High-standard terrace integrated construction method and separator

Abstract

The invention belongs to the technical field of building terrace construction, and provides a high-standard terrace integrated construction method and a separator, and the construction method comprises the following steps: S1, foundation treatment; s2, laying a graded broken stone hardcore; s3, a concrete cushion layer is poured; s4, laying a moisture-proof and vapor-resistant film; s5, pre-burying a metal galvanized armored seam; s6, steel fiber concrete terraces are poured in different bins in a lattice-jumping mode; s7, composite high-hardness wear-resistant aggregate is spread; s8, inducing joint cutting treatment; s9, a concrete sealing curing agent is applied, and grinding and polishing are conducted; and S10, locally coating a wear-resistant organic coating. Compared with the prior art, the full-chain high-performance terrace system from a base layer to a surface layer is constructed through the working procedures of system integration foundation treatment, damp-proof isolation, structural bin separation, steel fiber reinforcement, laser leveling, wear-resistant layer compounding, induced joint cutting, sealing curing and the like. According to the method, the technical bottlenecks of poor flatness, easiness in cracking, insufficient wear resistance, moisture-proof failure, single function and the like of the traditional terrace are effectively solved.

Description

Technical Field

[0001] This invention belongs to the field of building flooring construction technology, specifically relating to a high-standard integrated flooring construction method and separator. Background Technology

[0002] With the rapid development of e-commerce, intelligent manufacturing, and modern logistics systems, the performance requirements for indoor flooring in large-scale automated warehousing and logistics centers are becoming increasingly stringent. Modern high-standard logistics flooring not only needs to withstand the high-frequency, high-concentration loads from high-bay racks, heavy forklifts, and automated guided vehicles (AGVs), but also needs to meet multiple technical indicators such as ultra-flat precision (e.g., a drop of ≤2mm with a 2m straightedge), high wear resistance, dustproofing, moisture resistance, crack resistance, and long-term durability to ensure the stable operation of automated equipment and the efficient operation of intelligent sorting systems.

[0003] However, traditional concrete floor construction techniques have significant shortcomings in meeting the above-mentioned comprehensive performance requirements:

[0004] First, controlling the flatness is difficult. Conventional manual leveling or ordinary vibratory leveling cannot achieve millimeter-level precision on large areas of the ground, which cannot meet the stringent requirements of AGV navigation for ground continuity.

[0005] Secondly, crack control is ineffective. Large-area concrete floors are prone to irregular cracks during the hardening process due to drying shrinkage, temperature changes, and foundation constraints. Traditional methods often rely on later-stage cutting of dummy joints to guide cracking, but these joints lack structural protection and are prone to edge chipping and corner breakage under heavy loads and repeated compaction, leading to joint expansion, height differences, and seriously affecting equipment passage safety.

[0006] Third, its wear resistance and dustproof performance are limited. Ordinary concrete has a low surface hardness (Mohs hardness is usually 4-5), and it is prone to sand and dust generation under frequent mechanical operations, which not only pollutes the storage environment but also accelerates equipment wear. Although there are practices such as spreading wear-resistant materials like corundum, their bonding strength with the base layer is insufficient, and they are prone to peeling off after long-term use.

[0007] Fourth, the moisture-proof system is weak. Groundwater vapor rises to the surface layer through capillary action, causing dampness in the floor, blistering of the coating, and even deterioration of the concrete. Conventional moisture-proof measures, such as applying asphalt or a thin layer of plastic film, often fail due to construction damage or poor overlap.

[0008] Fifth, low functional integration. Existing construction techniques are mostly "segmented" operations, with foundation treatment, moisture-proofing, structural layers, wear-resistant layers, and joint treatment being isolated from each other and lacking systematic collaborative design. This results in long construction periods, high costs, and quality problems such as hollowing and delamination between layers.

[0009] Therefore, there is an urgent need for a high-standard integrated floor construction method that combines high-bearing foundation, systematic moisture protection, precise leveling, composite crack resistance, high hardness and wear resistance, and intelligent joint control, along with a new type of separator with controllable fracture and sliding force transmission functions, in order to fundamentally solve the bottlenecks of existing technologies in terms of performance, durability and construction efficiency. Summary of the Invention

[0010] The technical problem to be solved by the present invention is to provide a high-standard integrated construction method and separator for flooring, in light of the current state of the technology.

[0011] The technical solution adopted by the present invention to solve the above-mentioned technical problems is as follows: a high-standard integrated construction method for flooring is proposed, including the following steps: S1, the original soil is treated by compacting the plain soil or using composite foundation reinforcement to make the foundation reach the compaction degree and bearing capacity required by the design.

[0012] S2. Lay a graded crushed stone cushion layer of predetermined thickness on the treated foundation and compact it to a dense state that meets the bearing capacity requirements.

[0013] S3. Pour a concrete base layer on the graded crushed stone base layer, and perform slurry finishing and surface cleaning to form a smooth base layer.

[0014] S4. A moisture-proof and vapor-barrier membrane is fully laid on the concrete cushion layer to prevent groundwater and water vapor from rising.

