WO2022115886A1 - A semi-assembled wall and floor structural system and construction method using this system - Google Patents

A semi-assembled wall and floor structural system and construction method using this system Download PDF

Info

Publication number
WO2022115886A1
WO2022115886A1 PCT/VN2021/000023 VN2021000023W WO2022115886A1 WO 2022115886 A1 WO2022115886 A1 WO 2022115886A1 VN 2021000023 W VN2021000023 W VN 2021000023W WO 2022115886 A1 WO2022115886 A1 WO 2022115886A1
Authority
WO
WIPO (PCT)
Prior art keywords
wall
floor
panels
panel
assembled
Prior art date
Application number
PCT/VN2021/000023
Other languages
French (fr)
Inventor
Do Duc Thang
Tran Huu ANH
Original Assignee
Pytago Science Joint Stock Company
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Pytago Science Joint Stock Company filed Critical Pytago Science Joint Stock Company
Publication of WO2022115886A1 publication Critical patent/WO2022115886A1/en

Links

Classifications

    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • E04B1/16—Structures made from masses, e.g. of concrete, cast or similarly formed in situ with or without making use of additional elements, such as permanent forms, substructures to be coated with load-bearing material
    • E04B1/161—Structures made from masses, e.g. of concrete, cast or similarly formed in situ with or without making use of additional elements, such as permanent forms, substructures to be coated with load-bearing material with vertical and horizontal slabs, both being partially cast in situ
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B5/00—Floors; Floor construction with regard to insulation; Connections specially adapted therefor
    • E04B5/02—Load-carrying floor structures formed substantially of prefabricated units
    • E04B5/04—Load-carrying floor structures formed substantially of prefabricated units with beams or slabs of concrete or other stone-like material, e.g. asbestos cement
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B5/00—Floors; Floor construction with regard to insulation; Connections specially adapted therefor
    • E04B5/16—Load-carrying floor structures wholly or partly cast or similarly formed in situ
    • E04B5/32—Floor structures wholly cast in situ with or without form units or reinforcements
    • E04B5/36—Floor structures wholly cast in situ with or without form units or reinforcements with form units as part of the floor
    • E04B5/38—Floor structures wholly cast in situ with or without form units or reinforcements with form units as part of the floor with slab-shaped form units acting simultaneously as reinforcement; Form slabs with reinforcements extending laterally outside the element
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
    • E04C2/02—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials
    • E04C2/04—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of concrete or other stone-like material; of asbestos cement; of cement and other mineral fibres
    • E04C2/044—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of concrete or other stone-like material; of asbestos cement; of cement and other mineral fibres of concrete
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
    • E04C2/02—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials
    • E04C2/04—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of concrete or other stone-like material; of asbestos cement; of cement and other mineral fibres
    • E04C2/049—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of concrete or other stone-like material; of asbestos cement; of cement and other mineral fibres completely or partially of insulating material, e.g. cellular concrete or foamed plaster
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
    • E04C2/02—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials
    • E04C2/04—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of concrete or other stone-like material; of asbestos cement; of cement and other mineral fibres
    • E04C2/06—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of concrete or other stone-like material; of asbestos cement; of cement and other mineral fibres reinforced

