Prestressed prefabricated wallboard

Abstract

The utility model discloses a pre-stressed prefabricated wallboard which comprises a pre-stressed concrete slab, a steel web member and a channel steel lower chord. Bottom plate reinforcing steel bars consisting of a plurality of longitudinal prestressed reinforcing steel bars and transverse reinforcing steel bars are arranged in the stress concrete plate; and the steel web member is continuously bent. The channel steel lower chord and the steel web member are connected together after the prestress of the prestressed concrete slab is released; and the bottom of the channel steel web member truss is arranged in the prestressed concrete slab. The bottom plate concrete and the channel steel web member truss are anchored to form the composite truss, the thin wall plate, the construction technology, the large span and the large width can be achieved, components are not cracked or arched, manufacturing is easy, industrial production of the components is achieved, and the production efficiency of the components is improved.

Description

Technical Field

[0001] The utility model relates specifically to the technical field of construction engineering, in particular to a prestressed prefabricated wall panel, which can be widely used in wall panels of various buildings. Background Art

[0002] Most of the existing prefabricated wall panels use non-prestressed concrete wall panels. The wall panels are complex to manufacture, thick, and heavy in weight. They are also prone to cracking during the manufacturing, transportation, and installation process. Especially as exterior wall panels, they are prone to natural cracking due to wind and sun exposure and large temperature fluctuations. Water leakage will often occur in the later period. The use of prestressed materials as wall panels can make the components thinner, reduce their own weight, and prevent cracking. However, due to the shrinkage and creep of concrete, the wall panels are prone to warping and deformation. Due to the aesthetic requirements of the building, the flatness requirements of the wall panels are relatively strict, and warping and deformation are not allowed. This seriously restricts the application of prestressed wall panels.

[0003] Existing metal-framed concrete wall panels have a wide range of application technologies. However, due to the excellent thermal conductivity of metal, the thermal insulation performance of the wall cannot be guaranteed. The use of thermal insulation materials for connection results in unreliable force distribution in the connectors, making the wall unreliable in the later stages of construction. This presents a difficult dilemma to resolve. Furthermore, the concrete wall panels are merely attached to the metal frame, not forming a composite steel-concrete structure. This results in a high steel consumption and low structural strength. Utility Model Content

[0004] To this end, the present invention proposes a prestressed prefabricated wall panel to solve the problems raised in the above background technology.

[0005] To achieve the above-mentioned purpose, the utility model discloses a prestressed prefabricated wall panel, which includes: a prestressed concrete slab, a steel web, and a channel steel lower chord. A bottom plate steel mesh composed of a plurality of longitudinal prestressed steel bars and transverse steel bars is arranged in the prestressed concrete slab; the steel web is continuously bent up and down; the steel web and the channel steel lower chord are fixedly connected together after the longitudinal prestressed steel bars are tensioned; the steel web and the channel steel lower chord are anchored side by side on the prestressed concrete slab in one or more groups.

[0006] In the device of the present invention, the lower chord of the channel steel and the steel webs form a device, which is anchored to the precast concrete slab and the steel web truss to form a composite slab truss. The concrete slab is the upper chord of the truss, the channel steel is the lower chord, and the continuously bent steel, flat steel or channel steel is the web. The lower chord of the channel steel is fixedly connected to the steel web after the prestressing is released, which fully releases the shrinkage deformation of the concrete and the prestressed creep deformation. The anti-arch deformation of the prestressed component is greatly reduced. The present invention adopts a cross bolt, and the bolt adopts a metal part with an insulation layer, and an insulation gasket is provided, which changes the tension at the connection to shear, which not only ensures the safety of the structure, but also ensures the thermal insulation effect of the wall. The present invention can realize a precast concrete slab that is thin, light in weight, does not crack the component, the component is flat and has no anti-arch, the slab width is large, the manufacturing is simple, and the component is easy to realize industrialized production.

[0007] Furthermore, preferably, the steel web is flat steel, and longitudinal concave and convex ribs are pressed on the web portion.

[0008] Furthermore, as a preference, the steel web is a channel steel, and the channel steel has flange cuts or slits at the bends of the wave crests and wave troughs.

[0009] Furthermore, preferably, the channel steel web has holes on the flange.

[0010] Furthermore, preferably, the holes on the flange contain steel bars perpendicular to the direction of the truss.

[0011] Furthermore, preferably, the steel web is buried in the bending part of the concrete slab. Furthermore, preferably, the lower chord opening of the channel steel is grooved toward the concrete slab.