[0015] S5. Galvanized metal armor joints are pre-embedded along the axis of the factory building structural columns and around the column bases. The height of the armor joints is matched with the thickness of the subsequent concrete floor. The armor joints at the column bases are arranged in a ring to release constraint stress.

[0016] S6. The steel fiber reinforced concrete floor is poured using the compartmentalized skip-grid method. The concrete strength grade meets the requirements for heavy-duty flooring, and hook-shaped steel fibers are incorporated to enhance crack resistance and toughness. High-precision paving and leveling are performed using laser leveling equipment.

[0017] S7. During the initial setting stage of the concrete floor, composite high-hardness wear-resistant aggregate is evenly spread twice. The wear-resistant aggregate includes inorganic wear-resistant powder and titanium alloy particles. The total amount of spread is sufficient to form a high wear-resistant surface layer. The surface is then mechanically smoothed and polished as the slurry is finished.

[0018] S8. When the concrete floor reaches the predetermined strength, induced slit treatment is carried out inside the compartment enclosed by the galvanized metal armored joint. The slit spacing is determined according to the floor thickness and shrinkage characteristics. The slit depth is a certain proportion of the floor thickness and is filled with caulking material.

[0019] S9. Apply an inorganic concrete sealant and curing agent to the floor surface to allow it to fully penetrate and form a dense hardened layer. Then grind and polish the surface to achieve high hardness, low wear rate and dustproof performance. The sealant and curing agent is non-toxic, non-flammable and meets national fire safety standards.

[0020] S10. Apply a wear-resistant organic coating to specific areas such as factory passageways and area markings to enhance scratch resistance and visual recognition in those areas.

[0021] In the above-mentioned high-standard integrated construction method for flooring, in step S1, the compaction coefficient of the subgrade soil is not less than 0.95; or a cement-soil mixing pile composite foundation is adopted.

[0022] In step S2, the graded crushed stone cushion layer has a thickness of 300 mm and a compaction coefficient of not less than 0.97. The characteristic value of the bearing capacity of the foundation after treatment is f. ak ≥100kPa.

[0023] In the above-mentioned high-standard integrated floor construction method, in step S3, the thickness of the concrete cushion layer is 100mm and the concrete strength grade is C20.

[0024] In step S6, the thickness of the steel fiber reinforced concrete floor is 200mm, and the concrete strength grade is C30.

[0025] In the above-mentioned high-standard integrated floor construction method, in step S4, the moisture-proof and vapor barrier membrane is a 0.4mm thick HDPE geomembrane.

[0026] In the above-mentioned high-standard integrated floor construction method, in step S5, the spacing between the column grid axes of the factory building structure is 12m×24m;

[0027] The galvanized metal armor seam is a permanent true seam that runs through the entire thickness of the floor slab and serves as the boundary for the compartmentalized, stepped pouring.

[0028] In the aforementioned high-standard integrated flooring construction method, in step S6, the dosage of end-hook steel fibers is 16 kg / m². 3 The steel fibers are 60mm long, 0.75mm in diameter, and have an aspect ratio of 80. The steel fibers are bonded together in rows with water-soluble adhesive and have hooks at both ends to ensure uniform dispersion in the concrete.

[0029] In the aforementioned high-standard integrated flooring construction method, in step S7, the total spreading amount of composite high-hardness wear-resistant aggregate is not less than 8 kg / m³. 2 This includes 5kg / m 2 Inorganic wear-resistant powder and not less than 3kg / m 2The silicon-titanium alloy particles contain at least 8% titanium; the two application rates are each 2.5 kg / m³. 2 During the initial setting stage, mechanical polishing and grinding are carried out as the slurry is collected.

[0030] In the above-mentioned high-standard integrated floor construction method, in step S8, the spacing of the induced cuts is 6 to 12m, the width of the cuts is 5mm, the depth of the cuts is 1 / 3 of the thickness of the concrete floor, and cement mortar is used for caulking.

[0031] In the aforementioned high-standard integrated flooring construction method, in step S9, the inorganic concrete sealant penetrates the concrete to a depth of 5–8 mm. After treatment, the floor's Mohs hardness is not less than 7, and its abrasion resistance is not greater than 0.030 g / cm². 2 ;

[0032] In step S10, the wear-resistant organic coating is an epoxy resin coating with a coating thickness of 1.0 mm.

[0033] In order to solve the above-mentioned technical problems, the present invention also proposes a separator for use in the above-mentioned galvanized metal armor seam. The separator includes: a first main body and a second main body, the first main body and the second main body are disposed opposite to each other and are connected by at least one easily broken bolt.

[0034] Both ends of the first main body and the second main body are provided with downward bending portions, and each bending portion is provided with multiple punch holes for embedding into the concrete layer during concrete floor pouring to achieve anchoring.

[0035] A force transmission component is provided between the first main body and the second main body. The force transmission component includes a force transmission steel plate and a plastic plate-shaped sheath sleeved around the outer periphery of the force transmission steel plate. The plastic plate-shaped sheath sleeve is fixedly connected to the first main body and the second main body respectively. The two ends of the force transmission steel plate extend into the concrete layer corresponding to the first main body and the second main body respectively.

