Patent Application
20200199868
The invention relates to buildings, more specifically to a prefabricated bathroom and methods for constructing and installing the prefabricated bathroom. The invention can be widely applied in a variety of high-rise buildings.
Bathroom is an essential part of residential or commercial buildings. Currently, there are two ways for constructing the bathroom. One is to use cast-in-situ concrete frame at a construction site directly, and then build the bathroom one plate by one plate. This is the most conventional bathroom constructing method widely used, which, however, takes a long construction period with a high construction cost. Moreover, since the building materials used may be out of standard, quality of the bathroom thus built cannot be satisfactorily ensured. The other way is to prefabricate a whole-set bathroom at factories, and then deliver it to the construction site for installation.
Chinese Utility Model Patent No. 201520298272.4 discloses a prefabricated bathroom, wherein four walls of the prefabricated bathroom include at least one wall, or part of at least one wall, that is a semi-prefabricated structural wall, which has a relatively small thickness. An outer surface of the semi-prefabricated structural wall is provided, along a normal direction thereof, with a plurality of protruding columns, each top surface thereof being provided with a bolt for accurately positioning and installing a cast-in-situ wall template. Therefore, the bolt, which is used for fixing the prefabricated bathroom, can pass through the protruding column, which is used for fixing the cast-in-situ wall template. The above construction method has the following disadvantages. Specifically, the installation is inconvenient and the procedure thereof is complicated; a large amount of construction materials have to be delivered, so that the cost is significant; the construction is inconvenient and time consuming; and the prefabricated bathroom is not equipped with bathtub and bathroom, so that the facility is not complete.
Based on the above-mentioned disadvantages, the present invention aims to provide a prefabricated bathroom, which has a satisfactory bearing capacity, and can be constructed conveniently without use of protruding columns and in-situ casting.
The prefabricated bathroom according to the present invention comprises a bottom unit, multiple wall units and a top plate unit that are connected to each other in a securing manner. One of the wall units is a structural wall, which is provided, at its top portion, with a recessed top region reserved for later pouring, the recessed top region being provided therein with top exposed reserve bars. The structural wall is configured as a full-prefabricated structural wall body at its middle portion, and is provided, at its bottom portion, with a recessed bottom region reserved for later pouring, the recessed bottom region being provided therein with bottom exposed reserve bars. The top exposed reserve bars of the prefabricated bathroom of a floor are inserted into the recessed bottom region of the prefabricated bathroom of a next floor, and connected with the bottom exposed reserve bars thereof, so that the prefabricated bathroom of said floor can be connected with the prefabricated bathroom of said next floor through pouring concrete in the recessed top region and the recessed bottom region.
In one embodiment, the bottom plate unit and the low portions of the wall units are provided with a glass reinforced plastic material layer.
In one embodiment, the recessed top region and the recessed bottom region are arranged on an outer side of the structural wall, and the inner sides of the recessed top region and the recessed bottom region are provided with toothed engagement surfaces respectively.
In one embodiment, the prefabricated bathroom is provided therein with a toilet and a bathtub.
In one embodiment, one of the wall units other than the structural wall extends outwardly to form an exterior wall unit, the end of which is provided with side exposed reserve bars.
The present invention further proposes a method for constructing the prefabricated bathroom, comprising the following steps: building the bottom plate unit and the lower portions of said multiple wall units with a bottom plate steel mold and a vertical steel mold, bundling the bars of the bottom plate unit and the wall units, and pouring concrete; forming the recessed bottom region reserved for later pouring at a bottom part of the structural wall, and providing exposed bars in the recessed bottom region; building the upper portions of said multiple wall units and the top plate unit with a vertical steel mold of the wall units and a top mold arranged at the top of the top plate unit, bundling the bars of the top plate unit and the wall units, and pouring concrete; and forming the recessed top region reserved for later pouring at a top part of the structural wall, and providing exposed bars in the recessed top region.
In one embodiment, the step for building the bottom plate unit and the lower portions of said multiple wall units further includes: disposing the glass reinforced plastic material layer at a position of the bottom plate unit before bundling the bars of the bottom plate unit and the wall units, wherein edges of the glass reinforced plastic material layer extend upwardly to the lower portions of the wall units.
The present invention further proposes a method for installing the prefabricated bathroom, comprising the following steps: Step A, lifting the prefabricated bathroom to a designated position of a floor plate of a floor to be installed with the prefabricated bathroom; Step B, bundling the bottom exposed reserve bars of the recessed bottom region of the structural wall with the top exposed reserve bars of the prefabricated bathroom of a next floor that are inserted into said recessed bottom region together, forming a bar mesh; and Step C, installing a cast-in-situ wall template outside said recessed bottom region, and pouring concrete in said recessed bottom region to form a cast-in-situ wall.
