Concrete module system of integrated formwork and construction method

Abstract

The invention relates to the technical field of modular construction, in particular to a concrete module system of an integrated formwork and a construction method. The module comprises a top plate, a bottom plate, a vertical component, an outer formwork and a connecting assembly, the outer formwork is detachably connected to the outer side of the vertical component, and the outer formwork and the vertical component jointly define a pouring cavity used for pouring concrete in place. The outer formwork comprises a pre-installed formwork unit which is pre-installed on the outer side of the vertical component in a factory and a post-installed formwork unit which is installed on the connecting portion of the pre-installed formwork unit and the horizontal splicing position of every two adjacent modules on site. A large amount of work needing to be completed on site traditionally is transferred to be completed in a factory environment, the workload of a construction site is greatly reduced, the overall construction efficiency is improved, only a small amount of steel bar binding, post-installation formwork unit installation, concrete pouring and other procedures need to be carried out on site, the construction process is simplified, and the construction period is shortened; the method is especially suitable for engineering projects needing rapid construction.

Description

Technical Field

[0001] This invention relates to the field of modular construction technology, and in particular to a concrete module system with integrated formwork and a construction method thereof. Background Technology

[0002] With the rapid development of industrialized construction and prefabricated building technologies, modular construction, as a new type of construction method that is efficient, environmentally friendly, and offers controllable quality, has been increasingly widely used in residential, hotel, and apartment buildings. Among these, concrete modular systems, due to their excellent integrity, durability, and fire resistance, have become one of the important technical approaches for modular construction. Currently, existing concrete modules typically involve the prefabrication of some structural components, such as walls and floor slabs, in a factory, followed by transportation to the construction site for hoisting and assembly.

[0003] However, the integration level of current concrete modules is generally low, with most remaining in a semi-prefabricated state. In actual construction, although some structures are prefabricated in the factory, a significant amount of work still needs to be done on-site at the connection points between modules, joint areas, and some structural extensions. A particularly prominent problem is the insufficient integration of formwork engineering in existing technologies, resulting in a substantial expenditure of manpower and time on-site for formwork installation and reinforcement.

[0004] Specifically, in traditional construction methods, formwork systems need to be erected on-site to pour concrete at connection points or to fill gaps. These formworks are often assembled from loose components, requiring on-site measurement, cutting, and fixing. This process is cumbersome, and the installation accuracy of the formwork directly affects the quality of the concrete. Furthermore, the formwork turnover rate is low, resulting in significant material waste. These on-site operations extend the construction period and increase labor costs and safety risks. Summary of the Invention

[0005] (a) Technical problems to be solved

[0006] In view of the above-mentioned shortcomings and deficiencies of the prior art, the present invention provides a concrete module system and construction method with integrated templates, which solves the technical problems of low integration of existing concrete modules, large workload of template installation, low construction efficiency, and difficulty in quality control.

[0007] (II) Technical Solution

[0008] To achieve the above objectives, the main technical solutions adopted by the present invention include:

[0009] In a first aspect, embodiments of the present invention provide a concrete module system with integrated formwork, comprising at least two layers of concrete modules connected sequentially in a vertical direction, each layer of concrete modules consisting of multiple modules spliced ​​in a horizontal direction; each module includes a top plate, a bottom plate, a vertical member connecting the top plate and the bottom plate, an outer formwork, and a connecting assembly; the outer formwork is detachably connected to the outside of the vertical member, and the outer formwork and the vertical member together enclose a pouring cavity for on-site concrete pouring; the outer formwork includes pre-installed formwork units and post-installed formwork units, the pre-installed formwork units being pre-installed in the factory on the outside of the vertical member, and the post-installed formwork units being used for on-site installation at the joints of the pre-installed formwork units and at the horizontal splicing positions of two adjacent modules; the connecting assembly is disposed within the pouring cavity and is used to connect two adjacent upper and lower modules.

[0010] Preferably, the vertical components include shear walls and partition walls. The shear walls include single-sided composite shear walls located in the edge component area and fully prefabricated shear walls located in the non-edge component area. The prefabricated template unit includes a first prefabricated template and a second prefabricated template. The first prefabricated template is L-shaped and installed on the outside of the shear wall at the outer edge corner. The first and second prefabricated templates are located on both sides of the fully prefabricated shear wall and are detachably connected to it. The second prefabricated template is detachably installed at the horizontal splice of the shear wall and partition wall. The post-installed formwork unit includes a first post-installed formwork and a second post-installed formwork. The first post-installed formwork is L-shaped and is located at the lower end of the first pre-installed formwork, the fully prefabricated shear wall, and the second pre-installed formwork, and is detachably connected to the three. The first pre-installed formwork, the second pre-installed formwork, the first post-installed formwork, the single-sided composite shear wall, the fully prefabricated shear wall, and the partition wall together enclose an annular casting cavity. The second post-installed formwork is located at the horizontal splicing point of two adjacent modules, and the second post-installed formwork and the single-sided composite shear wall together enclose a T-shaped casting cavity.