[0036] When the concrete layers on both sides of the separator undergo relative displacement due to shrinkage or deformation and reach a preset tensile force, the easily broken bolt breaks, causing the first main body to separate from the second main body. At the same time, the force-transmitting steel plate can slide within the plastic plate-shaped sheath to transmit vertical loads and allow relative displacement in the horizontal direction, thereby bearing the separated concrete layers and preventing height differences at the joint.

[0037] Compared with the prior art, the present invention has the following beneficial effects:

[0038] (1) By integrating processes such as foundation treatment, moisture-proof isolation, structural compartmentation, steel fiber reinforcement, laser leveling, composite wear-resistant layer, induced cutting and sealing curing, a full-chain high-performance flooring system from base layer to surface layer is constructed. This method effectively solves the technical bottlenecks of traditional flooring, such as poor flatness, easy cracking, insufficient wear resistance, moisture-proof failure and single function. It achieves multiple goals of ultra-flat precision, high crack resistance, ultra-high wear resistance, overall moisture-proof and green safety, significantly improving the comprehensive performance and service life of heavy-duty industrial flooring such as logistics and warehousing.

[0039] (2) By limiting the compaction coefficient of the subgrade soil to ≥0.95 or using a cement-soil mixing pile composite foundation, and setting the thickness of the graded crushed stone cushion layer to 300mm and the compaction coefficient to ≥0.97, the characteristic value f of the foundation bearing capacity is ensured. ak With a strength of ≥100kPa, it provides a stable, uniform, and high-load-bearing foundation support for the heavy-duty concrete floor above, effectively preventing floor cracking or deformation caused by uneven foundation settlement, and meeting the stringent requirements of automated warehousing equipment for long-term ground stability.

[0040] (3) Limiting the concrete subbase to 100mm thick C20 concrete can provide a flat and solid base interface; while 200mm thick C30 steel fiber concrete flooring takes into account both high strength and structural thickness, which can withstand the concentrated load of high-level racks and high-frequency passage of AGVs, and provide sufficient operating space and structural redundancy for subsequent wear-resistant layer and leveling process, ensuring the mechanical reliability and construction feasibility of the overall flooring system. Attached Figure Description

[0041] Figure 1 This invention provides a flowchart for the integrated construction process of high-standard flooring.

[0042] Figure 2 It is a diagram showing the layout of the galvanized metal armor seams and cuts for high-standard flooring.

[0043] Figure 3 This is a sectional view of the separator.

[0044] In the diagram, 100 is a galvanized metal armor seam; 200 is a structural column of the factory building; 300 is a cut; 400 is a partition; 410 is the first main body; 420 is the second main body; 430 is a easily broken bolt; 440 is a bent part; 450 is a punch; 460 is a force transmission steel plate; and 470 is a plastic plate-shaped sheath. Detailed Implementation

[0045] The following are specific embodiments of the present invention, which are described in conjunction with the accompanying drawings. However, the present invention is not limited to these embodiments.

[0046] It should be noted that all directional indications (such as up, down, left, right, front, back, etc.) in the embodiments of the present invention are only used to explain the relative positional relationship and movement of each component in a certain specific posture (as shown in the figure). If the specific posture changes, the directional indication will also change accordingly.

[0047] like Figures 1 to 2 As shown, the present invention provides a high-standard integrated flooring construction method, comprising the following steps:

[0048] S1. Perform foundation treatment on the original soil, using plain soil compaction or composite foundation reinforcement methods to ensure that the foundation reaches the required compaction degree and bearing capacity as designed.

[0049] S2. Lay a graded crushed stone cushion layer of predetermined thickness on the treated foundation and compact it to a dense state that meets the bearing capacity requirements.

[0050] S3. Pour a concrete base layer on the graded crushed stone base layer, and perform slurry finishing and surface cleaning to form a smooth base layer.

[0051] S4. A moisture-proof and vapor-barrier membrane is fully laid on the concrete cushion layer to prevent groundwater and water vapor from rising.

[0052] S5. Galvanized metal armor joints 100 are pre-embedded along the axis of the structural column 200 of the factory building and around the column base of the structural column 200. The height of the armor joint is matched with the thickness of the subsequent concrete floor. The armor joints at the column base are arranged in a ring to release the constraint stress.

[0053] S6. The steel fiber reinforced concrete floor is poured using the compartmentalized skip-grid method. The concrete strength grade meets the requirements for heavy-duty flooring, and hook-shaped steel fibers are incorporated to enhance crack resistance and toughness. High-precision paving and leveling are performed using laser leveling equipment.

[0054] S7. During the initial setting stage of the concrete floor, composite high-hardness wear-resistant aggregate is evenly spread twice. The wear-resistant aggregate includes inorganic wear-resistant powder and titanium alloy particles. The total amount of spread is sufficient to form a high wear-resistant surface layer. The surface is then mechanically smoothed and polished as the slurry is finished.

