Fabricated profile steel lightweight concrete composite board combined roof

Abstract

The utility model relates to the field of buildings, in particular to a fabricated profile steel lightweight concrete composite board combined roof. The roof panel is arranged on the structural beam, the acoustic board is arranged on the lower surface of the roof panel, the fireproof suspended ceiling is arranged on the lower portion of the structural beam, and the sound insulation device is used for insulating sound. The roof panel comprises a heat insulation concrete layer, an inner core plate, a three-dimensional galvanized steel wire mesh, a section steel beam, a concrete surface layer, a waterproof layer and a facing layer, wherein the inner core plate, the three-dimensional galvanized steel wire mesh and the section steel beam are arranged in the heat insulation concrete layer, the concrete surface layer is arranged on the heat insulation concrete layer, the waterproof layer is arranged on the concrete surface layer, and the facing layer is arranged on the waterproof layer. The inner core plate is made of efficient heat preservation materials, and the heat insulation concrete layer is made of cement porous polymer concrete. The fabricated profile steel lightweight concrete composite board combined roof is remarkable in impact sound inhibition effect and good in fireproof and heat-insulating performance and environment-friendly benefit.

Description

Technical Field

[0001] The present application relates to the field of construction, and in particular to an assembled steel-lightweight concrete composite panel combined roof. Background Art

[0002] Steel structure building roofing is a complex project that integrates multiple disciplines, requiring comprehensive design coordination to achieve multi-functionality. These requirements include load-bearing, earthquake resistance, wind resistance, waterproofing, fire protection, sound insulation, energy conservation, thermal insulation, anti-condensation, durability, and weather resistance. Related technologies often utilize lightweight concrete porous panels, composite panels, or lightweight concrete sandwich EPS panels. However, these structures suffer from poor impact sound suppression, poor fire and heat insulation performance, and high production costs. Summary of the Invention

[0003] In view of this, the present application provides an assembled steel-type lightweight concrete composite panel combined roof, which has a significant impact sound suppression effect, good fireproof and heat-insulating properties and environmental benefits.

[0004] In order to achieve the above objectives, this application is implemented through the following technical solutions:

[0005] An assembled steel-lightweight concrete composite panel composite roof, characterized in that it includes a roof panel arranged on a structural beam, a sound-absorbing panel arranged on the lower surface of the roof panel, a fire-proof ceiling arranged below the structural beam, and a sound insulation device for sound insulation; the roof panel includes an insulating concrete layer, an inner core panel arranged in the insulating concrete layer, a three-dimensional galvanized steel wire mesh and a steel beam, a concrete surface layer arranged on the insulating concrete layer, a waterproof layer arranged on the concrete surface layer, and a finishing layer arranged on the waterproof layer; the inner core panel is a high-efficiency thermal insulation material, and the insulating concrete layer is cement porous polymer concrete.

[0006] The above-mentioned invention is a prefabricated steel lightweight concrete composite panel combined roof, wherein the thermal insulation concrete layer adopts a bulk density of 600kg / m 3 The thermal conductivity coefficient is not greater than 1.2x10 -7 m 2 / s cement porous polymer concrete, and EVA and other crushed materials with a high elastic modulus are selected as aggregates for the cement polymer concrete. This not only achieves high thermal resistance and thermal inertia, but also excellent sound insulation, with a significant impact sound insulation effect similar to floating structures. It also allows for the comprehensive utilization of waste foam plastic scraps, resulting in significant environmental benefits. Furthermore, using foam board or rock wool board with a high sound absorption coefficient as the core of the roof panel further improves impact sound suppression. Furthermore, the insulated concrete layer incorporates three-dimensional galvanized steel mesh and steel beams, providing stable mechanical properties for the roof, meeting load-bearing, earthquake, and wind resistance requirements.

[0007] In some embodiments, the inner core board is one of PU, EPS, XPS, EVA, EPP, EPE foam board, rock wool board, glass wool board, phenolic foam board or melamine foam plastic board, or a combination thereof.

[0008] In some embodiments, the aggregate of the thermal insulation concrete layer is one of foamed EVA, foamed XPS, foamed phenolic, melamine foamed plastic and EPS porous polymer fragments, or a combination thereof.

