A prefabrication method of skeleton overhead stairs based on end skeleton support

Abstract

The present application relates to the technical field of stair manufacturing, and discloses a skeleton overhead stair prefabrication method based on end skeleton support, which comprises the following steps: S1, two conical cylinders are fixed by connecting ribs to obtain a support body; S2, four straight ribs are fixed based on the support ribs, and a mouth-shaped rib is obtained by bending based on the positions of the four straight ribs; S3, a conical tool rod is installed at the two end cavities of a mold; and S4, a horizontal overlap area is formed between the two end skeleton support bodies in the mold cavity; the end skeleton support bodies are introduced, the strength and conical shape of the original tool rod are utilized to realize overhead positioning and assembly of the end skeleton, the end skeleton can be prefabricated in advance, and the difficulty of assembly in the mold caused by the complexity of the end skeleton is solved; the strength of the tool rod is utilized to improve the overhead stability of the end skeleton, a horizontal overlap area is formed between the two end skeletons, and overhead support is provided for the grid keel at the ladder surface.

Description

Technical Field

[0001] This invention relates to the field of staircase manufacturing technology, specifically a method for prefabricating a frame-supported elevated staircase based on end-frame support. Background Technology

[0002] The interior of precast staircase molds needs to be reinforced with steel reinforcement to increase strength. Currently, precast staircases mainly have connecting structures at both ends, and the sides of the precast staircases are smooth with no exposed reinforcement. To improve the stability of the splicing between precast staircases and shear walls, or to improve the stability of the connection between two staircases, precast staircases are generally processed in the following ways: The precast staircase extends horizontally at both ends, and at least two conical tooling rods are placed in the mold cavity corresponding to each horizontal end. Before adding concrete to the mold, a release agent is applied to the surface of the tooling rods to ensure smooth demolding after the staircase has cured. After demolding, the horizontal ends of the staircase form two conical holes or cavities. After the precast staircase arrives on site, concrete is added a second time to allow the concrete to solidify with the fixed base surface and within the conical holes or cavities, thereby improving assembly stability.

[0003] The difference between a tooling rod and an embedded part is that the tooling rod is thicker, while the embedded part is relatively thinner. The larger the tooling rod, the larger the conical hole or conical cavity it forms, and the larger the subsequent assembly and curing area.

[0004] Due to connection requirements, the two horizontal ends of the prefabricated staircase also need to be supported by a skeleton. In the traditional structure, the cage-type end skeleton is installed into the cavity at the end of the mold, and the tooling rod is located at the gap of the cage-type end skeleton. The horizontal end of the horizontally placed staircase mold is tilted. The tooling rod can only prevent the cage-type end skeleton from sliding along the inclined surface, but it cannot guarantee the distance between the cage-type end skeleton and the bottom surface of the mold. Summary of the Invention

[0005] The purpose of this invention is to provide a prefabrication method for an elevated staircase based on end-frame support. By introducing an end-frame support body and utilizing the strength and conical shape of the existing tooling rod, the end-frame is positioned and assembled in an elevated manner, forming a horizontal overlap area between the two end frames, thereby providing elevated support for the grid keel at the step surface, thus solving the problems mentioned in the background art.

[0006] To achieve the above objectives, the present invention provides the following technical solution: A method for prefabricating a frame-supported elevated staircase, comprising: Step S1: The two cones are fixed together by welding connecting ribs, and the outer wall of the cones is fixed by welding supporting ribs to obtain the support body. A total of two support bodies are prepared. Step S2: Based on the supporting ribs, fix four straight ribs. Using the positions of the four straight ribs as the shape basis, bend them to form a mouth-shaped rib. Distribute the mouth-shaped ribs equidistantly along the long side of the straight ribs. Tie or weld the straight ribs and mouth-shaped ribs together to obtain the end skeleton support body. Step S3: Install tapered tooling rods on both ends of the mold cavity, align and insert the two tapered cylinders of the end frame support body with the tooling rods, and there is a gap between the lower end of the tapered cylinder and the lower end of the tooling rod; Step S4: A horizontal overlapping area is formed between the two end skeleton supports inside the mold cavity. Within the horizontal overlapping area, the grid keel is tied in sequence, and the two ends of the grid keel are respectively connected to the two end skeleton supports.

