U.S. patent application number 14/449105 was filed with the patent office on 2014-11-20 for house constructed from finished product components and constructing method thereof.
The applicant listed for this patent is Tao Huang, Zhenxi Huang. Invention is credited to Hao Hu, Zhenxi Huang, Zhong Yan, Chun Yang, Yinghui Zhang.
Application Number | 20140338283 14/449105 |
Document ID | / |
Family ID | 47752065 |
Filed Date | 2014-11-20 |
United States Patent
Application |
20140338283 |
Kind Code |
A1 |
Huang; Zhenxi ; et
al. |
November 20, 2014 |
HOUSE CONSTRUCTED FROM FINISHED PRODUCT COMPONENTS AND CONSTRUCTING
METHOD THEREOF
Abstract
A method for constructing such house is disclosed. The
components of the house such as the finished product main frame,
the finished product enclosed wall, the finished product floor
cover plate, the finished product top cover plate and the finished
product stair are finished product industrially constructed in
different manufactories, and then transported to the constructing
location respectively, and then assembled at the base of the house,
so as to form a house constructed from finished product components.
By using finished product components, the construction of the house
has high efficiency, good quality, less material consumption and
shorter construction period. Furthermore, comparing with
traditional site operation, constructing house from finished
product components is more environment-friendly.
Inventors: |
Huang; Zhenxi; (Shenzhen,
CN) ; Hu; Hao; (Shenzhen, CN) ; Yang;
Chun; (Shenzhen, CN) ; Yan; Zhong; (Shenzhen,
CN) ; Zhang; Yinghui; (Shenzhen, CN) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Huang; Tao
Huang; Zhenxi |
Shenzhen
Shenzhen |
|
CN
CN |
|
|
Family ID: |
47752065 |
Appl. No.: |
14/449105 |
Filed: |
July 31, 2014 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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13669405 |
Nov 5, 2012 |
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14449105 |
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12534920 |
Aug 4, 2009 |
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13669405 |
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Current U.S.
Class: |
52/741.2 |
Current CPC
Class: |
E04B 1/34869 20130101;
E04B 2001/2496 20130101; E04B 1/66 20130101; E04F 11/02 20130101;
E04B 1/348 20130101; E04B 2001/4192 20130101; E04B 1/4121 20130101;
E04B 1/6801 20130101; E04B 1/24 20130101; E04B 5/043 20130101; E04B
2001/2484 20130101; E04B 2001/2481 20130101 |
Class at
Publication: |
52/741.2 |
International
Class: |
E04B 1/348 20060101
E04B001/348; E04B 1/66 20060101 E04B001/66; E04F 11/02 20060101
E04F011/02 |
Foreign Application Data
Date |
Code |
Application Number |
Aug 4, 2008 |
CN |
200810142231.0 |
Claims
1. A method for constructing a house comprising a finished product
main frame, a finished product enclosed wall, a finished product
floor cover plate, a finished product top cover plate, a finished
product stair, wherein, the method comprising: step 1, individually
forming multiple finished product composite prefabricated external
wallboards in one piece at a manufactory; step 2, individually
forming the finished product main frame, the finished product floor
cover plate, the finished product top cover plate and the finished
product stair in one piece at different manufactories; step 3,
performing foundation construction of the house; step 4, installing
the columns and beams of the finished product main frame; step 5,
installing the finished product enclosed wall from assembling the
multiple finished product composite prefabricated external
wallboards onto the finished product main frame; step 6, installing
a finished product top cover plate and finished product stair onto
the finished product main frame.
2. The method for constructing a house according to claim 1,
wherein, the step 1 further comprising: step 11, forming the
multiple finished product composite prefabricated external
wallboards by casting light-weight filing block and heat insulation
materials, and post-casting, high-strength, waterproof and
fine-stone concrete of the reinforced net with doors and windows;
step 12, transferring the multiple finished product composite
prefabricated external wallboards to the foundation of the house
after inside and outside decoration.
3. The method for constructing a house according to claim 2,
wherein, the step 5 further comprising: step 51. installing the
multiple finished product composite prefabricated external
wallboards sequentially and upwardly with the finished product main
frame on different stories or simultaneously after the finished
product main frame is constructed; step 52, aligning multiple
positioning holes disposed on the finished product composite
prefabricated external wallboards with positioning pins disposed on
a supporting plate of the finished product main frame and disposing
the finished product composite prefabricated external wallboards on
the supporting plate; step 53, disposing a damping pad in a gap
between the finished product composite prefabricated external
wallboards and the finished product main frame, then tightening and
fixing via optimized fastening force by high-strength bolts.
4. The method for constructing a house according to claim 3,
wherein, in step 51, the finished product composite prefabricated
external wallboards on different stories are clutch connected,
sealing and waterproof caulking processing is performed on
connection between the finished product composite prefabricated
external wallboards on different stories.
5. The method for constructing a house according to claim 4,
wherein, in step 51, sealing and waterproof caulking processing is
performed between the finished product composite prefabricated
external wallboards.
6. The method for constructing a house according to claim 5,
wherein, in step 51, a gap between the finished product composite
prefabricated external wallboards is disposed on the finished
product main frame, which makes it convenient to perform caulking
sealing on the gap between the finished product composite
prefabricated external wallboards and ensures connecting
quality.
7. The method for constructing a house according to claim 1,
wherein, in step 6, the floor cover plate and the top cover plate
are light-weight laminated slabs comprising at least two substrates
formed by a hollow stripe board made of prefabricated and
reinforced light aggregate concrete disposed on the finished
product main frame through a support frame; a reinforced net and a
reinforced framework disposed between the at least two substrates;
fine-stone concrete filling gaps between the reinforced framework,
reinforced net, two substrates and the finished product main frame,
so as to form a laminated floor cover plate or top cover plate.
8. The method for constructing a house according to claim 7,
wherein, the support frame is provided with a stud jointed with the
reinforced net and/or the reinforced framework so as to form a
steel laminated floor cover plate or top cover plate.
