Integrated prefabricated formwork, steel-concrete combined fabricated building structure and construction method of steel-concrete combined fabricated building structure

Abstract

The invention provides an integrated prefabricated formwork, a steel-concrete combined fabricated building structure and a construction method thereof, and the integrated prefabricated formwork comprises a vertical bearing component and a horizontal bearing component which are fixedly connected to form a stable space stress structure. The vertical bearing component comprises a vertical prefabricated formwork, a second concrete layer, a vertical steel bearing part and a first concrete layer in the vertical steel bearing part which are sequentially arranged from outside to inside, and inner concrete and outer concrete are communicated through first pouring holes in the steel bearing part to form a whole. The horizontal bearing component comprises a horizontal prefabricated formwork, a channel steel bearing part and a steel bar truss floor bearing plate, and a pouring cavity is defined by the horizontal prefabricated formwork, the channel steel bearing part and the steel bar truss floor bearing plate. A third concrete layer is poured in the channel steel bearing part, a fourth concrete layer is poured in the cavity, and the third concrete layer and the fourth concrete layer are connected into a whole through a second pouring hole. A fifth concrete layer is poured above the steel bar truss floor support plate, and the fifth concrete layer and the fourth concrete layer jointly form an integral floor system. The building structure achieves full-assembly construction, and is good in structural integrity and high in bearing capacity.

Description

Technical Field

[0001] This invention relates to the fields of concrete pouring, composite building structures, and prefabricated structures, specifically to integrated prefabricated formwork, steel-concrete composite prefabricated building structures, and their construction methods. Background Technology

[0002] Traditional prefabricated building structural systems typically employ a separate design and independent construction approach for vertical load-bearing components (such as columns and shear walls) and horizontal load-bearing components (such as beams), followed by assembly with floor slabs. This approach suffers from a series of fundamental defects that limit its performance and efficiency. First, the connection nodes between components often rely on on-site grouting sleeves or bolt connections. These nodes are complex in construction, difficult to control in terms of quality, and often become weak points in the overall structural rigidity, severely impacting the effective transfer of loads and the collaborative performance between components. Second, from a construction perspective, traditional processes involve extensive on-site formwork erection, pouring, and subsequent formwork removal, resulting in cumbersome procedures, lengthy construction periods, and high labor and material costs. Third, at the component level, common issues include insufficient interfacial bonding between the steel pipe and the core concrete in concrete columns, exposed steel pipes prone to corrosion, and difficulties in fireproofing. Furthermore, horizontal channel steel beams and steel truss floor slabs are often simply supported connections, resulting in poor overall integrity and a tendency for interface slippage or concrete cracking under stress. Finally, and more importantly, because vertical components, horizontal components, and floor slab concrete are typically poured in batches and stages, it is difficult to guarantee the compactness and integrity of the connections between different layers of concrete. This not only weakens the overall stiffness and load-bearing capacity of the structure but also poses a potential threat to its long-term durability. Simultaneously, the extensive on-site wet work makes construction quality highly dependent on manual operation, increasing the difficulty of quality control. These shortcomings collectively limit the widespread application of prefabricated buildings in scenarios requiring higher performance and greater efficiency.

[0003] Therefore, this invention proposes an integrated prefabricated formwork, a steel-concrete composite prefabricated building structure, and its construction method. Summary of the Invention

[0004] To address the shortcomings of existing technologies, this invention proposes an integrated prefabricated formwork, a steel-concrete composite prefabricated building structure and its construction method. By combining the permanent and temporary use of prefabricated formwork with integrated concrete pouring, a fully prefabricated, rapid construction and a highly integrated structural system are achieved.

[0005] The technical solution of this invention is implemented as follows: An integrated prefabricated formwork, steel-concrete composite prefabricated building structure, comprising at least two vertical load-bearing components and at least one horizontal load-bearing component. The vertical load-bearing components are fixedly connected to the horizontal load-bearing components to form a stable spatial force-bearing structure. A steel truss floor deck is laid on top of the horizontal load-bearing components to form an integrated floor structure. The vertical load-bearing component includes a vertical precast template, a vertical steel load-bearing member, and a vertical connector. The vertical connector extends from the outside to the inside of the vertical precast template and is fixedly connected to the outer wall of the vertical steel load-bearing member. The vertical steel load-bearing member has an inner cavity located inside the vertical precast template. The inner cavity of the vertical steel load-bearing member has a first concrete layer. A second concrete layer is provided between the vertical steel load-bearing member and the vertical precast template. The vertical steel load-bearing member has several first pouring holes. The first concrete layer and the second concrete layer are connected through the first pouring holes and form an integral structure. The horizontal load-bearing component includes a horizontal precast template, a channel steel load-bearing component, and a horizontal connector. The horizontal connector is connected to the bottom of the steel truss floor slab and together with the steel truss floor slab, forms a vertically arranged casting cavity. The channel steel load-bearing component is disposed within the casting cavity. The top wall of the channel steel load-bearing component is connected to the horizontal precast template, and the side walls and / or bottom walls of the channel steel load-bearing component are connected to the horizontal precast template via the horizontal connector. The channel steel load-bearing component has an inner cavity in which a third layer of concrete is poured. A fourth layer of concrete is poured between the channel steel load-bearing component, the horizontal precast template, and the casting cavity enclosed by the steel truss floor slab. Several second pouring holes are provided on the outer wall of the channel steel load-bearing component. The third concrete layer and the fourth concrete layer are interconnected through the second pouring holes to form an integral structure.

