Fully assembled hollow panel building structure and method of erection thereof

Abstract

The application discloses a full-assembly hollow plate type building structure and a mounting method thereof, and belongs to the technical field of building industrialized assembly type structures, and aims to solve the problems of large on-site wet work amount, welding or bolt connection, complex construction and large self-weight of components of an existing plate type assembly building connecting joint. The full-assembly hollow plate type building structure is characterized in that: prefabricated hollow floor slabs with bidirectional lengthways bottom reinforcement and bidirectional support surface reinforcement and prefabricated hollow wall slabs with double-layer bidirectional steel mesh are adopted; wall slab connecting pieces and wall slab connecting pieces with toothed plates are pre-welded and formed in a factory; a closed rectangular steel pipe-shaped cavity is formed by toothed plate occlusion at a corner part on site, and concrete is poured to form a rectangular steel pipe concrete column; upper and lower prefabricated hollow wall slabs are connected by setting wall slab vertical lap reinforcement in a second hollow channel and filling components by post-pouring connection; zero welding, no bolt connection and less wet work in full-assembly construction are realized; and the overall stress performance of the building is ensured by a unique joint structure.

Description

Technical Field

[0001] This invention relates to the field of industrialized building technology. More specifically, this invention relates to a fully prefabricated hollow slab building structure and its installation method. Background Technology

[0002] Prefabricated construction is the future direction of the construction industry, offering advantages such as fast construction speed, high project quality, and less environmental pollution. However, existing prefabricated panel buildings still face numerous challenges in handling connection nodes: some nodes require on-site formwork, rebar tying, and large-scale concrete pouring, resulting in significant wet work and low construction efficiency; others utilize bolted or welded connections, demanding high precision, complex on-site operations, and difficult quality control; furthermore, the substantial weight of traditional solid precast components increases transportation and hoisting difficulties, impacting the overall economic efficiency of the structure. Therefore, there is an urgent need in this field for a fully prefabricated panel building system with simple connection node construction, minimal on-site wet work, no need for welding or bolted connections, lightweight construction, and excellent overall performance. Summary of the Invention

[0003] One object of the present invention is to solve at least the above-mentioned problems and to provide at least the advantages that will be described later.

[0004] Another objective of this invention is to provide a fully prefabricated hollow slab building and its installation method, which overcomes the shortcomings of existing prefabricated slab buildings, such as complex connection nodes, large amount of wet work, the need for welding or bolting connections, and heavy component weight. This invention provides a novel fully prefabricated hollow slab building and its installation method. This system aims to achieve "zero welding," "no bolts," and "minimal wet work" in on-site installation, and ensures the overall load-bearing performance of the building through a unique node structure.

[0005] To achieve these objectives and other advantages according to the present invention, a fully prefabricated hollow slab building structure is provided, comprising:

[0006] 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.

[0007] 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;

[0008] 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;

[0009] 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.

[0010] 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.

[0011] Preferably, 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.

[0012] 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.

[0013] Preferably, the overlap length of the precast hollow floor slab to the top of the corresponding precast hollow wall slab is 150mm-250mm, 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 overlap length.

[0014] 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.

[0015] Preferably, the concrete poured inside the rectangular steel tubular cavity is high-strength micro-expansion concrete, with a design strength grade of not less than C40 and a free expansion rate of 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-convex textures, with a depth of 3 mm-5 mm and a spacing of 20 mm-30 mm.

[0016] Preferably, a horizontal shear key component is 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 shapes of the shear groove and the shear protrusion are matched; wherein, 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.

[0017] Preferably, the toothed plate is integrally formed with the corresponding wall panel connector by stamping or welding.

[0018] Preferably, the bottom of the rectangular steel tubular cavity is provided with a detachable sealed template, and the sealed template has a pouring hole and an vent hole that communicate with the rectangular steel tubular cavity; wherein, the 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.

[0019] The present invention also provides an installation method for a fully prefabricated hollow slab building structure, which includes the following steps:

[0020] S1. Hoist the precast hollow wall panels with pre-welded wall panel connectors to the designed position;

[0021] 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.

[0022] S3. High-strength micro-expansion concrete is pressure-injected into the rectangular steel tubular cavity to form a rectangular steel tube concrete column.

[0023] 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;

[0024] 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.

[0025] 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.

[0026] Preferably, step S4 specifically includes the following steps:

[0027] 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.

[0028] The present invention has at least the following beneficial effects:

[0029] High construction efficiency and easy quality control: All connections of precast hollow wall panels and precast hollow floor slabs are completed within the closed cavities (corner cavities and vertical channels) of the precast components, eliminating the need for on-site formwork and steel reinforcement binding, which greatly simplifies the construction process and reduces the difficulty of quality control.

[0030] Less on-site work: On-site wet work is limited to local areas such as corner joints of wall panels and lap joints of vertical steel bars in wall panels, which greatly reduces the amount of work and truly achieves "less wet work".

[0031] Superior connection performance: The corners where the wall panels are subjected to the most concentrated stress adopt a rectangular steel tube concrete structure enclosed by connectors, which greatly enhances the integrity, rigidity and stress performance of the panel building, making the structure safe and reliable.

[0032] High degree of standardization and industrialization: All components (prefabricated hollow wall panels, prefabricated hollow floor slabs, wall panel connectors) can be mass-produced in the factory in a standardized manner, with stable quality, which facilitates industrial promotion and application.

[0033] Easy installation: The entire on-site installation process is "zero welding" and "no bolts," requiring only hoisting, splicing, and partial pouring, which simplifies the on-site workload and reduces reliance on the technical skills of workers.

[0034] Economical and energy-saving: The hollow structure of the floor slabs and wall panels effectively reduces the self-weight of the components, reduces the amount of materials used, and reduces transportation and hoisting costs, meeting the requirements of green building.

[0035] Other advantages, objectives and features of the present invention will become apparent in part from the following description, and in part from those skilled in the art through study and practice of the invention. Attached Figure Description

[0036] Figure 1 This is a three-dimensional exploded view of a fully assembled hollow slab building structure according to one embodiment of the present invention;

[0037] Figure 2 This is a schematic diagram of the composition of the wall panel connector in one embodiment of the present invention;

[0038] Figure 3This is a structural schematic diagram of a prefabricated hollow wall panel according to one embodiment of the present invention;

[0039] Figure 4 This is a schematic diagram of the structure of a prefabricated hollow floor slab in one embodiment of the present invention;

[0040] Figure 5 This is a structural schematic diagram of the vertical lap joint bars of the wall panel and the post-poured concrete in one embodiment of the present invention.

