Shear wall and construction method combining digitized prefabricated wall plate with demoulding template net

Abstract

The application discloses a kind of modular prefabricated wallboard and shear wall system and construction method combined with formwork net of free dismantling.The main body of modular prefabricated wallboard is formed by concrete pouring, with transverse reinforcement and longitudinal reinforcement arranged inside and extending outward, a longitudinal reinforcement lap cast-in-place area is provided at the lower part of the main body, a mounting hole is provided through the main body, and the main body size is designed using modularization.The shear wall includes modular prefabricated wallboard and cast-in-place wallboard, the cast-in-place wallboard includes formwork net on both sides, poured concrete and internal reinforcement framework, and U-shaped ribs and dense mesh are provided on the formwork net.The formwork net serves as free dismantling formwork, without the need for dismantling, simplifying the construction process.The mesh on the formwork net allows cement paste to seep out during pouring, forming a coarse-grained interface, enhancing the shear resistance with concrete, and avoiding surface cracking and plaster layer detachment.The application provides flexible combination of modular prefabricated wallboard and formwork net of free dismantling, adapts to different wall sizes, reduces production costs and improves construction efficiency.

Description

Technical Field

[0001] This invention relates to the field of building structural engineering technology, specifically to a shear wall system and construction method that combines modular prefabricated wall panels with formwork mesh. Background Technology

[0002] With the advancement of industrialized construction, prefabricated concrete structures have been widely used in the construction industry due to their advantages such as fast construction speed, easy control of project quality, and environmental friendliness. Shear wall structures, as one of the most commonly used structural forms in high-rise buildings, are also seeing increasingly mature prefabrication technology.

[0003] Currently, most precast shear walls are constructed by determining the required dimensions of the precast wall panels based on construction drawings. The factory then creates molds according to these dimensions and precasts the wall panels. This process results in inconsistent precast wall panel sizes, requiring repeated mold creation for different dimensions, which increases production costs. Furthermore, the molds made for one project cannot be used to produce precast wall panels for other projects, leading to significant waste.

[0004] Secondly, common shear wall structures divide the wall into precast sections (precast wall panels) and cast-in-place sections. The precast sections are manufactured and cured in the factory, then transported to the site where they are connected to edge members, joint areas, etc., by post-cast concrete. The quality of this connection method directly affects the integrity, safety, and durability of the entire structure. In actual engineering, before pouring concrete on-site, the cast-in-place section requires complex formwork erection work in the connection areas of the precast wall panels (such as edge members and horizontal joints). The installation, reinforcement, and dismantling of traditional wooden or steel formwork is cumbersome, consuming a lot of labor and time, directly affecting construction efficiency. Especially in some complex joints or confined spaces, the erection and dismantling of formwork is quite difficult. In addition, it requires the purchase, maintenance, and storage of large quantities of formwork materials, and the formwork is easily damaged after multiple uses, making the construction process complex, costly, and environmentally unfriendly. Summary of the Invention

[0005] The purpose of this invention is to overcome the defects in the prior art and provide a shear wall and construction method that combines modular prefabricated wall panels with non-removable formwork mesh.

[0006] To achieve the above objectives, the technical solution of the present invention is a modular precast wall panel, comprising a modular precast wall panel body, which is cast in concrete and has transverse and longitudinal reinforcing bars arranged interlaced inside. Both the transverse and longitudinal reinforcing bars extend outwards after passing through the modular precast wall panel body. A longitudinal reinforcing bar lap splicing zone is provided at the lower part of the modular precast wall panel body, and a concrete pouring hole is reserved above the longitudinal reinforcing bar lap splicing zone. Installation holes and bracket fixing holes are provided through the modular precast wall panel body (the bracket fixing holes are used to support and fix the precast wall panel with temporary support rods after it has been hoisted to a suitable position). The dimensions of the modular precast wall panel body are modularized. Modularization here means that during the factory production and processing of the precast wall panel, its dimensions are fixed at a few dimensions. For different projects, the dimensions of the precast wall panel are reasonably selected and combined with the dimensions of the formwork mesh. The two are combined to form shear walls of different total lengths after concrete pouring. Modularizing precast wall panels facilitates mold making and production in factories, standardizing or semi-standardizing the dimensions of precast shear walls produced in factories. This involves creating modular shear wall templates, suitable for the production of shear walls in different projects, reducing the production cost of precast shear walls, changing the current waste of making molds for each project and each wall panel, reducing mold making costs, and shortening the production cycle. By breaking down large precast shear walls into modular precast shear walls, the weight of individual precast components can be controlled, reducing the pressure of hoisting.

