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

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.