[0012] Furthermore, preferably, bolt holes are left in the steel web and the lower chord of the channel steel, and screws pass through the bolt holes to fix the steel web and the lower chord of the channel steel.

[0013] Furthermore, as a preference, the surface of the screw is covered with a heat-insulating material, and a heat-insulating material gasket is provided between the nut and the steel web.

[0014] Furthermore, preferably, the steel webs are arranged intermittently along the lower chord of the channel steel.

[0015] Furthermore, preferably, the longitudinal prestressed steel bars are placed on the center line of the concrete slab thickness.

[0016] Furthermore, preferably, concrete, mortar or gypsum is poured into the lower chord of the channel steel.

[0017] Furthermore, preferably, steel bars are laid in the lower chord of the channel steel.

[0018] Furthermore, preferably, both ends of the prestressed concrete slab are provided with lap joints to connect with the main structure.

[0019] Furthermore, preferably, the prestressed concrete slab has a thickness of 30 mm to 50 mm.

[0020] Furthermore, preferably, the prestressed concrete slab is made of ceramsite concrete.

[0021] Furthermore, preferably, a transverse truss is provided on the prestressed concrete slab, and the transverse truss is perpendicular to the lower chord of the channel steel.

[0022] Furthermore, preferably, a decorative pattern is provided on the surface of the prestressed concrete slab.

[0023] Furthermore, preferably, the back side of the prestressed concrete slab is filled with a heat insulation layer.

[0024] Furthermore, preferably, the steel webs and the lower chord of the channel steel are wrapped with polyurethane foam.

[0025] Furthermore, preferably, the lower chord of the channel steel is reliably connected to the decoration panel.

[0026] The present invention adopts the above technology and has the following beneficial effects compared with the existing technology: In the device of the present invention, a new type of prestressed concrete prefabricated wall panel is formed by combining steel webs, prestressed concrete slabs and channel steel lower chords. The deformation of the prestressed bottom plate is released by connecting the channel steel lower chord with the webs at the back. The concrete itself will produce shrinkage deformation during the pouring and hardening process. After the prestress is applied, compression deformation and concrete creep deformation will also occur. Most of these deformations are completed when the concrete reaches the initial strength, while the lower chord of the steel truss is not deformed. If the complete truss is pre-buried and then the concrete is poured, the steel truss will constrain the deformation of the concrete slab, resulting in arching deformation and unevenness of the component. This is the main reason for the deformation of the prestressed concrete slab caused by the existing technology. First, connect the webs with the prestressed concrete slab and cast them together. When the prestress reaches the release condition, the strength of the concrete basically reaches 70%, and most of the shrinkage due to the hydration reaction of the concrete has been completed. After the prestress is released, the compression deformation of the concrete is also basically completed. At this time, connect the steel webs with the lower chord of the channel steel. The deformation of the concrete has been released, and the component will not arch or deform, thus ensuring the flatness of the wall panel.

[0027] By continuously bending flat steel and imprinting longitudinal ribs on the web, the flat steel's turning radius is increased, the slenderness ratio is reduced, and the strength advantages of the steel are maximized. The flat steel maintains a flat surface at the peaks and troughs, making it easier to bend without damaging the steel at the bends. Flat steel is also easier to mechanically form and process. The wide width of the flat steel allows for a single row of web members, creating a monolithic truss that is more stable and saves both labor and materials.

[0028] Continuous bending of channel steel results in a larger and more stable turning radius and a smaller slenderness ratio for the same cross-sectional area, further maximizing the strength of steel. Channel steel is easier to mechanically form than steel pipes, making it more readily mechanized. The wider width of the channel steel allows for a single row of web members, forming a monolithic truss. This provides greater stability and saves labor and materials.

[0029] Channel steel is used as the bottom chord, serving as both compression and tension members, ensuring rigidity and strength during component fabrication, transportation, and hoisting. Because the bottom chord and web members are connected laterally, using channel steel is more convenient, improving component processing efficiency and industrial productivity. After the prefabricated wall panels are installed, the other side of the wall panels will be installed with decorative panels. The flat back of the channel steel facilitates connection with the decorative panels, saving steel keels and wall materials.

[0030] Holes are left in the steel webs and reinforced with steel bars. The transverse reinforcement is located on the side of the longitudinal reinforcement away from the bottom chord channel. Transverse reinforcement is left at the bend where the steel webs are embedded in the concrete slab, positioned between the webs and the longitudinal reinforcement. This helps secure the webs and concrete slab together, ensuring a secure connection for the wall panels.

