Structure-enhanced composition board structure and processing method thereof

Abstract

The invention relates to a structure-enhanced composition board structure and a processing method thereof, the structure-enhanced composition board structure comprises a structure-enhanced unit, a structural beam and a composition board composed of a steel plate and a concrete layer, the structure-enhanced unit is arranged on the steel plate and located in the concrete layer, and the composition board is installed on the structural beam. The composition board composed of the steel plate and the concrete layer gives full play to the material performance advantages of the steel plate and the concrete layer; compared with a reinforced concrete plate, only a small number of steel bars need to be arranged on the compression side, the steel plate can replace tension side steel bars on the concrete plate, anti-crack ribs are avoided, and the steel bar consumption and the construction workload are reduced. Meanwhile, the steel plate is also used as a template for concrete pouring construction, so that the cost of construction measures can be reduced, and the construction cost is still reduced by about 7% compared with that of a reinforced concrete plate although the steel plate with higher cost is adopted.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of composite board, in particular to a composite board structure with enhanced configuration and a processing method thereof. BACKGROUND

[0002] In the field of civil engineering, reinforced concrete slabs or steel-concrete composite slab structures are currently used to directly bear external loads. Reinforced concrete slabs must be configured with a large amount of steel reinforcement to bear tensile stress and improve structural bearing capacity due to the low tensile strength of concrete material. A large amount of steel reinforcement needs to be bound and tied, which requires a long construction period and the setting of a concrete structure forming template. During use, cracks in the concrete are prone to occur due to temperature changes, shrinkage, creep and load effects, providing a channel for harmful substances such as water, chloride ions and oxygen to enter, leading to steel corrosion. After the steel corrodes, the volume expands, causing the concrete cover to peel off, the effective cross-section to decrease and the bearing capacity to decrease, which may seriously threaten the safety of the structure. Once serious defects (such as large-area steel corrosion and structural cracking) occur, it is difficult to maintain and reinforce the structure, and complex procedures such as closure, rust removal, re-pouring or sticking of steel plates / carbon fibers are required, which is costly and has a large social impact.

[0003] To solve the problems of large amount of steel reinforcement, complex construction process and bottom edge cracking of the slab, steel-concrete composite slab structures have appeared in engineering: thin steel plates are arranged at the bottom of the slab, which are used as construction templates and components for bearing tensile force at the lower edge of the structure, facilitating construction and improving durability. However, small-span composite slabs currently use thin flat steel plates or profiled steel plates, which have small structural stiffness and small slab span, and are suitable for fewer scenarios. If used for large-span structures, steel plates with stiffening ribs need to be used to increase the structural stiffness and overall bearing capacity of the bottom steel plate, but this requires a large amount of steel and is costly.

[0004] The utility model patent with publication number CN208803373U discloses a steel plate concrete composite bridge deck structure; including bridge deck, the bridge deck is equipped with the shear strength enhancement structure, the bridge deck and the shear strength enhancement structure are wrapped into an organic whole through the concrete layer that is poured on the bridge deck. However, the bridge deck is in a wave shape, and the structural strength can be further improved.

[0005] Therefore, how to improve the structural strength of the composite board is a problem that needs to be solved at present. SUMMARY

[0006] The present application relates to the technical field of composite board, in particular to a composite board structure with enhanced configuration and a processing method thereof.

[0007] The object of the present application can be achieved by the following technical solutions: According to one aspect of the present invention, a structurally reinforced composite plate structure is provided, comprising a structural reinforcement unit, a structural beam, and a composite plate composed of a steel plate and a concrete layer, wherein the structural reinforcement unit is disposed on the steel plate and located in the concrete layer, and the composite plate is mounted on the structural beam.

[0008] As a preferred technical solution, the structural reinforcement unit includes reinforcement members and connecting members, both of which are disposed on a steel plate and located in a concrete layer.

[0009] As a preferred technical solution, the reinforcing members are evenly distributed on the steel plate, and connecting members are provided between adjacent reinforcing members; The connecting member is also located at the edge of the steel plate and near the outer reinforcing member.