[0011] Preferably, the pre-installed template unit further includes a third pre-installed template; the third pre-installed template is pre-installed in the factory on the upper part of the outside of the vertical member, and is detachably connected to the edge of the top plate and the first and second pre-installed templates. The third pre-installed template, together with the top plate and the vertical member, encloses the beam formwork casting cavity for on-site concrete pouring.

[0012] Preferably, the first pre-installed template includes a template panel and a plurality of horizontally and vertically arranged reinforcing ribs fixed to the outside of the template panel; the second pre-installed template, the third pre-installed template, the first post-installed template and the second post-installed template all have the same structure as the first pre-installed template.

[0013] Preferably, the pre-assembled template unit further includes a plurality of first connectors, which are arranged at intervals along the adjacent edges of the first pre-assembled template, the second pre-assembled template, and the third pre-assembled template and the vertical member, for the purpose of achieving a detachable connection; the post-assembled template unit further includes a plurality of second connectors and a plurality of third connectors, the second connectors being arranged at intervals along the adjacent edges of the first post-assembled template and the second post-assembled template and the vertical member, for the purpose of achieving a detachable connection, and the third connectors being arranged at intervals along the adjacent edges of the first post-assembled template and the first pre-assembled template, for the purpose of achieving a detachable connection between the two.

[0014] Preferably, multiple vertically connected pouring channels are opened at intervals on the fully precast shear wall; the annular pouring cavity, the beam formwork pouring cavity, and the pouring channels together form the pouring cavity.

[0015] Preferably, the connection assembly includes a pre-installed connection unit and a post-installed connection unit; the pre-installed connection unit is pre-installed in the factory between the pre-installed template unit and the steel reinforcement cage of the vertical component; the post-installed connection unit is installed on site between the post-installed template unit and the steel reinforcement cage of the vertical component at the splicing point of two horizontally adjacent modules.

[0016] Preferably, both the pre-installed connection unit and the post-installed connection unit include multiple vertical ribs and multiple threaded sleeves. The multiple vertical ribs are spaced apart between the outer template and the vertical components, and their upper ends extend vertically out of the upper edge of the module. Both ends are provided with external threaded sections. The threaded sleeves are used to connect and mate with the external threaded sections of the vertical ribs of the upper and lower adjacent modules.

[0017] Preferably, both the pre-installed connection unit and the post-installed connection unit further include multiple annular reinforcing ribs; the multiple annular reinforcing ribs are spaced apart on the outside of the multiple vertical ribs along the vertical direction.

[0018] Secondly, embodiments of the present invention provide a construction method for a concrete module system with integrated formwork, which includes the following steps:

[0019] S1. Hoisting and Positioning: Hoist the third module inside the first concrete module layer to the construction position, and perform calibration and positioning. Then hoist the first module located on one side of the outer edge of the concrete module layer and the second module located on the other side of the outer edge of the concrete module layer to the construction position, and perform calibration and positioning.

[0020] S2. Install the connection components: Install the connection components on the located module;

[0021] S3. Install the post-installed template unit: Install the post-installed template unit at the joint of the pre-installed template unit and at the horizontal splicing position of the adjacent module;

[0022] S4. Concrete pouring: Pouring concrete into the pouring cavity;

[0023] S5. Curing and Formwork Removal: After the poured concrete reaches the predetermined strength, remove the pre-installed formwork units and the post-installed formwork units.

[0024] S6. Layer-by-layer construction: Repeat steps S1 to S5, constructing layer by layer until the design height is reached.

[0025] (III) Beneficial Effects

[0026] The beneficial effects of this invention are:

[0027] This invention discloses an integrated formwork concrete module system and construction method. Because the modules are prefabricated in the factory, integrating the top slab, bottom slab, vertical components, and pre-installed formwork units, a significant amount of traditional on-site rebar tying and formwork installation work is transferred to the factory environment. This greatly reduces the workload and preparation work on-site, such as formwork support and rebar processing, thus improving overall construction efficiency. Only a small amount of rebar tying, installation of the pre-installed formwork units, and concrete pouring are required on-site, simplifying the construction process and significantly saving time, making it particularly suitable for projects requiring rapid construction. The key external formwork and connecting components are prefabricated and installed in the factory, with a stable processing environment and strict control standards, which helps ensure the dimensional accuracy of components, the quality of concrete forming, and the reliability of the overall structure, reducing quality fluctuations that may be caused by on-site human factors. Attached Figure Description

[0028] Figure 1 This is a schematic diagram of the overall structure of the pre-installed formwork unit of the integrated formwork concrete module system of the present invention.