[0006] A fifth concrete layer is poured on the steel truss floor slab, and the fifth concrete layer is connected with the fourth concrete layer to form an integrated floor structure.

[0007] Preferably, there are multiple vertical steel load-bearing members, and the multiple adjacent vertical steel load-bearing members are separated from each other, with a second concrete layer filling the gap between each adjacent vertical steel load-bearing member to form an integral structure. Or multiple adjacent vertical steel load-bearing components are fixedly connected to form a continuous load-bearing frame.

[0008] Preferably, both the vertical connector and the horizontal connector include a first nut, a first screw, and a second nut; the first nut is fixedly disposed on the outer wall of the vertical steel load-bearing member and the outer wall of the channel steel load-bearing member; one end of the first screw passes through the outer side of the vertical precast template and the outer side of the horizontal precast template and is connected to the first nut; the second nut is connected to the other end of the first screw and abuts against the outer side of the vertical precast template and the outer side of the horizontal precast template; a first pad is provided between the second nut and the outer side of the vertical precast template and the outer side of the horizontal precast template.

[0009] Preferably, the vertical steel load-bearing component is a steel pipe or a steel frame, and the steel frame is composed of multiple steel pipes, C-shaped steel, box-shaped steel or corrugated steel plates; the first casting holes are evenly distributed in a rectangular array on the vertical steel load-bearing component or are staggered along the height direction of the vertical steel load-bearing component.

[0010] Preferably, the cross-section of the channel steel load-bearing component is U-shaped or rectangular closed, and the second casting holes are evenly distributed in a rectangular array on the channel steel load-bearing component or staggered along the length of the channel steel load-bearing component.

[0011] Preferably, the vertical precast template and the horizontal precast template are integrally cast from resilient concrete.

[0012] This invention also proposes a construction method for an integrated prefabricated formwork and steel-concrete composite prefabricated building structure. Includes the following steps: S1: The factory prefabricates the vertical prefabricated templates and vertical steel load-bearing components for vertical load-bearing components, the horizontal prefabricated templates and channel steel load-bearing components for horizontal load-bearing components, and the steel truss floor deck; the first nut is fixedly connected to the outer wall of the vertical steel load-bearing component and the outer wall of the channel steel load-bearing component respectively, and the first pouring hole is opened on the vertical steel load-bearing component and the second pouring hole is opened on the channel steel load-bearing component respectively; S2: Transport the vertical steel load-bearing components to the construction site, hoist them into place, fix them with temporary supports, and calibrate their verticality; install and fix the vertical prefabricated template to the outside of the vertical steel load-bearing components through vertical connectors, so that the first cavity is formed between the two; S3: Transport the channel steel load-bearing component to the construction site, hoist it to the preset connection position of the vertical load-bearing component, fix the channel steel load-bearing component to the vertical steel load-bearing component, and weld the reinforcing steel plate at the connection; install and fix the horizontal prefabricated template to the outside of the channel steel load-bearing component through the horizontal connector, so that a second cavity is formed between the two. S4: Transport the steel truss floor deck to the construction site, lay it on top of the channel steel load-bearing components, and fix the floor deck and channel steel load-bearing components in place; S5: Integrated concrete pouring operation: S51: Pour concrete into the inner cavity of the vertical steel load-bearing member to form a first concrete layer; before the first concrete layer initially sets, pour concrete into the first cavity through the first pouring hole to form a second concrete layer that is connected to the first concrete layer. S52: Pour concrete into the inner cavity of the channel steel load-bearing component to form a third concrete layer; before the third concrete layer initially sets, pour concrete into the second cavity through the second pouring hole to form a fourth concrete layer that is connected to the third concrete layer, and the fourth concrete layer is closely connected to the second concrete layer during the pouring process. S53: Pour concrete into the steel truss floor slab to form the fifth concrete layer; the fifth concrete layer and the fourth concrete layer are poured continuously to form an integrated floor structure. S6: After the concrete is poured, it shall be kept warm and moist for no less than 14 days. After the curing is completed, there is no need to remove the vertical and horizontal precast formwork. They shall be retained as a permanent protective and decorative layer.

[0013] Preferably, the channel steel load-bearing member is provided with shear studs, the steel truss floor deck is welded and fixed to the upper flange of the channel steel load-bearing member through the support steel bars, and the steel truss floor deck is tied to the shear studs provided on the channel steel load-bearing member through the truss steel bars.

[0014] Preferably, step S5 adopts a dual-path synchronous pouring process to control the difference in concrete liquid level between adjacent parts to not exceed 300mm; during the pouring process, an immersion vibrator is used to assist in vibration, with the vibration point spacing not exceeding 500mm, to ensure that the concrete fills the cavity and flows fully through all pouring holes.

