A limited height and pipeline-intensive walkway fabricated gypsum board ceiling construction method

Abstract

The application provides a limited height and dense pipeline corridor assembled gypsum board ceiling construction method, comprising: BIM three-dimensional pipeline comprehensive deepening; installing a U-shaped horizontal steel rail along the lengthways of the corridor wall, a sliding groove is formed in the U-shaped horizontal steel rail, and the bottom is supported and reinforced by an inclined brace corner brace; prefabricating a main and auxiliary batten grid unit; sliding the end of the main batten in the main and auxiliary batten grid unit into the sliding groove, fixing after adjustment, staggered hoisting the prefabricated gypsum board module, fixing the module on the bottom of the auxiliary batten by shock-absorbing self-tapping screws, embedding joint gypsum, pasting a crack bandage, and brushing a top layer coating after puttying. The whole system load is all supported by the two side walls, the floor hanger is completely cancelled, the ceiling thickness is greatly reduced, the corridor evacuation clearance meets the fire safety regulations, all the battens and boards are prefabricated in advance, only assembly and splicing are carried out on site, there is no large amount of fire welding and drilling and cutting operation, the fire hazard of the construction site is reduced, and the original floor structure is not damaged.

Description

Technical Field

[0001] This invention belongs to the field of building construction technology, and in particular relates to a method for constructing prefabricated gypsum board ceilings in corridors with limited floor height and dense pipes. Background Technology

[0002] Many current designs have low structural floor heights, and BIM technology was not used for integrated pipeline layout during the electromechanical installation phase, resulting in underutilization of ceiling space and further reducing the achievable ceiling height. Conventional gypsum board ceiling construction requires drilling holes in the structural ceiling slab to install hangers. In areas with dense pipelines in corridors, there is no space for ceiling hangers to anchor, necessitating the addition of multiple transfer layers of joists. Adding ceiling transfer layers significantly increases the overall ceiling thickness, compressing the evacuation clearance in corridors and making it difficult to meet the minimum clearance requirements for evacuation corridors in fire safety regulations, easily leading to rework issues during fire safety inspections. At the same time, drilling numerous holes in the ceiling slab can damage the original floor structure, posing a safety hazard of ceiling collapse. Moreover, traditional construction methods involve on-site cutting and welding of joists, resulting in a large amount of wet work, serious accumulation of construction errors, poor ceiling flatness, frequent hot work, and high fire risk. There are no standardized prefabricated modules for joists and gypsum boards, making high-altitude work procedures complex, construction cycles long, frequent collisions between pipelines and hangers / joists, large amounts of on-site demolition and alteration, and high material waste, which does not meet the requirements of prefabricated green construction.

[0003] To ensure safe and efficient ceiling construction within limited floor height and densely piped corridors, while protecting the original building structure and meeting fire safety clearance requirements, the inventors, after multiple on-site trials and optimizations, developed a prefabricated gypsum board ceiling construction method specifically for corridors with limited floor height and dense pipes. This method utilizes wall tracks instead of top hangers for support, enabling modular prefabrication and rapid on-site assembly. It boasts advantages such as standardized replication, high headroom utilization, and on-demand adjustment. Summary of the Invention

[0004] To address the shortcomings of existing technologies, this invention provides a prefabricated gypsum board ceiling construction method for corridors with limited floor height and dense pipes. It is equipped with a horizontal steel track support system for the walls, prefabricated keel modules on the ground, and tongue-and-groove prefabricated gypsum board modules. Combined with BIM pre-detailed layout, the entire process eliminates the need for drilling holes in the ceiling slab for hangers, significantly saving vertical space for the ceiling. This solves problems such as dense pipes in the corridor ceiling, inability to install hangers in the ceiling slab, excessive vertical height occupation by traditional transfer layers, insufficient corridor clearance, damage to the original floor slab, and cumbersome on-site construction with frequent rework.