9. The method for constructing a house according to claim 7,
wherein, the multiple finished product composite prefabricated
external wallboards disposed on different floors are zigzag clutch
connected, outside protruding portions and inside grooves of the
multiple finished product composite prefabricated external
wallboards on different floors are clutch connected to each other,
vertical grooves are downwardly disposed on an end of each of the
multiple finished product composite prefabricated external
wallboards to form cavities, ends of multiple finished product
composite prefabricated external wallboards and the cavity are
filled with waterproof glue.
Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a Divisional Application of U.S. patent
application Ser. No. 13/669,405, filed on Nov. 5, 2012, which is a
continuation-in-part of U.S. patent application Ser. No.
12/534,920, filed on Aug. 4, 2009, which claims priority of Chinese
patent application No. 200810142231.0 filed on Aug. 4, 2008, the
entire content of which are hereby incorporated by reference.
FIELD OF THE INVENTION
[0002] The present invention relates to a house, and more
particularly to a house constructed from finished product
components and a method for constructing such house.
BACKGROUND OF THE INVENTION
[0003] Conventionally, houses are constructed with various masonry
materials via a wet construction method. However, there are some
problems with the method: firstly, a great deal of wood resources
are used as underside formworks and supporting materials, which
causes large power consumption, low construction efficiency, long
construction time, big noise and a great deal of dust; in addition,
the masonry materials used in traditional reinforced concrete
houses have large weight and poor ductility, and need a large
number of reinforced materials so as to meet anti-seismic
requirements; finally, enclosed bodies of the traditional
reinforced concrete houses have large thermal conductivity and
therefore consume energy.
SUMMARY OF THE INVENTION
[0004] In view of the above-described problem, it is one objective
of the invention to provide a house constructed from finished
product components that features low power consumption, high
construction efficiency, short construction time, low noise, little
dust, light weight, good anti-seismic performance, and small
thermal conductivity and is applicable for multi-storey houses and
high houses.
[0005] It is another objective of the invention to provide a method
for constructing a house from finished product components that
features low power consumption, high construction efficiency, short
construction time, low noise, little dust, light weight, good
anti-seismic performance, and small thermal conductivity and is
applicable for multi-storey houses and high houses.
[0006] To achieve the above objectives, in accordance with one
embodiment of the invention, provided is an house comprising a
finished product main frame comprising columns and beams connected
to each other; an enclosed wall assembled from multiple finished
product composite prefabricated external wallboards, wherein, the
multiple finished product composite prefabricated external
wallboards are individually formed in one piece and then assembled
to form a whole finished product enclosed wall; a finished product
floor cover plate; a finished product top cover plate; a finished
product stair; wherein, the finished product main frame, the whole
finished product enclosed wall, the finished product floor cover
plate, the finished product top cover plate and the finished
product stair are assembled at a base of the house, so as to form a
house constructed from finished product components.
[0007] In present embodiment, the finished product main frame, the
finished product enclosed wall, the finished product floor cover
plate, the finished product top cover plate and the finished
product stair are finished product industrially constructed in
different manufactories, and then transported to the constructing
location respectively, and then assembled at the base of the house,
so as to form a house constructed from finished product
components.
[0008] In present embodiment, the whole finished product enclosed
wall is produced in the manufactory according to the size
determined by the house design and assembled at the base of the
house.
[0009] By using finished product components, the construction of
the house has high efficiency, good quality, less material
consumption and shorter construction period. Furthermore, comparing
with traditional site operation, constructing house from finished
product components is more environment-friendly.
[0010] In a class of this embodiment, the finished product
composite prefabricated external wallboard comprises a structure
layer, at least one light-weight filling block disposed on an inner
side of the structure layer, and a heat insulation layer attached
to an outer side of the light-weight filling block. The structure
layer fills a gap between the heat insulation layer and the
light-weight filling block and attaches the heat insulation layer
to the light-weight filling block whereby forming the whole
finished product composite prefabricated external wallboard. The
structure layer is a reinforced concrete layer comprising a
reinforced framework arranged around and between the light-weight
filling blocks, a reinforced net disposed outside the heat
isolation layer and connected to the reinforced framework and
fine-stone concrete filling gaps between the reinforced framework,
reinforced net, light-weight filling blocks and heat isolation
layer, so as to form a finished product composite prefabricated
external wallboard in one piece.
[0011] In a class of this embodiment, the floor cover plate and the
top cover plate are light-weight laminated slabs comprising at
least two substrates formed by a hollow stripe board made of
prefabricated and reinforced light aggregate concrete disposed on
the finished product main frame through a support frame; a
reinforced net and a reinforced framework disposed between the at
least two substrates; fine-stone concrete filling gaps between the
reinforced framework, reinforced net, two substrates and the
finished product main frame, so as to form a laminated floor cover
plate or top cover plate. The laminated floor cover plate or top
cover plate is a concrete plate of waffle beam having fine
stiffness and more than 5-6 folds of design carrying capacity,
reducing 40% of concrete consumption.
[0012] In a class of this embodiment, the support frame is provided
with a stud jointed with the reinforced net and/or the reinforced
framework so as to form a steel laminated floor cover plate or top
cover plate.
[0013] In a class of this embodiment, the multiple finished product
composite prefabricated external wallboards disposed on different
floors are zigzag clutch connected, outside protruding portions and
inside grooves of the multiple finished product composite
prefabricated external wallboards on different floors are clutch
connected to each other, vertical grooves are downwardly disposed
on an end of each of the multiple finished product composite
prefabricated external wallboards to form cavities, ends of
multiple finished product composite prefabricated external
wallboards and the cavity are filled with waterproof glue.
[0014] In a class of this embodiment, each of the multiple finished
product composite prefabricated external wallboards is fixed on an
outside of the finished product main frame via coordination between
the plurality of wallboard mounts and a plurality of aseismatic and
energy-dissipation connector, wherein, the aseismatic and
energy-dissipation connector comprises a high-strength bolt, and
the wallboard mount comprises a bolt sleeve disposed in each of the
multiple finished product composite prefabricated external
wallboards, in such a way, the high-strength bolt passes through a
screw hole on the finished product main frame and thread connected
to the bolt sleeve and fixes the each of the multiple finished
product composite prefabricated external wallboards on the finished
product main frame, and a damping pad is disposed at a connection
of the high-strength bolt and between the each of the multiple
finished product composite prefabricated external wallboards and
the finished product main frame.