[0009] In some embodiments, the sound absorbing board is selected from one of wood wool board, perlite board, foam glass board, PU board, phenolic board, melamine foam plastic board or XPS board, or a combination thereof.

[0010] In some embodiments, the fireproof ceiling panel is a cement porous polymer concrete panel.

[0011] In some embodiments, the sound insulation system includes a floating sound-absorbing device installed at the joint between the roof panel and the main structure beam, a sound insulation pad installed on the ceiling hanger rod, and a sound insulation pad installed at the sound bridge between the roof panel and the main structure. The floating box device installed at the junction of the composite floor and the main structure not only meets the sound insulation requirements, but also provides joint restraint for earthquake and wind resistance.

[0012] In some embodiments, the concrete surface layer is one of waterproof concrete and ordinary concrete, or a combination thereof.

[0013] In some embodiments, the waterproof layer comprises one or a combination of waterproofing membrane, waterproof coating, and waterproof additives. To achieve waterproofing, the roof panels are either affixed with waterproofing membrane or coated with waterproof coating on the factory production line. During on-site installation, the vertical joints between the panel edges are fully coated with waterproof coating, and an additional layer of a certain width may be applied flatly at the joints. Holes penetrating the roof can be waterproofed according to the appropriate design.

[0014] In some embodiments, the finishing layer is one of a cement mortar protective layer, a finishing paint, a finishing block and a finishing board, or a combination thereof.

[0015] In some embodiments, the steel beam is a structural multi-rib beam composed of steel beams or composite steel beams.

[0016] It can be seen from the above technical solution that this application has at least the following advantages and positive effects:

[0017] 1. This application has a heat transfer coefficient of less than 0.3w / m·k. It saves energy in winter and prevents condensation on the surface of the steel structure. In summer, the indoor temperature is significantly lower than the outdoor temperature under natural ventilation.

[0018] 2. Excellent fireproof and heat-insulating performance, the fire resistance limit time can be designed according to the use requirements. It has the characteristics of Class A non-combustible materials.

[0019] 3. It has a significant effect on suppressing impact noise and is suitable for the requirements of eliminating impact noise in steel structure buildings.

[0020] 4. The waterproof layer is completed on the factory production line and the quality is controlled. The on-site waterproofing work is less.

[0021] 5. Roof surface density is not more than 130kg / m 2 , which is beneficial for earthquake resistance and also suitable for wind resistance.

[0022] 6. It meets the requirements of prefabricated construction, civilized construction, short construction period, low construction cost, and ready-to-move-in conditions.

[0023] 7. Comprehensive utilization of large amounts of waste foam plastics has obvious environmental benefits.

[0024] 8. Provide clean, quiet and safe housing that is warm in winter and cool in summer, and promote the modernization of the construction industry. BRIEF DESCRIPTION OF THE DRAWINGS

[0025] Figure 1 This is a schematic structural diagram of an embodiment of the present application;

[0026] Figure 2 This is a cross-sectional view of a roof panel in an embodiment of the present application;

[0027] Figure 3 This is a cross-sectional view of an embodiment of the present application.

[0028] Explanation of the numbers: 1. Roof panel; 2. Sound-absorbing panel; 3. Fireproof ceiling; 4. Sound insulation device; 5. Finishing layer; 6. Waterproof layer; 7. Concrete surface layer; 8. Insulating concrete layer; 9. Inner core board; 10. Three-dimensional galvanized steel wire mesh; 11. Steel beam. DETAILED DESCRIPTION

[0029] In order to make the purpose, technical solutions and advantages of this application clearer, this application will be further described in detail below with reference to the accompanying drawings. The terms used in the implementation methods of this application are only used to explain the specific embodiments of this application and are not intended to limit this application.

[0030] See Figures 1 to 2 The embodiment of the present application provides an assembled steel-type lightweight concrete composite panel composite roof, comprising a roof panel 1 arranged on a structural beam, a sound-absorbing panel 2 arranged on the lower surface of the roof panel 1, a fireproof ceiling 3 arranged at the lower part of the structural beam, and a sound insulation device 4 for sound insulation;

[0031] The roof panel 1 includes a heat-insulating concrete layer 8, an inner core board 9 arranged in the heat-insulating concrete layer 8, a three-dimensional galvanized steel wire mesh 10 and a steel beam 11, a concrete surface layer 7 arranged on the heat-insulating concrete layer 8, a waterproof layer 6 arranged on the concrete surface layer 7, and a finishing layer 5 arranged on the waterproof layer 6;

[0032] The inner core board 9 is one of PU, EPS, XPS, EVA, EPP, EPE foam board, rock wool board, glass wool board, phenolic foam board or melamine foam plastic board or a combination thereof;

[0033] The heat-insulating concrete layer 8 is cement porous polymer concrete, and its aggregate is one of foamed EVA, foamed XPS, foamed phenolic, melamine foamed plastic and EPS porous polymer fragments or a combination thereof.