[0005] The present invention achieves the above-mentioned technical objectives through the following technical means.

[0006] A method for constructing prefabricated gypsum board ceilings in corridors with limited floor height and dense pipes includes the following steps:

[0007] Step 1: Collect 3D data of corridor civil engineering and electromechanical systems to establish a BIM integrated model, complete pipeline collision optimization and divide the standard ceiling assembly module, and output prefabrication drawings;

[0008] Step 2: Install U-shaped horizontal steel tracks along the entire length of the side walkway walls;

[0009] Step 3: Prefabricate the main and secondary keel mesh units;

[0010] Step 4: After raising the main and secondary keel grid units to the elevation position, slide the end of the main keel into the reserved groove of the U-shaped horizontal steel rail, adjust it into place and fix it. Adjacent main and secondary keel grid units are connected by tongue and groove splicing to form an overall conversion frame.

[0011] Step 5: Hoist the prefabricated gypsum board modules and fix them to the bottom of the secondary keel of the main and secondary keel grid unit, and perform anti-crack treatment at the joints;

[0012] Step 6: Install protective barriers on both sides of the corridor to complete the protection of the finished ceiling.

[0013] Further, step 2 includes: marking the finished ceiling elevation and track installation control lines along the walls of both sides of the corridor; then using expansion bolts to install U-shaped horizontal steel tracks along the entire length of the walls of both sides of the corridor; adding multiple diagonal bracing brackets at even intervals at the bottom of the U-shaped horizontal steel tracks; fixing the lower vertical section of the diagonal bracing brackets to the corridor wall; and the upper horizontal section closely adhering to the lower flange of the U-shaped horizontal steel tracks; at the same time, a long strip adjustment groove is opened on the web of the U-shaped horizontal steel tracks.

[0014] Furthermore, the U-shaped horizontal steel track has a wall thickness of 5.0mm, an expansion bolt spacing of 600mm, and an angle bracket arrangement interval of 1200mm; the elevation of the U-shaped horizontal steel track is 80-100mm higher than the finished ceiling surface.

[0015] Furthermore, in step 3, the surface of the main and secondary keel mesh units is coated with an anti-rust and fireproof coating.

[0016] Furthermore, the main keel is made of galvanized square tubing with a cross-sectional size of 50×50×15mm, and the secondary keel is a U-shaped light steel secondary keel.

[0017] Furthermore, in step 4, the main keel and the U-shaped horizontal steel track are locked and fixed together by shock-absorbing self-tapping screws.

[0018] Further, step 5 includes:

[0019] Pre-fabricated gypsum board modules with tongue and groove joints are installed in a staggered manner and fixed to the bottom of the secondary keel with shock-absorbing self-tapping screws. The gypsum board modules are spliced ​​together to form tongue and groove joints, which are filled with joint compound, anti-crack tape is applied, putty is applied, and then a top coat of paint is applied. Finished Z-shaped strips are attached to the sides of the gypsum board modules to form a natural joint with the wall, creating a floating ceiling and enhancing the appearance and sense of space of the gypsum board ceiling. The gypsum board modules also have pre-drilled holes for sprinklers, lighting, and smoke detectors. After all the gypsum board modules are assembled, the overall flatness of the ceiling is checked again with a laser level.

[0020] Furthermore, the spacing between the shock-absorbing self-tapping screws at the bottom of the secondary keel is 180mm.