[0015] Accordingly to present embodiment, the multiple finished
product composite prefabricated external wallboards is fixed on an
outside of the finished product main frame when the high-strength
bolt is screwed, a certain press is generated on the damping pad.
In such a way, earthquake energy can be weakened or absorbed and
the house safe factor can be improved.
[0016] In a class of this embodiment, the finished product floor
cover plate and the finished product top cover plate are directly
fixed on the finished product main frame.
[0017] In a class of this embodiment, the finished product main
frame is a steel frame formed by steel columns and steel beams
connected to each other.
[0018] In a class of this embodiment, the finished product main
frame is a steel frame.
[0019] In a class of this embodiment, the finished product
composite prefabricated external wallboards on the same storey are
planarly connected.
[0020] In a class of this embodiment, a supporting plate is
disposed on the finished product main frame and operates to support
the multiple finished product composite prefabricated external
wallboards, multiple positioning pins are vertically disposed on
the supporting plate, and multiple positioning holes are disposed
on a top surface and a bottom surface of the multiple finished
product composite prefabricated external wallboards and correspond
to the positioning pins.
[0021] To achieve the above objectives, in accordance with one
embodiment of the invention, provided is a method for constructing
a house comprising a finished product main frame, an enclosed wall,
a finished product floor cover plate, a finished product top cover
plate, a finished product stair, wherein, the method comprising
step 1, individually forming multiple finished product composite
prefabricated external wallboards in one piece; step 2,
individually forming the finished product stair in one piece; step
3, performing foundation construction of the house; step 4,
installing the columns and beams of the finished product main
frame; step 5, installing an enclosed cover from assembling the
multiple finished product composite prefabricated external
wallboards onto the finished product main frame; step 6, installing
a finished product top cover plate and finished product stair onto
the finished product main frame.
[0022] Components of a main part of the house, such as the finished
product main frame, the finished product floor cover plate, the
finished product top cover plate and the enclosed wall are
prefabricated except for a basic part of the house, and thus
industrial production is realized. Construction of the house is
implemented by industrially produced components and products and
processes such as field installation, connection, modification and
so on. At the time a base of the house is constructed, factory
production of various house components are performed. After the
base is constructed, the finished product main frame, the finished
product floor cover plate, the finished product top cover plate and
the enclosed wall are installed. The invention reduces a great deal
of field work, and storey structure and external wall construction
do not need a large amount of support frames and scaffolds, which
saves energy consumption, water consumption, construction land and
construction materials, and reduces construction noise and dust and
construction time. Standardization and integration of house
components and products are beneficial for application of new
technology and materials and renewable energy such as solar energy.
For example, solar devices are disposed on roofs, balconies and
sunny sides of wall, or outside the structure layer, and the house
is capable of improving residence comfort and increasing available
use area, reducing consumption of energy and water, and thus
facilitating a green house and green construction. Moreover, the
invention is capable of implementing standardization, serialization
and finalization, house drawing libraries, performing house design
via digital management, and presenting architectural styles and
aesthetic perception via design techniques such as difference of
house layout, modeling of balconies, materials of decorative
surface, color configuration and so on.
[0023] The finished product main frame of the invention may employ
a steel frame since steel is a renewable material that features
good technical performance and ductility and capable of improving
structural bearing capacity and seismic performance. Various steel
components are easy for large-scale production, and feature high
production efficiency and high product quality in manufacturing.
With increasing demand for steel, to construct houses with steel is
a development trend.
[0024] The finished product floor cover plate and the finished
product top cover plate are light-weight laminated slabs. The
light-weight laminated slab uses a hollow stripe board made of
prefabricated and reinforced light aggregate concrete as a
substrate to replace a traditional process of laying wooden
formworks for a finished product floor cover plate and a finished
product top cover plate made of cast-in-situ concrete. The
substrate is disposed on a special support frame to replace a
support headframe.
[0025] A reinforced framework is disposed between the substrates, a
reinforced net is disposed on an upper surface of the substrate,
and the reinforced framework and the reinforced net are cast via
C30-grade fine-stone concrete to form the light-weight laminated
slab. Since the hollow stripe board of the floor cover plate and
the top cover plate can be directly disposed on a finished product
main frame that is already constructed via the support frame, the
number of bottom formworks and supports is reduced, which improves
production efficiency, reduces effect to surrounding environment,
and overcomes limitation of storey-by-storey construction. After
the finished product main frame is constructed, construction can be
performed from any storey upwardly or downwardly, or from multiple
stories simultaneously whereby reducing construction time. After
the light-weight laminated slab is formed, the only wet
construction process--filed concrete casting is performed. After
consolidation, the light-weight laminated slab is firmly combined
with the finished product main frame to form a combined structure
interacted by a composite concrete floor cover or top cover and the
finished product main frame and bearing different acting force of
the house. Construction of the light-weight laminated slab does not
need to dismount a top bracing, a form spacer and a hoisting
machine, and decreases some dominant processes. Moreover, the
hollow stripe board, the reinforced framework and the reinforced
net can be directly processed in factories based on standards and
transmitted to a construction field for installation, which greatly
improves production efficiency, reduces construction time and helps
to implement industrialization of manufacturing.
[0026] The finished product composite prefabricated external
wallboard of the invention comprises a structure layer, a
light-weight filling block, and a heat insulation layer. The
structure layer is a reinforced (the reinforced framework and the
reinforced net) concrete layer in the shape of a rib, and disposed
on an outer side and surrounding of a wall board, and in a gap of
the light-weight filling block, which makes the structure layer
capable of bearing external force, climate change and rain
erosion.