[0041] Reference numerals: 1: Precast hollow wall panel; 11: Second hollow duct; 2: Precast hollow floor slab; 21: First hollow duct; 22: Two-way support top reinforcement; 23: Two-way continuous bottom reinforcement; 3: Wall panel connector; 31: Channel steel plate; 32: L-shaped steel plate; 33: Tie bar; 4: Toothed plate; 5: Rectangular steel tube concrete column; 6: Vertical lap reinforcement of wall panel; 7: Connecting infill component. Detailed Implementation

[0042] The present invention will now be described in further detail so that those skilled in the art can implement it based on the description.

[0043] It should be understood that terms such as "having," "comprising," and "including" used in the embodiments of this application do not exclude the presence or addition of one or more other elements or combinations thereof. All directional indications (such as up, down, left, right, front, back, etc.) in the embodiments of this application are only used to explain the relative positional relationship and movement of components in a specific posture. If the specific posture changes, the directional indication will also change accordingly. When an element is referred to as "fixed to" or "set on" another element, it can be directly on the other element or may have an intervening element present. 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 an intervening element. Descriptions involving "first," "second," etc., in the embodiments of this application are for descriptive purposes only and should not be construed as indicating or implying their relative importance or implicitly specifying the number of indicated technical features. Therefore, a feature defined with "first" or "second" may explicitly or implicitly include at least one of those features.

[0044] It should be noted that, unless otherwise specified, the experimental methods described in the following implementation plan are all conventional methods, and the reagents and materials described are all commercially available unless otherwise specified.

[0045] It should be noted that the technical solutions of the various embodiments of this application can be combined with each other, but only if they are based on the ability of those skilled in the art to implement them. When the combination of technical solutions is contradictory or cannot be implemented, it should be considered that such combination of technical solutions does not exist and is not within the scope of protection claimed by this application.

[0046] like Figure 1-5 As shown, the present invention provides a fully prefabricated hollow slab building structure, which includes:

[0047] The precast hollow floor slab 2 has bidirectional continuous bottom reinforcement 23 and bidirectional support top reinforcement 22 laid inside. The precast hollow floor slab 2 has a first hollow channel 21 through which the self-weight of the structure is reduced.

[0048] Multiple prefabricated hollow wall panels 1, each prefabricated hollow wall panel 1 has a double-layer bidirectional steel mesh inside, and a second hollow channel 11 is vertically opened through it;

[0049] Multiple wall panel connectors 3, each wall panel connector 3 is made of channel steel plate 31 and / or L-shaped steel plate 32, and tie rod 33, and a toothed plate 4 is fixed on each wall panel connector 3; the horizontal steel bars at the end of each prefabricated hollow wall panel 1 are pre-welded and fixed to the corresponding wall panel connector 3 to form multiple prefabricated integrated components; multiple intersecting prefabricated hollow wall panels 1 interlock with each other in the corner area of ​​the building through the toothed plates 4 of their respective wall panel connectors 3 to form a closed rectangular steel tube cavity;

[0050] The vertical lap bar 6 of the wall panel is set in the second hollow channel of the precast hollow wall panel 1 with the upper and lower layers aligned. The spacing of the vertical lap bar 6 in the second hollow channel is 150 mm-250 mm.

[0051] The rectangular steel tube cavity is filled with concrete to form a rectangular steel tube concrete column 5, which fixes the intersecting precast hollow wall panels 1. The second hollow channel with vertical lap reinforcement bars 6 inserted into it is partially filled with concrete to form a connecting filling component 7, which forms precast hollow wall panels 1 with upper and lower alignment. The fully assembled hollow panel building structure achieves mechanical interlocking between wall panels through the interlocking of the toothed plates 4 of the wall panel connector 3, and forms an integral structure by post-pouring concrete in the closed cavity, achieving zero welding and boltless connection during on-site installation.

[0052] The present invention provides a fully prefabricated hollow slab building structure, the core of which lies in achieving structural integrity and construction efficiency through the combination of prefabricated components and post-cast concrete. The prefabricated hollow floor slab 2 is prefabricated in a factory, with bidirectional continuous bottom reinforcement 23 and bidirectional support top reinforcement 22 inside, and a first hollow channel 21 is provided to reduce its weight. The prefabricated hollow wall panel 1 is also prefabricated in a factory, with a double-layer bidirectional steel mesh inside, and a second hollow channel 11 vertically provided. The wall panel connector 3 is composed of a channel steel plate 31 and an L-shaped steel plate 32, with toothed plates 4 welded onto them. The horizontal steel bars at the end of the precast hollow wall panel 1 are pre-welded to the wall panel connector 3 to form an integrated component. The weld seams must be subjected to penetrant testing (PT) with a testing ratio of 100%. The weld quality must meet the Class II requirements in GB / T 3323-2005 "Radiographic Examination of Metal Fusion Welded Joints". The allowable deviation of the component flatness is ≤3 mm / m, and the allowable deviation of the perpendicularity between the wall panel connector and the end of the wall panel is ≤1 mm / m. The component can only be shipped after passing the acceptance test.

[0053] Two-way continuous bottom reinforcement 23: Double-layer reinforcement is used in both the length (longitudinal) and width (transverse) directions of the precast hollow floor slab 2. The longitudinal reinforcement has a diameter of 12mm (HRB400 grade) and a spacing of 180mm; the transverse reinforcement has a diameter of 10mm (HRB400 grade) and a spacing of 180mm; 8mm diameter stirrups are set between the upper and lower layers of reinforcement, with a stirrup spacing of 800mm×800mm, to ensure that the spacing between the two layers of reinforcement is not less than 50mm, and the thickness of the reinforcement protective layer (from the bottom reinforcement to the bottom surface of the floor slab) is not less than 20mm;

[0054] Two-way support reinforcement 22: Only set in the support area where the precast hollow floor slab 2 overlaps the top of the precast hollow wall slab 1 (width is the same as the overlap length, i.e., 200 mm). Double-layer reinforcement is used in both the length direction (longitudinal) and width direction (transverse) of the precast hollow floor slab. The longitudinal reinforcement has a diameter of 12 mm (HRB400 grade) and a spacing of 120 mm; the transverse reinforcement has a diameter of 10 mm (HRB400 grade) and a spacing of 120 mm. Stirrups with a diameter of 8 mm are set between the upper and lower layers of reinforcement. The stirrups are spaced 800 mm × 800 mm to ensure that the spacing between the two layers of reinforcement is not less than 50 mm and the thickness of the concrete cover (from the two-way support reinforcement 22 to the bottom surface of the precast hollow floor slab 2) is not less than 20 mm.

