A new prefabricated prestressed concrete ribbed composite slab

Abstract

The utility model discloses a novel prefabricated prestressed concrete ribbed composite slab relates to the technical field of fabricated building, including prefabricated part and superimposed part, the prefabricated part includes a plurality of parallelly arranged prestressed bottom longitudinal reinforcement, and the bottom horizontal muscle is tied up between the prestressed bottom longitudinal reinforcement, and the below of each prestressed bottom longitudinal reinforcement is equipped with a plurality of bottom longitudinal reinforcement cushion block respectively, the bottom plate is formed with the bottom plate at the prestressed bottom longitudinal reinforcement, the bottom horizontal muscle and bottom longitudinal reinforcement cushion block department pouring forming, the top of prestressed bottom longitudinal reinforcement is equipped with a plurality of prestressed rib longitudinal reinforcement, and the below of each prestressed rib longitudinal reinforcement is equipped with a plurality of rib longitudinal reinforcement support respectively, and at least one prestressed rib longitudinal reinforcement is a group, and the prestressed rib longitudinal reinforcement at each group is integrally formed with the concrete longitudinal rib of bottom plate pouring forming. The utility model ensures the plate body strength, reduces the reinforcement binding, reduces the artificial workload, reduces the steel consumption, is favorable for reducing the prefabricated cost and improving the prefabrication efficiency.

Description

Technical Field

[0001] This utility model relates to the field of prefabricated building technology, and in particular to a novel precast prestressed concrete ribbed composite slab. Background Technology

[0002] Composite slabs are prefabricated monolithic floor slabs composed of precast components (floor slabs) and composite components (post-cast reinforced concrete layers), and are an important part of prefabricated buildings. Currently, the precast components of composite slabs, such as reinforced concrete slabs and reinforced concrete floor decks, involve first fabricating a steel truss, which is then arranged at certain intervals to improve the bending capacity of the precast components and reduce mid-span deflection. However, due to the relatively small height and stiffness of the steel trusses, and the thinness of the precast reinforced concrete slabs, the overall stiffness of the precast components is relatively low. This results in significant mid-span deflection during construction, leading to problems such as insufficient load-bearing capacity and susceptibility to cracking. Therefore, temporary supports are still required under the precast components during construction, resulting in complex construction and higher costs.

[0003] To address this, existing technologies disclose ribbed composite slabs, such as the composite slab disclosed in the applicant's utility model application with publication number "CN222275897U". In this type of composite slab, concrete longitudinal ribs are formed in the precast portion. These ribs, together with the base slab, create stronger bending resistance, improving load-bearing capacity, reducing cracking during construction, and minimizing the need for temporary supports, thus simplifying on-site construction. In this type of composite slab, bottom longitudinal and bottom transverse reinforcing bars are arranged within the precast base slab, while rib-bearing reinforcing bars and stirrups are arranged within the concrete longitudinal ribs. After the stirrups are tied to the rib-bearing reinforcing bars and the bottom longitudinal or transverse reinforcing bars, the slab is integrally cast. While this type of composite slab offers the advantage of high strength, the precast process involves a large amount of rebar tying work, resulting in a high workload, large steel consumption, high overall precasting costs, and low efficiency. Therefore, further optimization is needed. Utility Model Content

[0004] The technical problem to be solved by this utility model is to provide a new type of precast prestressed concrete ribbed composite slab that ensures the strength of the slab, reduces the amount of steel reinforcement binding, reduces the amount of manual labor, reduces the amount of steel used, and helps to reduce precast costs and improve precast efficiency.

[0005] To solve the above-mentioned technical problems, the technical solution of this utility model is: a novel precast prestressed concrete ribbed composite slab, comprising a precast part and a composite part. The precast part includes several parallel prestressed bottom longitudinal bars, with bottom transverse bars tied between the prestressed bottom longitudinal bars. Several bottom longitudinal bar pads are respectively provided below each prestressed bottom longitudinal bar. A base plate is cast at the prestressed bottom longitudinal bars, the bottom transverse bars, and the bottom longitudinal bar pads. Several prestressed rib longitudinal bars are provided above the prestressed bottom longitudinal bars, and several rib longitudinal bar supports are respectively provided below each prestressed rib longitudinal bar. At least one prestressed rib longitudinal bar is a group, and a concrete longitudinal rib integral with the base plate is cast at each group of prestressed rib longitudinal bars.