Definitions

  • the present invention relates to the construction field, and in particular, to a semi-assembled wall and floor structural system that can be easily and quickly assembled, reducing construction and installation costs, in addition, the present invention relates to a construction method using the said structural system.
  • the wall area can be 1.5 times as much to the floor area, the wall is directly affected by rain, sun, and wind, therefore, requirements for sound and heat insulations, lightweight, quickly construction, low cost are also important, in addition to requirement for strength.
  • the Vietnamese Patent No. VN1 -0019455 with title “Wall panel, a quickly assembled wall panel systems and a construction method using the wall panels” disclosed a construction method for quickly assembled wall panel using the panels that are the same height as the wall, these panels are engaged together by the coupling grooves and the coupling ribs on the panels, and fixed by inserting the plastic pipe through the connection holes that formed in the horizontal direction of the panel without locating reinforcement and pouring concrete within the wall panels.
  • This wall panel is highly industrialized with good finished surface, easy to install the wall in construction process, it is easy to install for unskilled workers.
  • it is required to install temporary supports to prevent the wall panel from falling before insert the plastic pipes through the connecting holes of the wall panels. The use and installation of these temporary supports increases construction time and costs.
  • the Vietnamese Utility Model Patent No. VN2-00001988 with title “Construction method for pre-assembled wall” disclosed a construction method for pre-assembled wall without using temporary supports. This method is accomplished by firstly stacking assembled blocks so that their vertical holes are staggered to form rows of assembled blocks of the wall, then inserting steel bars and pouring concrete into the holes in the blocks to connect the rows of blocks together.
  • This construction method allows easy and quickly assembly and fixation of the blocks to form a wall without the use of mortar and temporary supports in construction process.
  • this method requires many staggeringly assembled blocks in the vertical direction to form a wall. Since the blocks are connected together by shallow male-female joints, it is required to insert the reinforcement steel bars and pour concrete mortar into the vertically available holes of the blocks, thereby formed a skeleton for the wall.
  • Wall assembled by the above methods have longitudinal sliding displacement when settlement occurs during the use of the building, that caused by the wall panels, the assembled blocks, the concrete bricks are positioned together through the male-female joints. This leads to cracks are formed between the wall panels or the assembled blocks, as a result affecting the waterproofing and noise resistance of the wall.
  • the current buildings are constructed with pre-cast concrete columns and beams and walls are built of bricks or assembled panels between columns and beams, this structure is limited in that walls and the columns and beam frame system is not monolithic, leading to the formation of cracks on the wall during use, the columns protrude from the wall, reducing the aesthetics of the building.
  • the Vietnamese Utility Model Patent No. VN2-0002524 with title “Steel formwork floor frame system” disclosed steel formwork floor frame system including U-shaped beam with serrated anti-slip lugs; steel formwork panels of isosceles trapezoidal shape with two supporting flanges fitted in the serrated anti- slip lugs of the beam; and the shields are fitted with the flanges of the beam to cover the gap between the below wave part of the steel formwork and the beam.
  • Concrete is cast inside the U-shaped beam and on the surface of the steel formwork to create a monolithic structure for the concrete floor and beams, increase the bearing capacity of the beams, and at the same time reduce the thickness of the concrete floor-beam system.
  • this solution has not yet solved the problem of the gap between the wall and beams during use because it is not monolithic structure. This affects the waterproofing and noise resistance of the wall.
  • One aspect of the present invention provides a semi-assembled wall and floor structural system that can be easily and quickly assembled, creating a monolithic structure between the wall, beams and floor, solving the problem of cracks on the wall appearing between the wall and beams due to horizontal and vertical displacement of the structures during use.
  • the present invention provides the semi- assembled wall and floor structural system including rectangular wall panels with hollow holes; beam caps are clad on the top of the wall panels; and floor panels are located on the beam flanges of the beam caps, characterized in that, the concrete wall panel assembled by at least two comb-shaped surface plates combined together, in which one side of the surface plate has longitudinal reinforced ribs arranged apart from a predetermined distance; the beam cap includes two L-shaped beam flanges symmetrically arranged apart from a distance equal to the thickness of the wall panel, and fixed together by connecting bars on the top surface of the beam cap, reinforced ribs are arranged apart from a predetermined distance on the side surface of the beam cap and on the beam flange such that the distance between the reinforced ribs is equal to the width of the floor panel; the concrete floor panels cover about two third of the triangular reinforcement steel cage of floor such that the top steel bar and part of the oblique bars of the triangular reinforcement steel cage protrude at least 2 cm from the top surface
  • the wall panels are provided with self- drilling studs or anchoring elements protruding from the inner surface of the wall panels.
  • aggregate compositions of wall panel include 65-75% of fly ash, 10-20% of cement, 10-15% of lime, 2-5% of gypsum, 0.05-0.15% of aluminum powder, 0.1-0.2% of polyester reinforced fiber, and additives.
  • At least one longitudinal reinforced rib at the end of the surface plate is recessed at opening apart from the side surface of the surface plate at a distance equal to the thickness of the longitudinal reinforced rib.
  • Another aspect of the present invention provides a construction method using a semi-assembled wall and floor structural system that can be easily and quickly constructed, reducing the number of temporary supports for construction process, the method includes the following steps: step 1: constructing the foundation structure and column reinforcement steel cage according to the design; step 2: assembling the bearing wall from the wall panels by mounting the surface plates according to the constructed column reinforcement steel cages; step 3: fixing the wall panels together by mounting the beam caps on the top of the wall panels; step 4: assembling the floor panels on the beam flanges of the beam caps; and step 5: pouring the concrete to monolithically complete wall panels, columns inside wall, beam caps and floors.
  • the step 2 of assembling the surface plates to form the wall panels further includes screwing the self-drilling studs so that protrudes from the inner surface of the wall panels.
  • the step 2 of assembling the bearing wall from the wall panels is implemented by placing the comb-shaped surface plates symmetrically or staggeringly together so that the side surface of the longitudinal reinforced ribs of two opposite surface plates are against each other.
  • Fig. 1 is a perspective view of a semi-assembled wall and floor structural system according to the present invention
  • Fig. 2 is a perspective view of the wall panels according to an embodiment of the present invention.
  • Fig. 3 is an exploded perspective view of the wall panel shown in Fig. 2;
  • Fig. 4 is a perspective view of wall panel according to another embodiment of the present invention.
  • Fig. 5 is a perspective view of the beam cap according to the present invention.
  • Fig. 6 is a perspective view of the floor panel according to an embodiment of the present invention.
  • Fig. 7 is a cross-sectional view of the floor using the floor panels according to the present invention.
  • Fig. 8 is a cross-sectional view of the floor panel according to another embodiment of the present invention.
  • the present invention provides a semi- assembled wall and floor structural system as shown in Figs. 1 to 7.
  • the semi-assembled wall and floor structural system comprises the wall panels 10 in rectangular shape with hollow holes; the beam caps 20 are clad on the top of the wall panels 10; and the floor panels 30 are located on the beam flanges of the beam caps 20.
  • the wall panels 10 are made of aerated autoclaved concrete (AAC), is assembled from the comb-shaped surface plates 11 mounted together, in which one side of the surface plate 11 has longitudinal reinforced ribs 111 spaced equally.
  • AAC aerated autoclaved concrete
  • the present invention is not limited to the wall panel cast of AAC concrete, in another embodiment of the present invention, the wall panel 10 may be casted of foam concrete, EPS foam concrete or the like.
  • the surface plate 11 is manufactured with dimensions of 3,000 mm (length) x 900 mm (width) x 130 mm (thickness). As shown in Fig. 3, the surface plate 11 has a comb shape with a thickness of 30 mm, the longitudinal reinforced ribs 111 with a thickness equal to that of the surface plate 11 and are equally spaced protruding from one side of the surface plate 11, in which the first longitudinal reinforced rib 111 at one end of the surface plate 11 is protruded at the edge of the side surface of the surface plate 11 while the last longitudinal reinforced rib 111 at the other end of the surface plate 11 is recessed at an opening apart from the other side surface of the surface plate 11 so that the opening is equal to the thickness of the longitudinal reinforced rib 111.