[0034] The insulating concrete layer 8 utilizes porous cement polymer concrete, with EVA and other materials with a high elastic modulus used as aggregate. This not only provides high thermal resistance and excellent sound insulation, achieving a significant floating sound insulation effect against impact noise, but also allows for the comprehensive utilization of waste foam plastic materials, resulting in significant environmental benefits. Furthermore, using foam board or rock wool board with a high sound absorption coefficient as the core material for the roof panel 1 further improves the impact sound suppression effect. Furthermore, the insulated concrete layer 8 also incorporates a three-dimensional galvanized steel mesh 10 and steel beams 11, providing the roof with stable mechanical properties and meeting load-bearing, earthquake, and wind resistance requirements.

[0035] The sound absorbing board 2 is selected from one of wood wool board, perlite board, foam glass board, PU board, phenolic board, melamine foam plastic board or XPS board or a combination thereof.

[0036] The fireproof ceiling 3 board is a cement porous polymer concrete board.

[0037] The sound insulation system 4 includes a floating sound-absorbing device installed at the junction of the roof panel 1 and the main structure beam, a sound insulation pad installed on the ceiling hanger rod, and a sound insulation pad installed at the sound bridge between the roof panel 1 and the main structure. The floating box device installed at the junction of the composite floor and the main structure not only meets the sound insulation requirements, but also provides joint restraint for earthquake and wind resistance.

[0038] The concrete surface layer 7 is waterproof concrete and ordinary concrete or a combination thereof.

[0039] The waterproof layer 6 is composed of one or a combination of waterproofing membrane, waterproof coating, and waterproof additives. To achieve waterproofing, the roof panels 1 are either affixed with waterproofing membrane or coated with waterproof coating on the factory production line. During on-site installation, the vertical joints between the panel edges are fully coated with waterproof coating, and an additional layer of a certain width can be applied flatly at the joints. Holes that penetrate the roof can be waterproofed according to the corresponding design.

[0040] The finishing layer 5 is one of cement mortar protective layer, finishing paint, finishing block material and finishing board material, or a combination thereof.

[0041] The section steel beam 11 is a structural dense-rib beam made of section steel or composite steel beams.

[0042] The following briefly describes the implementation method of the above embodiment of a prefabricated steel lightweight concrete composite panel combined roof

[0043] 1. Select the appropriate porous polymer concrete formula and proportion based on building performance requirements, and determine the processing methods and technical standards for porous polymer recycling equipment. Develop technical regulations for porous polymer concrete production through on-site trial mixing and testing. Components must be inspected and accepted through actual measurement.

[0044] 2. Complete the roof architectural and structural design according to project requirements. Begin by designing the steel beams or composite steel beams that will serve as the multi-ribbed beams. Integrate this with other specialized design considerations to refine the pre-embedded components. The factory will complete the detailed design, review it, and, upon approval, organize production according to the specifications and layout drawings. Qualified roof and ceiling panels will be numbered and stored for future use. Sound insulation components will be processed and inspected, then stored for future use.

[0045] 3. The contractor will prepare for construction according to the roof construction plan in the construction organization design, including the schedule, materials and equipment plan, technical safety measures, and roof panel layout. After construction begins, the contractor will arrange for the arrival of personnel, materials, and equipment according to the construction plan and project schedule. The contractor will also organize the roof panel acceptance, hoisting, and installation of the floating structure. The contractor will also coordinate the completion of waterproofing work and improve the waterproofing of reserved and embedded areas. After acceptance, the protective surface layer will be repaired and refinished.

[0046] 4. Check and adjust the fit and connection between the roof panel and the floating box and tighten them after they are qualified.