[0027] In factories, the multiple finished product composite
prefabricated external wallboards is formed by casting light-weight
filing block and heat insulation materials, and post-casting,
high-strength, waterproof and fine-stone concrete of the reinforced
net with doors and windows. After inside and outside decoration,
the integral external wallboard is transmitted to the field for
installation, which replaces traditional processes such as
installing scaffolds, house walls, decorating and so on. The
multiple finished product composite prefabricated external
wallboards can be installed sequentially and upwardly with the
finished product main frame or on different stories simultaneously
after the finished product main frame is constructed. A supporting
plate is disposed on a supporting point of the finished product
main frame, multiple positioning holes are disposed on the multiple
finished product composite prefabricated external wallboards are
aligned with positioning pins disposed on the supporting plate,
which makes it easy for adjacent finished product composite
prefabricated external wallboards to be positioned. After
positioning, high-strength bolts are used for tightening and fixing
via optimized fastening force, and a damping pad is disposed in a
gap between the finished product composite prefabricated external
wallboard and the finished product main frame. Pressure is
generated after the bolt is tightened, under the action of the
pressure, the damping pad is worn and deformed, and therefore is
capable of implementing a seismic and energy dissipation effect,
reducing force applied by an earthquake to the house, and improving
seismic performance of the house. The finished product composite
prefabricated external wallboards on different stories are clutch
connected, which is beneficial for stabilization and firmness of
installation of the external wallboard. Ends of the finished
product composite prefabricated external wallboards on the same
storey are parallel connected. Connection between the finished
product composite prefabricated external wallboards on different
stories and that on the same storey are caulk sealed to improve a
sealing effect. A pair of vertical slots is disposed on both ends
of the connection between finished product composite prefabricated
external wallboards on the same storey and form a cavity, which
increases space of caulk sealing, guarantees tight connection
between the finished product composite prefabricated external
wallboards, facilitates a rain-proof and anti-seepage effect, and
keeps warm and prevents colds. A joint between the finished product
composite prefabricated external wallboards is disposed on the
finished product main frame, which helps to perform caulk sealing
of the finished product composite prefabricated external wallboards
and ensures connecting quality.
[0028] The finished product composite prefabricated external
wallboard forms an integral external wallboard made based on a
dimension of one room, namely one finished product composite
prefabricated external wallboards is an external wall of one
room.
[0029] According to present invention, the enforced light aggregate
concrete is C30-grade and has a seepage-resistant grade of P6. The
light-weight filling block is light-weight-material prefabricated
plate with a bulk density less or equal to 500 kg/m.sup.2 with
certain strength. The light-weight filling block is dispose on an
inner side of the finished product composite prefabricated external
wallboard whereby reducing an overall weight of the external
wallboard and insulating (absorbing) sound. A squeezed foam board
has a very low heat transfer coefficient, and is disposed on a
middle portion of the finished product composite prefabricated
external wallboard as a heat insulation layer and operates as a
heat insulation material for the wall. An external-wall door and a
window frame are disposed in a mould before concrete is cast, so
that the door and the window frame are firmly disposed in the wall,
which improves weather ability of the door and the window frame.
The invention can facilitate construction of the external wall of
the house by transferring the finished product composite
prefabricated external wallboard to the field and perform
installation one by one and caulk sealing, which decreases
construction time, greatly reduces work amount of field
construction, construction cost, and effect of construction land to
the environment, increases the number of renewable materials, and
facilitates real industrialization.
[0030] In a class of this embodiment, a gap between the finished
product composite prefabricated external wallboards is disposed on
the finished product main frame, which makes it convenient to
perform caulking sealing on the gap between the finished product
composite prefabricated external wallboards and ensures connecting
quality.
[0031] In a class of this embodiment, the multiple finished product
composite prefabricated external wallboards disposed on different
floors are zigzag clutch connected, outside protruding portions and
inside grooves of the multiple finished product composite
prefabricated external wallboards on different floors are clutch
connected to each other, vertical grooves are downwardly disposed
on an end of each of the multiple finished product composite
prefabricated external wallboards to form cavities, ends of
multiple finished product composite prefabricated external
wallboards and the cavity are filled with waterproof glue.
[0032] Except for industrialization of the main part of the house,
standardization and industrialization of indoor bathrooms and
stairs are also implemented. The bathrooms are configured to have
several styles, sanitary wares are selected and molded in an
integral or a combined form via polyester composites with pipe
joints and connectors being reserved, and processes such as
production of the wall, the sanitary wares and other accessories,
decorative processing and so on are implemented in factories. Then,
they are transmitted to the field for installation and connected to
the reserved pipe joint, whereby facilitating convenient
construction of the bathrooms, reliable quality and reduced
construction cost.
[0033] The finished product main frame employs a steel frame that
is mature, safe and reliable, makes it convenient for
industrialization, large-scale production and recycling use of
resources, reduces weight of an upper portion of the house,
features comparatively large ductility, a good seismic performance
and convenient field installation and construction.
BRIEF DESCRIPTION OF THE DRAWINGS
[0034] Detailed description will be given below in conjunction with
accompanying drawings, in which
[0035] FIG. 1a is a schematic view of a house of an exemplary
embodiment of the invention;
[0036] FIG. 1b is a front view of a house of an exemplary
embodiment of the invention;
[0037] FIG. 2 is a partial enlarged view of an F joint in FIG. 1b
of an exemplary embodiment of the invention;
[0038] FIG. 3 is a partial enlarged view of an F joint in FIG. 1b
of another exemplary embodiment of the invention;
[0039] FIG. 4 is a partial enlarged view of a G joint in FIG. 1b of
an exemplary embodiment of the invention;
[0040] FIG. 5 is a partial enlarged view of a P joint in FIG. 1b of
an exemplary embodiment of the invention;
[0041] FIG. 6 is a partial enlarged view of an I joint in FIG. 1b
of an exemplary embodiment of the invention;
[0042] FIG. 7 illustrates connection between finished product
composite prefabricated external wallboards on different
stories;
[0043] FIG. 8 is a partial enlarged view of a G position in FIG.
2;
[0044] FIG. 9 is a partial enlarged view of an R position in FIG.
