How to Make a Prefabricated House Mezzanine
Common methods for constructing a prefabricated house mezzanine include steel frame + prefabricated panels, conventional steel beam combinations, TD-LOFT ultra-thin systems, and prefabricated floor slab construction plans. The specific choice should be determined based on a combination of span, thickness, cost, and functional requirements.
Steel Frame + Prefabricated Panel Method
This method is suitable for scenarios such as LOFT duplexes or apartments, using a steel frame as the main load-bearing structure, paired with prefabricated panels (such as concrete panels, composite panels, etc.) to form the floor. This approach offers high construction efficiency, as the steel frame can be prefabricated in advance and assembled on-site conveniently. Additionally, the prefabricated panels are highly standardized and of stable quality. However, attention should be paid to the anti-corrosion treatment of the steel frame and the design of connection nodes with the prefabricated panels to avoid local stress concentration leading to cracking.
Conventional Steel Beam Combination Plans
- Steel Beam + Checkered Steel Plate: Using steel beams as the main load-bearing components, the floor construction consists of, in order, a decorative surface layer, 50mm fine aggregate concrete, a 5mm checkered steel plate, steel beams, and a fire-resistant gypsum board ceiling. The total thickness for a 4m span is approximately 280mm, suitable for scenarios with high load-bearing requirements. However, it has a significant self-weight, necessitating verification of the original structure's load-bearing capacity.
- Steel Beam + Cement Fiber Board: The construction includes a decorative surface layer, a 20mm cement pressure board, steel beams, and a ceiling, with a thickness of approximately 160mm. The cost is relatively high, and the cement pressure board is a brittle material that may crack due to vibration or deformation over long-term use, requiring additional anti-cracking measures (such as steel mesh reinforcement).
- Other Combinations: Such as steel beams + ALC floor slabs, steel beams + Tianji expanded perlite slabs, etc., generally have a thickness exceeding 200mm, with a comprehensive cost of over 600 yuan/m². They are suitable for scenarios with special requirements for sound insulation and fire resistance but are less economical.
TD-LOFT Ultra-Thin Mezzanine System
This system uses patented corrugated steel plates as the load-bearing components, integrating decorative, waterproof, fireproof, and soundproof functions, with a finished building thickness of only 100mm~120mm. Under conventional spans, the thickness is 120mm, which can be reduced to 100mm for spans less than 3.3m, significantly saving space. Construction is assembly-type dry work, without wet pouring, resulting in a short construction period and environmental friendliness. However, it requires installation by a professional team to ensure the node strength between the corrugated steel plates and connectors.
Prefabricated Floor Slab Construction Plan
- Project Preparation: Clearly define the mezzanine's location, area, slab thickness, and span, selecting standard components such as prestressed concrete slabs.
- Construction Process: Prefabricated floor slabs need to be completed in the factory, including formwork making, steel bar processing, concrete pouring, and prestress application. During transportation, special vehicles should be used to protect the surface. During installation, clean the base layer, position and set out lines, hoist and position the slabs, check the connection nodes, and clean the surface. Subsequently, set up a support system, pour connection concrete, and cure it.
- Quality Control: Strictly inspect raw materials (such as steel bar strength, concrete mix ratio), implement process standards during construction (such as hoisting sequence, concrete vibration compactness), and regularly inspect the flatness and load-bearing capacity of the floor slabs.