[0047] 5. Fireproof ceiling installation can only be carried out after the roof has passed the water filling test and the sound-absorbing panels have been repaired and accepted.

[0048] Parameter calculation

[0049] A residential project is located in an earthquake-resistant zone with a basic wind pressure of 80 kg / m 2The roof is for people to walk on. The lightweight fireproof, soundproof and heat-insulating roof panels used are 3.6m long, 0.6m wide and 0.18m thick. The panel density is 130kg / m 2 The three-dimensional ф3 galvanized steel wire mesh inside the panel is 10cm×10cm, with no less than 4 oblique wires per square meter. The two dense rib beams inside each panel are C-shaped steel (C120×50×20×3) with the same length as the roof panel and placed on the side of the panel. Together with the three-dimensional steel wire mesh, they form the steel skeleton inside the panel. Figure 3 .

[0050] 1. Structural verification

[0051] In this example, the composite strip prefabricated roof panels with steel multi-ribbed beams are connected to the main structure using a flexible connection. The main structure is hollowed out at this point, and the restraint effect of the panels on the frame beams is not considered.

[0052] 1.1 Load calculation

[0053] The dead weight of the roof panel is 1.3KN / m 2 The standard value of uniformly distributed live load is 2.0KN / ㎡, and the design value of wind load is 0.84kN / ㎡.

[0054] The compressive strength of the roof slab surface concrete is 30MPa, and the compressive strength of the insulation concrete is 5MPa.

[0055] The spacing between the ribbed beams is 0.5m, using C-shaped steel C120x50×20×3, weighing 4.7kg per meter, and the moment of inertia of the section is Ι=129cm 2 , cross-sectional resistance W x =21cm 3 The maximum span of the multi-ribbed beam is L = 3.6m.

[0056] Allowable deflection of simply supported beams Steel strength design value f y =310N / mm 2 , f ν =180N / mm 2 Elastic modulus E = 206 × 10 3 N / mm 2 .

[0057] Load combination under ultimate bearing capacity limit state (plate width 0.6m).

[0058] Combination of control for variable load effects: q = y G .σ Gk +y Q .σ Qik =1.2x0.6x1.30+1.4×0.6×(2.0+1.4)=3.792KN / m.

[0059] Combination of control for permanent load shear effect: q = y G ·σ GK +y Q ·σ Qik =1.35×0.6×1.30+1.4×0.7×0.6×(2.0+1.4)=3.052KN / m.

[0060] Take the combination of control for variable load effect, i.e. q = 3.792 kN / m.

[0061] The tensile and compressive strengths of the concrete parts are not considered in structural calculations.

[0062] 1.2 Calculation of bending strength

[0063] Maximum bending moment at mid-span of multi-ribbed beam:

[0064] Known W x =2×21=42cm 3 ;

[0065] Bending strength

[0066] Therefore: max =146.3N / mm 2 <310N / mm 2 .

[0067] It can be seen that the bending strength meets the design requirements

[0068] 1.3 Verification of shear strength of support section

[0069] Design value of shear force at the shear support section:

[0070] The area moment of the gross cross-sectional area below the neutral axis of the beam support section to the neutral axis is: S x =3.0×50x2=300mm 2 .

[0071] The shear stress at the neutral axis of the beam support section is:

[0072] The shear strength meets the design requirements.

[0073] 1.4 Stiffness verification

[0074] Under normal use conditions, the load effect combination on the steel beam is:

[0075] q k =σ Gk +σ Qik =0.78+1.2+0.84=2.82kN / m

[0076] The maximum deflection of the beam at mid-span is

[0077]

[0078] It can be seen that the stiffness meets the requirements.

[0079] 2. Sound insulation verification

[0080] 2.1 Airborne sound insulation

[0081] The upper concrete of the floor is made of 2cm thick concrete (bulk weight 2000kg / m 3 ) and 3cm thick porous polymer concrete (bulk density 600kg / m 3 )composition.

[0082] M1=2×20+3×6=56kg / m 2 .

[0083] The lower concrete layer of the floor and the ceiling are made of 10cm thick porous polymer concrete (bulk density 600kg / m 3 )composition.

[0084] M2=10×6=60㎏ / m 2 .

[0085] According to the formula R = 13.5Lg (M1 + M2) + 14 + ΔR, where M1 = 56 kg / m 2 , M2=60㎏ / m 2 , ΔR=12dB.