[0029] Figure 2 This is a schematic diagram of the overall structure of a concrete module system with integrated template according to the present invention;

[0030] Figure 3 for Figure 2 Enlarged view of point A in the middle;

[0031] Figure 4 This is a schematic diagram of the overall structure of the first module;

[0032] Figure 5 for Figure 4 Enlarged view of point B in the middle;

[0033] Figure 6 This is a schematic diagram of the overall structure of the second module;

[0034] Figure 7 This is a schematic diagram of the overall structure of the third module;

[0035] Figure 8 This is a top view schematic diagram of a concrete module system with integrated template according to the present invention;

[0036] Figure 9 for Figure 8 Enlarged view of point C in the middle;

[0037] Figure 10 for Figure 8 Enlarged view of point D in the middle;

[0038] Figure 11 This is a front view diagram of the connecting components.

[0039] [Explanation of Labels in the Attached Image]

[0040] 1: Vertical structural member; 11: Shear wall; 111: Single-sided composite shear wall; 112: Fully precast shear wall; 1121: Casting channel; 1122: Installation hole; 113: Wall formwork; 12: Partition wall; 121: Partition wall body; 122: Ring beam; 123: Structural column;

[0041] 2: Top slab;

[0042] 3: Outer template; 31: Pre-installed template unit; 311: First pre-installed template; 3111: Template panel; 3112: Reinforcing rib; 312: Second pre-installed template; 313: First connector; 314: Third pre-installed template; 315: Fourth connector; 32: Rear-installed template unit; 321: First rear-installed template; 322: Second rear-installed template; 323: Second connector; 324: Third connector;

[0043] 4: Connecting assembly; 41: Pre-installed connecting unit; 411: Vertical rib; 4111: External thread section; 412: Threaded sleeve; 413: Annular reinforcing rib; 414: Fastening nut; 42: Post-installed connecting unit;

[0044] 5: Base plate;

[0045] a: Module 1; b: Module 2; c: Module 3. Detailed Implementation

[0046] To better explain and facilitate understanding of the present invention, the present invention will be described in detail below with reference to the accompanying drawings and specific embodiments.

[0047] To better understand the above technical solutions, exemplary embodiments of the present invention will be described in more detail below with reference to the accompanying drawings. Although exemplary embodiments of the present invention are shown in the drawings, it should be understood that the present invention can be implemented in various forms and should not be limited to the embodiments set forth herein. Rather, these embodiments are provided so that the present invention can be understood more clearly and thoroughly, and that the scope of the present invention can be fully conveyed to those skilled in the art.

[0048] Example 1:

[0049] like Figure 1 and Figure 2 As shown, this embodiment provides a concrete module system with integrated formwork, including at least two layers of concrete modules connected sequentially in the vertical direction. Each concrete module layer consists of multiple modules spliced ​​together in the horizontal direction. Specifically, the module includes a top plate 2, a bottom plate 5, a vertical member 1 connecting the top plate 2 and the bottom plate 5, an outer formwork 3, and a connecting component 4. The outer formwork 3 is detachably connected to the outside of the vertical member 1. The outer formwork 3 and the vertical member 1 together enclose a pouring cavity for on-site concrete pouring. The connecting component 4 is disposed within the pouring cavity and is used to connect two adjacent upper and lower module layers.

[0050] Furthermore, the vertical member 1 includes a shear wall 11 and a partition wall 12. The shear wall 11 includes a single-sided composite shear wall 111 located in the edge member area and a fully prefabricated shear wall 112 located in the non-edge member area.

[0051] Specifically, the partition wall 12 includes a partition wall body 121 and ring beams 122 and structural columns 123 arranged around the partition wall body 121. The partition wall body 121 is preferably made of ALC (autoclaved aerated concrete) panels, which have a low density, significantly reducing the overall weight of the module and facilitating transportation and hoisting. The ring beams 122 are cast-in-place or precast concrete beams, fixedly installed on the upper and lower sides of the partition wall body 121, and the structural columns 123 are cast-in-place or precast concrete columns, fixedly installed on the left and right sides of the partition wall body 121. The ring beams 122 and structural columns 123 reinforce and enclose the partition wall body 121, together forming a stable lightweight partition wall 12, effectively enhancing the integrity and structural strength of this part of the wall.