7;
[0045] FIG. 10 is a schematic view of a finished product composite
prefabricated external wallboards of a first exemplary embodiment
of the invention;
[0046] FIG. 11 is a cross-sectional view of FIG. 10 along a line
A-A;
[0047] FIG. 12 is a top view of FIG. 10;
[0048] FIG. 13 is a schematic view of a finished product composite
prefabricated external wallboard of a second exemplary embodiment
of the invention;
[0049] FIG. 14 is a cross-sectional view of FIG. 13 along a line
B-B;
[0050] FIG. 15 is a top view of FIG. 13;
[0051] FIG. 16 is a schematic view of a finished product composite
prefabricated external wallboard of a third exemplary embodiment of
the invention;
[0052] FIG. 17 is a cross-sectional view of FIG. 16 along a line
C-C;
[0053] FIG. 18 is a top view of FIG. 16;
[0054] FIG. 19 illustrates a wallboard mount disposed in a finished
product composite prefabricated external wallboard;
[0055] FIG. 20 is a top view of a wallboard mount in FIG. 19;
[0056] FIG. 21 is a schematic view of a light-weight laminated slab
of an exemplary embodiment of the invention;
[0057] FIG. 22 is a cross-sectional view of a light-weight
laminated slab in FIG. 21;
[0058] FIG. 23 illustrates connection between a light-weight
laminated slab and a finished product main frame;
[0059] FIG. 24 illustrates connection between an finished product
composite prefabricated external wallboard and supporting plate of
a finished product main frame; and
[0060] FIG. 25 is a schematic view of FIG. 24 along a K
direction.
DETAILED DESCRIPTION OF THE EMBODIMENTS
[0061] As shown in FIGS. 1a and 1b, an house of the invention
comprises a finished product main frame 101, an enclosed wall 102,
a finished product top cover plate 103, a finished product floor
cover plate 104, a separation wall 106, a finished product stair
107, a bathroom 108, and a balcony 109. The enclosed wall is
assembled by multiple finished product composite prefabricated
external wallboards 202. The bathroom 108, the balcony 109, and the
finished product stair 107 are respectively an integral
prefabricated bathroom, an integral prefabricated balcony, and an
integral prefabricated finished product stair which are hoisted to
a designed position for installation. The finished product main
frame 101 is a steel frame, and comprises steel columns and steel
beams connected to each other via welding or high-strength bolts.
The finished product main frame 101 can also be a steel frame.
[0062] The finished product composite prefabricated external
wallboards and the finished product stair 107 are fixed on the
finished product main frame 101. The bathroom 108 is disposed on
the finished product floor cover plate 104, and comprises sanitary
wares and accessories. The bathroom 108 is configured to have
several styles, and sanitary wares are selected, and are molded in
an integral or a combined form via polyester composites with pipe
joints and connectors being reserved. Processes such as production
of the wall, the sanitary wares and other accessories, decorative
processing and so on are implemented in factories. Then, they are
transmitted to the field for installation and connected to the
reserved pipe joint. Kitchen stoves can be directly installed for
approved products. The finished product top cover plate 103 and the
finished product floor cover plate 104 are light-weight laminated
slabs. Field cast concrete is fixedly connected to the finished
product main frame 101. The separation walls 106 are transmitted to
field and installed one-by-one on the finished product floor cover
plate 104 after being prefabricated, and an upper end and a lower
end thereof are fixed on the finished product floor cover plate 104
via a buckle.
[0063] As shown in FIGS. 10-12, a schematic view of the finished
product composite prefabricated external wallboard. The finished
product composite prefabricated external wallboard is an external
wallboard formed by a structure layer 1 operating as a support
framework, 12 light-weight filling blocks 3 arranged in three rows
and disposed on an inner side of the structure layer, and a heat
insulation layer 2. There is no specific requirement for a shape
and dimension of the light-weight filling block 3, and it is
normally square, rectangular, triangular and so on and has a
dimension between 500 and 850 mm. The heat insulation layer 2 is
attached to the outside of the light-weight filling block 3. The
heat isolation layer 2 is disposed outside of the light-weight
filling block 3, and the structure layer 1 is disposed on a lateral
side of the external wallboard. The structure layer 1 fills a gap
between the heat isolation layer 2 and the light-weight filling
block 3, and attaches them altogether whereby forming the integral
external wallboard. The heat isolation layer 2 is a squeezed foam
board layer. The light-weight filling block 3 is a
light-weight-material prefabricated plate having a bulk density
less or equal to 500 kg/m.sup.2. The light-weight filling blocks 3
are parallel disposed on one layer, and a gap is disposed between
adjacent light-weight filling blocks 3. The structure layer 1 is a
reinforced concrete layer, and comprises a reinforced framework 11
disposed around the finished product composite prefabricated
external wallboard and between the light-weight filling blocks 3,
and a reinforced net 12 disposed outside the heat isolation layer 2
and connected to the reinforced framework 11. The reinforced
framework 11 around the finished product composite prefabricated
external wallboard is formed by reinforcing bars that are bent and
bound, and in the shape of a pane. The reinforced net 12 is a
reinforced net formed via a circular weft knitting technology.
Concrete is cast into the reinforced framework 11 and the
reinforced net 12, and gaps around the heat isolation layer 2 and
the light-weight filling blocks 3 whereby forming a reinforced
concrete layer. The concrete is fine-stone concrete having a
C30-grade and a seepage-resistant grade of P6. The reinforced
concrete layer attaches the light-weight filling blocks 3 and the
heat isolation layer 2 whereby forming the integral external
wallboard 3 whereby forming the integral external wallboard. Heat
insulation materials are disposed in a gap between adjacent
light-weight filling blocks 3 whereby forming the heat insulation
layer 2. Light-weight pearlite mortar is used to float inner
surface of the light-weight filling blocks 3 whereby forming inner
surface 20 of the wallboard. A hoisting part 5 and multiple
positioning holes 7 are disposed on the finished product composite
prefabricated external wallboard, and the hoisting part 5 is
disposed at the top of the finished product composite prefabricated
external wallboard and operates to hoist the finished product
composite prefabricated external wallboard. The positioning holes 7
are vertically disposed on an upper end and a lower end of a side
plate of the external wall, and operate to install and position the
finished product composite prefabricated external wallboard on the
finished product main frame 1. A pair of protruding parts 9 and
grooves 8 is disposed on an upper end and a lower end of the
finished product composite prefabricated external wallboard, and
the protruding parts 9 and the grooves 8 are fit with each other.