[0015] Compared with the prior art, the present invention has the following advantages: The core working principle of this invention lies in "permanent prefabricated formwork" and "integrated casting of the core structure." Specifically, both vertical and horizontal load-bearing components are prefabricated in the factory. The external vertical and horizontal prefabricated formwork is reliably connected to the internal steel load-bearing components (vertical steel load-bearing components and channel steel load-bearing components) through connectors, forming a stable casting cavity. During construction, concrete fills the inner cavity (forming the first and third concrete layers) and the outer cavity (forming the second and fourth concrete layers) in stages but continuously through pre-set casting holes on the steel load-bearing components. This allows the concrete inside and outside the steel component to interlock and solidify into an absolutely integral load-bearing unit through the casting holes, completely eliminating the risk of debonding at the steel-concrete interface. Based on this, the fourth concrete layer of the horizontal components and the fifth concrete layer on the floor slab are continuously cast again, ultimately solidifying the columns, beams, and floor slabs into a seamless, rigid spatial structure.

[0016] The resulting benefits are remarkable: First, the overall structural integrity is unprecedentedly improved, with all components and joints seamlessly integrated through concrete, resulting in load-bearing capacity and seismic performance far exceeding traditional prefabricated structures. Second, construction efficiency is revolutionized, as prefabricated formwork functions as both construction formwork and a permanent protective decorative layer, enabling construction without demolition, significantly shortening the construction period and reducing costs. Third, durability and fire resistance are superior, with steel load-bearing components tightly encased in high-performance concrete, solving the problems of exposed corrosion and fire prevention. Finally, project quality is controllable, with core processes involving factory prefabrication and controlled on-site integrated casting, reducing on-site wet work and human subjective factors, ensuring stable and reliable quality. This system fundamentally and comprehensively solves a series of bottlenecks in traditional prefabricated structures regarding connection, integrity, efficiency, and durability. Attached Figure Description

[0017] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0018] Figure 1 This is a structural diagram of the integrated prefabricated template and steel-concrete composite prefabricated building structure of the present invention; Figure 2 This is a schematic diagram of the vertical load-bearing component of the present invention as a column. Figure 3 This is a schematic diagram of the vertical load-bearing component of the present invention as a shear wall; Figure 4 This is a structural diagram of horizontal load-bearing components and steel truss floor decking. Figure 5 A schematic diagram showing the connection between the vertical load-bearing component as a column and the horizontal load-bearing component; Figure 6 A schematic diagram showing the connection between vertical load-bearing components as shear walls and horizontal load-bearing components; Figure labels: 1-Vertical load-bearing component; 11-Vertical precast formwork; 12-Vertical steel load-bearing component; 121-First pouring hole; 122-First concrete layer; 123-Second concrete layer; 13-Vertical connector; 131-First nut; 132-First threaded rod; 133-Second nut; 134-First washer; 14-Inner partition; 2-Horizontal load-bearing component; 21-Horizontal precast formwork; 22-Channel steel load-bearing component; 221-Second pouring hole; 222-Third concrete layer; 223-Fourth concrete layer; 224-Shear stud; 23-Horizontal connector; 231-Third nut; 232-Second threaded rod; 233-Fourth nut; 234-Second pad; 24-Beam reinforcement; 25-Connecting side plate; 3-Reinforced truss floor slab; 31-Fifth concrete layer; 32-Support reinforcement; 33-Truss reinforcement. Detailed Implementation

[0019] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0020] In the description of this invention, it should be noted that the terms "center," "upper," "lower," "left," "right," "vertical," "horizontal," "inner," and "outer," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are used only for the convenience of describing the invention and for simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on the invention. Furthermore, the terms "first," "second," "third," and "fourth," etc., are used for descriptive purposes only and should not be construed as indicating or implying relative importance.

[0021] In the description of this invention, it should be noted that, unless otherwise explicitly specified and limited, the terms "installation," "connection," and "linking" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; 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; and they can refer to the internal connection of two components. Those skilled in the art can understand the specific meaning of the above terms in this invention based on the specific circumstances.

[0022] This invention provides a revolutionary overall solution for prefabricated buildings. Its core technology lies in three fundamental innovations: First, functional integration and permanent / temporary combination, upgrading traditional temporary construction formwork into high-performance precast concrete components that combine molding, permanent protection, fireproofing, and decorative functions, extending to the floor slab formwork; Second, interface fusion and overall molding, by systematically opening pouring holes in the steel load-bearing components, allowing the inner and outer layers of concrete to flow and blend during pouring, forming mechanically interlocking "concrete pins" through the holes after solidification, thus transforming the steel-concrete composite component into a homogeneous component with continuous material and unified stress; Third, system synergy and node rigidity, through refined node construction specifically designed for column and wall vertical component forms (including through-reinforcement bars and paired connecting side plates), combined with a strictly controlled integrated concrete pouring process, ensuring continuous stress transfer in three-dimensional space among vertical load-bearing components, horizontal load-bearing components, and the floor system in the node areas, ultimately constructing a prefabricated spatial structure system with overall performance equivalent to cast-in-place concrete.