[0007] Preferably, the width of the modular prefabricated wall panel is 600mm, 900mm, or 1200mm. These dimensions are illustrative examples and do not represent mandatory width dimensions for the modular prefabricated wall panel of this invention.

[0008] Another technical solution of the present invention is to design a shear wall system comprising modular precast wall panels and a formwork mesh, including modular precast wall panels and cast-in-place wall panels. The cast-in-place wall panels include formwork mesh located on both sides of the cast-in-place wall panels, concrete poured within the formwork mesh, and an internal steel reinforcement skeleton. The formwork mesh is installed on the steel reinforcement skeleton and / or the modular precast wall panels, and the formwork mesh has multiple mesh openings. By setting a formwork mesh with mesh on both sides of the cast-in-place portion, the formwork mesh completely replaces the traditional wooden formwork. Compared with traditional wooden formwork, installation is more convenient, and the formwork mesh does not need to be removed after pouring, thus simplifying the construction process, improving efficiency, and reducing the overall cost of using the formwork mesh. In addition to serving the shaping function of traditional formwork, the mesh allows some of the cement paste in the concrete to seep out during pouring. After the concrete hardens, the formwork mesh is tightly bonded to the cast-in-place concrete, becoming part of the structure. This is equivalent to forming a reinforcing layer with good adhesion on the surface of the cast-in-place wall panel. The rough surface of this reinforcing layer can serve as an excellent base, facilitating subsequent plastering, tiling, and other decorative layer construction without the need for roughening, thus improving construction efficiency and structural integrity.

[0009] Optionally, the template mesh is further provided with U-shaped ribs, and the mesh is densely woven. These U-shaped ribs can improve the lateral strength of the template mesh, prevent lateral bending, increase the edge rigidity of the template mesh, and form deeper mechanical interlocking points during concrete pouring, further enhancing the bonding force between the template mesh and the concrete, and improving the integrity and load-bearing capacity of the shear wall.

[0010] Furthermore, installation grooves are provided around the perimeter of the modular precast wall panel body and the cast-in-place area of ​​the longitudinal reinforcement lap joint. Installation holes are spaced apart along the edges of the installation grooves. The depth of the installation grooves is equal to the thickness of the formwork mesh, and the edges of the formwork mesh are fitted and fixed within the installation grooves. By providing installation grooves along the edges of the modular precast wall panel, the formwork mesh can be embedded within them, ensuring the flatness of the surface at the connection point. The width of the installation groove is generally not less than 50mm.

[0011] Preferably, the connection surface between the modular precast wall panel and the cast-in-place wall panel is a rough surface and / or a keyway. A rough surface or keyway can enhance the connection strength between the precast wall panel and the cast-in-place wall panel.

[0012] Optionally, multiple threaded sleeves are pre-embedded in the mounting groove, and the template mesh is fixed to the mounting groove by bolts that match the sleeves. This connection method is a mechanical connection, which is simple and quick to operate, easy to assemble and disassemble, and has high connection strength and reliability, facilitating rapid installation and positioning on the construction site. In use, the template mesh can be installed and fixed simply by passing bolts through the pre-drilled holes in the template mesh and screwing them onto the sleeves. The bolts are recyclable.

[0013] Optionally, the template mesh is cut and overlapped in the factory, and reinforced by keels along its long sides or around its perimeter. The keel-reinforced template mesh is fixed to the modular precast wall panel by first fasteners passing through the mounting holes and clamping plates located at both ends of the first fasteners and on the outside of the template mesh. This connection method eliminates the need for pre-embedded connectors in the modular precast wall panel. By directly pre-drilling mounting holes during the processing of the modular precast wall panel, and using fasteners and clamping plates to press the template mesh into the mounting groove from the outside, the installation is more flexible. The mounting holes are preferably located at the edge or inside the mounting groove. When template mesh needs to be connected in both directions, it is preferable to pre-drill holes at the intersection. When located inside the mounting groove, holes corresponding to the mounting hole positions need to be pre-drilled or secondary-processed on the template mesh. During fixing, the first fasteners are passed through the template mesh and the modular precast wall panel, and then the clamping plates and bolts are used for fixing. When located outside the mounting groove, only the clamping plates are used to press the template mesh.