[0010] As a preferred technical solution, the reinforcing member is located at the center of the adjacent connecting member.

[0011] As a preferred technical solution, the reinforcing member is a spherical groove; the connecting member is a stud or a reinforcing bar head.

[0012] As a preferred technical solution, the structure further includes a connecting groove and a connecting reinforcing bar. The connecting groove is disposed on the composite slab, one end of the connecting reinforcing bar is located in the concrete layer of the composite slab, and the other end of the connecting reinforcing bar is located in the connecting groove.

[0013] As a preferred technical solution, two connecting steel bars are provided in the same connecting groove, and there is a height difference between the two connecting steel bars.

[0014] As a preferred technical solution, the structure further includes a connecting column, which is disposed in the connecting slot, and the other end of the connecting steel bar is located in the connecting column.

[0015] As a preferred technical solution, the structure further includes pads, the combined plate is mounted on the structural beam through the pads, and the connecting column is mounted on the structural beam through the pads.

[0016] According to another aspect of the present invention, a method for fabricating a composite plate structure reinforced as described above is provided, the method comprising: S1. Fabricate structural reinforcement units on the steel plate; S2. Concrete or ultra-high performance concrete is poured onto a steel plate with structural reinforcement units to form a concrete layer, and the concrete layer and the steel plate are combined to form a composite plate. The concrete must meet the following requirements: coarse aggregate particle size not exceeding 2cm and water content not exceeding 160kg / m³. 3High-performance water-reducing agents are used, and the initial slump of the pumped concrete is not greater than 200 mm and the spread is not less than 450 mm. The ultra-high performance concrete meets the requirements of a silica content of not less than 90%, a maximum aggregate particle size of not more than 10 mm, and the use of a high-performance water-reducing agent. The ultra-high performance concrete contains steel fibers with a length of 6-25 mm, a diameter of 0.1-0.25 mm, a tensile strength of not less than 2000 MPa, and a volumetric admixture of 2.0-3.0%.

[0017] Compared with the prior art, the present invention has the following beneficial effects: 1. This invention employs a composite slab composed of a steel plate and a concrete layer, fully leveraging the material performance advantages of both. Compared to reinforced concrete slabs, only a small amount of reinforcement is required on the compression side. The steel plate can replace the tension reinforcement on the concrete slab, eliminating the need for anti-cracking reinforcement and reducing the amount of reinforcement and construction work. Furthermore, the steel plate also serves as formwork for concrete pouring, reducing construction costs. Although this invention uses more expensive steel plates, it still reduces the project cost by approximately 7% compared to reinforced concrete slabs.

[0018] 2. The structural reinforcement unit of this invention is set on the steel plate, and the reinforcement component is designed as a spherical groove, which greatly improves the shape stiffness of the steel plate and also enhances the structural stiffness of the overall composite plate. Compared with conventional composite plates of the same thickness, tensile stress can be reduced by 30%, vertical deflection can be reduced by 35%, and the stress and performance are significantly improved. If the stress performance is similar to that of a conventional composite plate without grooves, the total thickness of the composite plate can be reduced by 17%, which can save material usage, reduce project costs by about 22%, and reduce carbon emissions by more than 18%.

[0019] 3. The structural base plate of this invention is made of reinforced steel plate, the concrete layer is made of concrete or ultra-high performance concrete, and the connecting columns are made of ultra-high performance concrete. This avoids the problem of ordinary reinforced concrete being prone to cracking and damage under tension, improves durability, and increases structural rigidity. If the concrete layer is damaged, it can be quickly repaired without the need for scaffolding or formwork, and there is no need for large-scale demolition of the slab structure. This makes maintenance and management easier, reduces the maintenance cost throughout the entire life cycle, and effectively improves the construction quality and life cycle performance of the structure. Attached Figure Description

[0020] Figure 1 This is a schematic diagram of the overall structure of the present invention; Figure 2 This is a top view of the steel plate structure of the present invention; Figure 3 This is a side view of the steel plate structure of the present invention; Figure 4 This is a schematic diagram of the installation of the present invention; 1. Composite plate; 2. Steel plate; 3. Connecting component; 4. Structural beam; 5. Connecting reinforcement; 6. Connecting groove; 7. Spacer block. Detailed Implementation

[0021] 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, not all, of the embodiments of the present invention. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort should fall within the scope of protection of the present invention.