[0055] S8. When the concrete floor reaches the predetermined strength, induced slits 300 are made inside the compartment enclosed by the galvanized metal armored joints 100. The spacing of the slits 300 is determined according to the floor thickness and shrinkage characteristics. The depth of the slits 300 is a certain proportion of the floor thickness and is filled with caulking material.

[0056] S9. Apply an inorganic concrete sealant and curing agent to the floor surface to allow it to fully penetrate and form a dense hardened layer. Then grind and polish the surface to achieve high hardness, low wear rate and dustproof performance. The sealant and curing agent is non-toxic, non-flammable and meets national fire safety standards.

[0057] S10. Apply a wear-resistant organic coating to specific areas such as factory passageways and area markings to enhance scratch resistance and visual recognition in those areas.

[0058] This integrated construction method provides a comprehensive, high-performance flooring system that integrates foundation treatment, moisture-proofing, structural compartmentation, steel fiber reinforcement, laser leveling, composite wear-resistant layer, induced 300mm grooving, and sealing and curing. This system constructs a complete chain from base layer to surface layer. This method effectively solves the technical bottlenecks of traditional flooring, such as poor flatness, easy cracking, insufficient wear resistance, moisture-proofing failure, and limited functionality. It achieves multiple goals including ultra-flat precision, high crack resistance, ultra-high wear resistance, overall moisture protection, and green safety, significantly improving the overall performance and service life of heavy-duty industrial flooring in logistics and warehousing environments.

[0059] Furthermore, in step S1, the compaction coefficient of the compacted soil is not less than 0.95; or a cement-soil mixing pile composite foundation is adopted.

[0060] In step S2, the graded crushed stone cushion layer has a thickness of 300 mm and a compaction coefficient of not less than 0.97. The characteristic value of the bearing capacity of the foundation after treatment is f. ak ≥100kPa.

[0061] By limiting the compaction coefficient of the subgrade soil to ≥0.95 or using a cement-soil mixing pile composite foundation, and setting the thickness of the graded crushed stone cushion layer to 300mm and the compaction coefficient to ≥0.97, the characteristic value f of the foundation bearing capacity is ensured. ak With a strength of ≥100kPa, it provides a stable, uniform, and high-load-bearing foundation support for the heavy-duty concrete floor above, effectively preventing floor cracking or deformation caused by uneven foundation settlement, and meeting the stringent requirements of automated warehousing equipment for long-term ground stability.

[0062] In step S3, the thickness of the concrete cushion layer is 100mm, and the concrete strength grade is C20.

[0063] In step S6, the thickness of the steel fiber reinforced concrete floor is 200mm, and the concrete strength grade is C30.

[0064] Limiting the concrete subbase to 100mm thick C20 concrete provides a smooth and robust base interface; while the 200mm thick C30 steel fiber concrete floor balances high strength and structural thickness, which can withstand the concentrated load of high-level racks and the high-frequency passage of AGVs, while providing sufficient operating space and structural redundancy for subsequent wear-resistant layers and leveling processes, ensuring the mechanical reliability and construction feasibility of the overall flooring system.

[0065] In step S4, the moisture-proof and vapor barrier membrane is a 0.4 mm thick HDPE geomembrane.

[0066] Using a 0.4mm thick HDPE geomembrane as a moisture-proof and vapor-barrier membrane, it has excellent puncture resistance, low permeability and chemical stability. It can effectively block the capillary rise of groundwater and the migration of water vapor, preventing the floor from becoming damp, blistering or the sealant and curing agent from failing. It fundamentally ensures the dryness and long-term durability of the floor, and is especially suitable for industrial plants in areas with high groundwater levels or humid conditions.

[0067] In step S5, the spacing between the 200 grid lines of the factory building structure columns is 12m × 24m;

[0068] The galvanized metal armor seam 100 is a permanent true seam that runs through the entire thickness of the floor slab and serves as the boundary for the compartmentalized, stepped pouring.

[0069] A full-thickness galvanized metal armored joint 100mm is arranged along the 12m×24m column grid axis, and a circumferential armored joint is set at the column base. This not only coordinates with the deformation of the building structure, but also actively releases the restraint stress around the column and avoids radial cracks. At the same time, the armored joint serves as the physical boundary of the compartmentalized and stepped pouring, which facilitates the control of the construction sequence, reduces the amount of formwork used, and provides a continuous elevation benchmark for laser leveling, significantly improving the flatness and construction efficiency of large-area flooring.

[0070] In step S6, the amount of end-hook steel fiber added is 16 kg / m. 3 The steel fibers are 60mm long, 0.75mm in diameter, and have an aspect ratio of 80. The steel fibers are bonded together in rows with water-soluble adhesive and have hooks at both ends to ensure uniform dispersion in the concrete.

[0071] End-hook type steel fiber at 16kg / m 3 The steel fibers, with a length of 60mm and a diameter of 0.75mm (length-to-diameter ratio of 80), are added to the concrete and bonded in rows using water-soluble adhesive. This ensures uniform dispersion of the steel fibers during mixing and pumping, and significantly enhances the concrete's crack bridging ability and toughness through the hook-shaped structure at both ends. Under this mix design, the concrete's crack resistance is significantly improved, greatly reducing the occurrence of early plastic shrinkage cracks and later drying shrinkage cracks.