  • the first longitudinal reinforced rib 111 of the opposite surface plate 11 is mounted in the opening of the other surface plate 11 to combine into the wall panel 10 in box shape as shown in Fig. 2 with internal hollow holes, this combination type of the wall panel 10 is suitable for partition walls in the building.
  • the longitudinal reinforced rib 111 of the opposite surface plate 11 is inserted into the opening of the other surface plate 11 to form a rectangular wall panel 10 by mounting the wall panels 11 staggered from each other, this construction is characterized in that one surface plate 11 connects to two opposite wall panels 11 so that there is no a gap in the wall panel 10 assembled by these surface plates 11, accordingly, thereby the wall panel 10 is suitable for the exterior walls of the building.
  • the surface plate 11 of the wall panel 10 further has the self-drilling studs 112 that protrude from the inside surface of the surface plate 1 1, thereby the casted concrete in the hollow holes of the wall panel 10 to firmly fix the surface plates, which can prevent the horizontal and vertical displacement of the wall panel 10 that often leads to cracks as the conventional walls constructed using existing techniques.
  • the surface plate 11 is made of aerated autoclaved concrete (AAC) with aggregate compositions including 70% of fly ash, 15% of cement, 12% of lime, 3% of gypsum, 0.1% of aluminum powder, 0.15% of polyester reinforced fiber, and additives. Concrete is autoclaved at 180°C at a pressure of 10 atm. Since the polyester reinforced fiber in the aggregate compositions, the surface plate 11 of the present invention can reduce the thickness of the wall panel to a minimum (30 mm), obtain high compressive, tensile and bending strengths, so that the surface plate 11 of the present invention has light weight, large size, easy construction and assembly.
  • the results of strength testing of the surface plate 11 according to the present invention with dimensions of 3,000 mm (length) x 900 mm (width) x 130 mm (thickness) are shown below in Table 1 :
  • the steel beam cap 20 consists of two L-shaped beam flanges 21 symmetrically arranged apart from a distance equal to the thickness of the wall panel 10, and fixed together by the connecting bars 22 at the top surface of the beam cap, the reinforced ribs 23 are spaced equally on the side surface of beam flanges 21 so that the distance between reinforced ribs 23 is equal to the width of the floor panel 30.
  • the inner surface of the two beam flanges 21 against the outer surface at the top end of the wall panel 10 is assembled from the surface plates 11 to connect the surface plates with each other, fix the top of the wall panels 10 and surface plates 11 without the use of the anchoring elements.
  • the connecting bars 22 in the form of inverted U-shaped flat bars are welded on the top surface of the beam flanges 21, the connecting bars 22 are arranged apart from each other to create a connection between the beam flanges and create gaps for insert the column reinforcement cages through, and for easy concreting of columns and walls.
  • the reinforced ribs 23 are equally spaced on the side surface of beam flange 21 so that the distance between the reinforced ribs 23 is equal to the width of the floor panel 30 to increase the stiffness of the beam cap 20, and at the same time to position and fix the floor panels 30 which are located on the beam flanges 21.
  • the beam cap 20 may have an inverted U-shape having two beam shoulders to support the end of the floor panel, and having a hollow hole in the top surface corresponding to the hollow hole of the assembled wall panel.
  • the floor panel 30 made of aerated autoclaved concrete (AAC) covering two third of the triangular reinforcement steel cage 32 such that the top steel bar and part of the oblique bars of the triangular reinforcement steel cage 32 protrudes at least 2 cm from the upper surface of the floor panel 30, the wedge-shaped recesses 31 are formed on the side surfaces of the floor panel 30.
  • AAC aerated autoclaved concrete
  • the present invention is not limited to the floor panel casted of AAC concrete, in another embodiment of the present invention, the floor panel 30 may be casted of foam concrete, EPS foam concrete or the like.
  • the triangular reinforcement steel cage 32 protrudes from the top surface of the floor panel 30 to facilitate crane, strengthen the connection between triangular reinforcement steel cage 32 and concrete layer 50, and increase the thickness of monolithic concrete layer 50 up to 4-5 cm at the construction site, which increases the stiffness of the finished floor.
  • the floor panel is molded with dimensions of 5,850 mm (length) x 600 mm (width) x 154 mm (thickness) of AAC concrete after autoclaving to achieve a compressive strength of 6 Mpa which is strong enough to combine with two triangular reinforcement steel cages 32 buried about two third in mortar to form a lightweight floor panel with great anti-bending stiffness because the triangular reinforcement steel cages are not destroyed due to instability, bears all construction loads, this can reduce the number of the temporary supports during construction process.
  • the floor panel 30 has the recesses 31 having a ellipse cross-section recessed deep into the inside of the side surface of the floor panel 30, these recesses 31 will form stopper strips between the floor panels 30 with the concrete layer 50 to monolithically complete the floor structure.
  • the stopper strips extending over the entire side surface of the floor panels 30 effectively prevent horizontal and vertical displacement of the floor panels 30 during use, thereby avoiding the formation of the floor cracks as the conventional pre-assembled floor panels.
  • Fig. 8 is a cross-sectional view of the floor panel 30 in another embodiment of the present invention, in which the recesses 31 have a semicircular cross- section to limit stress concentration at the transition point of the stopper strip when pouring the concrete layer 50 to monolithically complete the floor structure, this can help increase the bond strength between the floor panels 30 and the concrete layer 50.
  • the present invention provides a construction method using a semi-assembled wall and floor structural system as described above, the method includes the following steps: step 1: constructing the foundation structure and column reinforcement steel cage 40 according to the design; step 2: assembling the bearing wall from the wall panels 10 by mounting the surface plates 11 according to the constructed column reinforcement steel cages; step 3: fixing the wall panels 10 together by mounting the beam caps 20 on the top of the wall panels 10; step 4: assembling the floor panels 30 on the beam flanges 21 of the beam caps 20; and step 5: pouring concrete to monolithically complete the wall panels, the columns inside wall, the beam caps 20 and floors.
  • the surface plates 11 are combined into the wall panel 10 by staggered facing with each other so that one surface plate 11 connects to two opposite wall panels 11 through the side surfaces of longitudinal reinforced ribs 11 against each other.
  • the wall panel 10 is formed to extend integrally over the entire wall surface, without creating gaps between the wall panels as the walls assembled from the separate wall panels, which can effectively prevent cracks from appearing in the wall, ensuring waterproofing and noise resistance.
  • the step 2 of assembling the surface plates to form the wall panels further includes screwing the self-drilling studs 112 or the anchoring elements so that protrudes from the inner surface of the wall panels 10 to increase the connection between concrete poured in the wall panel 10 and the surface plates 11 when concreting the monolithic concrete. Which prevent displacement of surface plate, thereby preventing cracks from appearing in the wall.
  • the concrete in the step 5 of pouring concrete to monolithically complete wall panel 10, the columns inside wall, the beam caps 20 and the floor, the concrete can be frilly casted in all hollow holes of the wall panel 10 or can be poured only in the hollow holes having installed the column reinforcement steel cage 40 to form the column in the wall inside the wall panel
  • the system of columns, beams and floors of the building are concreted once, ensuring the monolithic of concrete, increasing the rigidity of the whole building.
  • the semi-assembled wall and floor structural system according to the present invention allows concrete to be casted inside the wall panel 10, the beam cap 20 and on the surface of the floor panel 30, to creat a monolithic structure for the concrete floor, beams and walls, increasing the bearing capacity of the bearing frame system of the whole building;
  • the wall panels are combined from the comb-shaped wall panels to form internal hollow holes, wet joints are implemented at the construction site, good connection between surface plates avoids wall cracking, allowing arrangement of the reinforcement concrete columns inside the wall that is completely inside the wall panel;
  • the beam cap structure fixs the top of the wall panel, link the intersecting wall panels, and create space for the floor panel;
  • the AAC concrete layer or similar material of the floor panel together with about two third of the triangular reinforcement steel cage buried in the mortar form a lightweight panel with great anti-bending stiffness.
  • the lightweight concrete layer maximizes the bearing capacity of the triangular reinforcement steel cage because the triangular reinforcement steel cage is not damaged due to instability, reduce the weight of the floor panel, reduce the number of temporary supports in construction process, reduce the amount of steel bars of the floor panel, as well as the floor load on the beams and foundation columns are significantly reduced, save construction costs;
  • the floor panel has the side sufaces of the floor panels creating recesses to form the stopper strips between the floor panels when monolithic concrete is casted on the surface of the floor panels.