[0022] To address the shortcomings of existing reinforced concrete slabs, such as low tensile strength, high reinforcement requirements, susceptibility to cracking, poor durability, difficult maintenance, and high upkeep costs, as well as the limited application range, large steel consumption, and high cost of steel-concrete composite slab structures, a more effective approach is to utilize a structure with densely distributed spherical grooves. This structure enhances rigidity, load-bearing capacity, and durability, thereby improving structural quality and life-cycle performance. This increases structural rigidity, replacing existing structural forms and fully utilizing the material properties of the structure. Simultaneously, the steel plate with the spherical grooves serves as both a formwork structure and a permanent structure during the operational phase, reducing construction steps, improving structural durability, and lowering life-cycle costs.

[0023] Example 1 A structurally reinforced composite slab structure includes a structural reinforcement unit, a structural beam 4, and a composite slab 1 composed of a steel plate 2 and a concrete layer. The structural reinforcement unit is disposed on the steel plate 2 and located in the concrete layer, and the composite slab 1 is installed on the structural beam 4.

[0024] The structural reinforcement unit includes a reinforcement member and a connecting member 3, both of which are mounted on the steel plate 2 and located in the concrete layer.

[0025] The reinforcing members are evenly distributed on the steel plate 2, and connecting members 3 are provided between adjacent reinforcing members.

[0026] The connecting member 3 is also provided at the edge of the steel plate 2 and near the outer reinforcing member.

[0027] The reinforcing member is located at the center of the adjacent connecting member 3.

[0028] The reinforcing member is a spherical groove; the connecting member 3 is a stud or a reinforcing bar head.

[0029] In this embodiment, a structural reinforcement unit is provided on the steel plate 2 to enhance the overall structural strength of the composite plate 1. The structural reinforcement unit includes reinforcing members and connecting members 3. The reinforcing members are multiple spherical crown-shaped grooves, and the connecting members 3 are studs or short steel bar ends. The spherical crown-shaped grooves are periodically and uniformly distributed in an array along the transverse and longitudinal directions of the steel plate 2. The spherical crown-shaped grooves can be regarded as part of a hollow sphere, with one side of the steel plate 2 being convex and the other side being concave. The connecting members 3 are installed on the convex side of the spherical crown-shaped grooves on the steel plate 2. Since the spherical crown-shaped grooves are periodically and uniformly distributed, a connecting member 3 is provided between adjacent spherical crown-shaped grooves. At the same time, connecting members 3 are provided at the edge of the steel plate 2, close to the outer spherical crown-shaped grooves. It is ensured that there are four connecting members 3 around any spherical crown-shaped groove, and the spacing between the four connecting members 3 is the same. The reinforcing member is located at the center of the four adjacent connecting members 3.

[0030] A concrete layer is poured onto the steel plate 2 with structural reinforcement units to form the composite plate 1. The width of the spherical groove is 130~180mm and the depth is 30~35mm. The spacing between adjacent spherical grooves is 1.5 times the width of the spherical groove. The thickness of the steel plate 2 is 3~12mm.

[0031] The structure also includes a connecting slot 6 and a connecting steel bar 5. The connecting slot 6 is provided on the composite slab 1, one end of the connecting steel bar 5 is located in the concrete layer of the composite slab 1, and the other end of the connecting steel bar 5 is located in the connecting slot 6.

[0032] Two connecting steel bars 5 are provided in the same connecting slot 6, and there is a height difference between the two connecting steel bars 5.

[0033] The structure also includes a connecting column, which is disposed in the connecting slot 6, and the other end of the connecting steel bar 5 is located in the connecting column.