[0072] In step S7, the total spreading amount of composite high-hardness wear-resistant aggregate is not less than 8 kg / m³. 2 This includes 5kg / m 2 Inorganic wear-resistant powder and not less than 3kg / m 2 The silicon-titanium alloy particles contain at least 8% titanium; the two application rates are each 2.5 kg / m³. 2 During the initial setting stage, mechanical polishing and grinding are carried out as the slurry is collected.

[0073] The total application rate should be no less than 8 kg / m² through two applications. 2Composite wear-resistant aggregate (containing 5kg / m³) 2 Inorganic powder + ≥3kg / m 2 The titanium alloy particles (with a titanium content of ≥8%) form a deeply bonded, high-hardness surface layer during the initial setting stage of concrete. The titanium alloy particles significantly improve the surface Mohs hardness and impact resistance. The two-stage spreading process ensures that the aggregate is fully embedded in the slurry, preventing the surface layer from peeling off. This makes the floor's wear resistance more than 5 times higher than ordinary concrete, and it remains dust-free and colorfast over long-term use.

[0074] In step S8, the spacing of the induced cuts 300 is 6 to 12 m, the width of the cut is 5 mm, the depth of the cuts 300 is 1 / 3 of the thickness of the concrete floor, and cement mortar is used for caulking.

[0075] Inside the large storage compartment enclosed by the armored joints, induced cuts of 300mm are set at intervals of 6 to 12m and a depth of 1 / 3 of the floor thickness. Cement mortar is used to fill the joints. This can actively guide regular cracking before the concrete shrinkage stress concentrates, preventing irregular cracks from damaging the ultra-flat surface. The shallow cuts of 300mm (non-penetrating) preserve the continuity of the bottom concrete. With the bridging effect of steel fibers, crack control is achieved while maintaining the integrity of the structure. At the same time, the caulking material ensures the aesthetics and anti-fouling performance of the joints.

[0076] In step S9, the inorganic concrete sealant penetrates the concrete to a depth of 5–8 mm, resulting in a treated floor with a Mohs hardness of not less than 7 and an abrasion resistance of not more than 0.030 g / cm³. 2 ;

[0077] In step S10, the wear-resistant organic coating is an epoxy resin coating with a coating thickness of 1.0 mm.

[0078] Inorganic concrete sealant penetrates to a depth of 5–8 mm, reacting chemically with the concrete to form a dense silica gel, resulting in a floor surface with a Mohs hardness ≥7 and a wear resistance ≤0.030 g / cm². 2 It achieves permanent dustproofing, hardening, and impermeability; its non-toxic, non-flammable, and A1-grade fire-resistant properties meet the requirements of green building and fire safety. The 1.0mm epoxy resin coating in certain areas specifically enhances the scratch resistance and color recognition function of passageways and signage areas, taking into account both functionality and human-computer interaction needs.

[0079] Reference Figure 3 This solution also proposes a separator 400, which is applied to the above-mentioned galvanized metal armor seam 100. The separator 400 includes: a first main body 410 and a second main body 420. The first main body 410 and the second main body 420 are disposed opposite to each other and are connected by at least one easy-break bolt 430.

[0080] Both ends of the first main body 410 and the second main body 420 are provided with downward bending portions, and each bending portion is provided with multiple punch holes 450 for embedding into the concrete layer during concrete floor pouring to achieve anchoring.

[0081] A force transmission component is provided between the first main body 410 and the second main body 420. The force transmission component includes a force transmission steel plate 460 and a plastic plate-shaped sheath 470 sleeved on the outer periphery of the force transmission steel plate 460. The plastic plate-shaped sheath 470 is fixedly connected to the first main body 410 and the second main body 420 respectively. The two ends of the force transmission steel plate 460 extend into the concrete layers corresponding to the first main body 410 and the second main body 420 respectively.

[0082] When the concrete layers on both sides of the separator 400 undergo relative displacement due to shrinkage or deformation and reach a preset tensile force, the easily broken bolt 430 breaks, causing the first main body 410 and the second main body 420 to separate. At the same time, the force-transmitting steel plate 460 can slide within the plastic plate-shaped sheath 470 to transmit vertical loads and allow relative displacement in the horizontal direction, thereby bearing the separated concrete layers and preventing height differences at the joint.

[0083] The separator 400 connects the first and second main bodies 420 via a breakable bolt 430, which automatically breaks when the concrete shrinkage force exceeds a threshold, achieving controllable separation of the joint. The force-transmitting steel plate 460 slides within the plastic plate-shaped sheath 470, allowing horizontal displacement to accommodate deformation while effectively transmitting vertical loads to prevent joint misalignment. The perforated structure 450 on the bent portion strengthens the mechanical interlocking force with the concrete, ensuring reliable anchoring. This design solves the dilemma of traditional armored joints where "rigid constraints lead to cracking" or "complete separation leads to height differences," significantly improving the durability and driving stability of the joint area, and is particularly suitable for scenarios with extremely high requirements for ground continuity, such as narrow AGV tunnels.