[0006] As a preferred technical solution, at least two adjacent prestressed longitudinal bars are grouped together, and a shallow tie groove is provided on the concrete longitudinal rib between two adjacent prestressed longitudinal bars.

[0007] As a preferred technical solution, the prestressed bottom longitudinal reinforcement is a prestressed steel wire, a prestressed steel strand, or a prestressed steel bar.

[0008] As a preferred technical solution, the prestressed longitudinal rib is a prestressed steel wire, a prestressed steel strand, or a prestressed steel bar.

[0009] As a preferred technical solution, the ribbed longitudinal bar support includes supporting steel bars, and the upper part of the supporting steel bars is provided with a ribbed longitudinal bar support portion.

[0010] As a preferred technical solution, the overlapping portion includes a steel mesh above the concrete longitudinal ribs, and a concrete overlapping layer higher than the steel mesh is cast and formed above the bottom plate.

[0011] As a preferred technical solution, at least one side of the base plate is provided with a splicing node for splicing with an adjacent base plate.

[0012] As a preferred technical solution, the splicing node includes a splicing section extending from the side of the bottom horizontal rib of the bottom plate, and the splicing section is bent upward.

[0013] As a preferred technical solution, the prefabricated part is manufactured using mold equipment; the mold equipment includes a long line table, on which two oppositely arranged tie bases are fixedly mounted, and tie components are respectively provided on the two tie bases corresponding to each of the prestressed bottom longitudinal bars and prestressed rib longitudinal bars, and the two ends of the prestressed bottom longitudinal bars and prestressed rib longitudinal bars are respectively connected to the corresponding tie components; a floor slab forming machine is installed at the long line table.

[0014] As a preferred technical solution, the tie assembly includes a tie bar, one end of which is provided with a connector for connecting with the corresponding prestressed bottom longitudinal bar or prestressed rib longitudinal bar, and a tension nut is installed on the end of the tie bar that passes through the corresponding tie base.

[0015] Due to the adoption of the above technical solution, a novel precast prestressed concrete ribbed composite slab includes a precast part and a composite part. The precast part includes several parallel prestressed bottom longitudinal bars, with bottom transverse bars tied between them. Several bottom longitudinal bar pads are provided below each prestressed bottom longitudinal bar. A base slab is cast at the prestressed bottom longitudinal bars, the bottom transverse bars, and the bottom longitudinal bar pads. Several prestressed rib longitudinal bars are provided above the prestressed bottom longitudinal bars, and several rib longitudinal bar supports are provided below each prestressed rib longitudinal bar. At least two adjacent prestressed rib longitudinal bars form a group, and a concrete longitudinal rib integral with the base slab is cast at each group of prestressed rib longitudinal bars. In this invention, the longitudinal reinforcement in both the base slab and the concrete longitudinal ribs is prestressed. Thus, the prestressed bottom longitudinal reinforcement and the prestressed rib longitudinal reinforcement, at different heights, rely on higher tensile strength, combined with the rib structure, to achieve higher bending strength in the precast portion, improving load-bearing capacity, reducing cracking, and minimizing the need for temporary supports during construction, thereby simplifying on-site construction. Furthermore, the use of the prestressed bottom longitudinal reinforcement and the prestressed rib longitudinal reinforcement eliminates the need for additional stirrups between them, thus reducing stirrup binding work and manual labor. The reduction in stirrups also reduces steel consumption, thereby lowering precast costs and improving precast efficiency. Attached Figure Description

[0016] The following figures are intended only to illustrate and explain the present invention and do not limit the scope of the present invention. Wherein:

[0017] Figure 1 This is a schematic diagram of the structure of the prefabricated part in Embodiment 1 of this utility model;

[0018] Figure 2 This is a structural schematic diagram of the prefabricated part in Embodiment 1 of this utility model;

[0019] Figure 3 This is a schematic diagram of the overall structure of Embodiment 1 of this utility model;

[0020] Figure 4 This is a schematic diagram of the prefabricated part in Embodiment 2 of this utility model.