[0023] like Figure 1 As shown in the overall schematic diagram, this system consists of three major modular parts: vertical load-bearing component 1, horizontal load-bearing component 2, and steel truss floor deck 3. These parts are integrated into one unit through the following precision construction and process.

[0024] I. Dual Forms and Refined Construction of Vertical Load-Bearing Components Vertical load-bearing component 1 is the core of the vertical support system. According to the structural requirements of the building, it is specifically implemented in two standardized forms: "steel-concrete composite column" or "steel-framed concrete composite shear wall". Although the two have different functional focuses, they both follow the unified design paradigm of "external precast formwork - internal steel load-bearing components - infill concrete integration".

[0025] Type 1: Steel-concrete composite column (corresponding to) Figure 2 Cross-sectional view and Figure 5 Node details): Core steel frame – vertical steel load-bearing component 12: As the main bearer of axial pressure, it is preferably made of hot-rolled or welded carbon structural steel pipe of Q355B or higher strength grade. Common cross-sections are square (e.g., □400×400×12) or circular (e.g., Φ400×12). To achieve seamless integration between the core and the surrounding concrete, a large number of first pouring holes 121 need to be regularly opened in the pipe wall. These holes are not process holes, but structural holes, and their diameter needs to be determined by calculation, usually 40mm to 80mm, to ensure that the concrete can pass through smoothly during pouring and form an effective key. The hole arrangement schemes include: 1) matrix uniform distribution, that is, holes are arranged at fixed intervals (such as @500mm x 500mm) along the height and circumference of the steel pipe, which facilitates standardized processing; 2) staggered distribution, that is, adjacent rows of holes are staggered by half a hole distance in the height direction. This arrangement can more effectively disrupt the vertical shrinkage path of concrete, enhance the three-dimensional interlocking effect, and significantly improve the interface shear resistance and the integrity of the component.

[0026] Permanent Outer Formwork and Protective Shell – Vertical Precast Formwork 11: This is the core carrier for realizing the concept of "combining permanent and temporary formwork". This formwork is prefabricated in the factory using a streamlined method or vertical molding process, and is made of fiber-reinforced tough concrete. Its mix design is specifically tailored, with a compressive strength of no less than C90, and incorporates polypropylene or steel fibers to significantly improve crack resistance and toughness (ultimate tensile strain can reach over 0.02%). The inner surface of the formwork is roughened (e.g., by spraying exposed aggregate agent or mechanical scoring) to provide excellent mechanical bonding with the subsequently poured concrete. It not only replaces all temporary formwork but also serves as a permanent fireproof layer for columns (its concrete itself has a fire resistance limit of over 2 hours), an anti-corrosion protective layer, and an exterior decorative layer (which can be formed in one step using colored aggregate, fair-faced concrete, or decorative formwork technology), achieving multi-functional integration.

[0027] Reliable connection mechanism – Vertical connector 13: This component is responsible for precisely fixing the precast template 11 to the steel frame 12 before pouring and for withstanding the lateral pressure of the newly poured concrete. Its standard components include: a first nut 131 welded to the outer wall of the steel pipe in the factory; a first threaded rod 132 inserted from the outside of the template during on-site installation; and a first pad 134 and a second nut 133 fitted onto the threaded rod and located on the outside of the template. The first threaded rod 132 can innovatively be made of high-performance engineering plastics (such as glass fiber reinforced nylon), whose tensile strength meets design requirements and possesses excellent corrosion resistance, electrical insulation, and low thermal conductivity, fundamentally eliminating the "cold bridge" condensation and electrochemical corrosion problems easily caused by traditional metal connectors. During installation, a torque wrench is used to tighten the second nut 133, and the pressure is evenly distributed to the template surface through the first pad 134, forming a firm connection. The vertical joints between templates must be double-sealed using elastic sealant and water-stop strips to ensure no grout leakage during pouring.

[0028] Type 2: Steel-framed concrete composite shear wall (corresponding to) Figure 3 Cross-sectional view and Figure 6 Node details): Core steel frame – vertical steel load-bearing component 12: In this configuration, the steel load-bearing component expands into a planar or spatial steel framework adapted to the stress characteristics of the wall. Its structural forms are diverse and highly flexible. Distributed steel pipe bundle: Composed of multiple small-diameter (e.g., Φ150×6) rectangular or circular steel pipes arranged side by side, with a spacing of 100-200mm between the steel pipes, forming a structure similar to a "steel pipe bundle". Each steel pipe is filled with concrete (first concrete layer 122), while the gaps between the steel pipes and the outside are filled with integral concrete (second concrete layer 123), working together.

[0029] Lattice steel frame (preferred option): Standard C-shaped cold-formed thin-walled steel (such as C160×60×20×2.5) is welded together with its flanges, and then welded to rectangular steel tubes (such as □200×200×8) located at the ends and corners to form a continuous lattice wall frame. This frame is lightweight, uses less steel, and has a high degree of prefabrication.

[0030] Box-shaped ribbed frame: Steel plates are welded into a closed box-shaped section, with transverse stiffening ribs spaced at regular intervals inside the box. Studs can be welded to the inner wall to enhance bonding with concrete.