[0021] The present invention has the following beneficial effects:

[0022] The entire system's load is borne by the walls on both sides, completely eliminating floor slab hangers, significantly reducing ceiling thickness, and ensuring that the corridor's evacuation clearance meets fire safety regulations. All keels and panels are prefabricated, requiring only assembly and splicing on-site, eliminating extensive welding, drilling, and cutting work, thus reducing fire hazards on the construction site. Components are uniformly prefabricated in the factory / on-site, significantly reducing construction waste and dust pollution, meeting green prefabricated construction standards. This invention features a matching horizontal steel track load-bearing system for the walls, prefabricated floor keel modules, and tongue-and-groove prefabricated gypsum board modules. Combined with BIM-based pre-planning, the entire process eliminates the need for ceiling drilling and hangers, significantly saving vertical ceiling space. This solves problems such as dense pipes in the corridor ceiling, inability to install hangers in the ceiling, excessive vertical height occupation by traditional transfer layers, insufficient corridor clearance, damage to the original floor slab, and cumbersome on-site construction with frequent rework. The overall width of the keel can be adjusted laterally via the grooves on the U-shaped horizontal steel track. The self-tapping screws between the keel and the U-shaped horizontal steel track allow for fine-tuning of the overall levelness, adapting to wall construction dimensional deviations and ensuring that the overall flatness error of the ceiling is controlled within the required range. If localized damage to plasterboard or equipment maintenance is required later, the corresponding plasterboard module can be individually removed using suction cups. After maintenance, it can be reinstalled without large-scale dismantling of the ceiling. It is easy to install and remove and can be reused. Attached Figure Description

[0023] Figure 1 This is a schematic cross-sectional view of the prefabricated gypsum board ceiling structure described in this invention;

[0024] Figure 2 Detailed drawing of the connection node between the corridor wall and the U-shaped horizontal steel track;

[0025] Figure 3 Schematic diagram of the prefabricated main and secondary keel grid unit structure on the ground;

[0026] Figure 4 This is a schematic diagram of tongue-and-groove splicing of gypsum board modules;

[0027] In the diagram: 1-Walkway wall; 2-Main keel; 3-Secondary keel; 4-Connecting clip; 5-U-shaped horizontal steel track; 6-Diagonal bracing bracket; 7-Expansion bolt; 8-Top multi-layer electromechanical pipeline; 9-Vibration-damping self-tapping screw; 10-Gypsum board module; Detailed Implementation

[0028] The present invention will be further described below with reference to the accompanying drawings and specific embodiments, but the scope of protection of the present invention is not limited thereto.

[0029] The prefabricated gypsum board ceiling construction method for corridors with limited floor height and dense pipes, as described in this invention, relies on the U-shaped horizontal steel track 5 on both sides of the wall as the load-bearing carrier of the transfer layer, and is assembled with main and secondary keel grid units and gypsum board modules 10. The specific process includes the following:

[0030] Step 1: BIM 3D pipeline integration and detailing;

[0031] First, a total station and laser rangefinder were used to collect all three-dimensional dimensional data of the corridor walls, floors, air ducts, water supply and drainage pipes, and power and communication cable trays. A BIM model integrating civil engineering, electromechanical systems, and ceiling was built using Revit. A collision detection program was run to check for conflict points between pipelines and traditional hangers. The cable trays and small-diameter water pipes were raised vertically in layers, and vertical space was reserved for the installation of the ceiling below. Standard ceiling modules were divided according to the width of the corridor, and design drawings such as wall track positioning diagrams, keel prefabrication diagrams, and gypsum board opening layout diagrams were output, and the components were uniformly numbered.

[0032] Step 2: Fix the wall track;

[0033] like Figure 1 , 2 As shown, the finished ceiling elevation and track installation control lines are marked along the two side corridor walls 1 to ensure that the elevation of the subsequently installed U-shaped horizontal steel track 5 is only 80-100mm higher than the finished ceiling surface (preferably 90mm in this embodiment). Only a single layer of keel occupies vertical space, saving 100-180mm of net height compared to the traditional double-layer transition layer. Then, U-shaped horizontal steel tracks 5 with a wall thickness of 5.0mm are installed along the length of the two side corridor walls 1 using expansion bolts 7. The spacing of the expansion bolts 7 is preferably set to 600mm. Multiple diagonal bracing brackets 6 are added at even intervals (preferably 1200mm in this embodiment) at the bottom of the U-shaped horizontal steel track 5 to further reinforce it. The lower vertical section of the diagonal bracing bracket 6 is fixed to the corridor wall 1, and the upper horizontal section is close to the lower flange of the U-shaped horizontal steel track 5. At the same time, 600mm equidistant long strip adjustment grooves are opened on the web of the U-shaped horizontal steel track 5.

