How to Make a Prefabricated House Mezzanine

The construction of a prefabricated house mezzanine should follow standardized procedures, with core steps including construction preparation, measurement and layout, steel bar planting, hoisting, fixation, welding, grouting, waterproofing, and acceptance.

I. Construction Preparation

1. Material Preparation:

   • Prefabricated Mezzanine Panels: These are reinforced concrete prefabricated components with specifications of 2400-3600mm in length, 600mm in width, and 120mm in thickness. The concrete strength grade is C30, with main reinforcement of HRB400E grade φ12mm steel bars and distribution reinforcement of φ8mm @ 200mm, ensuring structural load-bearing capacity.
   • Connecting Steel Materials: Including E43 type welding rods, 40×60×4mm connecting steel plates, and φ10mm connecting steel bars for the stable connection between the prefabricated panels and the wall.
   • Steel Bar Planting Materials: Epoxy resin steel bar planting adhesive and φ12mm threaded steel bars for drilling holes in the wall and implanting steel bars to enhance anchoring effects.
   • Auxiliary Materials: Cement, fine aggregate concrete (for panel joint grouting), sealing materials (such as polyurethane sealant), and supporting materials.

2. Equipment and Site Preparation:

   • Equipment: Truck cranes (for hoisting prefabricated panels), electric welders (for welding connecting steel plates), steel bar planting drills (for drilling holes), and level gauges (for measuring elevations).
   • Site: The storage area for prefabricated panels should be leveled and compacted, with a brick胎膜 (brick formwork) cushion layer. The panels should be stored vertically using stacking racks to prevent deformation.

II. Core Construction Techniques

1. Measurement and Layout:

   • According to the design drawings, mark the installation axis, elevation line, and panel end positioning line for the mezzanine panels on the wall, and perform closed verification to ensure accurate positioning.

2. Steel Bar Planting Construction:

   • Drill holes in the wall (with a hole diameter matching the diameter of the planted steel bars). After cleaning the holes, inject epoxy resin steel bar planting adhesive and insert φ12mm threaded steel bars, rotating them to fix them and ensuring a firm bond between the steel bars and the wall.

3. Prefabricated Panel Hoisting and Fixation:

   • Use a truck crane to hoist the prefabricated panels to the designated positions and fix them with temporary supports to prevent overturning.
   • Adjust the positions of the prefabricated panels to meet the design requirements and fix them by welding the connecting steel plates to the planted steel bars.

4. Panel Joint Treatment and Waterproofing:

   • Grouting: Fill the panel joints with fine aggregate concrete and vibrate evenly with a vibrating rod to ensure density and no voids.
   • Waterproofing: Apply polyurethane sealant to the panel joints to form a waterproof layer and prevent leakage.

5. Formwork Removal and Acceptance:

   • After the concrete reaches the design strength, remove the formwork.
   • Conduct a comprehensive acceptance of the mezzanine, checking structural stability, connection reliability, and waterproofing effects to ensure compliance with design specifications.

III. Key Considerations

• Material Quality: Prefabricated panels, steel bars, steel bar planting adhesive, etc., must comply with national standards to avoid safety hazards caused by material issues.
• Construction Accuracy: Strictly control the measurement and layout and the positions of planted steel bars, with errors kept within allowable limits.
• Safety Measures: Set up warning zones for hoisting operations and implement fire prevention measures during welding to ensure construction safety.