includes the following steps: S1. Hoist the prefabricated hollow wall panel 1 with pre-welded wall panel connectors 3 to the designed position; S2. At the corner of the precast hollow wall panel 1, the wall panel connectors 3 of adjacent precast hollow wall panels 1 are interlocked by toothed plates 4 to form a closed rectangular steel tube cavity. S3. High-strength micro-expansion concrete is pressure-injected into the rectangular steel tube cavity to form a rectangular steel tube concrete column 5. S4. Hoist the precast hollow floor slab 2 so that it overlaps with the precast hollow wall panel 1 at the pre-set overlap area. S5. Insert the vertical lap bar 6 of the wall panel into the second hollow channel 11 of the prefabricated hollow wall panel 1 that is aligned with the upper and lower layers. S6. Pressure-inject concrete into the local area of ​​the second hollow duct 11, where the wall panel vertical lap reinforcement 6 is inserted, to form a connecting filling component 7.

[0081] In the above technical solution, the installation method of the fully prefabricated hollow slab building structure is carried out according to the following steps: First, perform step S1. Use lifting equipment to hoist the precast hollow wall panel 1, with the wall panel connectors 3 pre-welded in the factory, to the designed axis position of the foundation or lower-level precast hollow floor slab 2, and perform preliminary positioning and correction. Use a total station for positioning. The allowable range for the axis deviation of the precast hollow wall panel 1 is ±3mm, the allowable range for the elevation deviation is ±2mm, and the allowable range for the verticality deviation is ≤0.5‰H (H is the height of the precast hollow wall panel 1). After positioning, use temporary supports for fixation. Next, step S2 is performed. At corners or T-junctions of the building, the operator guides adjacent prefabricated hollow wall panels 1 to move closer together, so that the pre-installed wall panel connectors 3 (channel steel plates 31 or L-shaped steel plates 32) are precisely aligned and interlocked by their own toothed plates 4. Multiple wall panel connectors 3, through the interlocking of the toothed plates 4, naturally form a closed rectangular steel tubular cavity at the corner.

[0082] Then, step S3 is executed. C40 high-strength micro-expansion concrete (slump 180 mm-200 mm) is injected using a pressure grouting device (UBJ3.0 electric high-pressure grouting pump) through a sealed template with a pouring hole and an vent hole pre-installed at the bottom of the rectangular steel tube cavity. The grouting pressure is set to 0.6MPa-0.8MPa (0.6 MPa when the cavity height is ≤3m, and 0.8MPa when the height is >3m). The grouting speed is controlled at 8 L / min-15 L / min (lower speed for smaller cavities, higher speed for larger cavities). The grouting pipe is inserted into the pouring hole to a depth of not less than 50mm. When the vent hole (diameter 20 mm) continuously overflows with grout that is free of air bubbles and has the same consistency as the poured concrete, the current pressure is maintained for 30 s-60 s. Then, the grouting pump is turned off and the pouring hole and vent hole are sealed to prevent concrete backflow. Concrete is injected from the bottom, filling the entire rectangular steel tube cavity. After it hardens, it forms a solid rectangular steel tube concrete column 5, which firmly connects the intersecting precast hollow wall panels 1 into one unit.

[0083] Then, proceed to step S4, hoist the precast hollow floor slab 2, and lower it smoothly at both ends so that it accurately overlaps the pre-set overlap area on the top of the precast hollow wall panel 1 that has been installed below.

[0084] Before performing step S5, the alignment of the upper and lower second hollow channels 11 must be completed: During the prefabrication stage, ring-shaped positioning marks were processed on the edges of the upper and lower openings of the second hollow channels 11 in the prefabricated hollow wall panel 1. The ring marks are 10 mm wide and painted with yellow environmentally friendly paint to ensure that they can be quickly identified by the naked eye during on-site hoisting; at the same time, positioning pins are pre-embedded at the bottom of the upper prefabricated hollow wall panel 1, corresponding to the center position of each second hollow channel 11. The positioning pins are made of Q235 steel, with a diameter of 15 mm and a length of 80 mm. The bonding strength between the positioning pins and the wall panel concrete is not less than 3 MPa; at the top of the lower prefabricated hollow wall panel 1, positioning holes are pre-reserved at the center position of each second hollow channel 11. The positioning holes are 15.5 mm in diameter and 80 mm deep. The inner walls of the positioning holes are smooth and free of concrete residue. When hoisting the upper precast hollow wall panel 1 on site, first align the positioning pin at the bottom of the upper precast hollow wall panel 1 with the positioning hole at the top of the lower precast hollow wall panel 1, and slowly lower it so that the positioning pin is fully inserted into the positioning hole, thus initially achieving the positioning of the channel. Then, with the assistance of a level, ensure that the annular positioning marks of the upper and lower precast hollow wall panels 1 are completely aligned. If there is a deviation, correct it by fine-tuning the position of the precast hollow wall panel 1 (using the fine-tuning function of the hoisting equipment) until the alignment deviation of the annular positioning marks does not exceed 1 mm. At this time, the deviation of the second hollow channel axis can be controlled within ±2 mm, which meets the requirements for the smooth insertion of the vertical lap reinforcement of the wall panel and subsequent concrete grouting.

