How to Install a Prefabricated Panel House
The installation of a prefabricated panel house requires a step-by-step process based on specific component types, following standardized procedures. The core steps include tool preparation, mold making, component fabrication, precise installation, and fixation.
1. Tool and Foundation Preparation
Before construction, ensure the environment meets standards, focusing on checking the flatness and load-bearing capacity of the ground base. Clear debris and repair defects. All materials and tools must be complete, including galvanized square tubes, prefabricated welded connectors, films, varnishes, etc. Construction personnel must complete technical briefings. The ground beam construction should follow the process of "marking lines → reinforcing bar planting → formwork erection → grouting → full grouting → formwork removal → curing" to ensure the strength and positional accuracy of the ground beams, providing a stable foundation for subsequent installations.
2. Prefabricated Panel Mold Making
Weld a mold frame using galvanized square tubes according to the design dimensions. The frame must be square with dimensional deviations controlled within ±2mm. Lay a film inside the frame, ensuring it is flat and wrinkle-free, with edges secured with tape to prevent concrete leakage or adhesion to the mold during pouring, facilitating subsequent demolding.
3. Prefabricated Panel Fabrication
Place a steel reinforcement mesh inside the mold, with the diameter and spacing of the reinforcing bars meeting design requirements to enhance the crack resistance of the prefabricated panels. Pour concrete in layers and vibrate it densely to avoid honeycombing and pitting. Simultaneously, embed prefabricated welded connectors (such as L-shaped angle steels) into the concrete at the designed positions, with the exposed parts of the connectors requiring anti-rust treatment. After initial concrete setting, cover and moisturize for curing. Once the design strength (usually C30) is reached, remove the mold, avoiding damage to the component edges during demolding.
4. Prefabricated Panel Installation and Fixation
- Positioning and Alignment: After demolding the prefabricated panels, use a laser level or total station to set out installation control lines (such as elevation lines and axis lines). Precisely align the embedded parts of the prefabricated panels with those on the ground beams, walls, and ceilings, with deviations controlled within ±3mm.
- Fixation Methods:
- Welding Fixation: After alignment, use segmented welding, starting with spot welding for fixation followed by full welding. The weld length must meet design requirements (usually not less than 50mm) to ensure a secure connection.
- Bolt Connection: Some prefabricated panels (such as composite panels) may use high-strength bolt connections. Pre-drill bolt holes in the components and structures in advance. During installation, tighten the bolts to the specified value using a torque wrench.
- Special Component Installation:
- Bay Window Installation: First, install elevation adjustment control bolts and temporary positioning pieces. Slowly lift the bay window using a tower crane and fine-tune the elevation and verticality with bolts.
- Composite Panel Installation: Use a lifting steel beam during hoisting to ensure even load distribution at the lifting points, preventing component cracking. After hoisting to the designated position, temporarily fix it with adjustable supports and then pour the post-pouring layer concrete.
- Exterior Wall Panel Installation: Before hoisting, set out positioning lines, correct skewed reinforcing bars, use a special positioning plate to verify the positions of reserved reinforcing bars, place adjustment shims, and recheck the elevation with a level. Finally, pour concrete at the connection points.
After installation, check the verticality, flatness, and reliability of connection nodes of the components to ensure the overall stability and safety of the house.