[0031] Corrugated steel plate composite frame: Corrugated steel plates (wave height 50-100mm) are welded to rectangular steel pipes at the edges. The huge surface area of ​​the corrugated plates provides exceptional concrete bond strength and shear resistance.

[0032] Regardless of the form, the first pouring hole 121 must be opened on each plate of the frame (steel pipe wall, C-shaped steel web / flange, corrugated plate) to ensure that the wall is a whole concrete wall rather than a sandwich wall encased in steel frame.

[0033] Permanent External Formwork – Vertical Precast Formwork 11: For walls, precast formwork is typically a large plate-shaped or channel-shaped component. It can be precast in one piece using resilient concrete of the same material as the composite columns, or it can be designed as modular panels to facilitate transportation and hoisting, assembled on-site using pre-set metal connectors or post-cast concrete strips. Its functions also integrate formwork, protection, and decoration.

[0034] Connector 13: Its form, function and installation requirements are completely consistent with those of the combined column form, ensuring reliable connection between the formwork and various complex steel frames.

[0035] II. Standardized Composition of Horizontal Load-Bearing Components Horizontal load-bearing member 2, namely the composite beam, is the main horizontal load-bearing member of the floor system (see [link]). Figure 4 Its design also adheres to the principle of integration.

[0036] The main steel beam structure—channel steel load-bearing component 22: typically made of hot-rolled or welded H-beams, U-beams, or box girders. To facilitate integration with the floor slab, a series of shear studs 224 (e.g., Φ19×100, spaced 200mm) need to be welded to the upper flange. The key to achieving a monolithic beam section lies in creating a second casting hole 221 on its web and lower flange. The arrangement of these holes must consider the reduction in shear strength of the beam section; multiple rows of staggered holes are commonly used, with a hole diameter generally 30-50mm.

[0037] The permanent formwork at the bottom of the beam—horizontal precast formwork 21: is usually precast into an inverted U-shape, wrapping around the bottom and two sides of the beam. The material is the same as the vertical formwork, which is fiber-reinforced tough concrete. It is fixed to the channel steel by horizontal connectors 23. The structure (third nut 231, second screw 232, second pad 234, fourth nut 233) and principle of the horizontal connectors 23 are exactly the same as those of the vertical connectors 13.

[0038] Composite floor slab interface – reinforced concrete truss floor slab 3: Composed of truss reinforcement 33, integrated precast resilient concrete bottom formwork, and support reinforcement 32. The bottom formwork is made of fiber-reinforced resilient concrete of the same material as the vertical precast formwork 11 and horizontal precast formwork 21, precast into strips in the factory, serving as both the bottom formwork during construction and a permanent floor slab bottom protection and decorative layer. During installation, the support reinforcement 32 must be fully welded to the upper flange of the channel steel using fillet welds; the lower chord reinforcement of the truss reinforcement 33 should be tightly attached to the shear studs 224 and securely tied. This ensures that the floor slab concrete (fifth concrete layer 31) and the beam concrete (fourth concrete layer 223) can achieve complete cooperative stress distribution through the shear studs and reinforcement.

[0039] III. The core of the system: refined node connection and spatial integration The outstanding overall performance of this system ultimately rests on the meticulous design of column-beam and wall-beam joints. These joints are not simple connections, but rather "stress integrators" that have been carefully calculated and constructed.

[0040] Beam-column rigid joint (for composite column systems) (see) Figure 5 ): Connections between steel members: The end of the channel steel load-bearing member 22 and the column steel pipe (vertical steel load-bearing member 12) are preferably connected by end plate type high-strength bolts. The end plates are welded to the beam end and the column body at the preset position in the factory, and then fastened on site with 10.9 grade high-strength bolts. Direct full penetration bevel welding can also be used.

[0041] Stress continuity construction in the concrete zone – beam top reinforcement anchorage: To reliably transfer the negative bending moment at the beam end to the column, the longitudinal reinforcing bars at the top of the beam, i.e., the beam top reinforcement 24, need to extend outward at the beam end to meet the anchorage length required by the code (usually 35-40 times the diameter of the reinforcement). This reinforcement will directly penetrate through the sleeve or hole pre-reserved in the vertical precast formwork 11 of the column, extending into the column concrete area jointly formed by the first core concrete layer 122 and the outer second concrete layer 123. Rigid anchorage is formed under the bond of the subsequently poured concrete.

[0042] Node domain connecting side plates 25: At least one pair of parallel connecting side plates 25 are provided at the beam-column steel frame connection. These connecting side plates 25 are thick steel plates, with one side fully penetratedly welded to the web and upper and lower flanges of the beam (channel steel load-bearing member 22); the other side is firmly welded to the outer wall of the column steel tube (vertical steel load-bearing member 12). This set of parallel connecting side plates 25, together with the beam end, forms a reinforced node domain, serving three purposes: 1) more effectively transferring the bending moment and shear force at the beam end to the column body; 2) greatly improving the shear stiffness and strength of the node domain; 3) providing strong constraint on the concrete in the core area of ​​the node, enhancing its compressive strength and deformation capacity.