[0014] Optionally, after the reinforced formwork mesh is installed into the mounting groove via the reinforced keel, a reinforcing main keel is provided on the outer side of the reinforced keel. The reinforcing main keel is fixed to the modular precast wall panel by a second fastener passing through the mounting hole. This connection method uses the reinforced keel to evenly press the edges of the formwork mesh into the mounting groove, increasing the stress-bearing area and preventing deformation of the formwork mesh due to localized stress concentration. The reinforcing main keel further enhances the stability of the connection and the overall rigidity by fixing multiple reinforced keels to the modular precast wall panel.

[0015] Furthermore, the template mesh is expanded metal mesh. Expanded metal mesh is made by punching holes in steel plates. It has the advantages of being lightweight, high-strength, having uniform mesh size, and strong bond with concrete, making it an ideal template material.

[0016] Furthermore, the width of the template mesh (excluding the overlap length with the precast wall panel) is generally not less than the wall panel thickness and not less than 200mm. The cast-in-place wall panel is divided into end cast-in-place sections (the end cast-in-place sections are the ends of the modular precast wall panels and the locations where concrete needs to be poured at intersections) and inter-panel cast-in-place sections (referring to the locations where concrete needs to be poured between two modular precast wall panels). The seismic performance of the cast-in-place and precast combined shear wall system, characterized by "cast-in-place at the ends of the wall panels and intersections," is generally superior to or equal to that of traditional cast-in-place shear wall structures, especially in terms of node integrity, stress coordination, and ductility reserve, fully meeting the structural safety requirements under the same seismic fortification intensity.

[0017] Furthermore, the width of the template mesh (excluding the overlap length with the precast wall panel) is 200mm or 300mm. These dimensions are illustrative examples of preferred solutions and do not represent the mandatory width dimensions of the template mesh of this invention. These specific preferred width values ​​facilitate standardized production and design selection, improving the efficiency of industrial production. By modularizing the width of the template mesh, the factory only needs to set two core modules for the illustrative dimensions during production, which facilitates processing and can adapt to commonly used bay and depth modules in architectural design. When coordination with door and window openings, beams, and columns is required, the dimensions can be configured according to design requirements.

[0018] Another technical solution of the present invention is a construction method for a shear wall system comprising modular prefabricated wall panels and formwork mesh. This includes the following steps: S1. Determine the combination form of modular precast wall panels and formwork mesh according to the required shear wall size; the combination form is 2 end cast-in-place wall panels located at both ends of the shear wall, n modular precast wall panels, and n-1 inter-wall cast-in-place wall panels located between two adjacent modular precast wall panels, where n≥1, and there are no inter-wall cast-in-place wall panels when n=1; S2. Determine the required quantity of modular prefabricated wall panel bodies and formwork mesh of each size according to the combination form; S3. Hoist the modular prefabricated wall panels to the corresponding positions and fix them in place; S4. Place the steel reinforcement cage in the corresponding position and tie it in place; S5. The pre-configured template mesh (cut, connected to the appropriate size, and reinforced with keel) is fixed in the installation groove of the modular prefabricated wall panel. S6. Pour concrete into the assembled shear wall; S7. After the concrete reaches the demolding strength, remove the installed fasteners.

[0019] This construction method combines shear wall structures according to the pattern of "end cast-in-place wall panel - modular precast wall panel - cast-in-place wall panel between wall panels - modular precast wall panel - end cast-in-place wall panel". This fully leverages the advantages of industrialized production of precast components while ensuring the integrity and continuity of the structure through cast-in-place sections. The construction steps are simple and clear, easy to operate, and easy to control quality. In particular, when n=1, the combination form is simplified to "end cast-in-place wall panel - modular precast wall panel - end cast-in-place wall panel", which is suitable for simple wall structures with single precast wall panels.