[0052] It should be noted that the combination of shear wall 11 and partition wall 12 described above is only one specific implementation of vertical component 1, and is not the only limitation on the modular structure. Under the modular system framework provided by this invention, the specific composition of the vertical component 1 of the module can be changed and adjusted according to actual engineering needs. For example, other types of structural walls or non-load-bearing walls can also be used for combination and substitution.

[0053] like Figure 2As shown, the outer formwork 3 includes pre-installed formwork units 31 and post-installed formwork units 32. The pre-installed formwork units 31 are pre-installed in the factory on the outside of the vertical component 1, and the post-installed formwork units 32 are installed on-site at the joints of the pre-installed formwork units 31 and at the horizontal splicing positions of adjacent modules. Since the modules integrate the top slab 2, bottom slab 5, vertical component 1, and pre-installed formwork units 31 during factory prefabrication, a large amount of rebar tying and formwork installation work that traditionally needs to be completed on-site is transferred to the factory environment. This greatly reduces the amount of work and preparation required for formwork support, rebar processing, etc., on the construction site, and improves overall construction efficiency. Only a small amount of rebar tying, installation of post-installed formwork units 32, and concrete pouring are required on-site, simplifying the construction process and significantly saving construction time, especially suitable for projects requiring rapid construction. The critical outer formwork 3 and connecting components 4 are prefabricated and installed in the factory, with a stable processing environment and strict control standards, which helps ensure the dimensional accuracy of components, the quality of concrete forming, and the reliability of the overall structure, reducing quality fluctuations that may be caused by human factors on-site.

[0054] like Figure 2 As shown, the prefabricated template unit 31 includes a first prefabricated template 311 and a second prefabricated template 312. The first prefabricated template 311 is L-shaped and is installed on the outer side of the shear wall 11 at the outer edge corner. The first prefabricated template 311 and the second prefabricated template 312 are located on both sides of the fully prefabricated shear wall 112 and are detachably connected to the fully prefabricated shear wall 112. The second prefabricated template 312 is detachably installed at the horizontal splice of the shear wall 11 and the partition wall 12. The second prefabricated template 312 and the first prefabricated template 311 are arranged opposite to each other, jointly defining the pouring space on both sides of the fully prefabricated shear wall 112. This allows the concrete to be poured and vibrated simultaneously and evenly on both sides of the fully prefabricated shear wall 112, effectively avoiding quality problems such as uneven lateral pressure, incomplete filling, or component displacement that may occur with unilateral pouring, thereby ensuring the symmetry and integrity of the newly poured concrete on both sides of the fully prefabricated shear wall 112.

[0055] Preferably, the pre-installed template unit 31 further includes a third pre-installed template 314, which is pre-installed at the upper end of the outside of the vertical member 1 in the factory and is detachably connected to the edge of the top plate 2 and the first pre-installed template 311 and the second pre-installed template 312. The third pre-installed template 314, together with the top plate 2 and the vertical member 1, encloses a beam formwork casting cavity for on-site concrete pouring.

[0056] Specifically, the third pre-installed template 314 is pre-installed on the top of the partition wall 12, the upper area outside the fully prefabricated shear wall 112, and between the first pre-installed template 311 and the post-installed template unit 32.

[0057] It should be noted that the above embodiments are merely one specific implementation of the present invention, used to illustrate the installation position and connection relationship of the third pre-installed template 314. Those skilled in the art should understand that the installation position, connection method, and specific structure of the beam casting cavity formed by the third pre-installed template 314 are not limited thereto, and other equivalent alternatives or variations can be adopted according to actual engineering needs. These alternatives should all be included within the protection scope of the present invention.

[0058] like Figure 8 As shown, the post-installed template unit 32 includes a first post-installed template 321 and a second post-installed template 322. The first post-installed template 321 is L-shaped and is located at the lower end of the first pre-installed template 311, the fully prefabricated shear wall 112, and the second pre-installed template 312, and is detachably connected to the three. The first pre-installed template 311, the second pre-installed template 312, the first post-installed template 321, the single-sided composite shear wall 111, the fully prefabricated shear wall 112, and the partition wall 12 together enclose an annular casting cavity. The second post-installed template 322 is located at the horizontal splicing point of two adjacent modules, and the second post-installed template 322 and the single-sided composite shear wall 111 together enclose a T-shaped casting cavity.

[0059] Preferably, such as Figure 9 As shown, to further ensure the uniformity, fluidity, and density of the concrete pouring, especially to ensure sufficient filling in the vertical height, multiple vertically penetrating pouring channels 1121 are opened at intervals on the fully precast shear wall 112. The pouring channels 1121 allow the concrete slurry to flow from one side of the pouring chamber to the other side through the channels, balancing the liquid level and pressure of the concrete on both sides, ensuring that the fully precast shear wall 112 is uniformly and densely wrapped, while enhancing the bond strength and mechanical interlocking of the new and old concrete, forming a composite structure with better overall integrity.