[0034] The structure also includes a pad 7, the combined plate 1 is mounted on the structural beam 4 via the pad 7, and the connecting column is mounted on the structural beam 4 through the pad 7.

[0035] In this embodiment, a connecting slot 6 is provided on the composite plate 1, passing through the steel plate 2 and the concrete layer; a portion of the connecting reinforcing bar 5 is placed in the concrete layer (placed together with the concrete layer during pouring), and the remaining portion is located in the connecting slot 6; two connecting reinforcing bars 5 are placed in the same connecting slot 6, with a height difference between the two connecting reinforcing bars 5, staggered by a distance not less than the diameter of one connecting reinforcing bar 5. Concrete is poured into the connecting slot 6 to form a connecting column, at which point a portion of the connecting reinforcing bar 5 is located in the connecting column. A spacer 7 is placed on the structural beam 4, and the composite plate 1 is installed on the structural beam 4 through the spacer 7; the connecting column protrudes slightly from the steel plate 2, and the connecting column passes through the spacer 7 and is installed on the structural beam 4; the spacer 7 is made of rubber; the structural beam 4 is a concrete structure or a steel structure. The connecting slots 6 are located at both ends of the composite plate 1, with one connecting slot 6 corresponding to one structural beam 4.

[0036] Example 2 A processing method for constructing reinforced composite panel structures, the method comprising: S1. Fabricate structural reinforcement units on steel plate 2; S2. Concrete or ultra-high performance concrete is poured onto the steel plate 2 with structural reinforcement units to form a concrete layer, and the concrete layer and the steel plate 2 are combined to form a composite plate 1. The concrete must meet the following requirements: coarse aggregate particle size not exceeding 2cm and water content not exceeding 160kg / m³. 3 High-performance water-reducing agents are used, and the initial slump of the pumped concrete is not greater than 200 mm and the spread is not less than 450 mm. The ultra-high performance concrete meets the requirements of a silica content of not less than 90%, a maximum aggregate particle size of not more than 10 mm, and the use of a high-performance water-reducing agent. The ultra-high performance concrete contains steel fibers with a length of 6-25 mm, a diameter of 0.1-0.25 mm, a tensile strength of not less than 2000 MPa, and a volumetric admixture of 2.0-3.0%.

[0037] In this embodiment, the steel plate 2 is formed with densely packed spherical grooves by stamping or hot casting. The length and width dimensions of the steel plate 2 are designed as needed, and connecting components 3 such as studs or short steel bar ends are welded on the steel plate 2. The connecting components 3 need to be welded to the straight section on the protruding side of the groove on the steel plate 2. Use steel plate 2 as the bottom formwork, pour concrete or ultra-high performance concrete on it to form composite plate 1. The top layer of steel bars can be set in composite plate 1 according to the stress requirements, and the connecting steel bars 5 are reserved. The prefabricated composite slabs 1 are hoisted and placed on the completed structural beams 4 in sequence. Rubber pads 7 need to be pre-set at the corresponding placement points on the beams. Ultra-high performance concrete is poured into the connecting groove 6 formed by adjacent plates to form connecting columns, ultimately forming a continuous and complete structure.

[0038] The concrete used must meet the following requirements: coarse aggregate particle size not exceeding 2cm, and water content not exceeding 160kg / m³. 3 High-performance water-reducing agents must be used, and the water reduction rate of the high-performance water-reducing agents must be not less than 25%. The initial slump of the pumped concrete must not be greater than 200 mm and the spread must not be less than 450 mm. The ultra-high performance concrete used must meet the following requirements: silica content should not be less than 90%, maximum aggregate size should not be greater than 10mm, and high-performance water-reducing agent should be used, with a water reduction rate of not less than 30%. Ultra-high performance concrete also contains steel fibers. The steel fibers in ultra-high performance concrete have a length of 6~25mm, a diameter of 0.1~0.25mm, a tensile strength of not less than 2000MPa, and a volumetric admixture of 2.0~3.0%.