[0031] The lower chord of the channel steel is filled with mortar or other fillers, and steel bars or prestressed steel bars can be placed in the fillers. This is beneficial to increase the strength and rigidity of the component and reduce the amount of steel used.

[0032] By aligning the prestressed steel bars with the centroid of the prestressed concrete slab, deformation of the concrete slab caused by eccentric prestressing is eliminated. After the concrete hardens, it is then connected to the steel ribs to form a composite member. This differs significantly from existing technologies in that the centroid of the prestressing steel coincides with the centroid of the composite section.

[0033] The web members are connected to the lower chord of the channel steel using bolts. Thermal insulation material is applied to the bolts, and a gasket made of thermal insulation material is placed between the nut and the connector. The insulation coating on the metal bolts ensures both a secure connection and thermal insulation of the wall panel. The bolts are shear-resistant, so even if the insulation material ages and loses its strength, the internal metal components will maintain the strength of the connection.

[0034] When installing wall panels, they must be connected to the main structure, typically to the upper and lower beams or to the left and right shear walls or columns. Connectors, such as embedded iron bars, are placed within the concrete to connect the panels to the main structure, and then the lower chords are connected to the main structure. This provides greater stability and structural safety.

[0035] When using prestressed concrete walls as wall panels, the panels should not be too thick. Otherwise, the structure will be heavy and rigid, which will be detrimental to the earthquake resistance of the main structure. This will increase the building's weight, the cross-sectional dimensions of the main structural components, the amount of steel required, and the amount of foundation required. Using 30-50mm thick wall panels with prestressing can ensure that the wall panels will not crack.

[0036] Concrete wall panels are made of expanded clay concrete, which can reduce the weight of the wall and increase the thermal insulation performance of the wall.

[0037] The transverse trusses can be in the form of steel trusses, steel pipe trusses, plane trusses, and three-dimensional trusses. Adding transverse trusses can enhance the rigidity and strength of the wall panels perpendicular to the steel trusses, ensuring that the wall panels do not crack and facilitating their installation.

[0038] Filling the wall with insulation material is superior to existing external or internal insulation and does not increase wall thickness. Internally, insulating nails can be used to connect the decorative panels, reducing thermal bridges and integrating them with the bottom chord for greater safety. Interior panels can be made of gypsum board, fibercement board, or paint-free board.

[0039] The wall panel surface is integrated with ceramic tiles, imitation stone and other decorative surface layers, and the bonding and stability of the decorative materials are more reliable and the durability is better. BRIEF DESCRIPTION OF THE DRAWINGS

[0040] Figure 1 It is a structural plan diagram of a prestressed prefabricated wall panel;

[0041] Figure 2 The following is a schematic structural plan of a prestressed prefabricated wall panel (with transverse trusses);

[0042] Figure 3 A schematic diagram of composite layering of a prestressed prefabricated wall panel;

[0043] Figure 4 This is a schematic diagram of a flat steel truss structure cross-section of a prestressed prefabricated wall panel;

[0044] Figure 5 A schematic diagram of a flat steel pressing structure of a prestressed prefabricated wall panel;

[0045] Figure 6 This is a schematic diagram of the cross-section of a channel steel truss structure of a prestressed prefabricated wall panel;

[0046] Figure 7 A schematic side view of a discontinuous channel steel truss structure of a prestressed prefabricated wall panel;

[0047] Figure 8 It is an enlarged side view of a discontinuous channel steel truss structure of a prestressed prefabricated wall panel;

[0048] Figure 9 It is an enlarged side view of a discontinuous channel steel truss structure of a prestressed prefabricated wall panel;

[0049] Figure 10 This is an enlarged schematic diagram of the AA structural section of a channel steel truss of a prestressed prefabricated wall panel;

[0050] Figure 11 A schematic diagram of a connecting screw for a prestressed prefabricated wall panel;

[0051] In the figure: 1. Prestressed concrete slab; 2. Steel web; 3. Channel steel lower chord; 4. Longitudinal prestressed steel bars; 5. Transverse steel bars; 6. Connectors; 7. Decorative pattern layer; 8. Insulation layer; 9. Decorative panel; 10. Transverse reinforcement trusses; 12. Bolt holes for connectors and longitudinal steel ribs; 13. Screws; 14. Insulation material on the screws; 15. Insulation gaskets. DETAILED DESCRIPTION

[0052] The following will be combined with the drawings in the embodiments of the present invention to clearly and completely describe the technical solutions in the embodiments of the present invention. Obviously, the embodiments described are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making creative efforts are within the scope of protection of the present invention.