[0043] Beam-wall rigid joint (for composite shear wall systems) (see) Figure 6 ): Connection between steel frames: The connection between the channel steel load-bearing component 22 of the beam and the steel frame 12 of the wall (such as the edge rectangular steel pipe of the C-shaped steel frame) is also made by end plate bolt connection or welding.

[0044] Stress continuity construction in concrete areas: Here, beam reinforcement 24 also needs to penetrate the wall formwork and be anchored into the wall.

[0045] The critical shear force transfer component—connecting side plates 25: In beam-wall joints, the design of at least one pair of vertically parallel connecting side plates 25 is crucial. One side is fully penetrated welded to the beam end web and upper and lower flanges; the other side is firmly welded to the flanges or webs of the shear wall edge members (such as end rectangular steel pipes or C-shaped steel composite columns). The core function of this set of connecting side plates 25 is to serve as the main shear force transfer path, directly and efficiently introducing most of the horizontal shear force from the beam end into the vertical lateral force resisting frame of the shear wall through the steel plates, avoiding the brittle failure that may occur if the shear force is only transferred through concrete, while also participating in the transfer of bending moment.

[0046] IV. Core Technology: Integrated Concrete Casting and Cavity Filling The essence and quality assurance of this construction system lies in the consistent "integrated casting" concept. The goal of this process is to allow all pre-installed components to solidify into a continuous whole through concrete.

[0047] Formation of the cavity system: After all steel components and precast formwork are installed, a two-tiered cast-in-place cavity system naturally forms within the system: Primary cavities (core cavities of components): These are the inner cavities of the vertical steel load-bearing member 12 and the inner cavities of the channel steel load-bearing member 22. They will be filled with the core pressure-bearing concrete forming the core of the component—the first concrete layer 122 and the third concrete layer 222.

[0048] Secondary cavity (component-encased cavity): This is the key space for achieving "encapsulation" and "integration".

[0049] The first external cavity of the vertical component is an annular or flat space enclosed by the inner wall of the vertical precast template 11 and the outer wall of the vertical steel load-bearing member 12. This cavity will eventually form the second concrete layer 123 that encloses the steel frame.

[0050] The horizontal component's outer cavity (second outer cavity): a U-shaped closed cavity formed by the inner wall of the horizontal precast formwork 21, the bottom and side outer surfaces of the channel steel load-bearing component 22, and the bottom formwork of the steel truss floor slab 3 above. This cavity will eventually form the fourth concrete layer 223 that encloses the lower part and sides of the steel beam.

[0051] Integrated casting process: Step 1: Pour the core of the vertical component (first concrete layer 122). Use high-flow self-compacting concrete (slump ≥ 260mm) and pour it into the inner cavity (first-level cavity) of the vertical steel load-bearing component 12 through the pre-reserved pouring port at the top of the column / wall. Use an attached vibrator or a high-level drop-down process without vibration to ensure the core concrete is dense.

[0052] Step 2: Connecting and pouring the outer layer of the vertical component (second concrete layer 123). Before the core concrete initially sets (usually within 2 hours), immediately pour concrete of the same or higher strength into the first outer cavity through the first pouring hole 121. The concrete flows out of the pouring hole under pressure, mixes with the still plastic core concrete at the hole opening, and fills the entire outer cavity. A vibrator needs to be inserted into the cavity to ensure compaction. At this point, the first concrete layer 122 and the second concrete layer 123 are completely bonded together by the concrete "pins" in the hundreds of first pouring holes 121, and the vertical component is formed.

[0053] Step 3: Pour the core of the horizontal component (third concrete layer 222). Make holes at appropriate positions in the beam end formwork and pour concrete into the inner cavity (first-level cavity) of the channel steel load-bearing component 22.

[0054] Step 4: Connecting and pouring the outer layer and joint of the horizontal component (fourth concrete layer 223). Also before the core concrete has initially set, pour concrete into the second outer cavity through the second pouring hole 221. This is the most crucial step. During construction, two pump trucks or one pump truck with dual pipelines must be used to simultaneously pour concrete at the joint between the beam's outer cavity and the connected column / wall's outer cavity at the same node. Strictly control the difference in concrete level between the two locations to not exceed 300mm, ensuring that the fourth concrete layer 223 of the beam and the second concrete layer 123 of the column / wall achieve complete fusion in the joint area under plastic conditions, seamlessly encasing the beam reinforcement 24 and the connecting side plate 25. This process eliminates any possibility of cold joints.

[0055] Step 5: Pour the floor slab (fifth concrete layer 31). Immediately following, pour the floor slab concrete on top of the beams and on the steel truss floor slab 3, integrating it with the top surface of the fourth concrete layer 223 of the beams. The entire pouring process should be continuous, with the total time controlled within the initial setting time of the concrete.

[0056] Curing and Finished Product: Immediately after pouring, cover with plastic film and insulation layer for at least 14 days of standard curing. After curing, all precast formwork (11, 21) and floor deck bottom formwork become the permanent exterior surface of the building, requiring no demolition work, truly achieving green and efficient construction.

