How to Build a House with Prefabricated Floor Slabs

Building a house with prefabricated floor slabs involves combining factory-prefabricated components with on-site assembly, enabling rapid completion of the main structure akin to 'building with blocks'. Key steps include foundation treatment, installation of foundation piles and beams, prefabrication of floor slabs, slab installation, and joint treatment.

1. Foundation Treatment: First, level the foundation and pour a cushion layer to ensure the excavation depth and ground elevation meet design requirements. For example, in a rural South Korean case, foundation pits were excavated, covered with white plastic sheeting, and then filled with concrete without using steel reinforcement. This step provides a stable base for subsequent structural elements, ensuring overall stability of the house.
2. Installation of Foundation Piles and Beams: After the concrete sets, install footplates and secure foundation piles (e.g., using 5-ton prefabricated piles), followed by beam assembly. During assembly, gaps between beams and piles are filled with expanding foam, while nut-fastened areas are sealed with cement to ensure tight connections and enhance structural integrity.
3. Prefabrication of Floor Slabs:
   • Formwork Preparation: Construct wooden formwork and arrange steel reinforcement inside (e.g., using steel strands as load-bearing bars). Apply release agents to prevent concrete adhesion, ensuring slab quality and appearance.
   • Concrete Pouring: First, lay a bottom cement layer, insert large foam blocks for lightweight design, and then fill with concrete. Use vibrating rods during pouring to eliminate air bubbles and prevent cracking.
   • Prestressing Process: Apply the 'pre-tensioning method' to stretch steel reinforcement to design strength. After concrete curing, the steel contracts, compressing the concrete to enhance tensile strength and improve slab load-bearing capacity.
   • Curing and Cutting: Harden the concrete through high-temperature steam curing or natural curing, then precisely cut it with CNC electric saws to create hollow designs for easy cable routing and sewage drainage.
4. Slab Installation: Lift prefabricated slabs onto beams and lay them to form a 5 cm-thick floor layer, completing the house's floor structure.
5. Joint Treatment: Grout all component joints to ensure structural stability, preventing water leakage or air infiltration caused by gaps, thereby guaranteeing the house's functionality and durability.