[0021] In the diagram: 1-Precast section; 11-Prestressed bottom longitudinal reinforcement; 12-Bottom transverse reinforcement; 13-Bottom longitudinal reinforcement pad; 14-Base slab; 15-Prestressed rib longitudinal reinforcement; 16-Rib longitudinal reinforcement support; 17-Concrete longitudinal rib; 18-Tie-up shallow groove; 2-Splicing node; 21-Splicing section; 22-Splicing transverse reinforcement; 23-Splicing longitudinal reinforcement; 3-Overlapping section; 31-Steel mesh; 32-Concrete composite layer; 4-Mold equipment; 41-Long line table; 42-Tie-up base; 43-Tie-up component; 44-Tie-up reinforcement; 45-Connector; 46-Tension nut; 5-Floor slab forming machine. Detailed Implementation

[0022] The present invention will be further described below with reference to the accompanying drawings and embodiments. In the following detailed description, only certain exemplary embodiments of the present invention are described by way of illustration. Undoubtedly, those skilled in the art will recognize that various modifications can be made to the described embodiments without departing from the spirit and scope of the present invention. Therefore, the drawings and description are illustrative in nature and not intended to limit the scope of the claims.

[0023] Example 1: As Figure 3 As shown, a novel precast prestressed concrete ribbed composite slab includes a precast portion 1 and a composite portion 3. Figure 1 and Figure 3 As shown, the precast part 1 includes several prestressed bottom longitudinal bars 11 arranged in parallel. The bottom longitudinal bars are prestressed tendons. The prestressed bottom longitudinal bars 11 can be prestressed steel wires, prestressed steel strands or prestressed steel bars, and there is no limitation here.

[0024] like Figure 1 and Figure 3 As shown, bottom transverse bars 12 are tied between the prestressed bottom longitudinal bars 11, forming a mesh structure with the prestressed bottom longitudinal bars 11. Several bottom longitudinal bar spacers 13 are provided below each prestressed bottom longitudinal bar 11. These spacers 13 are used to support the prestressed bottom longitudinal bars 11, ensuring that the prestressed bottom longitudinal bars 11 do not have significant sag during the fabrication of the precast part 1, thus ensuring the thickness of the protective layer of the prestressed bottom longitudinal bars 11 in the concrete. Their use will be described later in the fabrication process and will not be repeated here. A base plate 14 is cast at the locations of the prestressed bottom longitudinal bars 11, the bottom transverse bars 12, and the bottom longitudinal bar spacers 13.

[0025] like Figure 1 and Figure 3As shown, several prestressed longitudinal ribs 15 are provided above the prestressed bottom longitudinal rib 11, meaning these ribs are also prestressed tendons. The prestressed longitudinal ribs 15 can be prestressed steel wire, prestressed steel strand, or prestressed steel bar, without limitation. Several longitudinal rib supports 16 are provided below each prestressed longitudinal rib 15. These supports 16 only support the prestressed longitudinal ribs 15 to prevent significant sag of the prestressed longitudinal ribs 15 during fabrication of the precast part 1, ensuring the positioning of the prestressed longitudinal ribs 15 and guaranteeing the prestressing meets the standards. Their use will be described later in the fabrication process and will not be repeated here. In this embodiment, the ribbed longitudinal bar support 16 includes supporting steel bars, and the upper part of the supporting steel bars is provided with a ribbed longitudinal bar support part. That is, the ribbed longitudinal bar support 16 is directly made of steel bars, and it can be made into a shape that is roughly "7" or "Z" to achieve the supporting function. The structure is simple and easy to manufacture. Of course, the ribbed longitudinal bar support 16 can also be made of other types of steel as needed.