[0055] Coordination with the duct: All reinforcing bars must avoid the first hollow duct 21. The distance between the center of the reinforcing bar and the edge of the first hollow duct 21 shall not be less than 30 mm. The center-to-center spacing of adjacent first hollow ducts 21 shall be uniformly 250 mm. The width of the concrete ribs between the first hollow ducts 21 shall not be less than 80 mm to ensure sufficient space for the reinforcing bar arrangement and to avoid conflict between the reinforcing bars and the first hollow duct 21, which would affect the formation of the first hollow duct 21.

[0056] Reinforcing bar connection: The intersection of the bidirectional continuous bottom reinforcement 23 and the bidirectional support top reinforcement 22 shall be connected by binding (the binding wire is No. 22 galvanized iron wire), the spacing between binding points shall not be greater than 200mm, and each intersection shall be bound; the intersection of the edge of the precast hollow floor slab 2 and the intersection around the first hollow duct 21 shall be fixed by spot welding (spot welding current 120A-150A), the diameter of the weld point shall not be less than 6mm, to prevent the reinforcement from shifting;

[0057] Coordination with the duct: All reinforcing bars must avoid the first hollow duct, and the distance between the center of the reinforcing bar and the edge of the duct should not be less than 30mm, so as to avoid the reinforcing bars and the duct from conflicting with each other and affecting the duct formation.

[0058] The first hollow duct 21, which runs through the precast hollow floor slab 2, adopts a circular cross-section design. This reduces the interference of the first hollow duct 21 with the internal reinforcement arrangement of the precast hollow floor slab 2, and also reduces the risk of air bubbles remaining during concrete pouring. The specific parameters are designed as follows: the diameter of the first hollow duct 21 is set at 120 mm (which can be adjusted according to the thickness of the precast hollow floor slab 2; 100 mm-120 mm for a thickness of 200 mm-250 mm, and 120 mm-150 mm for a thickness of 250 mm-300 mm); the center-to-center spacing of adjacent first hollow ducts 21 is uniformly 250 mm (minimum not less than 200 mm, maximum not more than 300 mm). The spacing design must ensure that the width of the concrete ribs between the first hollow ducts 21 is not less than 80 mm to guarantee the flexural and shear bearing capacity of the floor slab.

[0059] The first hollow duct 21 is evenly and parallel to the length of the precast hollow floor slab 2. During installation, it must avoid the intersection of the bidirectional continuous bottom reinforcement 23 and the bidirectional support reinforcement 22. The distance between the edge of the first hollow duct 21 and the edge of the precast hollow floor slab 2 is strictly controlled within the range of 100 mm-120 mm to prevent edge cracking during hoisting or use due to excessively small edge distance. During factory prefabrication, the first hollow duct 21 is formed using a rubber core mold in a special mold. The core mold diameter is consistent with the diameter of the first hollow duct 21. After pouring concrete and curing to the design strength, the core mold is removed to ensure that the inner wall of the duct is smooth and free from leakage or damage.

[0060] The channel steel plate 31 and L-shaped steel plate 32 of the wall panel connector 3 are made of Q355 grade low alloy high-strength structural steel. This steel has a higher strength than conventional Q235 steel, which can reduce the thickness of the steel plate while ensuring the overall load-bearing capacity of the connector. The specific thickness parameters are determined according to the thickness of the precast hollow wall panel 1: when the thickness of the precast hollow wall panel 1 is 180 mm-200 mm, the web thickness of the channel steel plate 31 is 10 mm, the flange thickness is 12 mm, and the groove width of the channel steel plate 31 is 5 mm-8 mm smaller than the thickness of the precast hollow wall panel 1 to ensure that the end of the precast hollow wall panel 1 can be embedded in the groove and fit tightly with the channel steel plate; the thickness of the two right-angled sides of the L-shaped steel plate 32 is 10 mm, and the length of the right-angled sides is 30 mm-50 mm larger than the thickness of the precast hollow wall panel 1 to facilitate welding with the channel steel plate 31 and subsequent fixing of the toothed plate. Tie bar 33: Made of Q355 grade steel, rolled into a rectangle with a cross section of 20mm×10mm. The length is determined according to the distance between the channel steel plate 31 and the L-shaped steel plate 32 (usually 80 mm-100mm, to ensure that it forms a 60°-70° angle with the two after installation). The surface is sandblasted to remove rust (rust removal grade Sa2.5). The core function of the tie rod 33 is to enhance the lateral bending and torsional stiffness of a single wall panel connector 3. During the engagement of the toothed plate 4 and subsequent concrete pouring, the "T"-shaped structure of the wall panel connector 3 will bear horizontal compressive force and lateral pressure from the concrete, which can easily cause warping or deformation at the connection between the channel steel plate 31 and the L-shaped steel plate 32 inside. The triangular support formed by the tie rod 33 inside the connector can effectively distribute and transfer the above forces to the overall structure of the channel steel plate 31 and the L-shaped steel plate 32, avoiding local stress concentration and excessive deformation of the connector itself. At the same time, during the subsequent pouring of concrete into the cavity, the tie rod 33 can enhance the ability of a single wall panel connector 3 to resist the lateral pressure of the concrete, ensuring that it does not deform under pressure, thereby ensuring the stability of the cross-sectional dimensions of the rectangular steel tubular cavity formed by them (deviation not exceeding ±3mm), meeting the requirements for concrete compactness. The tie rod 33 is independently arranged in the wall panel connector 3 and connects different wall panel connectors.