[0020] When the width of the formwork mesh (excluding the overlap length with the precast wall panel) is 200mm or 300mm, and the width of the precast wall panel is 600mm (M1), 900mm (M2), or 1200mm (M3), by combining modular precast wall panels of different widths with modular formwork mesh of different widths, and by combining the placement of end cast-in-place wall panels and cast-in-place wall panels between the modular precast wall panels, shear wall segments of various lengths not less than 1000mm can be formed. This covers various wall dimensions and layout requirements commonly found in building structures, allowing designers to select the most suitable combination form according to specific project needs, greatly simplifying the design process and improving design efficiency. At the same time, standardized combination types also facilitate the industrialized production of precast components and the organization and management of on-site construction, resulting in good economic and social benefits.

[0021] The advantages and beneficial effects of this invention are as follows: 1. Modularize precast wall panels. Modular precast wall panels facilitate mold making and production in factories, standardizing or semi-standardizing the dimensions of precast shear walls produced in factories. By creating modular shear wall templates, it is suitable for the production of shear walls in different projects, reducing the production cost of precast shear walls, changing the current waste of making molds for each project and each wall panel, and shortening the production cycle.

[0022] 2. Using formwork mesh as the permanent formwork for cast-in-place wall panels eliminates the need for formwork removal after pouring; only the corresponding reinforcing components need to be removed. Wooden formwork is also unnecessary during installation; simple reinforcement components suffice. This installation and non-removal process shortens the construction period, saves labor costs, and greatly simplifies on-site construction procedures. Furthermore, the formwork mesh has low production costs, requires no disassembly, and does not pollute the environment.

[0023] 3. Both the formwork mesh and the modular precast walls are prefabricated. The formwork mesh is easy to cut and can be pre-cut and manufactured in the factory. The modular precast walls can be made using specific standard modular sizes as needed. The formwork mesh can be directly installed on the modular precast wall panels, which is quick to install and precise in positioning, significantly shortening the construction cycle and reducing labor costs and formwork material consumption.

[0024] 4. The mesh design of the formwork allows cement slurry from the poured concrete to penetrate into the mesh openings. After hardening, this forms a mechanical interlocking structure, firmly embedding the formwork into the surface of the cast-in-place concrete. This not only eliminates the smooth seams left after traditional formwork removal, avoiding the difficulties of seam treatment, but also makes the formwork itself an integral part of the concrete structure. It can restrain the concrete, improve surface crack resistance, and enhance the bonding strength between the old and new concrete, as well as the performance of the cast-in-place concrete itself. A small amount of cement slurry penetrates to the outside of the mesh, making the surface of the formwork rough. This rough surface serves as an excellent base, facilitating subsequent plastering, tiling, and other decorative layer construction without the need for further roughening or slurry application. Attached Figure Description

[0025] Figure 1 This is a structural schematic diagram of the modular prefabricated wall panel of the present invention; Figure 2 This is a schematic diagram of the shear wall bolt sleeve connection method of the present invention; Figure 3 This is a schematic diagram of the connection method of the clamping plate of the present invention; Figure 4 This is a schematic diagram of the structure of the reinforced main keel connection method of the present invention; Figure 5 This is a schematic diagram of the connection method between the clamping plate and the reinforcing keel of the present invention; Figure 6 This is a schematic diagram of the structure of one embodiment of the template network of the present invention; Figure 7 This is a schematic diagram of another embodiment of the template network of the present invention; Figure 8 This invention describes the partial combination forms and total width of the shear wall when n=1; Figure 9 This invention describes the partial combination forms and total width of the shear wall when n=2. Figure 10 This invention describes the partial combination forms and total width of the shear wall when n=3.

[0026] In the diagram: 1. Modular precast wall panel; 10. Main body of modular precast wall panel; 101. Horizontal reinforcement; 102. Longitudinal reinforcement; 103. Longitudinal reinforcement lap splice cast-in-place zone; 104. Mounting hole; 105. Support fixing hole; 11. Mounting groove; 12. Sleeve; 13. Bolt; 2. Cast-in-place wall panel; 3. Formwork mesh; 31. Mesh; 32. U-shaped rib; 33. Reinforcing rib; 4. Reinforcing steel skeleton; 52. First fastener; 53. Pressure plate; 62. Reinforcing keel; 63. Reinforcing main keel; 64. Second fastener. Detailed Implementation

[0027] The specific embodiments of the present invention will be further described below with reference to the accompanying drawings and examples. The following examples are only used to more clearly illustrate the technical solutions of the present invention and should not be construed as limiting the scope of protection of the present invention.