[0026] At least one of the prestressed longitudinal ribs 15 is formed as a group, and each group of prestressed longitudinal ribs 15 has a concrete longitudinal rib 17 cast integrally with the base plate 14. In this embodiment, only two prestressed longitudinal ribs 15 are shown as a group, and two concrete longitudinal ribs 17 are formed on each prefabricated part 1. The forming of the base plate 14 and the concrete longitudinal ribs 17 will also be described uniformly in the later manufacturing process, and will not be repeated here.

[0027] The prefabricated part 1 is manufactured using mold equipment 4. For example... Figure 2 As shown, the mold equipment 4 includes a long line table 41, which can be set according to the actual production length requirements, such as 100m to 200m. Two opposing tie bases 42 are fixedly mounted on the long line table 41. Tie components 43 are respectively provided on the two tie bases 42 corresponding to each of the prestressed bottom longitudinal reinforcement 11 and prestressed rib longitudinal reinforcement 15. The two ends of the prestressed bottom longitudinal reinforcement 11 and prestressed rib longitudinal reinforcement 15 are respectively connected to the corresponding tie components 43. A floor slab forming machine 5 is installed at the long line table 41 to continuously form the precast portion 1 along the length of the long line table 41. The floor slab forming machine 5 is a known device that continuously vibrates concrete and forms it into the desired shape by means of a forming plate during extrusion; its specific structural principle will not be described in detail here.

[0028] The tie assembly 43 described in this embodiment includes a tie bar 44. One end of the tie bar 44 is provided with a connector 45 for connecting with the corresponding prestressed bottom longitudinal bar 11 or prestressed rib longitudinal bar 15. A tension nut 46 is installed on the end of the tie bar 44 that passes through the corresponding tie base 42. The connector 45 may be a connector 45 for connecting rebars to rebars, rebars to steel strands, or rebars to steel wires, as needed. These connectors 45 are all known technologies and will not be described in detail here.

[0029] When making the prefabricated part 1, as follows Figure 2 As shown, a platform is formed with the long line platform 41 as its base. The two ends of each of the prestressed bottom longitudinal bars 11 and prestressed rib longitudinal bars 15 are connected to the corresponding tie-in components 43, or more specifically, to the corresponding connectors 45. The prestressed bottom longitudinal bars 11 or prestressed rib longitudinal bars 15 are tensioned by tightening the tension nut 46. During this process, bottom longitudinal bar pads 13 are spaced apart below the prestressed bottom longitudinal bars 11 on the long line platform 41, and rib longitudinal bar supports 16 are spaced apart below the prestressed rib longitudinal bars 15. The spacing is designed to reduce the impact of the weight of the longer longitudinal bars on the tie-in force, such as a spacing of 8m to 10m. This spacing significantly reduces the amount of manual binding work and steel consumption compared to the original 200mm spacing of the stirrups.

[0030] Continue tightening the tension nut 46 until the prestressed bottom longitudinal reinforcement 11 and the prestressed longitudinal rib reinforcement 15 reach their design stresses. Then, starting from one end of the prestressed bottom longitudinal reinforcement 11, the floor slab forming machine 5 integrally casts the base slab 14 and the concrete longitudinal ribs 17. After casting, the bottom longitudinal reinforcement pad 13 and the longitudinal rib support 16 are directly located within the concrete structure and do not need to be removed before casting. Furthermore, there are no obvious protrusions along the entire casting path, allowing for continuous casting in one go, significantly improving the efficiency of prefabrication. After casting, once the concrete reaches its design strength, it is cut sequentially according to the design length of the prefabricated part 1. The bottom longitudinal reinforcement pad 13 and the longitudinal rib support 16 are embedded within the concrete structure and do not affect the overall structural strength of the prefabricated part 1.