[0061] The channel steel plate 31 and L-shaped steel plate 32 are processed using CNC cutting technology to ensure that the edges of the steel plates are flat and the dimensional deviation does not exceed ±1mm. Carbon dioxide gas shielded welding is used for welding, and the weld height is not less than 1.2 times the minimum thickness of the steel plate. The weld must undergo penetrant testing to ensure there are no cracks, porosity, or other defects. After welding, the surface of the wall panel connectors is hot-dip galvanized with a zinc layer thickness of not less than 80μm to improve the connectors' corrosion resistance and meet the long-term use requirements of the building.

[0062] The wall panel connector 3 is formed by combining a channel steel plate 31 (specifications: channel width 180mm-200mm, web height 150mm, web thickness 10mm, flange thickness 12mm) and / or an L-shaped steel plate 32 (specifications: right-angle side length 150mm, thickness 10mm) and a tie rod 33, as follows:

[0063] like Figure 2 As shown, Figure 2 The left and right sides of the image show different implementations of the wall panel connector 3. Figure 2 The wall panel connector 3 on the left side consists of two channel steel plates of different sizes and a tie rod 33. Figure 2 The wall panel connector 3 on the right side consists of a channel steel plate 31, two L-shaped steel plates 32, and tie rods.

[0064] Positioning: Lay the channel steel plate 31 flat with the groove facing upwards and its web in a vertical plane; place one right-angled side (long side) of the L-shaped steel plate 32 horizontally and perpendicularly align it with the web of the channel steel plate. The alignment point is the intersection of the vertical centerline of the web of the channel steel plate and the horizontal centerline of the right-angled side of the L-shaped steel plate, ensuring that the assembled connector forms a "T" shaped load-bearing structure; the alignment point is temporarily fixed by spot welding (8 mm diameter welds, 50 mm spacing);

[0065] Installation of tie rod 33: Tie rod 33, as a stiffening rib, is set between the web of the channel steel plate 31 and the long side (flange) of the L-shaped steel plate 32. During installation, the two ends of tie rod 33 are tightly fitted 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 connector.

[0066] Carbon dioxide gas shielded welding is used to fully weld the mating edges of the tie rod 33 with the channel steel plate 31 and the L-shaped steel plate 32. The weld should be continuous and full. The core function of the tie rod 33 is to significantly enhance the stiffness and stability of the "T" or "L" shaped joint area composed of the channel steel plate 31 and the L-shaped steel plate 32, and prevent it from deforming under the interlocking force of the toothed plates and the lateral pressure of the concrete.

[0067] Toothed plate welding: Toothed plate 4 (toothed plate height 60 mm-70 mm, thickness 10 mm) is welded to the outer surface of the short side of L-shaped steel plate 32. The center line of toothed plate 4 coincides with the center line of the short side of L-shaped steel plate 32. The weld is arranged around the toothed plate with a weld height of 8 mm, forming a cooperative force-bearing system with tie rod 33.

[0068] Size control: After assembly, the outer edge of the flange of the channel steel plate 31 and the outer edge of the L-shaped steel plate 32 should be flush, with a deviation of no more than ±1mm. The overall height of the wall panel connector 3 should be consistent with the height of the precast hollow wall panel 1 to ensure that it can be fully fitted with the end of the precast hollow wall panel 1 during installation.

[0069] As the core component for the interlocking of the wall panel connector 3, the toothed plate 4 needs to be designed to balance interlocking reliability and ease of processing. Specific parameters are as follows: The height of the toothed plate 4 is determined according to the thickness of the precast hollow wall panel 1. When the thickness of the precast hollow wall panel 1 is 180mm-200mm, the height of the toothed plate is 60mm-70mm to ensure that the interlocking depth of the toothed plate 4 is not less than 30mm, so as to avoid loosening of the joint due to insufficient depth after interlocking; The thickness of the toothed plate 4 is consistent with the thickness of the channel steel plate 31 and L-shaped steel plate 32 of the wall panel connector 3 (10mm) to ensure that the toothed plate 4 and the wall panel connector 3 are evenly stressed after welding, without stress concentration.

[0070] The tooth pitch of the toothed plate 4 is set to 40 mm, the tooth tip 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 reduces friction during engagement, facilitating rapid on-site connection. Simultaneously, it forms a reliable mechanical interlock after engagement, resisting horizontal shear forces. The toothed plate 4 is integrally formed by stamping (for thickness ≤ 10 mm) or CNC milling (for thickness > 10 mm). Stamped toothed plates 4 must have burr-free tooth edges, while milled toothed plates 4 have a surface roughness not exceeding Ra 6.3 μm. When welding the toothed plate 4 to the wall panel connector 3, a full weld is used. The weld seam is arranged around the perimeter of the toothed plate 4, with the weld seam height consistent with the thickness of the toothed plate 4. After welding, the tooth tips are ground to prevent scratching operators or damaging the wall panel during hoisting.

[0071] The toothed plate 4 is connected to the channel steel plate 31 and the L-shaped steel plate 32 with a pre-set positioning scale line. The positioning scale line is set at intervals of 20 mm along the length of the toothed plate 4. The meshing surface of the toothed plate 4 of the adjacent wall panel connector 3 is provided with matching positioning protrusions and positioning grooves (positioning protrusion diameter 5 mm, height 2 mm, positioning groove depth 2 mm, inner diameter 5 mm). When the toothed plate 4 meshes, the positioning protrusion is embedded in the positioning groove, and the positioning scale line of the adjacent wall panel connector 3 is aligned, so as to realize the meshing accuracy control of the toothed plate 4 and ensure that the cross-sectional dimension deviation of the enclosed rectangular steel tube cavity does not exceed ±3 mm.