[0057] V. Overall Technical Effects and Advantages Through the above-described specific, detailed, and feasible solutions, this invention represents a significant advancement over traditional technologies: A qualitative leap in structural performance: Through "concrete pins" and refined rigid nodes (including connecting side plates), the overall structural performance indicators (such as node rotation stiffness and inter-story drift angle) have reached the same level as cast-in-place concrete structures, far exceeding the current national standards for prefabricated structures, and exhibiting excellent seismic performance.

[0058] Durability guaranteed for a century: The steel components are completely sealed and encased in dense, high-performance concrete, placing them in an excellent anti-corrosion environment; the tough concrete precast formwork (column, wall, beam, and floor slab bottom formwork) has excellent resistance to carbonation, freeze-thaw, and impermeability, providing a complete and unified composite protection system for the structure, with a design service life that can easily exceed 100 years.

[0059] Revolutionary improvement in construction efficiency: On-site operations are simplified to three steps: hoisting, connection, and pouring. Formwork work is reduced by more than 80%, labor demand is reduced by 50%, the construction speed of the main structure is more than doubled, and the overall construction cost is significantly reduced.

[0060] The perfect combination of industrialized and green building: the components are highly standardized and prefabricated, which is in line with the development direction of industrialized building; no formwork removal, less support, and no external scaffolding are required, which greatly reduces construction waste and construction energy consumption, resulting in significant green benefits.

[0061] The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. An integrated prefabricated formwork and steel-concrete composite prefabricated building structure, characterized by: It includes at least two vertical load-bearing components (1) and at least one horizontal load-bearing component (2). The vertical load-bearing component (1) and the horizontal load-bearing component (2) are fixedly connected to form a stable spatial force-bearing structure. A steel truss floor deck (3) is laid on top of the horizontal load-bearing component (2) to form an integrated floor structure. The vertical load-bearing component (1) includes a vertical precast template (11), a vertical steel load-bearing component (12), and a vertical connector (13). The vertical connector (13) extends from the outside of the vertical precast template (11) to the inside and is fixedly connected to the outer wall of the vertical steel load-bearing component (12). The vertical steel load-bearing component (12) has an inner cavity located inside the vertical precast template (11). The inner cavity of the vertical steel load-bearing component (12) has a first concrete layer (122). A second concrete layer (123) is provided between the vertical steel load-bearing component (12) and the vertical precast template (11). The vertical steel load-bearing component (12) has several first pouring holes (121). The first concrete layer (122) and the second concrete layer (123) are connected through the first pouring holes (121) and form an integral structure. The horizontal load-bearing component (2) includes a horizontal precast template (21), a channel steel load-bearing component (22), and a horizontal connector (23). The horizontal connector (23) is connected to the bottom of the steel truss floor slab (3) and forms a vertically arranged casting cavity with the steel truss floor slab (3). The channel steel load-bearing component (22) is set in the casting cavity. The top wall of the channel steel load-bearing component (22) is connected to the channel steel load-bearing component (22), and the side wall and / or bottom wall of the channel steel load-bearing component (22) are connected to the horizontal precast template (21) through the horizontal connector (23). The channel steel load-bearing component (22) has an inner cavity in which a third concrete layer (222) is poured. A fourth concrete layer (223) is poured between the channel steel load-bearing component (22), the horizontal precast template (21), and the steel truss floor slab (3) enclosing the casting cavity. The outer wall of the channel steel load-bearing component (22) is provided with several second pouring holes (221). The third concrete layer (222) and the fourth concrete layer (223) are interconnected through the second pouring holes (221) and form an integral structure. A fifth concrete layer (31) is poured on the steel truss floor slab (3), and the fifth concrete layer (31) is connected with the fourth concrete layer (223) to form an integrated floor structure.

2. The integrated prefabricated formwork and steel-concrete composite prefabricated building structure according to claim 1, characterized in that: The vertical steel load-bearing members (12) are multiple, and the multiple adjacent vertical steel load-bearing members (12) are separated from each other and the gap between each adjacent vertical steel load-bearing member (12) is filled with a second concrete layer (123) to form an integral structure; Or multiple adjacent vertical steel load-bearing components (12) are fixedly connected to form a continuous load-bearing frame.

3. The integrated prefabricated formwork and steel-concrete composite prefabricated building structure according to claim 1, characterized in that: The vertical connector (13) and the horizontal connector (23) each include a first nut (131), a first screw (132), and a second nut (133); the first nut (131) is fixedly disposed on the outer wall of the vertical steel load-bearing member (12) and the outer wall of the channel steel load-bearing member (22); one end of the first screw (132) passes through the outside of the vertical precast template (11) and the outside of the horizontal precast template (21) and is connected to the first nut (131); the second nut (133) is connected to the other end of the first screw (132) and abuts against the outside of the vertical precast template (11) and the outside of the horizontal precast template (21); a first pad (134) is provided between the second nut (133) and the outside of the vertical precast template (11) and the outside of the horizontal precast template (21).

4. The integrated prefabricated formwork and steel-concrete composite prefabricated building structure according to claim 1, characterized in that: The vertical steel load-bearing component (12) is a steel pipe or a steel frame, which is composed of multiple steel pipes, C-shaped steel, box-shaped steel or corrugated steel plates; the first casting hole (121) is evenly distributed in a rectangular array on the vertical steel load-bearing component (12) or staggered along the height direction of the vertical steel load-bearing component (12).