[0031] The prefabricated sections 1 are cut out and transported to the site for assembly. Both ends of each prefabricated section 1 rest against a building beam, and adjacent sections 1 are spliced ​​together. The resting of the ends of the prefabricated sections 1 against the building beam is a well-known and known technique, and will not be elaborated upon here. Preferably, as... Figure 3As shown, at least one side of the base slab 14 is provided with a splicing node 2 for splicing with adjacent base slabs 14, so as to improve the splicing quality between two adjacent precast parts 1 and promote the composite slabs to form a floor slab together. In this embodiment, the splicing node 2 includes a splicing section 21 of the bottom horizontal reinforcement 12 extending out of the side of the base slab 14. The splicing section 21 is bent upwards. This bending avoids splicing gaps while achieving better composite quality, so that no formwork or support is needed at the splice, which simplifies on-site construction. Of course, splicing horizontal reinforcement 22 and splicing longitudinal reinforcement 23 are also tied near the base slabs 14 of the two adjacent precast parts 1 to promote the formation of an equal-strength connection between adjacent composite slabs after the concrete is poured.

[0032] After splicing, the overlapping part 3 is constructed on-site. (Example: ...) Figure 3 As shown, the composite portion 3 includes a steel mesh 31 above the concrete longitudinal rib 17, and a concrete composite layer 32 higher than the steel mesh 31 is cast and formed above the base slab 14. After the concrete composite layer 32 is cast, the composite portion 3 and the precast portion 1 form an integral floor slab structure. Because this embodiment is a ribbed structure, the composite portion 3 and the precast portion 1 are well connected, resulting in better overall load-bearing performance.

[0033] This embodiment improves the structure of the precast part 1. Both the prestressed bottom longitudinal reinforcement 11 and the prestressed rib longitudinal reinforcement 15 are prestressed, eliminating the need for binding or tightening between them. This significantly reduces manual labor during precasting, reduces steel consumption, and lowers precasting costs. During precasting, the bottom longitudinal reinforcement pads 13 and rib longitudinal reinforcement supports 16 are respectively placed below the prestressed bottom longitudinal reinforcement 11 and prestressed rib longitudinal reinforcement 15. These supports serve only an auxiliary function, do not participate in load-bearing, and are used sparingly. After reaching the design stress, the floor slab forming machine 5 can be used to continuously cast and form the bottom slab 14 and concrete longitudinal ribs 17. During this process, the bottom longitudinal reinforcement pads 13 and rib longitudinal reinforcement supports 16 do not need to be removed, significantly improving precasting efficiency. In the precast section 1, the strong tensile strength of the prestressed bottom longitudinal reinforcement 11, combined with the concrete longitudinal ribs 17, can significantly improve the load-bearing capacity of the precast section 1 during on-site construction and reduce construction cracking. Meanwhile, the strong tensile strength of the prestressed longitudinal ribs 15 can improve the load-bearing capacity of the precast section 1 during transportation and hoisting, preventing slab breakage and cracking. Overall, this embodiment achieves the goals of reducing labor and raw materials while ensuring the structural strength of the precast section 1, and significantly improves precast efficiency.

[0034] Example 2: Figure 4As shown, the difference between this embodiment and Embodiment 1 is that at least two adjacent prestressed longitudinal ribs 15 form a group, and a shallow tie groove 18 is provided on the concrete longitudinal rib 17 between two adjacent prestressed longitudinal ribs 15. This tie groove 18 enhances the interlocking and bonding between the precast part 1 and the overlapping part 3, ensuring the overall strength of the floor slab. Whether the tie groove 18 is provided at only one of the two adjacent prestressed longitudinal ribs 15 or at multiple adjacent prestressed longitudinal ribs 15 is within the scope of this utility model, and this embodiment does not impose any limitations. In this structure, the tie groove 18 effectively divides one concrete longitudinal rib 17 into multiple smaller ribs, and each smaller rib has one or more prestressed longitudinal ribs 15. This structural form can further improve the bearing capacity of the precast part 1 on the wide concrete longitudinal ribs 17. For example, the four prestressed longitudinal ribs 15 shown in this embodiment are a group of concrete longitudinal ribs 17, and the tie grooves 18 are provided at the positions between the three adjacent prestressed longitudinal ribs 15 formed by the four prestressed longitudinal ribs 15 shown in this embodiment.