[0034] Step 3: Prefabrication of ground keel modules;

[0035] like Figure 3As shown, main and secondary keel grid units are prefabricated on the ground in the on-site processing area. Specifically, the main and secondary keel grid units include main keel 2 and secondary keel 3, which are arranged perpendicularly to each other and connected by connecting buckles 4 at their intersections. All nodes are fastened with self-tapping screws, eliminating welding operations and significantly reducing high-altitude work procedures. Each set of main and secondary keel grid units matches the BIM standard unit size. After the main and secondary keel grid units are prefabricated, a second anti-rust and fireproof coating is applied, and the ground is corrected and leveled to control the flatness error to ≤1mm. In this embodiment, preferably, the main keel 2 is a galvanized square tube with a cross-sectional size of 50×50×15mm, and the secondary keel 3 is a U-shaped light steel secondary keel.

[0036] Step 4: Hoisting and connecting the keel module;

[0037] like Figure 1 , 3 As shown, two construction workers work together to lift the main and secondary keel grid units to the track elevation, and then slide the end of the main keel 2 into the reserved groove of the U-shaped horizontal steel track 5. According to the actual deviation of the wall, the main and secondary keel grid units are slid laterally to correct the overall width. After moving them into place, the shock-absorbing self-tapping screws 9 are inserted to lock and fix the plug-in end. The adjacent main and secondary keel grid units are connected by tongue and groove splicing to form an overall conversion frame. No holes need to be drilled in the top plate of the structure throughout the process. There is no collision or interference with the multi-layer electromechanical pipelines 8 on the top. A complete walkway evacuation clearance area is formed below the frame.

[0038] Step 5: Installation of gypsum board module 10 and joint crack prevention treatment;

[0039] like Figure 3 , 4 As shown, the gypsum board module 10 is prefabricated at the processing site. The sides of the board are processed with tongue and groove joints. The prefabricated gypsum board modules 10 with tongue and groove joints are hoisted with staggered joints and fixed to the bottom of the secondary keel 3 with shock-absorbing self-tapping screws 9 (the spacing is preferably set to 180mm). The tongue and groove joints of the gypsum board modules 10 form a 10mm tongue and groove joint. The joint is filled with joint compound, and anti-crack tape (preferably 100mm wide) is pasted on. After applying putty, the top coat is painted, which can effectively control the flatness of the joint. The sides of the gypsum board modules 10 are pasted with finished Z-shaped strips, forming a 10mm natural joint with the wall, forming a floating ceiling, which improves the appearance and sense of space of the gypsum board ceiling. The panels of the gypsum board modules 10 are pre-drilled with holes for sprinklers, lighting, and smoke detectors. After all the gypsum board modules 10 are assembled, the overall flatness of the ceiling is re-measured with a laser level to ensure that the maximum deviation does not exceed 2mm.

[0040] Step 6: Install protective barriers on both sides of the corridor to protect the finished ceiling. If localized damage to the plasterboard or equipment maintenance is required later, the corresponding plasterboard module 10 can be individually removed using suction cups. After maintenance, it can be reinstalled without large-scale dismantling or modification of the ceiling. It is easy to install and remove and can be reused.

[0041] The embodiments described above are preferred embodiments of the present invention, but the present invention is not limited to the above embodiments. Any obvious improvements, substitutions or modifications that can be made by those skilled in the art without departing from the essence of the present invention shall fall within the protection scope of the present invention.