[0028] like Figure 1 As shown, this invention provides a modular precast wall panel. The wall panel mainly comprises a modular precast wall panel body 10. This body 10 is integrally cast from concrete, forming a robust slab structure. Internally, transverse reinforcing bars 101 and longitudinal reinforcing bars 102 are arranged in an alternating pattern according to design specifications, forming a reinforcing mesh. Specifically, both ends of these transverse reinforcing bars 101 and longitudinal reinforcing bars 102 extend outwards for a certain length after passing through the concrete solid of the modular precast wall panel body 10, forming reinforcing bar joints for connection with adjacent components (such as beams, columns, or other wall panels), ensuring the continuity of structural connections. In the lower region of the modular precast wall panel body 10, a longitudinal reinforcing bar lap splicing area 103 is provided. This area is used for lap splicing and connection with pre-reserved reinforcing bars extending from the lower structure (such as lower wall panels or foundation beams) during on-site construction. Above the longitudinal reinforcement lap splice cast-in-place zone 103, the main body 10 has a through concrete pouring hole (not shown in the figure). This pouring hole is used to pour concrete into the longitudinal reinforcement lap splice cast-in-place zone 103 after the reinforcement lap splicing is completed, so that the upper and lower structures form a whole. Multiple installation holes 104 and multiple bracket fixing holes 105 are provided through the modular precast wall panel main body 10. These bracket fixing holes 105 are used for quick temporary fixing with temporary support rods after the precast wall panel is hoisted into place, ensuring installation accuracy and construction safety.

[0029] The dimensions of the modular prefabricated wall panel body 10 are strictly designed according to modular principles. To meet the standardized requirements of architectural design, the width of the modular prefabricated wall panel 1 in this embodiment is designed with several standard modular dimensions. Specifically, its width is 600mm, 900mm, or 1200mm (the above dimensions are preferred options for illustrative purposes and do not represent the mandatory width dimensions of the modular prefabricated wall panel of this invention). This design allows architects to flexibly achieve various bay sizes by combining standard panels of different widths when designing building plans, greatly improving design flexibility and component versatility.

[0030] according to Figure 2As shown, this invention is a shear wall system comprising modular precast wall panels and a formwork mesh. It includes a modular precast wall panel 1 (precast reinforced concrete shear wall panel) prefabricated in a factory, and a cast-in-place wall panel 2 (a shear wall formed by pouring concrete on-site). The cast-in-place wall panel 2 is typically located between two modular precast wall panels 1. The connection surface between the modular precast wall panel 1 and the cast-in-place wall panel 2 is designed as a rough surface or has machined keyways (not shown in the figure) to improve the connection strength between the two wall sections.

[0031] The structure of the cast-in-place wall panel 2 mainly includes formwork mesh 3 set on both sides, internal steel reinforcement skeleton 4, and concrete poured into the cavity formed by the formwork mesh 3 and the modular precast wall panel 1. In this embodiment, the formwork mesh 3 is preferably steel mesh with multiple evenly spaced mesh openings 31. The size and density of these mesh openings 31 are designed so that during concrete pouring, fine cement paste can partially seep out, but the aggregate is effectively blocked. After the concrete hardens, the formwork mesh 3 is permanently attached to the surface of the cast-in-place wall panel 2. The size of the mesh openings 31 is generally selected as holes with a diameter of 3mm-5mm or rectangular holes with a width of 1mm-3mm and a length of 3mm-5mm.

[0032] In another embodiment, such as Figure 6 As shown, the template mesh 3 is also provided with U-shaped ribs 32, and the mesh 31 is a dense mesh. Both the U-shaped ribs 32 and the dense mesh 31 can be obtained by stamping, which is simple to process. This U-shaped rib 32 can improve the transverse strength of the template mesh 3, prevent transverse bending, and also increase the edge rigidity of the template mesh 3. It can also form deeper mechanical interlocking points during concrete pouring, further enhancing the bonding force between the template mesh and the concrete, and improving the integrity and load-bearing capacity of the shear wall.