[0007] As a further aspect of the present invention: in step S1, there is an included angle between the supporting rib and the connecting rib.

[0008] As a further aspect of the present invention: in step S1, the included angle between the supporting rib and the connecting rib is 90 degrees.

[0009] As a further embodiment of the present invention: in step S2, the surface of the supporting rib has a groove or protrusion for supporting the straight rib, the straight rib is located on the top of the inner groove or protrusion, and the straight rib and the supporting rib are fixed by binding.

[0010] As a further aspect of the present invention: In step S2, based on the axial height of the cone, the connecting rib is higher than the supporting rib, and the highest point of the connecting rib is level with the highest point of the straight rib. The slit-shaped rib and the straight rib, as well as the slit-shaped rib and the connecting rib, are all fixed by binding or welding.

[0011] As a further embodiment of the present invention: in step S4: the connecting rib is located in the horizontal overlapping area, and the two ends of the long rib parallel to the long side of the mold in the grid keel are fixedly connected to the connecting rib.

[0012] As a further aspect of the present invention: In step S4: when the connecting rib is not present in the horizontal overlap area, a straight rib is added inside the mouth-shaped rib, the number of straight ribs is no more than two, and at least two straight ribs are located within the horizontal overlap area in each end skeleton support body, and the two ends of the long ribs parallel to the long side of the mold in the grid keel are fixedly connected to the added straight ribs.

[0013] Compared with the prior art, the beneficial effects of the present invention are: This technical solution employs a novel approach, introducing an end-frame support structure. Utilizing the inherent strength and conical shape of existing tooling bars, it achieves elevated positioning and assembly of the end frame. Furthermore, the end frame can be prefabricated, resolving the difficulties of in-mold assembly caused by its complexity. Simultaneously, the strength of the tooling bars enhances the elevated stability of the end frame, creating a horizontal overlap between the two end frames, thus providing elevated support for the grid keel at the step surface. When applied to short staircases, this technical solution eliminates the need to consider the bending issue of the grid keel, greatly simplifying construction and improving product consistency. Attached Figure Description

[0014] To more clearly illustrate the technical solutions in the embodiments of the present invention, 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.

[0015] Figure 1 A three-dimensional schematic diagram of a prefabricated staircase frame based on an end-frame support method for elevated staircases. Figure 2 for Figure 1 A three-dimensional schematic diagram after the side molds of the middle mold have been removed; Figure 3 This is a schematic diagram illustrating the fabrication of the end skeleton support. Figure 4 A schematic diagram of the end frame support being installed into the mold; Figure 5 for Figure 4 Front view diagram. Detailed Implementation

[0016] Please see Figures 1-5 Example 1: includes: step S1: two cones are fixed together by welding connecting ribs, and supporting ribs are welded to the outer wall of the cones to obtain a support body, and a total of two support bodies are prepared.

[0017] This technical solution introduces a novel concept, incorporating a support structure where the slope of the cone is matched to the tooling bar. Connecting ribs are welded between the two cones, with at least two ribs ideally equidistant from each other along the axial direction of the two cones. The two cones are integrated and share the load through the connecting ribs. Support ribs are distributed to both sides, located on either side of the connecting ribs, providing support for the subsequent end frame.

[0018] Additional explanation: There is an angle between the supporting reinforcement and the connecting reinforcement, specifically a 90-degree angle. This angle is for constructing straight reinforcement. When the angle between the supporting reinforcement and the connecting reinforcement is 90 degrees, the supporting reinforcement also forms a 90-degree angle with the straight reinforcement, making binding easier and more secure. The angle between the supporting reinforcement and the connecting reinforcement can also be changed to any angle, depending on the shape of the end frame.

[0019] Step S2: Based on the supporting rib, fix four straight ribs. Using the positions of the four straight ribs as the shape basis, bend them to form a mouth-shaped rib. Distribute the mouth-shaped ribs equidistantly along the long side of the straight ribs. Tie or weld the straight ribs and mouth-shaped ribs together to obtain the end skeleton support.

