How to Replace Prefabricated Floor Panels in Houses

Replacing prefabricated floor panels in houses requires step-by-step standardized operations based on the target floor type (cast-in-place or new prefabricated panels), with core processes including demolition, support, reinforcement, installation, and acceptance.

1. Demolish the original prefabricated panels and clear the floor surface

Whether replacing with cast-in-place floors or new prefabricated panels, the original prefabricated panels must first be removed. For cast-in-place floors, the floor surface must be thoroughly cleared down to the structural layer to ensure no residual concrete or debris remains. If replacing with new prefabricated panels, the floor base must be cleaned to ensure a flat contact surface, preventing uneven stress distribution after installation of the new panels.

2. Install support structures

• Cast-in-place floors: Floor formwork must be erected as a support system for the cast-in-place concrete. The formwork should be made of materials with high flatness and sufficient strength (such as steel formwork or high-quality wooden formwork), as the surface flatness directly affects the quality of subsequent plastering. After installation, the stability of the formwork must be checked to prevent deformation or displacement during pouring.
• Replacing hollow prefabricated panels without demolishing walls (rural self-built houses): A professional agency must be commissioned to inspect the load-bearing capacity of the walls and the original floor structure to confirm whether the condition of not demolishing the walls is met. If requirements are met, temporary supports (such as steel pipe scaffolding) must be installed on both sides of the walls to ensure wall stability during construction and avoid the risk of collapse due to floor demolition.

3. Reinforce the structure or adapt to new panels

• Cast-in-place floors: A steel reinforcement mesh must be installed on the floor surface, with the diameter and spacing of the steel bars complying with design specifications. All steel bar ends must be inserted and welded into the interior of the walls or columns to form an integrated load-bearing structure, enhancing the floor's crack resistance and load-bearing capacity.
• New prefabricated panels: New panels must be customized according to the dimensions and load parameters of the original floor panels to ensure they match the surrounding structure. For hollow prefabricated panels, products with the same hole diameter and arrangement pattern as the original panels must be selected to avoid structural imbalance due to load differences.

4. Pour or install new panels

• Cast-in-place floors: Pour concrete with a grade of C30 or higher, compact it thoroughly, and then cover it for moist curing. Remove the formwork after the concrete reaches the design strength (usually 28 days).
• New prefabricated panels: A professional construction team should use lifting equipment to hoist and install the new panels. During installation, ensure that the panel joints are aligned and securely connected, and fill the panel joints with cement mortar or special adhesive to prevent leakage.

5. Subsequent maintenance and acceptance

• Regular inspections: Even after replacing with new prefabricated panels, the overall structure of older houses may have been damaged. Inspect the floor and walls for cracks or deformation every six months.
• Overall renovation recommendations: If the house is very old, it is recommended to carry out an overall renovation or reconstruction in combination with seismic and energy-saving requirements.
• Quality acceptance: After construction is completed, commission a third-party agency to inspect the floor's load-bearing capacity, flatness, and connection joints to confirm compliance with safety standards before putting the house into use.