[0085] Then, step S5 is executed. After the vertical second hollow channels 11 of the upper and lower precast hollow wall panels 1 are aligned, the precast wall panel vertical lap bar 6 is inserted from above into the aligned second hollow channel 11, so that the hooks at the upper and lower ends are respectively anchored into the double-layer bidirectional steel mesh of the upper and lower precast hollow wall panels 1.

[0086] Finally, in step S6, a ZJ-20 handheld grouting machine is used to pressure-grout C40 fine aggregate concrete (slump 180 mm-200 mm) into a localized area of ​​the second hollow duct 11 into which the vertical lapped reinforcement 6 of the wall panel has been inserted. The grouting pressure is 0.4 MPa-0.6 MPa (0.4 MPa for duct length ≤ 2 m, 0.6 MPa for length > 2 m), and the grouting speed is 3 L / min-8 L / min. The grouting pipe is inserted from the top of the duct, and the grouting area must cover the anchoring hook area of ​​the vertical lapped reinforcement 6 of the wall panel. The grouting height must extend upwards from the top of the lower precast hollow wall panel 1 by 300 mm-400 mm and downwards from the bottom of the upper precast hollow wall panel 1 by 300 mm-400 mm. mm, ensuring the anchor hook is completely encased within the connecting infill component to guarantee a reliable connection between the upper and lower precast hollow wall panels 1. During grouting, slowly raise the grouting pipe. When concrete overflows from the top of the duct (the duct opening of the upper wall panel), stop grouting and immediately seal the duct opening with a special plug. Remove the plug after 7 days of curing. The concrete fills the gaps around the double-layer bidirectional steel mesh and completely encases it. After hardening, it forms the connecting infill component 7, thus reliably connecting the upper and lower precast hollow wall panels 1. All grouting operations must be completed before the initial setting of the concrete. Pressure changes must be monitored in real time during grouting. If the pressure suddenly increases (exceeding the set value by 10%), grouting must be stopped, and the pipe blockage must be checked. The fault must be rectified before continuing. If the pressure continues to drop (below the set value by 20%), the grouting must be checked for leakage. After repair, grouting should be restarted.

[0087] Traditional prefabricated panel building installation methods typically involve extensive on-site welding (such as welding steel plates and reinforcing bars), bolting (such as tightening high-strength bolts), and wet work such as setting up formwork, tying reinforcing bars, and pouring large amounts of concrete at joint areas. This method is complex, requires highly skilled construction workers, has a long construction cycle, and presents significant challenges and uncertainties in quality control. Furthermore, welding and bolting place extremely stringent requirements on component precision. The installation method provided by this invention completely eliminates on-site welding and bolting, employing a combination of dry mechanical interlocking (toothed plate 4 interlocking) and localized pressure grouting (forming rectangular steel-concrete composite columns 5 and connecting infill components 7). The entire installation process is logically clear and simplified, significantly reducing on-site manual operations and wet work, lowering reliance on worker skill levels, and significantly improving installation efficiency and quality control, truly achieving efficient, high-quality, and low-impact green construction.

[0088] In another technical solution, step S4 specifically includes the following steps: Concrete is pressure-injected into the groove at the top of the precast hollow wall panel 1, covering the extended section of the bidirectional continuous bottom reinforcement 23 of the precast hollow floor slab 2, forming an lap anchoring structure. First, preparations are made for the hoisting of the precast hollow floor slab 2. At the top of the precast hollow wall panel 1, which has been hoisted and aligned, and where the corner rectangular steel tube concrete column 5 has been formed, construction personnel clean the surface of the lap area and check whether the pre-set shear groove and the groove used for anchoring at the top of the precast hollow wall panel 1 are clean and free of debris.