[0053] Example: Please see the attached Figure 1-11 The present invention provides a technical solution comprising a prestressed concrete slab, a steel web, and a channel steel bottom chord. A bottom plate reinforcement mesh composed of a plurality of longitudinal prestressed steel bars and transverse steel bars is disposed within the prestressed concrete slab; the steel web is continuously bent vertically; the steel web and the channel steel bottom chord are securely connected after the longitudinal prestressed steel bars are tensioned; and the steel web and channel steel bottom chord are anchored side by side to the prestressed concrete slab in single or multiple groups.

[0054] In this embodiment, the flat steel is continuously bent, with longitudinal ribs formed on the web. This increases the flat steel's radius of gyration and reduces its slenderness, effectively leveraging the steel's strength. The flat steel maintains a flat surface at the peaks and troughs, making it easier to bend without damaging the steel at the bends. The flat steel is easily mechanically formed and more easily mechanized. The wide width of the flat steel allows for a single row of web members, forming a single-piece truss. This provides greater stability and saves both labor and materials.

[0055] In this embodiment, continuous bending of the channel steel is employed. Given the same cross-sectional area, the channel steel's turning radius is larger and more stable, and its slenderness ratio is smaller, further maximizing the strength advantages of steel. Channel steel is easier to mechanically form than steel pipes, making it more readily mechanized. The larger width of the channel steel allows for a single row of web members, forming a monolithic truss. This provides greater stability and saves both labor and materials.

[0056] In this embodiment, channel steel is used as the bottom chord. The channel steel serves as both a compression and tension member for the bottom chord, ensuring rigidity and strength during component fabrication, transportation, and hoisting. Because the bottom chord and web members are connected laterally, the use of channel steel is more convenient, improving component processing efficiency and industrial productivity. After the prefabricated wall panels are installed, the other side of the wall panels will be installed with decorative panels. The flat back of the channel steel facilitates connection with the decorative panels, saving steel keels and wall materials.

[0057] In this embodiment, holes are left on the steel web and steel bars are passed through. The transverse steel bars are on the side of the longitudinal steel bars away from the lower chord channel steel to strengthen the fixing strength of the web and the concrete slab.

[0058] In this embodiment, transverse reinforcement is left at the bend of the steel web embedded in the concrete slab, and the transverse reinforcement is between the steel web and the longitudinal reinforcement, which is more conducive to fixing the web and the concrete slab together and ensuring the connection safety of the wall panel.

[0059] In this embodiment, the prestressed steel bars are aligned with the centroid of the prestressed concrete slab, eliminating deformation of the concrete slab caused by eccentric prestressing. After the concrete hardens, it is then connected to the steel ribs to form a composite member. This differs significantly from existing technologies, where the centroid of the prestressing force coincides with the centroid of the composite cross-section.

[0060] In this embodiment, the web members are connected to the lower chord of the channel steel using bolts. Insulation material is applied to the bolts, and a gasket made of insulation material is placed between the nut and the connector. The insulation coating on the metal bolts ensures both a secure connection and thermal insulation of the wallboard. The bolts are shear-resistant, so even if the insulation material ages and loses its strength, the internal metal components will still maintain the strength of the connection.

[0061] In this embodiment, the lower chord of the channel steel is used to facilitate filling the channel steel with mortar or other fillers, and the fillers can be placed with steel bars or prestressed steel bars, which is beneficial to increasing the strength and rigidity of the component and reducing the amount of steel used.

[0062] In this embodiment, lap joints are embedded at both ends of the wall panel, such as pre-buried iron connected to the main body, and then the lower chord is connected to the main structure, so that the wall panel is more stable and the structure is safer.

[0063] In this embodiment, 30-50 mm prestressed concrete walls are used as wall panels, which effectively reduces the deadweight of the wall. With prestressing, the wall panels can be ensured not to crack.

[0064] In this embodiment, the concrete wall panels are made of ceramsite concrete, which can reduce the deadweight of the wall and increase the thermal insulation performance of the wall.

[0065] In this embodiment, a transverse truss is provided, and the transverse truss is a steel truss, which can enhance the rigidity and strength of the wall panel perpendicular to the steel truss, ensure that the wall panel does not crack, and facilitate the installation of the wall panel.

[0066] In this embodiment, insulation material is filled into the wall, which is superior to existing external or internal insulation and does not increase the wall thickness. Insulating nails can be used to connect the internal decorative panels, reducing thermal bridge effects. These panels are integrated with the bottom chord for greater safety. The interior decorative panels can be made of materials such as gypsum board, cement fiber board, or paint-free board.