5. The integrated prefabricated formwork and steel-concrete composite prefabricated building structure according to claim 1, characterized in that: The cross section of the channel steel load-bearing component (22) is U-shaped or rectangular closed, and the second casting hole (221) is evenly distributed in a rectangular array on the channel steel load-bearing component (22) or staggered along the length of the channel steel load-bearing component (22).

6. The integrated prefabricated formwork and steel-concrete composite prefabricated building structure according to claim 1, characterized in that: The vertical precast template (11) and the horizontal precast template (21) are integrally cast from resilient concrete.

7. The construction method of the integrated prefabricated formwork and steel-concrete composite prefabricated building structure as described in any one of claims 1-6, characterized in that, Includes the following steps: S1: The factory prefabricates the vertical prefabricated template (11) and vertical steel load-bearing component (12) of the vertical load-bearing component (1), the horizontal prefabricated template (21) and channel steel load-bearing component (22) of the horizontal load-bearing component (2), and the steel truss floor deck (3); the first nut (131) is fixedly connected to the outer wall of the vertical steel load-bearing component (12) and the outer wall of the channel steel load-bearing component (22), and the first pouring hole (121) is opened on the vertical steel load-bearing component (12) and the second pouring hole (221) is opened on the channel steel load-bearing component (22); S2: Transport the vertical steel load-bearing component (12) to the construction site, hoist it into place, fix it with temporary support, and calibrate its verticality; install and fix the vertical prefabricated template (11) on the outside of the vertical steel load-bearing component (12) through the vertical connector (13) so that the two form the first cavity; S3: Transport the channel steel load-bearing component (22) to the construction site, hoist it to the preset connection position of the vertical load-bearing component (1), fix the channel steel load-bearing component (22) and the vertical steel load-bearing component (12) together, and weld the connecting side plate at the connection point; install and fix the horizontal prefabricated template (21) on the outside of the channel steel load-bearing component (22) through the horizontal connector (23) so that a second cavity is formed between the two; S4: Transport the steel truss floor deck (3) to the construction site, lay it on top of the channel steel load-bearing component (22), and fix the steel truss floor deck (3) to the channel steel load-bearing component (22); S5: Integrated concrete pouring operation: S51: Pour concrete into the inner cavity of the vertical steel load-bearing member (12) to form a first concrete layer (122); before the first concrete layer (122) sets, pour concrete into the first cavity through the first pouring hole (121) to form a second concrete layer (123) that is connected to the first concrete layer (122). S52: Concrete is poured into the inner cavity of the channel steel load-bearing component (22) to form a third concrete layer (222); before the third concrete layer (222) sets, concrete is poured into the second cavity through the second pouring hole (221) to form a fourth concrete layer (223) that is connected to the third concrete layer (222), and the fourth concrete layer (223) is closely connected to the second concrete layer (123) during the pouring process; S53: Concrete is poured onto the steel truss floor slab (3) to form the fifth concrete layer (31); the fifth concrete layer (31) and the fourth concrete layer (223) are poured continuously to form an integrated floor structure; S6: After the concrete is poured, it shall be kept warm and moist for no less than 14 days. After the curing is completed, there is no need to remove the vertical precast formwork (11) and the horizontal precast formwork (21), which shall be retained as a permanent protective and decorative layer.

8. The construction method of the integrated prefabricated formwork and steel-concrete composite prefabricated building structure according to claim 7, characterized in that: In step S2, the first screw (132) is inserted from the outside of the vertical precast template (11) and connected to the first nut (131) pre-fixed to the outer wall of the vertical steel load-bearing member (12). The first pad (134) and the second nut (133) are installed sequentially at the end of the first screw (132) on the outside of the vertical precast template (11). The second nut (133) is tightened to press and fix it. In step S3, the second screw (232) is inserted from the outside of the horizontal precast template (21) and connected to the third nut (231) pre-fixed to the outer wall of the channel steel load-bearing member (22). The second pad (234) and the fourth nut (233) are installed sequentially at the end of the second screw (232) on the outside of the horizontal precast template (21), and the fourth nut (233) is tightened to press and fix it.

9. The construction method for the integrated prefabricated formwork and steel-concrete composite prefabricated building structure according to claim 7, characterized in that: The channel steel load-bearing member (22) is provided with shear studs (224), the steel truss floor deck (3) is welded and fixed to the upper flange of the channel steel load-bearing member (22) by the support steel bars (32), and the steel truss floor deck (3) is tied to the shear studs on the channel steel load-bearing member (22) by the truss steel bars (33).

10. The construction method of the integrated prefabricated formwork and steel-concrete composite prefabricated building structure according to claim 7, characterized in that: Step S5 adopts a dual-path synchronous pouring process to control the concrete liquid level difference between adjacent parts to not exceed 300mm; during the pouring process, an immersion vibrator is used to assist in vibration, with the vibration point spacing not exceeding 500mm, to ensure that the concrete fills the cavity and flows fully through all pouring holes.

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