[0072] The toothed plate 4 is integrally formed with the corresponding wall panel connector by stamping or welding. During the forming process, positioning scale lines need to be laser-engraved on the connection edge between the toothed plate 4 and the channel steel plate 31 and L-shaped steel plate 32. The scale lines are evenly distributed along the length of the toothed plate, with a spacing of 20 mm between adjacent scale lines, and the scale lines are red for easy visual identification on site. Simultaneously, positioning protrusions and positioning grooves are machined on the meshing surface of the toothed plate 4: the positioning protrusions are set at the middle position of the meshing surface of the toothed plate 4, and each toothed plate 4 has 2 positioning protrusions with a diameter of 5 mm and a height of 2 mm; the positioning grooves are set on the meshing surfaces of adjacent toothed plates 4, and the positions of the positioning grooves correspond one-to-one with the positioning protrusions. The positioning grooves have a depth of 2 mm and an inner diameter of 5 mm, ensuring that when the toothed plates 4 of the adjacent wall panel connectors 3 mesh, the positioning protrusions can be accurately embedded in the positioning grooves, and the meshing accuracy is judged by observing whether the positioning scale lines are aligned (the alignment deviation of the scale lines must be controlled within 1 mm). Finally, the cross-sectional dimensions of the enclosed rectangular steel tube cavity do not exceed ±3 mm, which meets the cavity sealing requirements of subsequent concrete pouring.

[0073] Interlocking Process: Interlocking Prerequisite: Precise hoisting of the wall panel: First, hoist the prefabricated hollow wall panel 1, pre-welded with wall panel connector 3, to the designed position. Use a total station to correct the wall panel's axis (deviation ≤ ±3mm) and verticality (deviation ≤ 0.5‰H, where H is the wall panel height), and fix it with temporary supports. Ensure that intersecting prefabricated hollow wall panels (such as 2-3 wall panels at a corner) form a preset splicing angle (such as a 90° right angle or a 135° oblique angle) in the corner area.

[0074] Engaging Operation: Mechanical Fitting of Toothed Plates: Adjust the relative positions of adjacent precast hollow wall panels 1 so that the toothed plates 4 on their respective wall panel connectors 3 approach each other. Using the 50° inclined tooth surface of the toothed plates as a guide, the "tooth tip" of one toothed plate is embedded into the "tooth groove" of another toothed plate until the positioning protrusion is completely embedded into the positioning groove and the positioning scale lines are aligned (alignment deviation ≤ 1mm). The toothed plates 4 of multiple intersecting wall panels, through the above-described engagement method, enclose a closed rectangular steel tubular cavity at the corner of the building. For example, at a right-angle corner, after the toothed plates of the wall panel connectors of two wall panels engage, the channel steel plate 31 and the L-shaped steel plate 32 together form the four side walls of the rectangular cavity. The cavity cross-sectional dimensions match the wall panel thickness (e.g., when the wall panel thickness is 200mm, the cavity cross-section is 200mm × 200mm).

[0075] 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.

[0076] 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.

[0077] 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.

[0078] 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.

[0079] The present invention overcomes the above problems in the following ways:

[0080] 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;

[0081] 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.

[0082] Vertical connection optimization: The vertical lap reinforcement 6 of the wall panel and the post-cast connection filling component 7 are used to achieve a reliable connection between the upper and lower wall panels, avoiding the need for on-site binding of steel bars;

[0083] Lightweight components: The precast hollow slab design significantly reduces the self-weight of the components, thereby reducing transportation and hoisting costs;

[0084] Low construction precision requirements: The interlocking connection method is more tolerant of installation errors and reduces construction difficulty.

[0085] Therefore, the above-mentioned technical solution of the present invention achieves high efficiency, lightweight and green construction while maintaining the integrity of the structure, and has strong practicality and promotion value.

[0086] In another technical solution, the diameter of the vertical lap bar 6 of the wall panel is 12 mm-20 mm, and the length of the vertical lap bar 6 of the wall panel is not less than 600 mm; both ends of the vertical lap bar 6 of the wall panel are provided with anchor hooks with a bending angle of 90° and a bending length of 100 mm-150 mm, and 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 1; and the axis of the vertical lap bar 6 of the wall panel coincides with the axis of the second hollow channel 11.

[0087] After the connecting filling component 7 is poured, the anchoring hooks of the vertical lap reinforcement 6 of the wall panel are completely wrapped inside the connecting filling component 7. The vertical lap reinforcement 6 of the wall panel and the double-layer bidirectional steel mesh of the upper and lower precast hollow wall panels 1 form a cooperative force-bearing system through the connecting filling component 7.

[0088] In the above technical solution, the vertical lap reinforcement 6 of the wall panel uses HRB400 grade steel bars with a diameter of 16 mm and a single bar length of 700 mm. Both ends of the vertical lap reinforcement 6 are equipped with 90° hooks, each 120 mm long, to ensure effective mechanical interlocking with the double-layer, bidirectional steel mesh inside the upper and lower precast hollow wall panels 1. The vertical lap reinforcement 6 is prefabricated in the factory before hoisting, and its axis is strictly aligned with the axis of the second hollow channel 11 of the precast hollow wall panel 1 to avoid installation deviation.

[0089] During construction, the lower precast hollow wall panel 1 is first hoisted into position and aligned. Then, the upper precast hollow wall panel 1 is hoisted, ensuring its second hollow channel 11 is accurately aligned with the channel of the lower wall panel. Next, the vertical lap reinforcement 6 of the wall panel is inserted from above into the aligned second hollow channel 11 until its lower hook is anchored into the double-layer, two-way steel mesh of the lower precast hollow wall panel 1, with the upper hook positioned at the predetermined elevation of the upper precast hollow wall panel 1. Subsequently, C40 fine aggregate concrete is injected into a localized area of ​​the second hollow channel 11 using an electric high-pressure grouting pump (e.g., model UBJ3.0), forming a connecting infill component 7. During the concrete pouring process, it is ensured to be dense, completely encasing the vertical lap reinforcement 6 and its hook. After the concrete hardens, the upper and lower precast hollow wall panels 1 form a rigid connection with the connecting infill component 7 through the vertical lap reinforcement 6, jointly bearing vertical loads and horizontal forces.

[0090] In traditional prefabricated buildings, vertical connections between upper and lower wall panels often involve on-site welding of reinforcing bars or pre-reserved reinforcing bar lap splices followed by concrete pouring. This method suffers from problems such as large welding workload, high precision requirements for reinforcing bar positioning, extensive wet work areas, and difficulty in quality control. This invention utilizes prefabricated vertical lap splices (6) in conjunction with standardized ducts to achieve rapid bar insertion and pressure grouting, eliminating the need for on-site welding or binding. This significantly reduces the wet work area and improves construction efficiency and connection reliability. Simultaneously, the hook design enhances mechanical anchoring, forming a unified load-bearing system after concrete pouring, resulting in structural performance superior to traditional lap splicing methods.

