Concrete prefabricated residential buildings represent an emerging industry that has yet to develop a fully integrated industrial production system. Currently, construction technologies fall short of meeting the demands of modern residential industrialization.
The key components of industrialized residential buildings—including architectural finishes, electrical systems, and equipment—must be planned and embedded during factory production. Therefore, before manufacturing prefabricated parts, detailed designs for electrical, equipment, production, and lifting requirements should be finalized.
Prior to constructing prefabricated residential buildings, a comprehensive construction organization plan must be developed. This plan should incorporate advanced, efficient construction methods and a robust quality control system to ensure the successful completion of the project, from component fabrication to the final residential structure.
1. Construction Method Characteristics and Principles
1.1 Characteristics of Construction Methods
The prefabricated concrete assembly system fully leverages the benefits of factory production. It enables standardized design, production, transportation, and specialized installation of prefabricated components. This approach enhances construction efficiency and minimizes waste generation.
(1) Standardized Component Design and High Production Accuracy
The prefabricated components include wall panels, composite panels, stairs, bay windows, and decorative panels. Components with similar cross-sectional dimensions and reinforcement are uniformly designed to ensure standardized manufacturing. Strict control is maintained over dimensional accuracy, steel bar positioning, flatness, and perpendicularity during production.
(2) Production, Transportation, and Support Facilities for Prefabricated Components
A production and transportation plan must be prepared in advance based on component usage requirements. The schedule for processing building components should align with the overall project timeline to guarantee coordinated production, transportation, and on-site installation, ensuring smooth workflow.
(3) Component Lifting Sequence
Using the standard unit’s component layout diagram, the lifting sequence follows the principle of starting from the farthest point and moving closer. Prefabricated components are numbered sequentially to control the hoisting order, ensuring an efficient and safe lifting process.
(4) Convenient and Rapid Tool Support
Design specialized tools to quickly support and position components according to their stress characteristics. Embedded support parts are installed during prefabricated component production and concrete casting at in-situ locations to facilitate easy and fast component positioning.
(5) Reduced Common Quality Issues
The prefabricated exterior wall panels use a sandwich insulation system that addresses common problems such as leakage, cracking, hollow bricks, and surface detachment. This is achieved through brick reverse punching technology and tongue-and-groove joints between components. Factory production also eliminates issues like damage to drip and decorative lines and significant deviations in room dimensions.
(6) Reliable Connection of Prefabricated Components
Connections between prefabricated components and cast-in-place structures are made using specialized methods tailored to component stress characteristics to meet structural load and deformation requirements. Wall panels are joined with sleeve grouting; composite components are connected by binding steel bars on composite surfaces followed by concrete pouring. Bay windows, stairs, and decorative panels are secured with bolts or welding. After assembly, concrete is poured at connection nodes to achieve a solid, durable structure.
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