Landscapes

  • Engineering & Computer Science (AREA)
  • Architecture (AREA)
  • Physics & Mathematics (AREA)
  • Electromagnetism (AREA)
  • Civil Engineering (AREA)
  • Structural Engineering (AREA)
  • Load-Bearing And Curtain Walls (AREA)

Abstract

The present invention refers to a semi-assembled wall and floor structural system including the rectangular wall panels (10) with hollow holes; the beam caps (20) are clad on the top of the wall panels (10); and the floor panels (30) are mounted on the beam flanges (21) of the beam caps (20). In addition, the present invention also refers to a construction method using the said system.

Description

A SEMI-ASSEMBLED WALL AND FLOOR STRUCTURAL SYSTEM AND CONSTRUCTION METHOD USING THIS SYSTEM
FIELD OF INVENTION
The present invention relates to the construction field, and in particular, to a semi-assembled wall and floor structural system that can be easily and quickly assembled, reducing construction and installation costs, in addition, the present invention relates to a construction method using the said structural system.
BACKGROUND ART
In construction works, the wall area can be 1.5 times as much to the floor area, the wall is directly affected by rain, sun, and wind, therefore, requirements for sound and heat insulations, lightweight, quickly construction, low cost are also important, in addition to requirement for strength.
Most of civil constructions are used walls that build by baked clay bricks or aggregate cement bricks, lightweight concrete bricks, as a result, labor productivity is low, the wall is often cracked, sound insulation and heat insulation are lowered, the heavy weight of construction increases the cost for the structural system of the building.
The Vietnamese Patent No. VN1 -0019455 with title “Wall panel, a quickly assembled wall panel systems and a construction method using the wall panels” disclosed a construction method for quickly assembled wall panel using the panels that are the same height as the wall, these panels are engaged together by the coupling grooves and the coupling ribs on the panels, and fixed by inserting the plastic pipe through the connection holes that formed in the horizontal direction of the panel without locating reinforcement and pouring concrete within the wall panels. This wall panel is highly industrialized with good finished surface, easy to install the wall in construction process, it is easy to install for unskilled workers. However, during the construction and assembly process, it is required to install temporary supports to prevent the wall panel from falling before insert the plastic pipes through the connecting holes of the wall panels. The use and installation of these temporary supports increases construction time and costs.
The Vietnamese Utility Model Patent No. VN2-00001988 with title “Construction method for pre-assembled wall” disclosed a construction method for pre-assembled wall without using temporary supports. This method is accomplished by firstly stacking assembled blocks so that their vertical holes are staggered to form rows of assembled blocks of the wall, then inserting steel bars and pouring concrete into the holes in the blocks to connect the rows of blocks together. This construction method allows easy and quickly assembly and fixation of the blocks to form a wall without the use of mortar and temporary supports in construction process. However, this method requires many staggeringly assembled blocks in the vertical direction to form a wall. Since the blocks are connected together by shallow male-female joints, it is required to insert the reinforcement steel bars and pour concrete mortar into the vertically available holes of the blocks, thereby formed a skeleton for the wall.
Wall assembled by the above methods have longitudinal sliding displacement when settlement occurs during the use of the building, that caused by the wall panels, the assembled blocks, the concrete bricks are positioned together through the male-female joints. This leads to cracks are formed between the wall panels or the assembled blocks, as a result affecting the waterproofing and noise resistance of the wall.
Further, the current buildings are constructed with pre-cast concrete columns and beams and walls are built of bricks or assembled panels between columns and beams, this structure is limited in that walls and the columns and beam frame system is not monolithic, leading to the formation of cracks on the wall during use, the columns protrude from the wall, reducing the aesthetics of the building.
The Vietnamese Utility Model Patent No. VN2-0002524 with title “Steel formwork floor frame system” disclosed steel formwork floor frame system including U-shaped beam with serrated anti-slip lugs; steel formwork panels of isosceles trapezoidal shape with two supporting flanges fitted in the serrated anti- slip lugs of the beam; and the shields are fitted with the flanges of the beam to cover the gap between the below wave part of the steel formwork and the beam. Concrete is cast inside the U-shaped beam and on the surface of the steel formwork to create a monolithic structure for the concrete floor and beams, increase the bearing capacity of the beams, and at the same time reduce the thickness of the concrete floor-beam system. However, this solution has not yet solved the problem of the gap between the wall and beams during use because it is not monolithic structure. This affects the waterproofing and noise resistance of the wall.
SUMMARY OF THE INVENTION
One aspect of the present invention provides a semi-assembled wall and floor structural system that can be easily and quickly assembled, creating a monolithic structure between the wall, beams and floor, solving the problem of cracks on the wall appearing between the wall and beams due to horizontal and vertical displacement of the structures during use.
To achieve the foregoing object, the present invention provides the semi- assembled wall and floor structural system including rectangular wall panels with hollow holes; beam caps are clad on the top of the wall panels; and floor panels are located on the beam flanges of the beam caps, characterized in that, the concrete wall panel assembled by at least two comb-shaped surface plates combined together, in which one side of the surface plate has longitudinal reinforced ribs arranged apart from a predetermined distance; the beam cap includes two L-shaped beam flanges symmetrically arranged apart from a distance equal to the thickness of the wall panel, and fixed together by connecting bars on the top surface of the beam cap, reinforced ribs are arranged apart from a predetermined distance on the side surface of the beam cap and on the beam flange such that the distance between the reinforced ribs is equal to the width of the floor panel; the concrete floor panels cover about two third of the triangular reinforcement steel cage of floor such that the top steel bar and part of the oblique bars of the triangular reinforcement steel cage protrude at least 2 cm from the top surface of the floor panel, wedge-shaped recesses are formed on the side surfaces of the floor panel.
According to the present invention, the wall panels are provided with self- drilling studs or anchoring elements protruding from the inner surface of the wall panels.
According to the present invention, aggregate compositions of wall panel include 65-75% of fly ash, 10-20% of cement, 10-15% of lime, 2-5% of gypsum, 0.05-0.15% of aluminum powder, 0.1-0.2% of polyester reinforced fiber, and additives.
According to the present invention, at least one longitudinal reinforced rib at the end of the surface plate is recessed at opening apart from the side surface of the surface plate at a distance equal to the thickness of the longitudinal reinforced rib.