[0091] In another technical solution, the overlap length of the precast hollow floor slab 2 to the top of the corresponding precast hollow wall slab 1 is 150 mm-250 mm, and the bidirectional continuous bottom reinforcement 23 of the precast hollow floor slab 2 extends to the top range of the corresponding precast hollow wall slab 1, with the extension length being consistent with the overlap length.

[0092] A groove is provided on the top of the precast hollow wall panel 1 corresponding to the overlapping area of ​​the precast hollow floor slab 2. The groove has a depth of 50mm-80mm and a width that matches the overlapping length. The extension section of the bidirectional continuous bottom reinforcement 23 is located in the groove, and concrete is poured into the groove to cover the extension section of the bidirectional continuous bottom reinforcement 23, forming an overlapping anchorage structure between the precast hollow floor slab 2 and the precast hollow wall panel 1.

[0093] The designed overlap length of the precast hollow floor slab 2 to the top of the precast hollow wall panel 1 is 200 mm. The bidirectional continuous bottom reinforcement 23 inside the precast hollow floor slab 2 extends 200 mm toward the precast hollow wall panel 1 accordingly, forming a reliable force transmission path.

[0094] During construction, the overlapping area at the top of the precast hollow wall panel 1, which has been installed and aligned, is first cleaned to ensure that the pre-set groove is clean and free of debris. The groove is 60 mm deep and its width matches the 200 mm overlap length, providing sufficient space for subsequent reinforcement anchoring and concrete pouring.

[0095] Subsequently, the precast hollow floor slab 2 is hoisted and lowered smoothly, ensuring that its ends accurately overlap the pre-designed area on top of the precast hollow wall panel 1. At this point, the extensions of the bidirectional continuous bottom reinforcement bars 23 of the precast hollow floor slab 2 are precisely embedded into the grooves on top of the precast hollow wall panel 1.

[0096] Finally, C40 fine aggregate concrete is pressure-injected into the groove using pneumatic grouting equipment (such as model PJ-50) to completely fill the groove space and cover and wrap the extension of the bidirectional continuous bottom reinforcement 23. After the concrete hardens, a solid lap anchoring structure is formed, connecting the precast hollow floor slab 2 and the precast hollow wall panel 1 into a whole.

[0097] Traditional prefabricated building construction often uses simple overlapping joints to connect floor slabs and wall panels, or involves setting up post-pouring strips on-site and binding a large amount of reinforcing steel. This results in problems such as a large amount of wet work in the joint area, reliance on external sealing materials for waterproofing, and insufficient overall connection integrity. This invention combines dry splicing with efficient localized wet work through prefabricated groove structures, precise positioning of reinforcing steel, and dense joints formed by pressure-cast concrete. This significantly reduces on-site formwork and reinforcing steel binding work. Simultaneously, the inherent density of the concrete and the waterproofing effect of the groove structure significantly improve the waterproofing reliability and overall connection integrity of the joint area, making construction simpler, faster, and easier to control in terms of quality.

[0098] In another technical solution, the concrete poured inside the rectangular steel tubular cavity is high-strength micro-expansion concrete. The design strength grade of the 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 panel 1. 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.

[0099] In the above technical solution, the rectangular steel tubular cavity formed by the interlocking toothed plates 4 of the wall panel connector 3 is filled with high-strength micro-expansion concrete with a design strength grade of C45. This concrete has a free expansion rate of 0.03% during the solidification process, which can effectively compensate for the shrinkage of the concrete, ensuring that the concrete in the cavity is densely filled and in close contact with the inner wall of the cavity formed by the wall panel connector 3, without shrinkage gaps.

[0100] The cross-sectional dimensions of the rectangular steel tubular cavity are designed as a 200 mm x 200 mm square cavity based on the thickness (e.g., 200 mm) of the intersecting precast hollow wall panels 1, to ensure the integrity of the structure and the directness of force transmission. To further enhance the bonding and mechanical interlocking force between the post-cast concrete and the steel wall panel connector 3, a uniform textured surface with a depth of 4 mm and a spacing of 25 mm is pre-processed on the inner wall of the wall panel connector 3 during factory prefabrication using a cold rolling process.

[0101] During construction, after the wall panel connector 3 forms a closed rectangular steel tubular cavity through the interlocking of the toothed plate 4, the prepared high-strength micro-expansion concrete is injected from the grouting hole at the top of the rectangular steel tubular cavity using pressure grouting equipment (such as the HGB20 high-pressure grouting machine). Under pressure, the concrete fills every corner of the cavity. Its micro-expansion characteristics cause the concrete to generate continuous compressive stress on the inner wall of the rectangular steel tubular cavity during the hardening process. The uneven texture of the inner wall greatly increases the contact surface area and mechanical interlocking effect between the concrete and the steel, together forming an exceptionally strong rectangular steel tubular concrete column 5.

[0102] Traditional prefabricated buildings often use cast-in-place reinforced concrete columns or rely heavily on on-site welding and bolting for corner joints, resulting in problems such as large amounts of wet work, long construction cycles, high skill requirements for workers, difficulty in controlling welding quality, and joints easily becoming weak points. This invention utilizes prefabricated wall panel connectors 3 with toothed plates 4 to quickly interlock and form a formwork-free closed cavity, which is then filled with high-strength concrete with micro-expansion properties. Combined with the textured design of the cavity's inner wall, this completely avoids on-site formwork erection, dismantling, and extensive welding. This method not only greatly improves construction speed but also produces rectangular steel-concrete composite columns 5 with significantly superior integrity, stiffness, and strength compared to traditional joints, significantly enhancing the seismic performance and overall stability of the slab building structure, truly achieving a perfect combination of efficient assembly and structural performance.

[0103] In another technical solution, a horizontal shear key component is also provided at the horizontal joint between the precast hollow floor slab 2 and the precast hollow wall panel 1. The horizontal shear key component includes a shear groove at the top of the precast hollow wall panel 1 and a shear protrusion at the bottom of the precast hollow floor slab 2. 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 a horizontal shear connection component is formed by post-pouring concrete at the joint.