[0020] Please see Figure 3 As can be seen from the attached diagram, the angle between the supporting ribs and the connecting ribs along the axial projection of the cone is 90 degrees. After the straight ribs are fixed by binding or welding over the surface of the supporting ribs, the four straight ribs form four points. Using these points as references, the beveled ribs are bent and then equidistantly fitted onto the straight ribs. The beveled ribs and straight ribs are fixed by binding or welding, thus producing the end frame support body. This solves the problem of the complex end frame structure and the difficulty of bending it in the mold. After the end frame is prefabricated externally, the support body and the tooling rod are matched. Utilizing the matching characteristics of the tooling rod and the mold, the end frame support body is placed in a standard position each time, thus meeting the requirements of standardized processing procedures.

[0021] To further explain, the surface of the support rib has grooves or protrusions to support the straight ribs. The straight ribs are located on top of the internal grooves or protrusions, and the straight ribs and support ribs are fixed together by binding. To improve the stability of the matching between the straight ribs and support ribs, the grooves or protrusions restrict the displacement of the straight ribs above the support ribs, and the binding method prevents the straight ribs from sliding in multiple directions on the support ribs. The only unidirectional sliding direction is limited by the binding, making the fixation between the straight ribs and support ribs more stable.

[0022] Furthermore, based on the axial height of the cone, the connecting ribs are higher than the supporting ribs, and the highest point of the connecting ribs is level with the highest point of the straight ribs. The slit-shaped ribs and straight ribs, as well as the slit-shaped ribs and connecting ribs, are all fixed by binding or welding.

[0023] When the connecting bars and supporting bars are misaligned, the supporting bars act as supports to fix the straight bars. This ensures that the connecting bars and the two supporting bars are on the same plane, thus ensuring the stable binding and fixing of the ribs, straight bars, and connecting bars. The overall structure is more integrated.

[0024] Step S3: Install tapered tooling rods on both ends of the mold cavity, align and insert the two tapered cylinders of the end frame support body with the tooling rods, and have a gap between the lower end of the tapered cylinder and the lower end of the tooling rod.

[0025] Please see Figure 5The end frame support is assembled to the tooling rod. Since the tooling rod is rectangular in shape, there is a gap between the lower end of the cone and the lower end of the tooling rod. The gravity generated by the end frame drives the cone to fit tightly with the tooling rod and prevents it from moving downward. The support of the tooling rod on the cone causes the end frame to form an empty area with the mold surface, thereby ensuring that the end frame is located in the center of the staircase and avoiding quality problems caused by the end frame being too close to the concrete surface.

[0026] As can be seen from the attached diagram, if the end frame is supported by pads inside the mold, a large number of pads are required because the end frame itself is not stable and requires multiple points of support from the pads. If the pads vibrate and shift during concrete compaction, it will lead to a decrease in product consistency.

[0027] Step S4: A horizontal overlapping area is formed between the two end skeleton supports inside the mold cavity. Within the horizontal overlapping area, the grid keel is tied in sequence, and the two ends of the grid keel are respectively connected to the two end skeleton supports.

[0028] Please see Figure 5 When the stair mold is in use, the mold's step cavity is horizontal. The area of ​​the grid keel used to build the step surface in the horizontal direction of the two end skeleton supports is called the horizontal overlap area, which is located inside the stair mold cavity.

[0029] With the addition of a horizontal overlapping zone, the end frame serves as the supporting structure, and a grid keel is constructed to drive the grid keel on the stair tread surface to be located at the center of the staircase, effectively controlling the keel position. Once the end frame and grid keel are assembled, they form a single integrated frame. Under the constraint of the tooling rod, the entire frame can only tilt, not move vertically. Furthermore, the weight of the entire frame is applied to the tooling rod, making it difficult for the entire frame to shift during concrete vibration. For staircase structures with tapered through holes, the length of the tooling rod is consistent with the cavity height at the staircase connection point in the mold, further preventing the entire frame from detaching.

[0030] Additional notes: The connecting ribs are located within the horizontal overlap area, and the two ends of the long ribs parallel to the long side of the mold in the grid keel are fixedly connected to the connecting ribs.