In one embodiment, after Step C the method further includes: Step D, establishing scaffolds around the prefabricated bathroom of said floor at positions where the floor plate is poured, and lifting a semi-prefabricated floor plate to the prefabricated bathroom and mounting it on the top of the scaffolds; and Step E, bundling bars on the top of prefabricated bathroom and on the top of the semi-prefabricated floor plate to form a bar mesh, on which concrete is poured to form the whole floor plate.
In one embodiment, in Step F, concrete is further poured in the recessed top region of the prefabricated bathroom of said next floor during pouring the floor plate.
Compared with the prior arts, the present invention has the following technical advantages. First, one of the wall units is a structural wall, which increases the bearing capacity, and enables the bathroom being constructed stronger. Second, according to the present invention, the top exposed reserve bars of the prefabricated bathroom on a floor are inserted into the recessed bottom region of the prefabricated bathroom on an upper floor and connected with the bottom reserved bars thereof. By means of which, precise positioning and installing procedures are unnecessary, and protruding columns and bolts are also dispensed. Therefore, the construction process is greatly facilitated and the construction efficiency is improved. Third, according to the constructing method for the prefabricated bathroom of the present invention, the bottom plate unit and the bottom portions of the wall units are poured with concrete as a whole in one time, and the top plate unit and the top portions of the wall units are poured with concrete as a whole in one time. Therefore, the construction process is facilitated, the joints formed are tight, and the waterproof performance of the prefabricated bathroom is improved. Finally, according to the installing method for the prefabricated bathroom of the present invention, the top exposed reserve bars of the prefabricated bathroom on a floor are inserted into the recessed bottom region of the prefabricated bathroom on a next floor and connected with the bottom reserved bars thereof, and through pouring concrete in the recessed top region reserved for later pouring and the recessed bottom region reserved for later pouring, the prefabricated bathroom of said floor is connected with the prefabricated bathroom of said next floor. By means of which, precise positioning and installing procedures are unnecessary, and protruding columns and bolts are also dispensed. Therefore, the construction process is greatly facilitated and the construction efficiency is improved.
In the following the present invention will be described in details with reference to the attached drawings and embodiments in order to enable the objective, technical solution and advantages of the present invention being more distinct. It should be understood that the particular embodiments as set forth herewith are intended to be illustrative, not to limit the scope of the invention in any way.
As shown in
One or more of the wall units 12 other than the structural wall 14 may extend outwardly to form an exterior wall unit 20, the end of which may be provided with side exposed reserve bars 21. During construction, the length of the exterior wall unit 20 can be prefabricated according to the on-site size. During the on-site installation of the prefabricated bathroom, transverse bars and vertical bars can be provided at the side exposed reserve bars 21, so as to form a side bar mesh 16 (see
The structural wall 14 has: a recessed top region 141, which is, as a semi-prefabricated structure, reserved for later pouring; a middle region 142, which is a full-prefabricated structural wall body; and a recessed bottom region 143, which is, also as a semi-prefabricated structure, reserved for later pouring. The recessed top region 141 reserved for later pouring is provided with top exposed reserve bars 144, and the recessed bottom region 143 reserved for later pouring is provided with bottom exposed reserve bars 146. In order to increase the bonding force between the prefabricated concrete and the cast-in-situ concrete, a tooth-shaped engaging surface may be provided on inner walls of the recessed top region 141 reserved for later pouring and the recessed bottom region 143 reserved for later pouring. The top exposed reserve bars 144 of the prefabricated bathroom 100 on a floor are inserted into the recessed bottom region 143 of the prefabricated bathroom 100 on an upper floor, and connected to the bottom exposed reserve bars 146 thereof. Through pouring concrete in the recessed top region 141 reserved for later pouring and the recessed bottom region 143 reserved for later pouring, the prefabricated bathroom 100 of said floor is connected with the prefabricated bathroom 100 of said upper floor. The recessed top region 141 reserved for later pouring and the recessed bottom region 143 reserved for later pouring can achieve the connection between the structural walls 14 of two adjacent floors after pouring concrete. In addition, the recessed top region 141 reserved for later pouring can be also used for mounting a cast-in-situ beam, and the reinforcing bars in the recessed top region 141 can be arranged in accordance with said beam.
According to the present invention, the bottom plate unit 11 and the lower portion of each of the wall units 12 are each provided with a glass fiber reinforced plastic material layer 103, which can not only increase the toughness of the bottom plate, but also prevent water leakage. In a preferred embodiment, the glass fiber reinforced plastic material layer 103 in the bottom plate unit 11 is formed into one piece with those in the lower portions of the wall units 12. The top plate unit 13, as a part of a structural floor plate of building, is embedded therein with pipelines and light control boxes. The thickness of the top plate unit 13, e.g., about 70 mm, is smaller than the overall thickness of the building floor plate. Therefore, the use of templates can be reduced during construction, the pressure from the top plate can be reduced, and the construction difficulty and the consumption of building materials can be both reduced.