[0089] Subsequently, the precast hollow floor slab 2 is hoisted and lowered smoothly, with both ends accurately overlapping at the designed positions on top of the precast hollow wall panel 1. During the hoisting process, a level and laser positioning instrument are used to assist in positioning, strictly controlling the elevation deviation of the precast hollow floor slab 2 to within ±2mm, the planar position deviation to within ±3mm, and the overlap length deviation to within ±5mm. During this process, the laser positioning instrument is used to assist in alignment, ensuring that the shear-resistant protrusion (30mm high, 80mm wide) at the bottom of the precast hollow floor slab 2 is precisely embedded into the shear-resistant groove (30mm deep, 80mm wide) at the top of the precast hollow wall panel 1. If there is a slight deviation, the fine-tuning function of the hoisting equipment (horizontal fine-tuning accuracy ±1mm) is immediately used for adjustment until the shear-resistant protrusion is completely embedded into the shear-resistant groove, and the horizontal joint gap between the floor slab and the wall panel does not exceed 2mm. At this point, the extension section of the bidirectional continuous bottom reinforcement 23 inside the precast hollow floor slab 2 should fall precisely into the pre-drilled anchoring groove at the top of the precast hollow wall panel 1. Once the floor slab is in place, it should be temporarily secured immediately to prevent displacement.

[0090] Next, using a PJ-50 pneumatic grouting device, C40 fine aggregate concrete (maximum aggregate size 10 mm, slump 160 mm-180 mm) was pressure-injected into the anchoring groove at the top of the precast hollow wall panel 1. The grouting pressure was controlled at 0.3 MPa-0.5 MPa based on the groove depth (0.3 MPa for groove depth ≤ 50 mm, 0.5 MPa for depth > 50 mm), and the grouting speed was controlled at 5 L / min-10 L / min. Grouting was continuously performed from one end of the groove to the other until the groove was completely filled with concrete and no air bubbles emerged from the surface. After grouting, the concrete surface was promptly smoothed to make it flush with the top of the wall panel. Under pressure, the concrete fully filled all the spaces in the groove, completely covering and encasing the extended section of the bidirectional continuous bottom reinforcement 23 of the precast hollow floor slab 2. After the poured concrete hardens, it forms a solid lap anchorage structure together with the groove and the extended steel bars, thereby effectively transferring the load of the precast hollow floor slab 2 to the precast hollow wall slab 1 below.

[0091] In traditional prefabricated buildings, the connection between floor slabs and wall panels is often treated rather crudely. To achieve integrity and waterproofing at the joints, it is often necessary to tie a large number of complex connecting steel bars within the post-cast strip at the top of the wall, and to erect formwork and pour large areas of concrete. This involves a large amount of wet work, and waterproofing often relies on additional external waterproofing coatings or sealants applied later, resulting in poor reliability and durability. This invention achieves efficient sealing and structural connection of joints through a precise groove structure and pressure grouting technology. By performing local pressure grouting on pre-set grooves, the sealing and filling of joints, reliable anchoring of steel bars, and effective load transfer are completed simultaneously with minimal wet work. This method greatly simplifies on-site operations, reduces reliance on skilled workers, and ensures waterproofing effectiveness through the combined effect of structural waterproofing and the high density of the grout itself. It significantly improves construction speed, joint waterproofing reliability, and connection strength, representing a key detail for achieving efficient, high-performance, fully prefabricated construction.

[0092] Although the technical solutions of the present invention have been disclosed above, they are not limited to the applications listed in the specification and embodiments. They can be applied to various fields suitable for the present invention. For those skilled in the art, other modifications can be easily made. Therefore, without departing from the general concept defined by the claims and their equivalents, the present invention is not limited to the specific details and embodiments shown and described herein.

Claims

1. A fully prefabricated hollow slab building structure, characterized in that, include: The precast hollow floor slab has bidirectional continuous bottom reinforcement and bidirectional support top reinforcement inside, and a first hollow channel is opened through the precast hollow floor slab to reduce the self-weight of the structure. Multiple prefabricated hollow wall panels, each prefabricated hollow wall panel is filled with a double-layer bidirectional steel mesh, and a second hollow channel is opened vertically through it; Multiple wall panel connectors, each made of channel steel plate and / or L-shaped steel plate and tie rods, with toothed plates fixed on each wall panel connector; the horizontal steel bars at the end of each precast hollow wall panel are pre-welded and fixed to the corresponding wall panel connector to form multiple precast integrated components; multiple intersecting precast hollow wall panels interlock with each other in the corner area of ​​the building through the toothed plates of their respective wall panel connectors to form a closed rectangular steel tubular cavity; The vertical lap joints of the wall panels are set in the second hollow ducts of the precast hollow wall panels that are aligned with the upper and lower layers. The spacing of the vertical lap joints of the wall panels in the second hollow ducts is 150 mm-250 mm. The rectangular steel tube cavity is filled with concrete to form a rectangular steel tube concrete column, which fixes and connects the intersecting precast hollow wall panels. The second hollow channel, which has vertical lap bars inserted for the wall panels, is partially filled with concrete to form a connecting filling component, which forms precast hollow wall panels aligned with the upper and lower layers. The fully assembled hollow panel building structure achieves mechanical interlocking between the wall panels through the interlocking of the toothed plates of the wall panel connectors, and forms an integral structure by post-pouring concrete in the closed cavity, achieving zero welding and boltless connection during on-site installation.