[0086] R=13·5×Lg(56+60)+14+12=13·5x2.06+26=53.9dB.

[0087] The sound insulation of airborne sound meets the requirements of relevant specifications for building sound insulation.

[0088] 2.2 Impact sound

[0089] The lower layer of the composite floor is regarded as a solid uniform concrete floor. When a standard impactor hits the lower layer, the impact sound pressure level L no The following formula can be used for calculation:

[0090] Where f is the frequency, Hz; E is the elastic modulus of the floor material, P a ;ρ-floor material density, kg / m 3 ; h-floor thickness, m; C-constant.

[0091] Take f = 500 Hz, E = 1 × 10 4 N / mm 2 ,ρ=600kg / m 3, h = 0.05;

[0092]

[0093] The composite roof panel can be regarded as a floating floor with elastic cushion material (core board) laid between the lower floor base and the upper floor panel. The improvement value ΔL of the impact sound insulation value can be estimated by the following formula:

[0094]

[0095] Where f-impact noise frequency, Hz;

[0096] f o -Natural frequency of the surface layer and elastic cushion system, Hz;

[0097] E-elastic modulus of cushion material, kg / cm2;

[0098] M-surface material density, kg / m 2 ;

[0099] d-thickness of cushion material, m.

[0100] Take f = 500 and E = 2.5x10 4 kg / cm 2 , m = 58 kg / m 2 ,d=0.05m.

[0101] So ΔL=55dB.

[0102] according to

[0103] It has a significant effect on improving the sound insulation of impact sounds.

[0104] 3. Fire resistance limit verification

[0105] The fire resistance limit time of the roof is not less than 1 hour. The thermal conductivity coefficient of cement EVA concrete is λ = 0.1w / m·K, and the bulk density is ρ = 600kg / m 3 , specific heat capacity C = 1.4kj / kg·K.

[0106] The temperature of the steel structure should not be higher than 350℃, and the temperature limit of the back-fire surface of the floor should be t w =83℃, take t at room temperature o =18℃, flame combustion temperature t1 = 1200℃.

[0107] 3.1 Floor backfire surface temperature

[0108] 1) The thermal bridge is located at the steel section, and the ribbed beam has a total insulation layer of 6cm above and below. According to the calculation formula:

[0109]

[0110] (Check the integral value of Gaussian error complement function)

[0111] Get t w =40.6℃

[0112] Maximum temperature of the floor slab on the back side of fire t w =40.6℃, which does not reach the limit of 83℃.

[0113] 2〕The thickness of the upper and lower protective layers of the core plate in the board is 5cm. According to the above formula, t w =73.8℃. That is, the maximum temperature of the core board can reach 73.8℃, which is lower than the maximum operating temperature of foamed polyurethane of 150℃.

[0114] 3.2. Maximum temperature of C-shaped steel in multi-ribbed beam

[0115] The thickness of cement EVA concrete on the upper and lower parts of the steel beam is 3cm. According to the above formula, we can get: w = 233°C. That is, the temperature of the steel structure multi-ribbed beam will rise to 233°C, which does not reach the upper limit of 350°C.

[0116] 4. Energy saving verification

[0117] The composite roof can be divided into the following six layers: R = δ / λD = R·S.

[0118] Where R is thermal resistance; δ is a layer thickness in m; λ is thermal conductivity in w / m 2 K; S-heat storage coefficient w / m 2 K; D - thermal inertness index.

[0119] 1〕Surface cement concrete δ=0.02m, λ=0.9w / mK, R1=0.02m 2 K / w, S1=13.5W / m 2 K, D1 = 0.27.

[0120] 2〕Upper cement EVA concrete δ=0.04m, λ=0.1w / m·k, R2=0.4m 2 k / w, S2=3.5W / m 2 K, D2 = 1.4.

[0121] 3〕Middle layer PU core board δ=0.08m, λ=0.022w / mK, R3=3.63×0.876=3.18m 2 K / W, S3=0.036w / m 2 K, D3 = 1.3 × 1.07 = 1.4.

[0122] Middle layer thermal bridge influence coefficient εR =0.876,ε D =1.07.