[0060] The annular casting cavity, the T-shaped casting cavity, the beam formwork casting cavity, and the casting channel 1121 together constitute the casting cavity.

[0061] like Figure 3 As shown, the first pre-assembled template 311 includes a template panel 3111 and multiple horizontally and vertically arranged reinforcing ribs 3112 fixed to the outside of the template panel 3111. The reinforcing ribs 3112 are used to provide support and reinforcement for the template panel 3111 during concrete pouring, effectively resisting the lateral pressure of the concrete, preventing excessive deformation or bulging of the template panel 3111, thereby ensuring the flatness and verticality of the concrete forming surface.

[0062] Preferably, the template panel 3111 is an aluminum template, and the reinforcing ribs 3112 are metal profiles. Of course, the template panel 3111 can also be made of other materials such as wood templates.

[0063] Preferably, the thickness of the template panel 3111 is 4mm-6mm.

[0064] The second pre-installed template 312, the third pre-installed template 314, the first post-installed template 321 and the second post-installed template 322 are all structurally the same as the first pre-installed template 311, and will not be described in detail here.

[0065] It should be noted that the L-shaped first pre-installed template 311 and the L-shaped first post-installed template 321 can be integral components formed in one piece, or they can be formed by connecting two or more independent template panels 3111.

[0066] like Figure 3 and Figure 5 As shown, the pre-assembled template unit 31 further includes multiple first connectors 313 and multiple fourth connectors 315. The first connectors 313 are arranged at intervals along the adjacent edges of the first pre-assembled template 311 and the second pre-assembled template 312 and the vertical member 1, for detachable connection. The fourth connectors 315 are arranged at intervals along the adjacent edges of the first pre-assembled template 311 and the second pre-assembled template 312 and the third pre-assembled template 314, for detachable connection. The post-assembled template unit 32 further includes multiple second connectors 323 and multiple third connectors 324. The second connectors 323 are arranged at intervals along the adjacent edges of the first post-assembled template 321 and the second post-assembled template 322 and the vertical member 1, for detachable connection. The third connectors 324 are arranged at intervals along the adjacent edges of the first post-assembled template 321 and the first pre-assembled template 311, for detachable connection between the two.

[0067] Specifically, the precast shear wall 112 is provided with a plurality of mounting holes 1122 spaced apart, and the reinforcing rib 3112 is provided with a plurality of first connecting holes at corresponding positions. The first connecting member 313 and the second connecting member 323 can both pass through the mounting holes 1122 and the first connecting holes 3113 in sequence along the horizontal direction, thereby realizing the detachable connection between the precast template unit 31 and the post-installed template unit 32 and the precast shear wall 112.

[0068] Multiple sets of second connecting holes are provided at corresponding intervals on the reinforcing ribs adjacent to the first pre-installed template 311 and the first post-installed template 321. The third connector 324 passes through the vertically aligned second connecting holes to realize the detachable connection between the first pre-installed template 311 and the first post-installed template 321.

[0069] Furthermore, the first connector 313, the fourth connector 315, the second connector 323, and the third connector 324 have the same structure, each including a connecting screw, a nut, and a washer. During installation, one end of the connecting screw is screwed into the mounting hole 1122 or the second connecting hole of a reinforcing rib, while the other end passes sequentially through the corresponding first connecting hole or the second connecting hole of another reinforcing rib, then the washer is fitted, and finally, the screw is tightened with the nut. During disassembly, simply loosening the nut and removing the washer allows the connecting screw to be removed, enabling quick disassembly of each template.

[0070] like Figure 8 As shown, the connecting component 4 includes a pre-installed connecting unit 41 and a post-installed connecting unit 42. The pre-installed connecting unit 41 is pre-installed in the factory between the pre-installed template unit 31 and the steel reinforcement cage of the vertical component 1, while the post-installed connecting unit 42 is installed on-site between the post-installed template unit 32 and the steel reinforcement cage of the vertical component 1 at the splicing point of two horizontally adjacent modules.