The protruding parts 9 and the grooves 8 on adjacent stories are
clutch connected. A semicircular vertical groove 15 is disposed on
a side of the finished product composite prefabricated external
wallboard, and operates to increase space for waterproof and
caulking processing between adjacent finished product composite
prefabricated external wallboards. Multiple wallboard mounts 6 are
disposed in the finished product composite prefabricated external
wallboard, specifically in four corners in the finished product
composite prefabricated external wallboard, and connected to the
finished product main frame.
[0064] As shown in FIGS. 13-15, a finished product composite
prefabricated external wallboard with a pre-buried door frame 16 is
illustrated. Other parts of the finished product composite
prefabricated external wallboard comprise a structure layer 1
operating as a support framework, two rows of light-weight filling
blocks 3 disposed on an inner side of the structure layer, and a
heat insulation layer 2. The light-weight filling blocks 3 are
disposed on both sides of the door frame 16.
[0065] As shown in FIGS. 16-18, a floating windowsill 17 and a
window frame 21 are pre-buried on the finished product composite
prefabricated external wallboard, and other parts of the finished
product composite prefabricated external wallboard comprise a
structure layer 1 operating as a support framework, three rows of
light-weight filling blocks 3 disposed on an inner side of the
structure layer, and a heat insulation layer 2. The light-weight
filling blocks 3 are disposed on both sides of the window frame 21
and below the floating windowsill 17. The floating windowsill 17 is
cast and prefabricated via fine-stone concrete, and a heat
insulation layer 18 is disposed in the floating windowsill 17.
[0066] As shown in FIGS. 24 and 25, a supporting plate 70 is
disposed on the finished product main frame 1 and operates to
support and position the finished product composite prefabricated
external wallboard 202. The supporting plate 70 is a T-shaped
plate, multiple positioning pins 72 are vertically disposed on a
horizontal part thereof, and multiple positioning holes 7
corresponding to the positioning pins 72 are disposed on a top
surface and a bottom surface of the finished product composite
prefabricated external wallboard.
[0067] As shown in FIGS. 19 and 20, a wallboard mount 6 is
pre-buried in the finished product composite prefabricated external
wallboard. The wallboard mount 6 comprises a bolt sleeve 63
disposed in a structure layer 1 of the finished product composite
prefabricated external wallboard and being perpendicular to the
wall of the finished product composite prefabricated external
wallboard. Internal thread is disposed on inner wall of the bolt
sleeve 63, a connecting plate 62 perpendicular to the bolt sleeve
63 is disposed on a front part of the bolt sleeve 63, a connecting
rod 65 is perpendicular thereto is disposed on a rear part of the
bolt sleeve 63, and a reinforced framework 61 is disposed outside
the bolt sleeve 63. The connecting plate 62 and the connecting rod
65 are strengthening parts operating to improve stability of the
bolt sleeve 63 in the structure layer 1 and connection strength of
the wallboard mount 6.
[0068] As shown in FIGS. 2, 3, 4, 5, 6 and 8, connection between
finished product composite prefabricated external wallboards on the
same storey and that between the finished product composite
prefabricated external wallboard and the finished product main
frame are illustrated, in which FIGS. 2 and 3 illustrate connection
between finished product composite prefabricated external
wallboards at corners, and FIGS. 4, 5 and 6 illustrate connection
between finished product composite prefabricated external
wallboards on the same storey on one side of the house. Finished
product composite prefabricated external wallboards 202 on the same
storey are planarly connected, Adjacent ends of adjacent finished
product composite prefabricated external wallboard 202 are planes.
The finished product composite prefabricated external wallboard 202
is fixed on a joint between a steel column and a steel beam of the
finished product main frame 101 by fitting the wallboard mounts 6
disposed on four corners of the finished product composite
prefabricated external wallboard with a seismic and
energy-dissipation connector. The seismic and energy-dissipation
connector comprises a high-strength bolt 404. The wallboard mount 6
comprises a bolt sleeve disposed in the finished product composite
prefabricated external wallboard 202. The bolt 404 passes through a
screw hole on the finished product main frame 101, is thread
connected to the sleeve and fixes the finished product composite
prefabricated external wallboard on the finished product main frame
101. A damping pad 303 is disposed at a connection of the bolt and
between the finished product composite prefabricated external
wallboard 202 and the finished product main frame 101.
[0069] An end at a connection between two finished product
composite prefabricated external wallboards 202 on the same storey
is a plane, and a vertical groove 15 is downwardly disposed on an
end of each of the finished product composite prefabricated
external wallboards 202. The two vertical grooves 15 form a cavity.
After installation of all finished product composite prefabricated
external wallboards is finished, a caulking sealing process is
performed between ends of the finished product composite
prefabricated external wallboard 202 and in the cavity. As shown in
FIG. 8, foaming polyurethane 53 is injected into a middle part of
the gap and into the cavity, a pair of double-faced foaming rubber
strips 52 are filled in both sides of the foaming polyurethane 53,
and waterproof glue 51 is filled in a lateral outside thereof.
Alternatively, the foaming polyurethane is not injected into the
cavity, and the double-faced foaming rubber strips 52 are filled in
both sides of the cavity. The waterproof glue 51 filled in a
lateral outside thereof fills a gap between the finished product
composite prefabricated external wallboard, which facilitate a
waterproof effect.
[0070] As shown in FIGS. 7 and 9, connection between finished
product composite prefabricated external wallboard 202 on adjacent
stories is illustrated. Finished product composite prefabricated
external wallboards on different stories are zigzag clutch
connected, and protruding portions and grooves of the finished
product composite prefabricated external wallboards on different
stories are clutch connected to each other. Caulk sealing and
waterproof processing are performed in a gap there between. Foaming
polyurethane 53 in injected into the middle of the gap,
double-faced foaming rubber strips 52 are filled in both sides of
the foaming polyurethane 53, and waterproof glue 51 is filled in a
lateral outside thereof, whereby filling the gap between the
finished product composite prefabricated external wallboard 202 on
adjacent stories and facilitating a waterproof effect.