[0039] Concrete: It is an artificial stone material made by mixing cement as the main binder with water, fine aggregate (sand), coarse aggregate (stone), and, when necessary, admixtures and mineral admixtures, and then curing and hardening it. It is the most commonly used structural load-bearing material in civil engineering, and it relies on the bond between the aggregate skeleton and cement stone to achieve load-bearing capacity.

[0040] Ultra-High Performance Concrete (UHPC): A cement-based composite material with ultra-high strength, ultra-high durability, and ultra-high toughness, made by using cement and mineral admixtures (silica fume, fly ash, mineral powder) as the cementitious system, using fine aggregate (no coarse aggregate), adding high-performance water-reducing agents, and adding steel fibers when necessary, through optimized proportioning, compaction molding, and standard curing.

[0041] The above description is merely a specific embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any person skilled in the art can easily conceive of various equivalent modifications or substitutions within the technical scope disclosed in the present invention, and these modifications or substitutions should all be covered within the scope of protection of the present invention. Therefore, the scope of protection of the present invention should be determined by the scope of the claims.

Claims

1. A composite panel structure with reinforced construction, characterized in that, It includes a structural reinforcement unit, a structural beam (4) and a composite plate (1) composed of a steel plate (2) and a concrete layer. The structural reinforcement unit is disposed on the steel plate (2) and located in the concrete layer, and the composite plate (1) is installed on the structural beam (4).

2. The composite plate structure with reinforced construction according to claim 1, characterized in that, The structural reinforcement unit includes a reinforcement member and a connecting member (3), both of which are mounted on a steel plate (2) and located in a concrete layer.

3. The composite plate structure with reinforced construction according to claim 2, characterized in that, The reinforcing members are evenly distributed on the steel plate (2), and connecting members (3) are provided between adjacent reinforcing members. The connecting member (3) is also provided at the edge of the steel plate (2) and near the outer reinforcing member.

4. The composite plate structure with reinforced construction according to claim 2, characterized in that, The reinforcing member is located at the center of the adjacent connecting member (3).

5. A reinforced composite plate structure according to claim 2, characterized in that, The reinforcing member is a spherical groove; the connecting member (3) is a stud or a steel bar head.

6. The composite plate structure with reinforced construction according to claim 1, characterized in that, The structure also includes a connecting slot (6) and a connecting steel bar (5). The connecting slot (6) is set on the composite plate (1). One end of the connecting steel bar (5) is located in the concrete layer of the composite plate (1), and the other end of the connecting steel bar (5) is located in the connecting slot (6).

7. A reinforced composite panel structure according to claim 6, characterized in that, Two connecting steel bars (5) are provided in the same connecting slot (6), and there is a height difference between the two connecting steel bars (5).

8. A reinforced composite plate structure according to claim 6, characterized in that, The structure also includes a connecting column, which is disposed in the connecting slot (6), and the other end of the connecting steel bar (5) is located in the connecting column.

9. A reinforced composite panel structure according to claim 8, characterized in that, The structure also includes a pad (7), the combined plate (1) is mounted on the structural beam (4) via the pad (7), and the connecting column is mounted on the structural beam (4) through the pad (7).

10. A method for processing a composite plate structure reinforced as described in any one of claims 1-9, characterized in that, The method includes: S1. Fabricate structural reinforcement units on steel plate (2); S2. Concrete or ultra-high performance concrete is poured onto the steel plate (2) with structural reinforcement units to form a concrete layer, and the concrete layer and the steel plate (2) are combined to form a composite plate (1). The concrete must meet the following requirements: coarse aggregate particle size not exceeding 2cm and water content not exceeding 160kg / m³. 3 High-performance water-reducing agents are used, and the initial slump of the pumped concrete is not greater than 200 mm and the spread is not less than 450 mm. The ultra-high performance concrete meets the requirements of a silica content of not less than 90%, a maximum aggregate particle size of not more than 10 mm, and the use of a high-performance water-reducing agent. The ultra-high performance concrete contains steel fibers with a length of 6-25 mm, a diameter of 0.1-0.25 mm, a tensile strength of not less than 2000 MPa, and a volumetric admixture of 2.0-3.0%.

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