In the following the construction method of the prefabricated bathroom according to the present invention will be described. The construction method is shown in
1. Construction of the bottom plate unit 11 and the lower portions of the wall units 12
In Step 1, outer steel molds are arranged. Specifically, as shown in
In Step 2, a glass fiber reinforced plastic material layer is arranged. Specifically, as shown in
In Step 3, a structural bar mesh is formed. Specifically, as shown in
In Step 4, inner steel molds are arranged. Specifically, an inner steel mold 104 for the bottom plate of the bottom plate unit 11 of the prefabricated bathroom 100 and a first vertical inner steel mold 105 for four wall units 12 are established.
In Step 5, at a position of the lower portion of the structural wall 14 corresponding to the recessed bottom region 143 reserved for later pouring, a region is reserved for later pouring, in which bottom exposed reserve bars 146 are provided.
In Step 6, a first concrete 106 is poured. Specifically, as shown in
2. Construction of the upper portions of the wall units 12 and the top plate unit 13
In Step 7, outer steel molds are arranged. Specifically, as shown in
In Step 8, an aluminum window frame 1 is installed. Specifically, as shown in
In Step 9, a second vertical inner steel mold is established. Specifically, a second vertical inner steel mold (not shown) for the wall units 12 is established.
In Step 10, a top mold is installed. Specifically, as shown in
In Step 11, size adjustment is performed. Specifically, as shown in
In Step 12, a second concrete 108 is poured. Specifically, as shown in
Since a portion for pouring the recessed bottom region 143 and the bottom exposed reserve bars 146 are provided in Step 5, and a portion for pouring the recessed top region 141 and the top exposed reserve bars 144 are provided in Step 7, the recessed bottom region 143 reserved for later pouring and the bottom exposed reserve bars 146 will be formed at the lower portion of the structural wall 14, while the recessed top region 141 reserved for later pouring and the top exposed reserve bars 144 will be formed at the upper portion of the structural wall 14, after the concrete is poured.
The prefabricated bathroom 100 according to the present invention can be constructed through the above-mentioned steps. As shown in
In the following the on-site installation method of the prefabricated bathroom 100 according to the present invention will be described. The on-site installation method is as shown in
In Step 1, a floor for installing the prefabricated bathroom 100 is designated, and accordingly, a top plate 7 of the floor is cleaned.
In Step 2, as shown in
In Step 3, as shown in
In Step 4, as shown in
In Step 5, as shown in
In Step 6, as shown in
In Step 7, as shown in
In Step 8, as shown in
In Step 9, as shown in
In Step 10, as shown in
In Step 11, as shown in
The advantages of the present invention are as follows.
1. One of the wall units 12 is a structural wall 14, which increases the bearing capacity.
2. The top and bottom regions of the structural wall 14 are both semi-prefabricated, while the middle region thereof is a full-prefabricated structural wall. Therefore, the integrity of the structural wall 14 is ensured.
3. The bottom plate unit 11 is composed of a concrete layer and the glass reinforced plastic material layer 103. Therefore, the bottom plate unit 11 has improved toughness, and can effectively prevent water seepage.
4. The prefabricated bathroom 100 is provided with the toilet 19 and the bathtub 18, so that it is more convenient to use.
5. The top plate unit 13 has a smaller thickness than that of conventional prefabricated bathrooms 100. Therefore, the use of templates can be reduced during construction, the pressure from the top plate on the wall units 12 can be reduced, and the construction difficulty and the consumption of building materials can be reduced.
6. According to the construction method for the prefabricated bathroom of the present invention, the bottom outer steel mold 102 and the first vertical outer steel mold 102 are each assembled and disassembled as a whole, and the top plate unit 13 and the upper portions of the surrounding wall units 12 are formed by pouring concrete once, thus obtaining tight joints without slurry leakage. Therefore, the waterproof performance of the prefabricated bathroom 100 is improved.
7. According to the installation method for the prefabricated bathroom of the present invention, the top exposed reserve bars 144 of the prefabricated bathroom 100 of a floor are inserted into the semi-prefabricated toothed joint of the prefabricated bathroom 100 of a next floor, and connected with the bottom exposed reserve bars 146 thereof. Therefore, accurate installing and positioning procedure is unnecessary, and the construction efficiency is improved.
While the invention has been described in conjunction with the preferred embodiments outlined above, it is evident that many alternatives, modifications and variations will be apparent to those skilled in the art. Various changes may be made without departing from the spirit and scope of the invention as defined in the following claims.
| Number | Date | Country | Kind |
|---|---|---|---|
| 201811552031.2 | Dec 2018 | CN | national |