Another aspect of the present invention provides a construction method using a semi-assembled wall and floor structural system that can be easily and quickly constructed, reducing the number of temporary supports for construction process, the method includes the following steps: step 1: constructing the foundation structure and column reinforcement steel cage according to the design; step 2: assembling the bearing wall from the wall panels by mounting the surface plates according to the constructed column reinforcement steel cages; step 3: fixing the wall panels together by mounting the beam caps on the top of the wall panels; step 4: assembling the floor panels on the beam flanges of the beam caps; and step 5: pouring the concrete to monolithically complete wall panels, columns inside wall, beam caps and floors.
According to the present invention, the step 2 of assembling the surface plates to form the wall panels further includes screwing the self-drilling studs so that protrudes from the inner surface of the wall panels.
According to the present invention, the step 2 of assembling the bearing wall from the wall panels is implemented by placing the comb-shaped surface plates symmetrically or staggeringly together so that the side surface of the longitudinal reinforced ribs of two opposite surface plates are against each other.
BRIEF DESCRIPTION OF THE DRAWINGS
Fig. 1 is a perspective view of a semi-assembled wall and floor structural system according to the present invention;
Fig. 2 is a perspective view of the wall panels according to an embodiment of the present invention;
Fig. 3 is an exploded perspective view of the wall panel shown in Fig. 2;
Fig. 4 is a perspective view of wall panel according to another embodiment of the present invention;
Fig. 5 is a perspective view of the beam cap according to the present invention;
Fig. 6 is a perspective view of the floor panel according to an embodiment of the present invention;
Fig. 7 is a cross-sectional view of the floor using the floor panels according to the present invention; and
Fig. 8 is a cross-sectional view of the floor panel according to another embodiment of the present invention.
DETAILED DESCRIPTION
A detailed description of the implemented embodiments according to the present invention will be described below. The detailed description is for the purpose of demonstrating the general principles according to the present invention, but not intended to limit the scope of the present invention. The scope of the present invention is clearly defined in the claims.
According to an embodiment, the present invention provides a semi- assembled wall and floor structural system as shown in Figs. 1 to 7. Referring to figures, the semi-assembled wall and floor structural system comprises the wall panels 10 in rectangular shape with hollow holes; the beam caps 20 are clad on the top of the wall panels 10; and the floor panels 30 are located on the beam flanges of the beam caps 20.
As shown in Figs. 2 to 4, the wall panels 10 are made of aerated autoclaved concrete (AAC), is assembled from the comb-shaped surface plates 11 mounted together, in which one side of the surface plate 11 has longitudinal reinforced ribs 111 spaced equally. However, the present invention is not limited to the wall panel cast of AAC concrete, in another embodiment of the present invention, the wall panel 10 may be casted of foam concrete, EPS foam concrete or the like.
According to the preferred embodiment of the present invention, the surface plate 11 is manufactured with dimensions of 3,000 mm (length) x 900 mm (width) x 130 mm (thickness). As shown in Fig. 3, the surface plate 11 has a comb shape with a thickness of 30 mm, the longitudinal reinforced ribs 111 with a thickness equal to that of the surface plate 11 and are equally spaced protruding from one side of the surface plate 11, in which the first longitudinal reinforced rib 111 at one end of the surface plate 11 is protruded at the edge of the side surface of the surface plate 11 while the last longitudinal reinforced rib 111 at the other end of the surface plate 11 is recessed at an opening apart from the other side surface of the surface plate 11 so that the opening is equal to the thickness of the longitudinal reinforced rib 111. In this structure, the first longitudinal reinforced rib 111 of the opposite surface plate 11 is mounted in the opening of the other surface plate 11 to combine into the wall panel 10 in box shape as shown in Fig. 2 with internal hollow holes, this combination type of the wall panel 10 is suitable for partition walls in the building. As shown in Fig. 4, the longitudinal reinforced rib 111 of the opposite surface plate 11 is inserted into the opening of the other surface plate 11 to form a rectangular wall panel 10 by mounting the wall panels 11 staggered from each other, this construction is characterized in that one surface plate 11 connects to two opposite wall panels 11 so that there is no a gap in the wall panel 10 assembled by these surface plates 11, accordingly, thereby the wall panel 10 is suitable for the exterior walls of the building.
As shown in Fig. 4, the surface plate 11 of the wall panel 10 further has the self-drilling studs 112 that protrude from the inside surface of the surface plate 1 1, thereby the casted concrete in the hollow holes of the wall panel 10 to firmly fix the surface plates, which can prevent the horizontal and vertical displacement of the wall panel 10 that often leads to cracks as the conventional walls constructed using existing techniques.
According to the embodiment of the present invention, the surface plate 11 is made of aerated autoclaved concrete (AAC) with aggregate compositions including 70% of fly ash, 15% of cement, 12% of lime, 3% of gypsum, 0.1% of aluminum powder, 0.15% of polyester reinforced fiber, and additives. Concrete is autoclaved at 180°C at a pressure of 10 atm. Since the polyester reinforced fiber in the aggregate compositions, the surface plate 11 of the present invention can reduce the thickness of the wall panel to a minimum (30 mm), obtain high compressive, tensile and bending strengths, so that the surface plate 11 of the present invention has light weight, large size, easy construction and assembly. The results of strength testing of the surface plate 11 according to the present invention with dimensions of 3,000 mm (length) x 900 mm (width) x 130 mm (thickness) are shown below in Table 1 :
Table 1
Figure imgf000010_0001
By assembling the wall panels 11 into the wall panels 10 with hollow holes, it is easy to install the technical pipelines, column reinforcement cage in the wall, as well as pour the reinforced concrete columns inside the wall. These holes can be concreted inside to create a wet joint which is a good connection between the wall panels 10 to avoid the cracks usually appearing in the conventional walls.
As shown in Fig. 5, the steel beam cap 20 consists of two L-shaped beam flanges 21 symmetrically arranged apart from a distance equal to the thickness of the wall panel 10, and fixed together by the connecting bars 22 at the top surface of the beam cap, the reinforced ribs 23 are spaced equally on the side surface of beam flanges 21 so that the distance between reinforced ribs 23 is equal to the width of the floor panel 30.
The inner surface of the two beam flanges 21 against the outer surface at the top end of the wall panel 10 is assembled from the surface plates 11 to connect the surface plates with each other, fix the top of the wall panels 10 and surface plates 11 without the use of the anchoring elements.
The connecting bars 22 in the form of inverted U-shaped flat bars are welded on the top surface of the beam flanges 21, the connecting bars 22 are arranged apart from each other to create a connection between the beam flanges and create gaps for insert the column reinforcement cages through, and for easy concreting of columns and walls.