[0071] As shown in FIGS. 21, 22 and 23, the invention uses
light-weight laminated slabs as the finished product top cover
plate 103 and the finished product floor cover plate 104. The
light-weight laminated slab uses a hollow stripe board made of
prefabricated and reinforced light aggregate concrete as a
substrate 40. The substrate 40 is disposed on a support frame 45. A
reinforced framework 42 and a reinforced net 43 are respectively
disposed between the substrates 40 and on the substrate 40, and are
cast via C30-grade fine-stone concrete 41 to form the light-weight
laminated slab fixedly connected to the finished product main frame
101. Since the substrate 40, namely the hollow stripe board can be
directly disposed on the finished product main frame 101 that is
already constructed via the support frame 45, the number of bottom
formworks and supports is reduced, which improves production
efficiency, reduces effect to surrounding environment. Post-casting
of the light-weight laminated slab is the only wet construction
process, after consolidation, the light-weight laminated slab is
firmly combined with the finished product main frame 1 to form a
combined structure interacted by a composite concrete floor cover
or top cover and the finished product main frame and bearing
different acting force of the house.
[0072] Construction of the house of the invention comprises steps
of:
[0073] 1. Firstly, an architecture design scheme is determined, a
detailed construction drawings are made based thereon according to
standardization and digitalization, foundation construction of the
house is performed based on the detailed construction drawings, and
large-scale production of upper parts such as the finished product
composite prefabricated external wallboard, the finished product
stair, the bathroom, the balcony, the light-weight laminated slab
and so on is conducted in factories.
[0074] 2. After foundation construction of the base is completed,
the finished product main frame is installed, which comprising
installing steel columns and then steel beams, connection between
the steel columns and the steel beams is implemented by
high-strength bolts or welding.
[0075] 3. After the finished product main frame is constructed, the
enclosed wall is installed, the finished product composite
prefabricated external wallboard using light-weight filing block
and heat insulation materials, and post-casting, high-strength,
waterproof and fine-stone concrete of the reinforced net are cast
with doors and windows to form an integral external wallboard.
After inside and outside decoration, the integral external
wallboard is transmitted to the field for installation, which
replaces traditional processes such as installing scaffolds, house
walls, decorating and so on. The finished product composite
prefabricated external wallboards can be installed sequentially and
upwardly with the finished product main frame or on different
stories simultaneously after the finished product main frame is
constructed. A supporting plate is disposed on a supporting point
of the finished product main frame, multiple positioning holes are
disposed on the external wallboard are aligned with positioning
pins disposed on the supporting plate. The finished product
composite prefabricated external wallboard is disposed on the
supporting plate, and then a damping pad is disposed in a gap
between the finished product composite prefabricated external
wallboard and the finished product main frame, high-strength bolts
are used for tightening and fixing via optimized fastening force.
The damping pad is capable of implementing a seismic and energy
dissipation effect, reducing force applied by an earthquake to the
house, and improving seismic performance of the house. Finished
product composite prefabricated external wallboards on different
stories are clutch connected, sealing and waterproof caulking
processing is performed on connection between finished product
composite prefabricated external wallboards on different stories
and that between finished product composite prefabricated external
wallboards on the same storey, whereby ensuring firm connection
between the finished product composite prefabricated external
wallboards. A gap between the finished product composite
prefabricated external wallboard is disposed on the finished
product main frame, which makes it convenient to perform caulking
sealing on the gap between finished product composite prefabricated
external wallboards and ensures connecting quality.
[0076] 4. After installation and construction of the enclosed wall
are completed, the finished product floor cover plate and the
finished product top cover plate are installed. The finished
product floor cover plate and the finished product top cover plate
use light-weight laminated slabs, the light-weight laminated slabs
use hollow stripe boards made of prefabricated and reinforced light
aggregate concrete as substrates, and the substrate is disposed on
the support frame. A reinforced framework and a reinforced net are
respectively disposed between the substrates and on an upper
surface of the substrate, cast via C30-grade fine-stone concrete,
and fixedly connected to the finished product main frame.
[0077] 5. Processes such as production of the wall, the sanitary
wares and other accessories, decorative processing and so on are
implemented in factories. Then, they are transmitted to the field
for installation and connected to the reserved pipe joint.
[0078] 6. The Separation Wall: a hollow stripe board is
prefabricated in factories according to a required size and
transmitted to the field for connection and installation.
[0079] 7. The Balcony: it is integrally prefabricated according to
design drawings and disposed on the steel beam protruding from the
finished product main frame.
[0080] 8. The Finished Product Stair: it is sectional prefabricated
according to design drawings and installed on the steel beam of the
finished product main frame in a finished product stair case.
[0081] 9. Electric Circuits: they are buried according to design
drawings at the time the wallboard is prefabricated and
post-casting of the floor top cover is performed, and circuits are
installed as indoor decoration is performed.
[0082] 10: Water Supply and Sewerage Pipelines: pipelines are
installed in reserved pipeline holes after the finished product
floor cover plate is constructed.
[0083] Table 1 indicates analysis and comparison between
consumables of the invention and those of a traditional
cast-in-situ reinforced concrete house.