[0031] Please see Figure 5 ,pass Figure 5 The tilt direction of the end frame support shows that the connecting ribs have points to support the long ribs, and the ribs are spaced apart, so they will not affect the long rib binding operation.

[0032] Furthermore, if the height of the grid keel does not have matching connecting ribs, straight ribs are added inside the slatted ribs. The number of straight ribs shall not exceed two, and at least two straight ribs shall be located within the horizontal overlap area of ​​each end frame support. The two ends of the long ribs parallel to the long side of the mold in the grid keel are fixedly connected to the added straight ribs as a supplement.

[0033] Step S5: Add concrete, vibrate, solidify, and open the mold to obtain the finished product.

[0034] After demolding, the tooling rod is removed, and the inner wall of the conical hole of the staircase is supported by the conical cylinder, which is integral with the entire end frame, improving stability. During subsequent staircase splicing and conical hole filling, the conical cylinder and the subsequent filling structure provide composite reinforcement, improving the stability of the assembly joint.

[0035] The above description is merely a preferred embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any equivalent substitutions or modifications made by those skilled in the art within the scope of the technology disclosed in the present invention, based on the technical solution and inventive concept of the present invention, should be covered within the scope of protection of the present invention.

Claims

1. A method for prefabricating a frame-supported elevated staircase, characterized in that: include: Step S1: The two cones are fixed together by welding connecting ribs, and the outer wall of the cones is fixed by welding supporting ribs to obtain the support body. A total of two support bodies are prepared. Step S2: Based on the supporting ribs, fix four straight ribs. Using the positions of the four straight ribs as the shape basis, bend them to form a mouth-shaped rib. Distribute the mouth-shaped ribs equidistantly along the long side of the straight ribs. Tie or weld the straight ribs and mouth-shaped ribs together to obtain the end skeleton support body. Step S3: Install tapered tooling rods on both ends of the mold cavity, align and insert the two tapered cylinders of the end frame support body with the tooling rods, and there is a gap between the lower end of the tapered cylinder and the lower end of the tooling rod; Step S4: A horizontal overlapping area is formed between the two end skeleton supports in the mold cavity. Within the horizontal overlapping area, the mesh keel is tied in sequence, and the two ends of the mesh keel are respectively connected to the two end skeleton supports. Step S5: Add concrete, vibrate, solidify, and open the mold to obtain the finished product.

2. The method for prefabricating a frame-supported elevated staircase based on end-frame support according to claim 1, characterized in that: In step S1, there is an angle between the support bar and the connecting bar.

3. The method for prefabricating a frame-supported elevated staircase based on end-frame support according to claim 2, characterized in that: In step S1, the angle between the support bar and the connecting bar is 90 degrees.

4. The method for prefabricating a frame-supported elevated staircase based on end-frame support according to claim 1, characterized in that: In step S2, the surface of the support rib has a groove or protrusion to support the straight rib, the straight rib is located on the top of the inner groove or protrusion, and the straight rib and support rib are fixed by binding.

5. The method for prefabricating a frame-supported elevated staircase based on end-frame support according to claim 1, characterized in that: In step S2, based on the axial height of the cone, the connecting rib is higher than the supporting rib, and the highest point of the connecting rib is level with the highest point of the straight rib. The slit-shaped rib and the straight rib, as well as the slit-shaped rib and the connecting rib, are fixed by binding or welding.

6. The method for prefabricating a frame-supported elevated staircase based on end-frame support according to claim 1, characterized in that: In step S4: the connecting rib is located in the horizontal overlapping area, and the two ends of the long rib parallel to the long side of the mold in the grid keel are fixedly connected to the connecting rib.

7. The method for prefabricating a frame-supported elevated staircase based on end-frame support according to claim 1, characterized in that: In step S4: when the connecting rib is not present in the horizontal overlap area, a straight rib is added inside the mouth-shaped rib. The number of straight ribs shall not exceed two, and at least two straight ribs shall be located within the horizontal overlap area in each end skeleton support body. The two ends of the long ribs parallel to the long side of the mold in the grid keel are fixedly connected to the added straight ribs.

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