2. The fully prefabricated hollow slab building structure as described in claim 1, characterized in that, The diameter of the vertical lap joint of the wall panel is 12 mm-20 mm, and the length of the vertical lap joint is not less than 600 mm; both ends of the vertical lap joint of the wall panel are provided with anchor hooks with a bending angle of 90° and a bending length of 100 mm-150 mm. The anchor hooks are used to form a mechanical interlock with the double-layer bidirectional steel mesh inside the upper and lower precast hollow wall panels; and the axis of the vertical lap joint of the wall panel coincides with the axis of the second hollow duct. After the connecting infill component is poured, the anchoring hooks of the vertical lap joints of the wall panel are completely wrapped inside the connecting infill component. The vertical lap joints of the wall panel and the double-layer bidirectional steel mesh of the upper and lower precast hollow wall panels form a cooperative force-bearing system through the connecting infill component.

3. The fully prefabricated hollow slab building structure as described in claim 1, characterized in that, The lap length of the precast hollow floor slab to the top of the corresponding precast hollow wall slab is 150 mm-250 mm, and the bidirectional continuous bottom reinforcement of the precast hollow floor slab extends to the top of the corresponding precast hollow wall slab, with the extension length being consistent with the lap length. The top of the precast hollow wall panel has a groove corresponding to the overlapping area of ​​the precast hollow floor slab. The groove has a depth of 50 mm-80 mm and a width that matches the overlapping length. The bidirectional continuous bottom reinforcement extension is located in the groove, and concrete is poured into the groove to cover the bidirectional continuous bottom reinforcement extension, forming an overlapping anchoring structure between the floor slab and the wall panel.

4. The fully prefabricated hollow slab building structure as described in claim 1, characterized in that, The concrete poured inside the rectangular steel tubular cavity is high-strength micro-expansion concrete. The design strength grade of this high-strength micro-expansion concrete is not lower than C40, and the free expansion rate is 0.03%-0.04%. The cross-sectional dimensions of the rectangular steel tubular cavity match the thickness of the intersecting precast hollow wall panels. The inner wall of the rectangular steel tubular cavity is provided with concave and convex textures, with a depth of 3 mm-5 mm and a spacing of 20 mm-30 mm.

5. The fully prefabricated hollow slab building structure as described in claim 1, characterized in that, A horizontal shear key component is also provided at the horizontal joint between the precast hollow floor slab and the precast hollow wall panel. The horizontal shear key component includes a shear groove at the top of the precast hollow wall panel and a shear protrusion at the bottom of the precast hollow floor slab. The shear groove and the shear protrusion are matched in shape. The depth of the shear groove is 20 mm-40 mm and the width is 50 mm-100 mm. The shear protrusion is embedded in the shear groove during the hoisting of the floor slab and concrete is poured at the joint to form a horizontal shear connection component.

6. The fully prefabricated hollow slab building structure as described in claim 3, characterized in that, The toothed plate is integrally formed with the corresponding wall panel connector by stamping or welding.

7. The fully prefabricated hollow slab building structure as described in claim 4, characterized in that, The bottom of the rectangular steel tubular cavity is equipped with a detachable sealed template, on which are opened a pouring hole and an vent hole that communicate with the rectangular steel tubular cavity. High-strength micro-expansion concrete is poured through the pouring hole using pressure grouting, and the degree of compaction is judged by observing the grout overflowing from the vent hole.

8. The installation method of the fully prefabricated hollow slab building structure as described in any one of claims 1-7, characterized in that, Includes the following steps: S1. Hoist the precast hollow wall panels with pre-welded wall panel connectors to the designed position; S2. At the corner of the precast hollow wall panel, the wall panel connectors of adjacent precast hollow wall panels are interlocked by toothed plates to form a closed rectangular steel tube cavity. S3. High-strength micro-expansion concrete is pressure-injected into the rectangular steel tubular cavity to form a rectangular steel tube concrete column. S4. Hoist the precast hollow floor slabs so that they overlap with the pre-set overlap area on top of the precast hollow wall panels; S5. Insert vertical lap bars into the second hollow duct of the precast hollow wall panel that is aligned with the upper and lower layers. S6. Pressure-inject concrete into the local area of ​​the second hollow duct where the wall panel vertical lap reinforcement is inserted to form a connecting filling component.

9. The installation method of the fully assembled hollow slab building structure as described in claim 8, characterized in that, Step S4 specifically includes the following steps: Concrete is pressure-injected into the groove at the top of the precast hollow wall panel to cover the bidirectional continuous bottom reinforcement extension section of the precast hollow floor slab, forming an lap anchoring structure.

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