[0084] The following section provides a detailed explanation of the high-standard integrated flooring construction method of this invention, using a large-scale automated logistics warehouse flooring project as an example. The factory building has a floor area of ​​approximately 30,000 m². 2 The design service life is 50 years, and it must meet the requirements of AGV automatic guided vehicle operation, high-level rack (12m high) load-bearing capacity and 2m straightedge drop ≤2mm.

[0085] S1: Foundation Treatment

[0086] First, the original site was cleared and leveled. According to the geological survey report, if the foundation soil is general cohesive soil or silt, a road roller was used to compact the soil, controlling the compaction coefficient to be no less than 0.95; if a soft soil layer (such as silty soil) was encountered, a cement-soil mixing pile composite foundation was used for reinforcement, with a pile diameter of 500mm, a pile spacing of 1.2m, and a replacement rate of no less than 15%, to ensure that the bearing capacity of the composite foundation after treatment meets the subsequent load requirements.

[0087] S2: Laying graded crushed stone subbase

[0088] A layer of graded crushed stone is laid on the treated foundation. The crushed stone particle size ranges from 20 to 60 mm, with a mud content of ≤3%. It is laid in two layers, each approximately 150 mm thick, and compacted using a vibratory roller until the compaction coefficient is ≥0.97. The characteristic value f of the foundation bearing capacity is determined by a plate load test. ak It reaches over 100kPa, meeting the requirements for heavy-duty floor foundations.

[0089] S3: Pouring concrete foundation layer

[0090] A formwork was erected on the compacted graded crushed stone layer, and a 100mm thick C20 commercial concrete was poured as a subbase. During the pouring process, a plate vibrator was used to compact the concrete, followed by mechanical finishing of the slurry to ensure a smooth surface free of laitance. After the subbase had set, it was cleaned and its flatness was checked. Areas with a height difference exceeding 5mm were ground to form a clean and solid base layer.

[0091] S4: Lay a moisture-proof and vapor barrier membrane

[0092] A 0.4mm thick high-density polyethylene (HDPE) geomembrane is laid on the cleaned concrete foundation as a moisture-proof and vapor-barrier layer. The overlap width between adjacent membrane sheets should not be less than 150mm, and the overlap should be sealed with hot air welding or special tape to ensure overall continuity and no damage, effectively blocking the capillary rise of groundwater and water vapor penetration.

[0093] S5: Pre-embedded galvanized armor seam 100

[0094] Based on the 200mm grid of the factory building's structural columns (typical column spacing 12m × 24m), the layout and positioning are carried out along the longitudinal and transverse axes, with 100mm galvanized armored joints pre-embedded. The height of the armored joint is consistent with the thickness of the subsequent surface layer (200mm), and it is made of galvanized steel sheet with downward-bent anchoring wings. A square, surrounding armored joint is set around the base of each structural column to form a stress-relieving ring, preventing radial cracks from forming around the column due to rigid constraints. During installation, the top surface of the armored joint is ensured to be horizontal, and it serves as the boundary template for subsequent segmented, stepped pouring.

[0095] S6: Sectionalized, stepped pouring of steel fiber reinforced concrete flooring

[0096] The C30 steel fiber reinforced concrete was poured using a "sectioned, skip-section method." Each section measured 12m x 24m, and the skip-section sequence was "sections one, three, five… poured first, sections two, four, six… poured last," minimizing construction cold joints. Hook-shaped steel fibers were incorporated into the concrete at a dosage of 16kg / m². 3 The steel fibers are bonded together in rows (60mm in length, 0.75mm in diameter, and an aspect ratio of 80) with water-soluble adhesive to ensure uniform dispersion and prevent clumping during mixing. Immediately after pouring, a laser screed is used for high-precision paving and leveling, controlling the height difference within a 2m range to ≤2mm.

[0097] S7: Spread composite high-hardness wear-resistant aggregate

[0098] During the initial setting stage of the concrete floor (when footsteps leave marks but no obvious indentation), apply composite wear-resistant aggregate evenly twice. The first application is 2.5 kg / m². 2 After the aggregate absorbs water and darkens, rough troweling is performed using a ride-on power trowel; then a second application of 2.5 kg / m³ of aggregate is applied. 2 Continue mechanical polishing and grinding. Aggregate composition: 5 kg / m³ 2 Inorganic wear-resistant powder with ≥3kg / m 2 It is composed of silicon-titanium alloy particles (titanium content ≥8%), forming a dense, high-hardness, wear-resistant surface layer.

[0099] S8: Induction kerf treatment 300

[0100] Once the concrete floor reaches 75%–80% of its design strength (usually 3–5 days after pouring), induced 300mm slits are made inside each 12m × 24m large cell. The 300mm slits are spaced 6–12m apart, 5mm wide, and 1 / 3 the thickness of the floor (approximately 65mm) deep. After the 300mm slits are completed, dust is cleaned from the slits, and cement-based jointing mortar is injected to prevent debris from embedding and maintain a neat appearance.

[0101] S9: Apply concrete sealant and hardener and grind / polish.