[0123] 4〕Lower layer cement EVA concrete δ=0.04m, λ=0.1W / m·K, R4=0.4㎡K / W, S4=3.5W / m 2 K, D4 = 1.4.

[0124] 5〕Bottom sound insulation phenolic board δ=0.01m,λ=0.03w / mK,R5=0.33m 2 K / w, S5=0.032W / m 2 K, D5 = 0.001.

[0125] 6〕cement polystyrene board for suspended ceiling δ=0.05,λ=0.11W / m 2 K, R6=0.45m 2 K / W, S6=2.5w / m 2 K, D6 = 1.12.

[0126] Internal and external surface exchange thermal resistance: R ie =0.15m 2 K / W.

[0127] Roof heat transfer resistance R0=R1+R2+R3+R4+R5+R6+R ie =4.9m 2 K / W.

[0128] Roof thermal inertia index D = D1 + D2 + D3 + D4 + D5 + D6 = 5.6.

[0129] Heat transfer coefficient of roof combination system K=0.18W / m 2 ·K.

[0130] 5. Condensation verification

[0131] 1〕Condensation on the surface of the interior ceiling

[0132] Minimum heat transfer resistance R of protective structure according to regulations 0·max It should be determined as follows:

[0133] where t i —Indoor temperature in winter is calculated as 18℃;

[0134] t e — The outdoor calculated temperature of the enclosure structure in winter is -42℃ for this project;

[0135] R i —The heat transfer resistance of the inner surface of the enclosure structure, taking 0.11m 2 ·K / W.

[0136] n=1.0,Δt=t i -t d The local dew point temperature is t d =10.12℃.

[0137]

[0138] R0=5.6>1.04, which can prevent condensation.

[0139] Ceiling surface temperature t 0i Calculate according to the following formula

[0140]

[0141] Suspended ceilings prevent condensation from occurring.

[0142] 2〕Verification of condensation on steel structure surface

[0143] Steel structure surface temperature

[0144] where R w =R6=0.45m 2 K / w

[0145] have to:

[0146] It can be seen that there will be no condensation on the surface of the steel structure.

[0147] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the embodiments of the present application, rather than to limit them. Although the embodiments of the present application have been described in detail with reference to the aforementioned embodiments, those skilled in the art should understand that they can still modify the technical solutions described in the aforementioned embodiments, or make equivalent replacements for some or all of the technical features therein. These modifications or replacements do not deviate the essence of the corresponding technical solutions from the scope of the technical solutions of the embodiments of the present application.

Claims

1. An assembled steel-lightweight concrete composite panel roof, characterized by: The invention comprises a roof panel arranged on a structural beam, a sound-absorbing panel arranged on the lower surface of the roof panel, a fireproof ceiling arranged at the lower part of the structural beam, and a sound insulation device for sound insulation; the roof panel comprises an insulating concrete layer, an inner core panel arranged in the insulating concrete layer, a three-dimensional galvanized steel wire mesh and a steel beam, a concrete surface layer arranged on the insulating concrete layer, a waterproof layer arranged on the concrete surface layer, and a finishing layer arranged on the waterproof layer; the inner core panel is a high-efficiency thermal insulation material, and the insulating concrete layer is a cement porous polymer concrete.

2. The assembled steel-lightweight concrete composite panel roof according to claim 1, characterized in that: The inner core board is one of PU, EPS, XPS, EVA, EPP, EPE foam board, rock wool board, glass wool board, phenolic foam board or melamine foam plastic board or a combination thereof.

3. The assembled steel-lightweight concrete composite panel roof according to claim 1, characterized in that: The sound absorbing board is selected from one of wood wool board, perlite board, foam glass board, PU board, phenolic board, melamine foam plastic board or XPS board or a combination thereof.

4. The assembled steel-lightweight concrete composite panel roof according to claim 1, characterized in that: The fireproof ceiling board is a cement porous polymer concrete board.

5. The assembled steel-lightweight concrete composite panel roof according to claim 1, characterized in that: The sound insulation device includes a sound-absorbing floating device arranged at the node between the roof panel and the main structure beam, a ceiling hanger sound insulation pad, and a sound insulation pad arranged at the sound bridge between the roof panel and the main structure.

6. The assembled steel-lightweight concrete composite panel roof according to claim 1, characterized in that: The steel beam is a structural dense-rib beam made of steel beams or composite steel beams.

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