[0104] In the above technical solution, to effectively transfer the horizontal shear force between the precast hollow floor slab 2 and the precast hollow wall panel 1, a horizontal shear key component is set at the horizontal joint between the two. This component is manufactured during the factory prefabrication stage: on the top surface of the precast hollow wall panel 1, shear grooves with a depth of 30 mm and a width of 80 mm are milled at certain intervals along the length direction. At the same time, at the corresponding position on the bottom of the precast hollow floor slab 2, a shear key with a perfectly matched shape and size is prefabricated, with a protrusion height of 30 mm and a width of 80 mm. The spacing of the horizontal shear key components is determined according to the span of the precast hollow floor slab 2; when the span is ≤4 m, the spacing is ≤1500 mm; when the span is >4 m, the spacing is ≤1200 mm. The shear key is embedded into the shear groove during the hoisting of the precast hollow floor slab 2, and concrete is poured at the joint to form a horizontal shear connection component.

[0105] During on-site construction, after the hoisting and alignment of the precast hollow wall panel 1 and the pouring of the corner rectangular steel tube concrete column 5 were completed, the installation of the precast hollow floor slab 2 was carried out. When hoisting the precast hollow floor slab 2, the operators precisely aligned it, ensuring that the shear-resistant protrusions at its bottom were accurately embedded into the shear-resistant grooves at the top of the precast hollow wall panel 1. This embedding process not only provided initial positioning and support for the floor slab, but more importantly, it created a mechanical interlock to resist horizontal shear forces.

[0106] Subsequently, concrete is poured at the horizontal joint between the precast hollow floor slab 2 and the precast hollow wall panel 1. The poured concrete encloses the interlocking area of ​​the shear groove and the shear key. After hardening, it works together with the mechanical action of the shear groove to form a strong and reliable horizontal shear connection member, ensuring that the horizontal load of the floor can be effectively transferred to the wall.

[0107] In traditional prefabricated buildings, horizontal shear connections between floor slabs and wall panels typically rely on pre-cast strips at the top of the wall and the on-site binding of numerous U-shaped shear reinforcement bars, or on-site welding of embedded parts. These methods suffer from drawbacks such as a large amount of on-site wet work, cumbersome reinforcement binding, high requirements for worker skills and weather conditions during welding, low construction efficiency, and difficulty in quality control. This invention achieves dry and rapid installation of shear connections through precise matching of prefabricated shear grooves and shear protrusions in the factory, significantly reducing on-site reinforcement work and welding. This combination of mechanical interlocking and wet concrete joints not only offers convenient and fast construction but also reliable shear performance and stable quality, significantly improving construction efficiency and the overall integrity of the structural connection.

[0108] In another technical solution, the toothed plate 4 is integrally formed with the corresponding wall panel connector 3 by stamping or welding.

[0109] In the above technical solution, the integrated molding of the toothed plate 4 and the wall panel connector 3 is completed in the factory prefabrication stage through one of two preferred processes. The first process is stamping: using a large-tonnage stamping equipment, the toothed plate 4 shape required by the design is directly stamped at a specific position on the steel plate (channel steel plate 31 or L-shaped steel plate 32) used for the wall panel connector 3. This process makes the base plate of the toothed plate 4 and the wall panel connector 3 a complete continuous body without any connecting interface, with consistent materials and high structural strength. The second process is welding: First, a precision blanking device is used to produce the base plate (channel steel plate 31 or L-shaped steel plate 32) and independent toothed plate blanks for the wall panel connector 3. The toothed plate blanks need to be preheated before welding (preheating temperature 150℃-200℃, holding time 30 min). Using a robotic automatic welding system, the toothed plate blanks are welded to the designated positions of the base plate of the wall panel connector 3 with high precision in a full welding manner, following the sequence of "symmetrical welding from the middle to both ends". The weld height is consistent with the thickness of the toothed plate 4. After welding, the position of the toothed plate 4 is corrected by mechanical straightening (using a special straightening fixture) to ensure that the flatness deviation of the toothed plate 4 does not exceed 0.5mm / m, and that the weld is full and defect-free, so that the two are combined into a strong integral component.

[0110] The toothed plate 4 wall panel connector 3, which is made in this way, is then welded to the horizontal steel bars at the end of the precast hollow wall panel 1 in subsequent processes to finally form a precast integrated component, which is then transported to the construction site for use.

[0111] Traditionally, complex node connections are often assembled and welded from multiple parts on-site, or connected using mechanical fasteners such as bolts. This approach not only increases on-site construction procedures and time but also places extremely high demands on the skills of on-site workers. Furthermore, human factors such as welding quality and bolt tightening torque are difficult to control consistently, easily leading to potential quality issues. This invention, by using stamping or automated welding processes in the factory, prefabricates the key force-transmitting component—the toothed plate 4—and the wall panel connector 3 into a high-precision, high-strength integrated unit, completely eliminating any on-site assembly or welding operations on the toothed plate 4. This significantly simplifies on-site installation, ensures consistency in the dimensions and performance of each connector, improves the reliability of node connections and the overall structural construction quality, and is a key technological guarantee for achieving rapid on-site installation with "zero welding" and "boltless" connections.

[0112] In another technical solution, a detachable sealed template is provided at the bottom of the rectangular steel tubular cavity. The sealed template has 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.

[0113] 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.

[0114] 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:

[0115] 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).

[0116] 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).

[0117] 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.

[0118] 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.

[0119] 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.

[0120] 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.

[0121] 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.

[0122] 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:

[0123] S1. Hoist the prefabricated hollow wall panel 1 with pre-welded wall panel connectors 3 to the designed position;

[0124] 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.

[0125] S3. High-strength micro-expansion concrete is pressure-injected into the rectangular steel tube cavity to form a rectangular steel tube concrete column 5.

[0126] 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.

[0127] 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.

[0128] 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.

[0129] In the above technical solution, the installation method of the fully prefabricated hollow slab building structure is carried out according to the following steps:

[0130] 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.

[0131] 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.

[0132] 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.

[0133] 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.

[0134] 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.

[0135] 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.

[0136] 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.

[0137] 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.