[0035] The foregoing has shown and described the basic principles, main features, and advantages of this utility model. Those skilled in the art should understand that this utility model is not limited to the above embodiments. The embodiments and descriptions in the specification are merely illustrative of the principles of this utility model. Various changes and modifications can be made to this utility model without departing from its spirit and scope. For example, a group of prestressed longitudinal ribs 15 may consist of one, three, more, or a mixture of these numbers, and one, three, or even more of the aforementioned concrete longitudinal ribs 17 may be provided, etc. All such changes and modifications fall within the scope of this utility model as claimed. The scope of protection of this utility model is defined by the appended claims and their equivalents.

Claims

1. A novel precast prestressed concrete ribbed composite slab, comprising a precast portion and a composite portion, characterized in that: The precast portion includes several parallel prestressed bottom longitudinal bars, with bottom transverse bars tied between them. Several bottom longitudinal bar pads are provided below each prestressed bottom longitudinal bar. A base plate is cast at the prestressed bottom longitudinal bars, the bottom transverse bars, and the bottom longitudinal bar pads. Several prestressed rib longitudinal bars are provided above the prestressed bottom longitudinal bars, and several rib longitudinal bar supports are provided below each prestressed rib longitudinal bar. At least one prestressed rib longitudinal bar is a group, and a concrete longitudinal rib integral with the base plate is cast at each group of prestressed rib longitudinal bars.

2. The novel precast prestressed concrete ribbed composite slab as described in claim 1, characterized in that: At least two adjacent prestressed longitudinal bars form a group, and a shallow tie groove is provided on the concrete longitudinal rib between two adjacent prestressed longitudinal bars.

3. A novel precast prestressed concrete ribbed composite slab as described in claim 1, characterized in that: The prestressed bottom longitudinal reinforcement is a prestressed steel wire, prestressed steel strand, or prestressed steel bar.

4. A novel precast prestressed concrete ribbed composite slab as described in claim 1, characterized in that: The prestressed longitudinal ribs are prestressed steel wires, prestressed steel strands, or prestressed steel bars.

5. A novel precast prestressed concrete ribbed composite slab as described in claim 1, characterized in that: The ribbed longitudinal reinforcement bracket includes supporting steel bars, and the upper part of the supporting steel bars is provided with a ribbed longitudinal reinforcement support part.

6. A novel precast prestressed concrete ribbed composite slab as described in claim 1, characterized in that: The overlapping portion includes a steel mesh above the concrete longitudinal ribs, and a concrete overlapping layer higher than the steel mesh is cast and formed above the base plate.

7. A novel precast prestressed concrete ribbed composite slab as described in claim 1, characterized in that: At least one side of the base plate is provided with a splicing node for splicing with an adjacent base plate.

8. A novel precast prestressed concrete ribbed composite slab as described in claim 7, characterized in that: The splicing node includes a splicing section extending from the side of the bottom horizontal rib of the base plate, and the splicing section is bent upward.

9. A novel precast prestressed concrete ribbed composite slab as described in any one of claims 1 to 8, characterized in that: The prefabricated part is manufactured using mold equipment; the mold equipment includes a long line table, on which two oppositely arranged tie bases are fixedly mounted, and tie components are respectively provided on the two tie bases corresponding to each of the prestressed bottom longitudinal bars and prestressed rib longitudinal bars, and the two ends of the prestressed bottom longitudinal bars and prestressed rib longitudinal bars are respectively connected to the corresponding tie components; a floor slab forming machine is installed at the long line table.

10. A novel precast prestressed concrete ribbed composite slab as described in claim 9, characterized in that: The tie assembly includes tie bars, one end of which is provided with a connector for connecting with the corresponding prestressed bottom longitudinal bar or prestressed rib longitudinal bar, and a tension nut is installed on the end of the tie bar that passes through the corresponding tie base.

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