The reinforced ribs 23 are equally spaced on the side surface of beam flange 21 so that the distance between the reinforced ribs 23 is equal to the width of the floor panel 30 to increase the stiffness of the beam cap 20, and at the same time to position and fix the floor panels 30 which are located on the beam flanges 21.
In another embodiment of the present invention, the beam cap 20 may have an inverted U-shape having two beam shoulders to support the end of the floor panel, and having a hollow hole in the top surface corresponding to the hollow hole of the assembled wall panel.
As shown in Fig. 6, the floor panel 30 made of aerated autoclaved concrete (AAC) covering two third of the triangular reinforcement steel cage 32 such that the top steel bar and part of the oblique bars of the triangular reinforcement steel cage 32 protrudes at least 2 cm from the upper surface of the floor panel 30, the wedge-shaped recesses 31 are formed on the side surfaces of the floor panel 30. However, the present invention is not limited to the floor panel casted of AAC concrete, in another embodiment of the present invention, the floor panel 30 may be casted of foam concrete, EPS foam concrete or the like. The triangular reinforcement steel cage 32 protrudes from the top surface of the floor panel 30 to facilitate crane, strengthen the connection between triangular reinforcement steel cage 32 and concrete layer 50, and increase the thickness of monolithic concrete layer 50 up to 4-5 cm at the construction site, which increases the stiffness of the finished floor.
According to the implemented embodiment of the present invention, the floor panel is molded with dimensions of 5,850 mm (length) x 600 mm (width) x 154 mm (thickness) of AAC concrete after autoclaving to achieve a compressive strength of 6 Mpa which is strong enough to combine with two triangular reinforcement steel cages 32 buried about two third in mortar to form a lightweight floor panel with great anti-bending stiffness because the triangular reinforcement steel cages are not destroyed due to instability, bears all construction loads, this can reduce the number of the temporary supports during construction process.
As shown in Fig. 6 and Fig. 7, the floor panel 30 has the recesses 31 having a ellipse cross-section recessed deep into the inside of the side surface of the floor panel 30, these recesses 31 will form stopper strips between the floor panels 30 with the concrete layer 50 to monolithically complete the floor structure. The stopper strips extending over the entire side surface of the floor panels 30 effectively prevent horizontal and vertical displacement of the floor panels 30 during use, thereby avoiding the formation of the floor cracks as the conventional pre-assembled floor panels.
Fig. 8 is a cross-sectional view of the floor panel 30 in another embodiment of the present invention, in which the recesses 31 have a semicircular cross- section to limit stress concentration at the transition point of the stopper strip when pouring the concrete layer 50 to monolithically complete the floor structure, this can help increase the bond strength between the floor panels 30 and the concrete layer 50.
According to another embodiment, the present invention provides a construction method using a semi-assembled wall and floor structural system as described above, the method includes the following steps: step 1: constructing the foundation structure and column reinforcement steel cage 40 according to the design; step 2: assembling the bearing wall from the wall panels 10 by mounting the surface plates 11 according to the constructed column reinforcement steel cages; step 3: fixing the wall panels 10 together by mounting the beam caps 20 on the top of the wall panels 10; step 4: assembling the floor panels 30 on the beam flanges 21 of the beam caps 20; and step 5: pouring concrete to monolithically complete the wall panels, the columns inside wall, the beam caps 20 and floors.
As shown in Fig. 1, the surface plates 11 are combined into the wall panel 10 by staggered facing with each other so that one surface plate 11 connects to two opposite wall panels 11 through the side surfaces of longitudinal reinforced ribs 11 against each other. In this way, the wall panel 10 is formed to extend integrally over the entire wall surface, without creating gaps between the wall panels as the walls assembled from the separate wall panels, which can effectively prevent cracks from appearing in the wall, ensuring waterproofing and noise resistance.
According to the embodiment of the present invention, the step 2 of assembling the surface plates to form the wall panels further includes screwing the self-drilling studs 112 or the anchoring elements so that protrudes from the inner surface of the wall panels 10 to increase the connection between concrete poured in the wall panel 10 and the surface plates 11 when concreting the monolithic concrete. Which prevent displacement of surface plate, thereby preventing cracks from appearing in the wall.
According to the present invention, in the step 5 of pouring concrete to monolithically complete wall panel 10, the columns inside wall, the beam caps 20 and the floor, the concrete can be frilly casted in all hollow holes of the wall panel 10 or can be poured only in the hollow holes having installed the column reinforcement steel cage 40 to form the column in the wall inside the wall panel
10.
By pouring monolithic concrete according to the method of the present invention, the system of columns, beams and floors of the building are concreted once, ensuring the monolithic of concrete, increasing the rigidity of the whole building.
ADVANTAGEOUS EFFECTS
The semi-assembled wall and floor structural system according to the present invention allows concrete to be casted inside the wall panel 10, the beam cap 20 and on the surface of the floor panel 30, to creat a monolithic structure for the concrete floor, beams and walls, increasing the bearing capacity of the bearing frame system of the whole building;
The wall panels are combined from the comb-shaped wall panels to form internal hollow holes, wet joints are implemented at the construction site, good connection between surface plates avoids wall cracking, allowing arrangement of the reinforcement concrete columns inside the wall that is completely inside the wall panel;
The beam cap structure fixs the top of the wall panel, link the intersecting wall panels, and create space for the floor panel; The AAC concrete layer or similar material of the floor panel together with about two third of the triangular reinforcement steel cage buried in the mortar form a lightweight panel with great anti-bending stiffness. The lightweight concrete layer maximizes the bearing capacity of the triangular reinforcement steel cage because the triangular reinforcement steel cage is not damaged due to instability, reduce the weight of the floor panel, reduce the number of temporary supports in construction process, reduce the amount of steel bars of the floor panel, as well as the floor load on the beams and foundation columns are significantly reduced, save construction costs;
The floor panel has the side sufaces of the floor panels creating recesses to form the stopper strips between the floor panels when monolithic concrete is casted on the surface of the floor panels.
Although the present invention has been disclosed through embodiments and the accompanying drawings, it should be recognized that the present invention is not limited to those embodiments, but skill persons in the art can still make many other similar modifications and supplements. Therefore, the scope of the present invention should be understood as embracing all changes or modifications derived from the definitions and scopes of the claims.