[0102] After 7 days of curing, with the surface dry and clean, evenly spray an inorganic concrete sealant (mainly composed of silicates), controlling the dosage according to the product instructions to ensure a penetration depth of 5-8mm. After 7 days of curing, sequentially grind and polish using 50-grit, 150-grit, 300-grit, and 800-grit resin grinding discs. The final floor should have a Mohs hardness ≥7 and a wear resistance ≤0.030g / cm². 2 (Gear method) The surface is smooth, dust-free, and non-slip.

[0103] S10: Locally coated with a wear-resistant organic coating

[0104] After marking out the main aisles, forklift turning areas, and functional zoning lines in the factory, apply a 1.0mm thick epoxy resin wear-resistant coating. The coating color is differentiated by function (e.g., yellow for aisle lines, green for safety zones), providing excellent adhesion, scratch resistance, and visual visibility, further enhancing the durability and management efficiency of key areas.

[0105] This solution provides a high-standard integrated flooring construction method. By systematically integrating key technologies such as foundation strengthening, moisture-proof isolation, structural compartmentation, steel fiber reinforcement, laser leveling, composite wear-resistant layer, intelligent joint control, and sealing and curing, it constructs a full-chain high-performance flooring system from base layer to surface layer. This method not only effectively solves the inherent defects of traditional industrial flooring in terms of flatness, crack resistance, wear resistance, moisture resistance, and durability, but also significantly improves construction efficiency and green safety levels.

[0106] Specifically, a high-bearing-capacity foundation is ensured through compacted subsoil or a composite foundation plus a 300mm graded crushed stone cushion layer; a 0.4mm HDPE geomembrane provides reliable moisture protection; 100mm galvanized armored joints are pre-embedded along the column grid axis and combined with a surrounding arrangement at the column base to actively release constraint stress; C30 steel fiber reinforced concrete is poured using a segmented, skip-grid method and laser leveling to ensure ultra-flat precision (2m / ≤2mm); a high-hardness surface layer is formed by spreading titanium-containing silicon-titanium alloy wear-resistant aggregate in two stages; 300mm induced cuts are set in the large grid cells to control cracking; and deep penetration of inorganic sealing and curing agents combined with grinding and polishing gives the floor a Mohs hardness ≥7 and a wear resistance ≤0.030g / cm². 2 Its superior performance; a localized 1.0mm epoxy coating enhances the functionality and visibility of the passageway and signage areas.

[0107] The new metal separator 400 further enhances the joint performance: its easy-break bolt 430 + sliding force transmission steel plate 460 + plastic sheath structure can automatically separate and maintain load transfer when concrete shrinks and cracks, effectively preventing joint misalignment and ensuring the stable operation of precision equipment such as AGVs.

[0108] It should be noted that in this invention, the use of terms such as "first," "second," and "a" is for descriptive purposes only and should not be construed as indicating or implying their relative importance or implicitly specifying the number of technical features indicated. Therefore, a feature defined as "first" or "second" may explicitly or implicitly include at least one of that feature. In the description of this invention, "a plurality of" means at least two, such as two, three, etc., unless otherwise explicitly specified. The terms "connection," "fixed," etc., should be interpreted broadly. For example, "fixed" can mean a fixed connection, a detachable connection, or an integral part; it can mean a mechanical connection or an electrical connection; it can mean a direct connection or an indirect connection through an intermediate medium; it can mean the internal communication of two elements or the interaction between two elements, unless otherwise explicitly specified. Those skilled in the art can understand the specific meaning of the above terms in this invention according to the specific circumstances.

[0109] Furthermore, the technical solutions of the various embodiments of the present invention can be combined with each other, but only if they are feasible for those skilled in the art. If 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 the present invention.

[0110] The specific embodiments described herein are merely illustrative of the spirit of the invention. Those skilled in the art to which this invention pertains may make various modifications or additions to the described specific embodiments or use similar methods to substitute them, without departing from the spirit of the invention or exceeding the scope defined by the appended claims.