[0071] like Figure 11 As shown, both the pre-installed connection unit 41 and the post-installed connection unit 42 include multiple vertical ribs 411, multiple threaded sleeves 412, and multiple fastening nuts 414. The multiple vertical ribs 411 are spaced apart between the outer template 3 and the single-sided composite shear wall 111, with their upper ends extending vertically outwards from the upper edge of the module. Both ends are provided with external threaded sections 4111. The threaded sleeves 412 are used to connect and mate with the external threaded sections 4111 of the vertical ribs 411 of adjacent upper and lower modules. The fastening nuts 414 are screwed onto the external threaded sections 4111 of the lower vertical rib 411 and supported at the bottom of the threaded sleeves 412, used to pre-tighten and lock the threaded sleeves 412 to ensure a firm and reliable connection. When connecting two adjacent modules, simply hoist and align the upper module, insert the lower threaded section 4111 of its vertical rib 411 into the corresponding threaded sleeve 412 of the lower module, and then rotate and tighten the nut 414 to achieve a quick and precise connection.

[0072] like Figure 9 As shown, both the pre-installed connection unit 41 and the post-installed connection unit 42 further include multiple annular reinforcing ribs 413. These annular reinforcing ribs 413 are spaced vertically around the external of the multiple vertical reinforcing ribs 411. The annular reinforcing ribs 413 provide effective lateral restraint for the vertical reinforcing ribs 411, significantly improving their stability under compression and preventing lateral bending or instability under concrete pouring pressure or structural loads, thus ensuring the reliability of the connection assembly 4 during construction and use.

[0073] It should be noted that the annular reinforcing rib 413 of the pre-installed connection unit 41 is pre-embedded in the factory between the pre-installed template unit 31 and the steel reinforcement skeleton of the vertical component 1, while the annular reinforcing rib 413 of the post-installed connection unit 42 needs to be installed and tied on site between the post-installed template unit 32 and the steel reinforcement skeleton of the vertical component 1 at the splicing point of two horizontally adjacent modules.

[0074] Preferably, such as Figure 9 As shown, the precast shear wall 112 located between the first precast template 311 and the second precast template 312 has multiple vertical reinforcing bars 411 embedded in it, each with externally threaded sections 4111 at both ends. These embedded vertical reinforcing bars 411 are tightly integrated with the concrete and internal steel reinforcement of the precast shear wall 112, working together to significantly improve the vertical bearing capacity and shear resistance of the precast shear wall 112 itself. Simultaneously, these vertical reinforcing bars 411, as key components for force transmission between upper and lower structural layers, effectively transfer the load to the entire shear wall section, avoiding stress concentration and optimizing the force flow path.

[0075] like Figure 1 , Figure 4 , Figure 6 and Figure 7 As shown, three types of modules are set up, including a first module a located at the outer edge of one side of the concrete module layer, a second module b located at the outer edge of the other side of the concrete module layer, and a third module c located inside the concrete module layer. When there are two modules in the concrete module layer, the concrete module layer includes the first module a and the second module b; when there are three modules in the concrete module layer, the concrete module layer includes the first module a, the second module b, and the third module c; when there are more than three concrete module layers, the concrete module layer includes the first module a, the second module b, and multiple third modules c.

[0076] like Figure 10 As shown, the T-shaped casting cavity is equipped with transversely and longitudinally distributed reinforcing bars and multiple spaced tie rods. By pouring concrete into this cavity, a transverse connection between two adjacent modules can be achieved.

[0077] like Figure 8 As shown, during concrete pouring construction, concrete can be poured simultaneously or in batches into the beam formwork pouring cavity, the annular pouring cavity, and the T-shaped pouring cavity. Finally, the modules are connected as a whole through the solidification of the concrete.

[0078] It should be understood that this embodiment is merely one specific implementation of the present invention, demonstrating a feasible structure for an integrated formwork concrete module. The core concept of the outer formwork 3 and connecting component 4 provided by the present invention can also be applied to other types of concrete modules. In practical applications, those skilled in the art can make adaptive adjustments and changes to the specific construction, dimensions, installation position, and connection method of the outer formwork 3 and / or connecting component 4 according to the specific structural form and functional requirements of the module. All such adjustments and changes should be considered as not departing from the protection scope of the present invention.

[0079] Example 2:

[0080] This embodiment provides a construction method for a concrete module system with integrated formwork, using the concrete module system with integrated formwork from Embodiment 1, and includes the following steps:

[0081] S1. Hoisting and positioning: Hoist the third module c inside the first concrete module layer to the construction position, and perform calibration and positioning. Then hoist the first module a, which is located on one side of the outer edge of the concrete module layer, and the second module b, which is located on the other side of the outer edge of the concrete module layer, to the construction position, and perform calibration and positioning.

[0082] S2. Install connection component 4: Install connection component 4 on the located module;

[0083] When constructing the first layer of concrete modules: install the post-installed connection unit 42 at the horizontal splicing position of two adjacent modules;

[0084] When constructing a non-first-layer concrete module: First, install the post-installed connection unit 42 at the horizontal splicing position of two adjacent modules. Then, align the external thread section 4111 at the lower end of the vertical rib 411 of the upper module and insert it into the corresponding threaded sleeve 412 of the lower module. Finally, connect the upper and lower modules by tightening the threaded sleeve 412.