[0067] In this embodiment, the wall panel surface layer is integrated with decorative surface layers such as ceramic tiles and imitation stone, and the bonding and stability of the decorative materials are more reliable and the durability is better.

[0068] Although the embodiments of the present invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and variations may be made to these embodiments without departing from the principles and spirit of the present invention, and the scope of the present invention is defined by the appended claims and their equivalents.

Claims

1. A prestressed prefabricated wall panel, characterized in that: It includes: prestressed A concrete slab (1), a steel web (2), and a channel steel lower chord (3); a bottom plate steel mesh consisting of a plurality of longitudinal prestressed steel bars (4) and transverse steel bars (5) is provided in the concrete slab (1); the steel web (2) is continuously bent up and down; the steel web (2) and the channel steel lower chord (3) are fixedly connected together after the longitudinal prestressed steel bars (4) are tensioned; the steel web (2) and the channel steel lower chord (3) are anchored side by side on the prestressed concrete slab (1) in a single group or in multiple groups.

2. The prestressed prefabricated wall panel according to claim 1, characterized in that: The steel web (2) is flat steel, and longitudinal concave-convex ribs are pressed on the web, while there are no longitudinal concave-convex ribs at the bends of wave crests and troughs.

3. The prestressed prefabricated wall panel according to claim 1, characterized in that: The steel web (2) is a channel steel, and the flanges of the channel steel are notched or slit at the bends of the wave crests and wave troughs.

4. The prestressed prefabricated wall panel according to claim 3, characterized in that: The channel steel web (2) has holes on the flange.

5. The prestressed prefabricated wall panel according to claim 4, characterized in that: The holes on the flanges are filled with steel bars perpendicular to the truss direction.

6. The prestressed prefabricated wall panel according to claim 1, characterized in that: The steel web member (2) is embedded in the bending part of the concrete slab (1) and has steel bars perpendicular to the truss direction.

7. The prestressed prefabricated wall panel according to claim 1, characterized in that: The lower chord (3) of the channel steel is opened into the concrete slab.

8. The prestressed prefabricated wall panel according to claim 1, characterized in that: The steel web (2) and the channel steel lower chord (3) are provided with bolt holes (12), and screw rods (13) pass through the bolt holes (12) to fix the steel web (2) and the channel steel lower chord (3).

9. The prestressed prefabricated wall panel according to claim 8, characterized in that: The surface of the screw rod (13) is covered with a heat insulating material (14), and a heat insulating material gasket (15) is provided between the lower chord (3) of the channel steel and the steel web (2).

10. The prestressed prefabricated wall panel according to claim 1, characterized in that: The steel web members (2) are intermittently arranged along the lower chord (3) of the channel steel.

11. The prestressed prefabricated wall panel according to claim 1, characterized in that: The longitudinal prestressed steel bars (4) are placed on the thickness center line of the concrete slab (1).

12. The prestressed prefabricated wall panel according to claim 1, characterized in that: Concrete, mortar or gypsum is poured into the lower chord (3) of the channel steel.

13. The prestressed prefabricated wall panel according to claim 1, characterized in that: Reinforcement bars are laid in the lower chord (3) of the channel steel.

14. The prestressed prefabricated wall panel according to claim 1, characterized in that: Both ends of the prestressed concrete slab (1) are provided with lap joints (6) connected to the main structure.

15. The prestressed prefabricated wall panel according to claim 1, characterized in that: The thickness of the prestressed concrete slab (1) is 30 mm to 50 mm.

16. The prestressed prefabricated wall panel according to claim 1, characterized in that: The prestressed concrete slab (1) is made of ceramsite concrete.

17. The prestressed prefabricated wall panel according to claim 1, characterized in that: A transverse truss (10) is provided on the prestressed concrete slab (1), and the transverse truss (10) is perpendicular to the lower chord (3) of the channel steel.

18. The prestressed prefabricated wall panel according to claim 1, characterized in that: The surface of the prestressed concrete slab (1) is provided with a decorative pattern (7).

19. The prestressed prefabricated wall panel according to claim 1, characterized in that: The back side of the prestressed concrete slab (1) is filled with a heat insulation layer (8).

20. The prestressed prefabricated wall panel according to claim 1, characterized in that: The steel web (2) and the channel steel lower chord (3) are wrapped with polyurethane foam.

21. The prestressed prefabricated wall panel according to claim 1, characterized in that: The lower chord of the channel steel (3) is fixedly connected to the decoration panel (9).

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