Claims

1. A method for constructing prefabricated gypsum board ceilings in corridors with limited floor height and dense pipework, characterized in that, The process includes the following: Step 1: Collect 3D data of corridor civil engineering and electromechanical systems to establish a BIM integrated model, complete pipeline collision optimization and divide the standard ceiling assembly module, and output prefabrication drawings; Step 2: Install U-shaped horizontal steel rails (5) along the entire length of the two side corridor walls (1); Step 3: Prefabricate the main and secondary keel mesh units; Step 4: After raising the main and secondary keel grid units to the elevation position, slide the end of the main keel (2) into the reserved groove of the U-shaped horizontal steel rail (5), adjust it into place and fix it. The adjacent main and secondary keel grid units form an overall conversion skeleton by tongue and groove splicing. Step 5: Hoist the prefabricated gypsum board module (10) and fix it to the bottom of the secondary keel (3) of the main and secondary keel grid unit, and perform anti-crack treatment at the joint; Step 6: Install protective barriers on both sides of the corridor to complete the protection of the finished ceiling.

2. The construction method for prefabricated gypsum board ceilings in corridors with limited floor height and dense pipes as described in claim 1, characterized in that, Step 2 includes: marking the ceiling finish elevation and track installation control line along the two side corridor walls (1), and then using expansion bolts (7) to install U-shaped horizontal steel rails (5) along the entire length of the two side corridor walls (1). Multiple diagonal bracing brackets (6) are evenly added at intervals at the bottom of the U-shaped horizontal steel rails (5). The lower vertical section of the diagonal bracing brackets (6) is fixed on the corridor wall (1), and the upper horizontal section is close to the lower flange of the U-shaped horizontal steel rails (5). At the same time, long strip adjustment grooves are opened on the web of the U-shaped horizontal steel rails (5).

3. The construction method for prefabricated gypsum board ceilings in corridors with limited floor height and dense pipes according to claim 2, characterized in that, The U-shaped horizontal steel track (5) has a wall thickness of 5.0mm, the expansion bolts (7) are spaced at 600mm intervals, and the diagonal bracing (6) is arranged at 1200mm intervals; the elevation of the U-shaped horizontal steel track (5) is 80-100mm higher than the finished ceiling surface.

4. The construction method for prefabricated gypsum board ceilings in corridors with limited floor height and dense pipes according to claim 1, characterized in that, In step 3, the surface of the main and secondary keel grid units is coated with an anti-rust and fireproof coating.

5. The construction method for prefabricated gypsum board ceilings in corridors with limited floor height and dense pipes according to claim 1, characterized in that, The main keel (2) is made of galvanized square tubing with a cross-sectional size of 50×50×15mm, and the secondary keel (3) is a U-shaped light steel secondary keel.

6. The construction method for prefabricated gypsum board ceilings in corridors with limited floor height and dense pipes according to claim 1, characterized in that, In step 4, the main keel (2) and the U-shaped horizontal steel rail (5) are locked and fixed by shock-absorbing self-tapping screws (9).

7. The construction method for prefabricated gypsum board ceilings in corridors with limited floor height and dense pipes according to claim 1, characterized in that, Step 5 includes: Prefabricated gypsum board modules (10) with tongue and groove joints are hoisted in a staggered manner and fixed to the bottom of the secondary keel (3) with shock-absorbing self-tapping screws (9). The gypsum board modules (10) are spliced ​​together to form tongue and groove joints. The joints are filled with caulking plaster, and anti-crack bandages are pasted on. After puttying, the top layer of paint is applied. Finished Z-shaped strips are pasted on the sides of the gypsum board modules (10) to form a natural joint with the wall, forming a suspended ceiling and improving the appearance and sense of space of the gypsum board ceiling. After all the gypsum board modules (10) are assembled, the overall flatness of the ceiling is re-measured with a laser level.

8. The construction method for prefabricated gypsum board ceilings in corridors with limited floor height and dense pipes according to claim 7, characterized in that, The spacing of the shock-absorbing self-tapping screws (9) at the bottom of the secondary keel (3) is 180mm.

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