[0085] S3. Install the post-installed template unit 32: Install the post-installed template unit 32 at the lower end of the pre-installed template unit 31 and at the horizontal splicing position of the adjacent modules;

[0086] S4. Concrete pouring: Pour concrete into the pouring cavity formed between the outer formwork 3 and the shear wall 11;

[0087] Specifically, concrete is poured simultaneously or separately in the annular pouring cavity, the T-shaped pouring cavity, the beam formwork pouring cavity, and the pouring channel 1121;

[0088] S5. Curing and formwork removal: After the poured concrete reaches the predetermined strength, remove the pre-installed formwork unit 31 and the post-installed formwork unit 32.

[0089] S6. Layer-by-layer construction: Repeat steps S1 to S5, constructing layer by layer until the design height is reached.

[0090] In the description of this invention, it should be understood that the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of indicated technical features. Therefore, a feature defined as "first" or "second" may explicitly or implicitly include one or more of that feature. In the description of this invention, "a plurality of" means two or more, unless otherwise explicitly specified.

[0091] In this invention, unless otherwise explicitly specified and limited, the terms "installation," "connection," "linking," and "fixing," etc., should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral part; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication of two components or the interaction between two components. Those skilled in the art can understand the specific meaning of the above terms in this invention according to the specific circumstances.

[0092] In this invention, unless otherwise explicitly specified and limited, "above" or "below" the second feature can mean that the first and second features are in direct contact, or that they are in indirect contact through an intermediate medium. Furthermore, "above," "over," or "on top" the second feature can mean that the first feature is directly above or diagonally above the second feature, or simply indicates that the first feature is at a higher horizontal level than the second feature. "Below," "below," or "beneath" the second feature can mean that the first feature is directly below or diagonally below the second feature, or simply indicates that the first feature is at a lower horizontal level than the second feature.

[0093] In the description of this specification, the terms "one embodiment," "some embodiments," "embodiment," "example," "specific example," or "some examples," etc., refer to specific features, structures, materials, or characteristics described in connection with that embodiment or example, which are included in at least one embodiment or example of the present invention. In this specification, the illustrative expressions of the above terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in one or more embodiments or examples. Moreover, without contradiction, those skilled in the art can combine and integrate the different embodiments or examples described in this specification, as well as the features of different embodiments or examples.

[0094] Although embodiments of the present invention have been shown and described above, it is understood that the above embodiments are exemplary and should not be construed as limiting the present invention. Those skilled in the art can make modifications, alterations, substitutions and variations to the above embodiments within the scope of the present invention.

Claims

1. A concrete module system with integrated formwork, characterized in that, It includes at least two layers of concrete modules connected in a vertical direction, each of which consists of multiple modules spliced ​​together in a horizontal direction; The module includes a top plate (2), a bottom plate (5), a vertical member (1) connecting the top plate (2) and the bottom plate (5), an outer template (3), and a connecting component (4); The outer template (3) is detachably connected to the outside of the vertical member (1), and the outer template (3) and the vertical member (1) together enclose a pouring cavity for on-site concrete pouring; The outer template (3) includes a pre-installed template unit (31) and a post-installed template unit (32). The pre-installed template unit (31) is pre-installed on the outside of the vertical component (1) in the factory. The post-installed template unit (32) is used to be installed on site at the joint of the pre-installed template unit (31) and at the horizontal splicing position of two adjacent modules. The connecting component (4) is disposed in the casting cavity and is used to connect the upper and lower adjacent modules.

2. The integrated formwork concrete module system as described in claim 1, characterized in that: The vertical member (1) includes a shear wall (11) and a partition wall (12). The shear wall (11) includes a single-sided composite shear wall (111) located in the edge member area and a fully prefabricated shear wall (112) located in the non-edge member area. The prefabricated template unit (31) includes a first prefabricated template (311) and a second prefabricated template (312). The first prefabricated template (311) is L-shaped and is installed on the outside of the shear wall (11) at the outer edge corner. The first prefabricated template (311) and the second prefabricated template (312) are located on both sides of the fully prefabricated shear wall (112) and are detachably connected to the fully prefabricated shear wall (112). The second prefabricated template (312) is detachably installed at the horizontal splice of the shear wall (11) and the partition wall (12). The post-installed template unit (32) includes a first post-installed template (321) and a second post-installed template (322). The first post-installed template (321) is L-shaped and is located at the lower end of the first pre-installed template (311), the fully prefabricated shear wall (112), and the second pre-installed template (312), and is detachably connected to the three. The first pre-installed template (311), the second pre-installed template (312), the first post-installed template (321), the single-sided composite shear wall (111), the fully prefabricated shear wall (112), and the partition wall (12) together enclose an annular casting cavity. The second post-installed template (322) is located at the horizontal splicing point of two adjacent modules. The second post-installed template (322) and the single-sided composite shear wall (111) together enclose a T-shaped casting cavity.