Claims

1. A semi-assembled wall and floor structural system including the rectangular wall panels (10) with hollow holes; the beam caps (20) are clad on the top of the wall panels (10); and the floor panels (30) are located on the beam flanges (21) of the beam caps (20), characterized in that, the concrete wall panel (10) assembled by at least two comb-shaped surface plates (11) assembled together, in which one side of the surface plate (11) has longitudinal reinforced ribs (111) arranged apart from a predetermined distance; the beam cap (20) consists of two L-shaped beam flanges (21) symmetrically arranged apart from a distance equal to the thickness of the wall panel (10), and fixed together by connecting bars (22) on the top surface of the beam cap (20), the reinforced ribs (23) are equally spaced on the side surface of the beam cap (20) and on the beam flange (21) so that the distance between the reinforced ribs (23) is equal to the width of the floor panel (30); the concrete floor panels (30) cover about two third of the triangular reinforcement steel cage (32) such that the top steel bar and part of the oblique bars of the triangular reinforcement steel cage (32) protruding at least 2 cm from tiie top surface of the floor panel (30), the wedge-shaped recesses (31) are formed in the side surfaces of the floor panel (30).
2. The semi-assembled wall and floor structural system according to claim 1, wherein the wall panel (10) with self-drilling studs or anchoring elements protruding from the inner surface of the wall panel (10).
3. The semi-assembled wall and floor structural system according to claim 1, wherein the wall panel (10) is cast of aerated autoclaved concrete (AAC), foam concrete, EPS foam concrete or the like.
4. The semi-assembled wall and floor structural system according to claim 1, wherein the beam cap (20) may have an inverted U-shape with two beam shoulders to support the end of the floor panel (30), and having a hollow hole in the top surface corresponding to the hollow hole of the wall panel (10).
5. The semi-assembled wall and floor structural system according to claim 1, wherein the floor panel (30) is cast of aerated autoclaved concrete (AAC), foam concrete, EPS foam concrete or the like so that it is possible to stabilize the triangular reinforcement steel cage (32) and replace the floor formwork.
6. The semi-assembled wall and floor structural system according to claim 1, wherein the aggregate compositions of wall panels (10) includes 65-75% of fly ash, 10-20% of cement, 10-15% of lime, 2-5% of gypsum, 0.05-0.15% of aluminum powder, 0.1 -0.2% of polyester reinforced fiber, and additives.
7. A semi-assembled wall and floor structural system according to claim 1, wherein at least one longitudinal reinforced rib (111) at the end of the surface plate (11) is recessed at opening apart from the side surface of the surface plate (11) at a distance equal to the thickness of the longitudinal reinforced rib (111).
8. A construction method using the semi-assembled wall and floor structural system according to any one of claims 1 to 7, the method including the following steps:
Step 1: constructing the foundation structure and column reinforcement steel cage according to the design; step 2: assembling the bearing wall from the wall panels by mounting the surface plates (11) according to the constructed column reinforcement steel cages; step 3 : fixing the wall panels (10) together by mounting the beam caps (20) on the top of the wall panels (10); step 4: assembling the floor panels (30) on the beam flanges (21) of the beam caps (20); and step 5: pouring concrete to monolithically complete the wall panels (10), columns inside the wall, beam caps (20) and floors.
9. The construction method according to claim 8, wherein the step of assembling the surface plates (11) to form the wall panels (10) further includes screwing the self-drilling studs or anchoring elements so that protrudes from the inner surface of the wall panels (10).
10. The construction method according to claim 8, wherein the step of assembling the bearing wall from the wall panels (10) is implemented by placing the combshaped surface plates (11) symmetrically or staggeringly together so that the side surface of the longitudinal reinforced ribs (111) of two opposite surface plates (11) are against each other.
PCT/VN2021/000023 2020-11-25 2021-11-22 A semi-assembled wall and floor structural system and construction method using this system WO2022115886A1 (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
VN1202006817 2020-11-25
VN1-2020-06817 2020-11-25