[0138] In another technical solution, step S4 specifically includes the following steps:

[0139] 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.

[0140] 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.

[0141] 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.

[0142] 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.

[0143] 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 assembled hollow panel building structure, characterised in that, The application relates to a full-assembly hollow plate type building structure. The prefabricated hollow floor slab is internally laid with bidirectional longitudinal bottom reinforcement and bidirectional support surface reinforcement, and a first hollow hole is vertically arranged in the prefabricated hollow floor slab to reduce the self weight of the component; A plurality of prefabricated hollow wall slabs are internally laid with double-layer bidirectional steel mesh, and a second hollow hole is vertically arranged in each prefabricated hollow wall slab; Each wall slab connecting piece is made of a groove-shaped steel plate and / or an L-shaped steel plate and a tie bar, and each wall slab connecting piece is fixed with a toothed plate; the horizontal steel bars at the end of each prefabricated hollow wall slab are pre-welded and fixed with the corresponding wall slab connecting piece 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 slab connecting pieces at the corner area of the building to form a closed rectangular steel pipe-shaped cavity; A wall slab vertical lap reinforcement is arranged in the second hollow hole of the upper and lower prefabricated hollow wall slabs, and the wall slab vertical lap reinforcement is arranged at a spacing of 150-250 mm in the second hollow hole; The rectangular steel pipe-shaped cavity is filled with concrete to form a rectangular steel pipe concrete column, and the rectangular steel pipe concrete column fixes and connects the intersecting prefabricated hollow wall slabs; the second hollow hole in which the wall slab vertical lap reinforcement is arranged is partially filled with concrete to form a connecting filling component, and the connecting filling component forms the upper and lower prefabricated hollow wall slabs; the full-assembly hollow plate type building structure realizes the mechanical interlocking between the wall slabs through the toothed plate engagement of the wall slab connecting pieces, and realizes the on-site installation, zero welding and bolt-free connection through the post-poured concrete in the closed cavity; The horizontal joint between the prefabricated hollow floor slab and the prefabricated hollow wall slab is further provided with a horizontal shear key component; the horizontal shear key component comprises a shear recess arranged at the top of the prefabricated hollow wall slab and a shear key arranged at the bottom of the prefabricated hollow floor slab, and the shear recess and the shear key are matched in shape; the depth of the shear recess is 20-40 mm, and the width is 50-100 mm; the shear key is embedded in the shear recess during the hoisting of the floor slab, and the post-poured concrete at the joint forms the horizontal shear key component; The bottom of the rectangular steel pipe-shaped cavity is provided with a detachable sealing formwork, the sealing formwork is provided with a pouring hole and an exhaust hole which are communicated with the rectangular steel pipe-shaped cavity; the high-strength micro-expansion concrete is poured through the pouring hole by using a pressure grouting method, and the pouring compactness is judged by observing the slurry overflowing from the exhaust hole.

2. The fully assembled hollow panel building structure according to claim 1, wherein The diameter of the wall slab vertical lap reinforcement is 12-20 mm, and the length of the wall slab vertical lap reinforcement is not less than 600 mm; the two ends of the wall slab vertical lap reinforcement are provided with anchoring hooks with a bending angle of 90 degrees and a bending length of 100-150 mm, and the anchoring hooks are used for forming mechanical engagement with the double-layer bidirectional steel mesh in the upper and lower prefabricated hollow wall slabs; and the axis of the wall slab vertical lap reinforcement is coincident with the axis of the second hollow hole; After the pouring of the connecting filling component is completed, the anchoring hooks of the wall slab vertical lap reinforcement are completely wrapped in the connecting filling component, and the wall slab vertical lap reinforcement and the double-layer bidirectional steel mesh of the upper and lower prefabricated hollow wall slabs form a cooperative stress system through the connecting filling component.

3. The fully assembled hollow panel building structure according to claim 1, wherein The overlap length of the prefabricated hollow floor slab overlapped on the top of the corresponding prefabricated hollow wall slab is 150 mm-250 mm, and the two-way long bottom rib of the prefabricated hollow floor slab extends to the top of the corresponding prefabricated hollow wall slab, and the extension length is consistent with the overlap length; The prefabricated hollow wall slab top corresponding to the prefabricated hollow floor slab overlap area is provided with a groove, the depth of the groove is 50 mm-80 mm, the width matches the overlap length, the two-way long bottom rib extension section is located in the groove, and the groove is poured with concrete and covers the two-way long bottom rib extension section, forming the overlap anchoring structure of the floor and the wall.

4. The fully assembled hollow panel building structure according to claim 1, wherein The concrete poured in the rectangular steel tubular 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 tubular cavity matches the thickness of the intersecting prefabricated hollow wall slab, and the inner wall of the rectangular steel tubular cavity is provided with concave-convex texture, the depth of the concave-convex texture is 3 mm-5 mm, and the interval is 20 mm-30 mm.

5. The fully assembled hollow panel building structure according to claim 3, wherein The tooth plate is integrally formed with the corresponding wall plate connector by stamping or welding.

6. The method of installing a fully assembled hollow panel building structure according to any one of claims 1 to 5, wherein, The method comprises the following steps: S1, hoist the prefabricated hollow wall slab with the wall plate connector pre-welded to the designed position; S2, at the corner of the prefabricated hollow wall slab, the wall plate connectors of adjacent prefabricated hollow wall slabs are engaged with each other through the tooth plate to form a closed rectangular steel tubular cavity; S3, pour high-strength micro-expansion concrete into the rectangular steel tubular cavity under pressure to form a rectangular steel tubular column; S4, hoist the prefabricated hollow floor slab to overlap the preset overlap area on the top of the prefabricated hollow wall slab; S5, insert the wall plate vertical overlap rib into the second hollow hole of the upper and lower aligned prefabricated hollow wall slabs; S6, pour concrete into the local area of the second hollow hole with the wall plate vertical overlap rib inserted to form a connecting filling member.

7. The method of installing a fully assembled hollow panel building structure according to claim 6, wherein, Step S4 specifically comprises the following steps: Pour concrete into the groove on the top of the prefabricated hollow wall slab to cover the two-way long bottom rib extension section of the prefabricated hollow floor slab to form an overlap anchoring structure.

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