TABLE-US-00001 TABLE 1 Analysis and comparison of consumables
(applicable for multi-storey and small sized multi-storey houses)
Consumables per Number Position Specific project square house area
Remark 1 Main I. the house structure 1. steel framework 42-50
kg/m.sup.2 2. hollow stripe 0.85 m.sup.2/m.sup.2 board substrate
made of reinforced light-weight concrete 3. post-casting C30 0.065
m.sup.3/m.sup.2 concrete 4. reinforced net 7.5 kg/m.sup.2 laminated
slab II. traditional cast-in-situ reinforced concrete house 1.
reinforcements of 52-70 kg/m.sup.2 cast-in-situ C25 reinforced
concrete 2. cast-in-situ C25 0.22 m.sup.2/m.sup.2 concrete 3. wood
form 1.6-1.8 m.sup.2/m.sup.2 can be reused for 3-4 times 4. top
bracing 40 kg/m.sup.2 renewable 2 External I. finished product
wallboard composite prefabricated external wallboard 1. 0.13
m.sup.3/m.sup.2 light-weight- material prefabricated plate 2. 25 mm
squeezed 0.025 m.sup.3/m.sup.2 foam board 3. C30 fine-concrete 0.06
m.sup.3/m.sup.2 composite layer and decorative surface 4.
installation and 0.6-0.7 m/m.sup.2 caulking sealing II. traditional
block external wall 1. 200 mm foaming 0.2 .sup.3/m.sup.2 concrete
block 2. cement mortar 1 m.sup.2/m.sup.2 substrate 3. 30-50 mm 1
m.sup.2/m.sup.2 plastic-extrusion- plate heat insulation layer 4.
combined layer 1 m.sup.2/m.sup.2 5. protection layer 1
m.sup.2/m.sup.2 and decorative surface 6. scaffold 1
m.sup.2/m.sup.2 equipments 7. vertical 1 m.sup.2/m.sup.2
transportation of various materials Remarks: 1. Indoor decoration,
facilities such as bath rooms, kitchens and so on, architectural
modeling of doors and windows, and decorative processing are the
same and will not be compared in economic. 2. Cost spent on
foundation construction can be reduced by 15-25% according to
different geological conditions since weight of upper structure
thereof is decreased by approximately 30-40%. 3. Construction time
of traditional field construction is long as being limited by a
main construction procedure, procedures of the invention can be
performed simultaneously and construction time thereof is reduced
by 40-50%. As construction time is extended for one month, interest
cost is increased by 1%-2%. Economic benefit of the invention
embodies capital amount and capital flow cost.
Test on the House of the Invention
[0084] 1. Structure Loading Test on the Finished Product Floor
Cover Plate Made by the Light-Weight Laminated Slab
[0085] The loading test aims at testing stress of relevant
positions of the floor cover structure (containing the steel beam
of the floor cover) under the action of loading, and deforming and
crack development of the structure part. The test is conducted by
Shenzhen Institute of House Research Co., Ltd, and test report is
also written thereby.
[0086] Test Basis: Standard Methods for Testing of Concrete
Structures (China national standard GB50152-92)
[0087] The finished product floor cover plate employs a
bi-directional plate (bi-directional forced) with a span of 4
m.times.4.5 m, and a unidirectional plate (unidirectional forced)
with a span of 2.5 m. The loading test is conducted for two times,
the first loading test comprises a scenario where stress of
surrounding supporting steel beams varies as the floor cover made
of laminated slabs is constructed, loading is stopped as a load
value of the unidirectional plate is twice than a designed standard
load value. Mid-span deflection of the plate is only 0.84 mm
(L.sub.o/2976), mid-span stress of a plate rib is
32.sup.N/mm.sup.2, and negative reinforcement stress of a support
is 54.sup.N/mm.sup.2.
[0088] As a load value of the bi-directional late is 4.2 times than
a designed standard load value and a first crack appears, loading
is stopped. Short mid-span deflection of the plate is 4.32 mm
(L.sub.o/926), and long mid-span deflection of the plate is 6.35 mm
(L.sub.o/710).
[0089] Central Reinforced Stress: [0090] short mid-span stress of a
plate rib 61.sup.N/mm.sup.2 [0091] long mid-span stress of a plate
rib 52.sup.N/mm.sup.2 [0092] short negative reinforcement of a
support 54.sup.N/mm.sup.2 [0093] long negative reinforcement of a
support 32.4.sup.N/mm.sup.2
[0094] To demonstrate bearing capability of the light-weight
laminated plate to be damaged, another damage load test is
conducted.
[0095] A Unidirectional Plate: load value thereof is 7.5 times than
a designed standard load (namely 35 KN/m.sup.2), the maximum
mid-span deflection is 6.4 mm (L.sub.o/390), since loading blocks
are highly piled, it is impossible to load any more.
[0096] A Bi-Directional Plate: load value thereof is 13 times than
a designed standard load (namely 32.5 KN/m.sup.2), the mid-span
deflection is 12.85 mm (L.sub.o/311), and a width of the crack at
the bottom of the plate is 1.5 mm. At this time the finished
product floor cover plate is regarded as entering a plastic
deforming phase. The test indicates the finished product floor
cover plate made of the light-weight laminated slab has high
bearing capacitance and enough safety reservation.
[0097] 2. Heat Resistance Test on the Finished Product Composite
Prefabricated External Wallboard
[0098] The loading test and heat resistance test are conducted by
Shenzhen Institute of House Research Co., Ltd, and test report is
also written thereby. The test is based on China national standard
GB/T13475-92 named "House Element--Determination of Steady-state
Thermal Transmission Properties--Calibrated and guarded hot box". A
test equipment employs a BW-1212WT-type stable heat transmission
test system JN002.
[0099] Test Condition: air temperature in the hot box is 35.degree.
C., air temperature in the cool box is -10.degree. C. Air flow rate
in the hot box is natural convection, and air flow rate in the cool
box is 3 m/s. Heat transmission direction of samples is from warm
to cool. Airflow direction in the cool box is upward. Emissivity on
inner surface of the box is 0.85. The samples' state is natural
drying.
[0100] By comparison of heat resistance, materials such as the
light-weight-material prefabricated plate, the squeezed form plate
and so on are selected as materials having heat insulation effect
in the laminated external wallboard. The reinforced net is cast via
C30-grade fine-stone concrete and post-cast in an embedded form.
After the heat resistance test, a thermal conductivity is 1.05
W/mK, which is less than an index of 1.5 W/mK defined by the
Power-saving Standard for thermal conductivity of wall.
[0101] While particular embodiments of the invention have been
shown and described, it will be obvious to those skilled in the art
that changes and modifications may be made without departing from
the invention in its broader aspects, and therefore, the aim in the
appended claims is to cover all such changes and modifications as
fall within the true spirit and scope of the invention.
* * * * *