Publications (1)

Publication Number Publication Date
WO2022115886A1 true WO2022115886A1 (en) 2022-06-02

Family

ID=81753717

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/VN2021/000023 WO2022115886A1 (en) 2020-11-25 2021-11-22 A semi-assembled wall and floor structural system and construction method using this system

Country Status (1)

Country Link
WO (1) WO2022115886A1 (en)

Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO1988002803A1 (en) * 1986-10-09 1988-04-21 Calvin Shubow Building construction using hollow core wall
JPH0681392A (en) * 1992-08-28 1994-03-22 Ishikawajima Harima Heavy Ind Co Ltd Building construction method
JPH06257241A (en) * 1993-03-04 1994-09-13 Fujita Corp Construction method of concrete wall
KR101001208B1 (en) * 2010-08-30 2010-12-15 대한이.이엔.씨(주) A constructing method of structure using sandwich pc-wall
CN211849961U (en) * 2020-01-17 2020-11-03 杨东佐 Wall formwork prefabricated unit and building structure with same

Patent Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO1988002803A1 (en) * 1986-10-09 1988-04-21 Calvin Shubow Building construction using hollow core wall
JPH0681392A (en) * 1992-08-28 1994-03-22 Ishikawajima Harima Heavy Ind Co Ltd Building construction method
JPH06257241A (en) * 1993-03-04 1994-09-13 Fujita Corp Construction method of concrete wall
KR101001208B1 (en) * 2010-08-30 2010-12-15 대한이.이엔.씨(주) A constructing method of structure using sandwich pc-wall
CN211849961U (en) * 2020-01-17 2020-11-03 杨东佐 Wall formwork prefabricated unit and building structure with same

Similar Documents

Publication Publication Date Title
US6085479A (en) Premanufactured structural building panels
US6363674B1 (en) Premanufactured structural building panels
EA007917B1 (en) Constructing the large-span self-braced buildings of composite load-bearing wall panels and floors
US20060096204A1 (en) Structural wall apparatuses, systems, and methods
CN108222270B (en) Assembling construction building method of prefabricated building
CN114541814A (en) Light concrete house system with steel frame and net nest
CN111877546B (en) Fabricated frame beam-column wet joint with buckling restrained brace and construction method
CN110409813A (en) Exempt to split into type beam forms, formwork structure and construction process containing steel reinforcement cage
KR100830241B1 (en) Method for hybridizing light-weight composite wall and concrete floor in light-weight composite structure using adapter
EA013175B1 (en) Outer multi-story frame building wall of arcos system and method of erection thereof
US20080289286A1 (en) Method of constructing foundation substructure and a building
KR20090098729A (en) Improved construction system for buildings
WO2022115886A1 (en) A semi-assembled wall and floor structural system and construction method using this system
CN209891381U (en) Building structure
CN216075494U (en) Assembled steel construction building system
WO2006032078A1 (en) Modular construction system and method
JP2009256890A (en) Building structure and its construction method
CN101260723A (en) Light steel keel
RU2107789C1 (en) Shuttering for walls
JP2016205073A (en) Foundation at peripheral part of steel frame building, and construction method thereof
CN217439150U (en) Prefabricated building external wall panel connection structure
US20240209616A1 (en) Framing member, construction panel, and methods of manufacturing
KR102679042B1 (en) PC half-slab construction method for quick construction of precast concrete apartment house
CN219931440U (en) Externally-hung prefabricated wall body and roof parapet wall structure of assembled steel structure
CN215888595U (en) Precast concrete strip plate structure with reinforcing beam column component

Legal Events

Date Code Title Description
121 Ep: the epo has been informed by wipo that ep was designated in this application

Ref document number: 21899275

Country of ref document: EP

Kind code of ref document: A1

NENP Non-entry into the national phase

Ref country code: DE

32PN Ep: public notification in the ep bulletin as address of the adressee cannot be established

Free format text: NOTING OF LOSS OF RIGHTS PURSUANT TO RULE 112(1) EPC (EPO FORM 1205 DATED 18.07.23 AND 29.09.23)

122 Ep: pct application non-entry in european phase

Ref document number: 21899275

Country of ref document: EP

Kind code of ref document: A1