Claims

1. A high-standard integrated flooring construction method, characterized in that, Including the following steps: S1. Perform foundation treatment on the original soil, using plain soil compaction or composite foundation reinforcement methods to ensure that the foundation reaches the required compaction degree and bearing capacity as designed. S2. Lay a graded crushed stone cushion layer of predetermined thickness on the treated foundation and compact it to a dense state that meets the bearing capacity requirements. S3. Pour a concrete base layer on the graded crushed stone base layer, and perform slurry finishing and surface cleaning to form a smooth base layer. S4. A moisture-proof and vapor-barrier membrane is fully laid on the concrete cushion layer to prevent groundwater and water vapor from rising. S5. Galvanized metal armor joints are pre-embedded along the axis of the factory building structural columns and around the column bases. The height of the armor joints is matched with the thickness of the subsequent concrete floor. The armor joints at the column bases are arranged in a ring to release constraint stress. S6. The steel fiber reinforced concrete floor is poured using the compartmentalized skip-grid method. The concrete strength grade meets the requirements for heavy-duty flooring, and hook-shaped steel fibers are incorporated to enhance crack resistance and toughness. High-precision paving and leveling are performed using laser leveling equipment. S7. During the initial setting stage of the concrete floor, composite high-hardness wear-resistant aggregate is evenly spread twice. The wear-resistant aggregate includes inorganic wear-resistant powder and titanium alloy particles. The total amount of spread is sufficient to form a high wear-resistant surface layer. The surface is then mechanically smoothed and polished as the slurry is finished. S8. When the concrete floor reaches the predetermined strength, induced slit treatment is carried out inside the compartment enclosed by the galvanized metal armored joint. The slit spacing is determined according to the floor thickness and shrinkage characteristics. The slit depth is a certain proportion of the floor thickness and is filled with caulking material. S9. Apply an inorganic concrete sealant and curing agent to the floor surface to allow it to fully penetrate and form a dense hardened layer. Then grind and polish the surface to achieve high hardness, low wear rate and dustproof performance. The sealant and curing agent is non-toxic, non-flammable and meets national fire safety standards. S10. Apply a wear-resistant organic coating to specific areas such as factory passageways and area markings to enhance scratch resistance and visual recognition in those areas.

2. The high-standard integrated flooring construction method as described in claim 1, characterized in that: In step S1, the compaction coefficient of the subgrade soil shall not be less than 0.95; or a cement-soil mixing pile composite foundation shall be adopted. In step S2, the graded crushed stone cushion layer has a thickness of 300 mm and a compaction coefficient of not less than 0.

97. The characteristic value of the bearing capacity of the foundation after treatment is f. ak ≥100kPa.

3. The high-standard integrated flooring construction method as described in claim 1, characterized in that: In step S3, the thickness of the concrete cushion layer is 100mm, and the concrete strength grade is C20. In step S6, the thickness of the steel fiber reinforced concrete floor is 200mm, and the concrete strength grade is C30.

4. The high-standard integrated flooring construction method as described in claim 1, characterized in that: In step S4, the moisture-proof and vapor barrier membrane is a 0.4 mm thick HDPE geomembrane.

5. The high-standard integrated flooring construction method as described in claim 1, characterized in that: In step S5, the spacing between the column grid axes of the factory building structure is 12m × 24m; The galvanized metal armor seam is a permanent true seam that runs through the entire thickness of the floor slab and serves as the boundary for the compartmentalized, stepped pouring.

6. The high-standard integrated flooring construction method as described in claim 1, characterized in that: In step S6, the amount of end-hook steel fiber added is 16 kg / m. 3 The steel fibers are 60mm long, 0.75mm in diameter, and have an aspect ratio of 80. The steel fibers are bonded together in rows with water-soluble adhesive and have hooks at both ends to ensure uniform dispersion in the concrete.

7. The high-standard integrated flooring construction method as described in claim 1, characterized in that: In step S7, the total spreading amount of composite high-hardness wear-resistant aggregate is not less than 8 kg / m³. 2 This includes 5kg / m 2 Inorganic wear-resistant powder and not less than 3kg / m 2 The silicon-titanium alloy particles contain at least 8% titanium; the two application rates are each 2.5 kg / m³. 2 During the initial setting stage, mechanical polishing and grinding are carried out as the slurry is collected.

8. The high-standard integrated flooring construction method as described in claim 1, characterized in that: In step S8, the spacing of the induced cuts is 6 to 12 m, the width of the cut is 5 mm, the depth of the cut is 1 / 3 of the thickness of the concrete floor, and cement mortar is used for caulking.

9. The high-standard integrated flooring construction method as described in claim 1, characterized in that: In step S9, the inorganic concrete sealant penetrates the concrete to a depth of 5–8 mm, resulting in a treated floor with a Mohs hardness of not less than 7 and an abrasion resistance of not more than 0.030 g / cm³. 2 ; In step S10, the wear-resistant organic coating is an epoxy resin coating with a coating thickness of 1.0 mm.

10. A separator, characterized in that, Applied to the galvanized metal armor seam as described in any one of claims 1 to 9, the separator comprises: A first main body and a second main body are disposed opposite to each other and connected by at least one easily broken bolt. Both ends of the first main body and the second main body are provided with downward bending portions, and each bending portion is provided with multiple punch holes for embedding into the concrete layer during concrete floor pouring to achieve anchoring. A force transmission component is provided between the first main body and the second main body. The force transmission component includes a force transmission steel plate and a plastic plate-shaped sheath sleeved around the outer periphery of the force transmission steel plate. The plastic plate-shaped sheath sleeve is fixedly connected to the first main body and the second main body respectively. The two ends of the force transmission steel plate extend into the concrete layer corresponding to the first main body and the second main body respectively. When the concrete layers on both sides of the separator undergo relative displacement due to shrinkage or deformation and reach a preset tensile force, the easily broken bolt breaks, causing the first main body to separate from the second main body. At the same time, the force-transmitting steel plate can slide within the plastic plate-shaped sheath to transmit vertical loads and allow relative displacement in the horizontal direction, thereby bearing the separated concrete layers and preventing height differences at the joint.

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