3. The integrated formwork concrete module system as described in claim 2, characterized in that: The pre-installed template unit (31) also includes a third pre-installed template (314); The third pre-installed template (314) is pre-installed at the upper end of the outside of the vertical member (1) in the factory, and is detachably connected to the edge of the top plate (2) and the first pre-installed template (311) and the second pre-installed template (312). The third pre-installed template (314), the top plate (2) and the vertical member (1) together enclose a beam casting cavity for on-site concrete pouring.

4. The integrated formwork concrete module system as described in claim 3, characterized in that: The first pre-installed template (311) includes a template panel (3111) and a plurality of horizontally and vertically arranged reinforcing ribs (3112) fixed to the outside of the template panel (3111). The second pre-installed template (312), the third pre-installed template (314), the first post-installed template (321) and the second post-installed template (322) are all structurally the same as the first pre-installed template (311).

5. The integrated formwork concrete module system as described in claim 3, characterized in that: The pre-installed template unit (31) also includes a plurality of first connectors (313), which are arranged at intervals along the adjacent edges of the first pre-installed template (311), the second pre-installed template (312) and the third pre-installed template (314) and the vertical member (1) to achieve detachable connection; The post-installed template unit (32) further includes a plurality of second connectors (323) and a plurality of third connectors (324). The second connectors (323) are arranged at intervals along the adjacent edges of the first post-installed template (321) and the second post-installed template (322) and the vertical member (1) to achieve a detachable connection. The third connectors (324) are arranged at intervals along the adjacent edges of the first post-installed template (321) and the first pre-installed template (311) to achieve a detachable connection between the two.

6. The integrated formwork concrete module system as described in claim 3, characterized in that: Multiple vertically connected pouring channels (1121) are opened at intervals on the precast shear wall (112). The annular casting cavity, the beam mold casting cavity, and the casting channel (1121) together constitute the casting cavity.

7. The integrated formwork concrete module system as described in claim 1, characterized in that: The connection component (4) includes a pre-installed connection unit (41) and a post-installed connection unit (42). The pre-installed connection unit (41) is pre-installed in the factory between the pre-installed template unit (31) and the steel reinforcement skeleton of the vertical member (1); The post-installed connection unit (42) is installed on site between the post-installed template unit (32) and the steel reinforcement skeleton of the vertical member (1) at the splicing point of two horizontally adjacent modules.

8. The integrated formwork concrete module system as described in claim 7, characterized in that: Both the pre-installed connection unit (41) and the post-installed connection unit (42) include multiple vertical ribs (411) and multiple threaded sleeves (412). The multiple vertical ribs (411) are spaced apart between the outer template (3) and the vertical member (1), and their upper ends extend vertically out of the upper edge of the module. Both ends are provided with external threaded sections (4111). The threaded sleeves (412) are used to connect and connect the external threaded sections (4111) of the vertical ribs (411) of the two adjacent layers of the module.

9. The integrated formwork concrete module system as described in claim 8, characterized in that: Both the pre-installed connection unit (41) and the post-installed connection unit (42) further include multiple annular reinforcing ribs (413). Multiple annular reinforcing ribs (413) are spaced apart on the outside of multiple vertical ribs (411) along the vertical direction.

10. A construction method for an integrated formwork concrete module system, characterized in that: The concrete module system using the integrated formwork as described in any one of claims 1-9 comprises the following steps in sequence: S1. Hoisting and positioning: Hoist the third module (c) inside the first concrete module layer to the construction position, and perform calibration and positioning. Then hoist the first module (a) located on one side of the outer edge of the concrete module layer and the second module (b) located on the other side of the outer edge of the concrete module layer to the construction position, and perform calibration and positioning. S2, Install the connecting component (4): Install the connecting component (4) on the positioned module; S3. Install the post-installed template unit (32): Install the post-installed template unit (32) at the joint of the pre-installed template unit (31) and at the horizontal splicing position of the adjacent modules. S4. Concrete pouring: Pouring concrete into the pouring cavity; S5. Curing and demolding: After the poured concrete reaches the predetermined strength, the pre-installed formwork unit (31) and the post-installed formwork unit (32) are removed. S6. Layer-by-layer construction: Repeat steps S1 to S5, constructing layer by layer until the design height is reached.

Images