[0033] In another embodiment, such as Figure 7 As shown, the template mesh 3 is a steel plate mesh, and its mesh 31 is preferably a rectangular shape arranged in a staggered manner. This arrangement helps to distribute stress evenly on the template mesh 3. Simultaneously, at the edge of each mesh 31, a reinforcing rib 33 is provided that bends inward (i.e., bends towards the inside of the cast-in-place wall panel 2). The reinforcing rib 33 can be formed in one piece with the mesh 31 through a stamping process. This reinforcing rib 33 not only increases the rigidity of the mesh 31 edges, preventing deformation during concrete pouring, but also forms a deeper mechanical interlocking structure after the concrete hardens, acting like multiple small anchors to more firmly embed the template mesh 3 into the cast-in-place concrete, significantly improving the bonding strength between the two.

[0034] To achieve a reliable connection between the template mesh 3 and the precast wall panel 1, refer to Figure 2As shown, at the four edges of the modular prefabricated wall panel 1, there are pre-set installation grooves 11 (i.e., template mesh 3 installation grooves) for connecting the template mesh 3. The depth (i.e., thickness direction) of the installation groove 11 is set to be equal to the thickness of the selected template mesh 3, and the width is not less than 50mm. In this way, when the edge of the template mesh 3 is fitted and fixed in the installation groove 11, its outer surface can be flush with the wall surface of the modular prefabricated wall panel 1, ensuring overall flatness.

[0035] This embodiment provides a specific fixing method. (Refer to...) Figure 2 Multiple threaded steel sleeves 12 are pre-embedded in the mounting groove 11 of the precast wall panel 1. The positions of these sleeves 12 correspond to the pre-set mounting holes on the template mesh 3. During on-site installation, the edge of the template mesh 3 is inserted into the mounting groove 11, aligning the mounting holes and sleeves 12. Then, matching bolts 13 are screwed into the sleeves 12, thus firmly pressing the template mesh 3 to the bottom surface of the mounting groove 11. This bolted connection method facilitates quick on-site operation. After pouring and solidification, the bolts 13 can be removed for reuse.

[0036] As another alternative implementation method, refer to Figure 3 This invention also provides a fixing scheme that eliminates the need for pre-embedded connectors within the modular prefabricated wall panel 1. Specifically, multiple mounting holes 104 can be pre-set on the modular prefabricated wall panel 1 (generally located at the edge of the mounting groove 11, with mesh openings at certain intervals to penetrate the modular prefabricated wall panel 1 for fixing the template mesh 3; when the template mesh 3 needs to be connected in both directions, the aforementioned mesh openings are reserved at the intersection). During installation, after placing the edge of the template mesh 3 into the mounting groove 11, a first fastener 52 (such as a long bolt) is passed through the mounting hole 104, and a clamping plate 53 is fitted onto the end of the first fastener 52 on the outside of the template mesh 3. By tightening nuts or other methods, the clamping plate 53 tightly presses the template mesh 3 against the bottom surface of the mounting groove 11. The mounting holes 104 are preferably located at the edge of the mounting groove 11 or within the mounting groove 11. When located inside the mounting groove 11, holes corresponding to the mounting holes 104 need to be pre-drilled or re-machined on the template mesh 3. During fixing, the first fastener 52 is passed through the template mesh 3 and the modular precast wall panel 1, and then fixed with the clamping plate 53 and bolts. When located outside the mounting groove 11, only the clamping plate 53 is used to clamp the template mesh 3. The first fastener 52 and the clamping plate 53 can be reused. After the pouring is completed and the demolding standard is met, they need to be removed (the removed first fastener 52 and clamping plate 53 can be reused), but the template mesh 3 does not need to be removed.

[0037] As another alternative implementation method, refer to Figure 4Alternatively, a reinforcement scheme with a keel can be adopted. Specifically, after the formwork mesh 3 is reinforced by the reinforcing keel 62 (preferably a square steel pipe), it is placed in the mounting groove 11 along with the formwork mesh 3. Then, a reinforcing main keel 63 is set on the outside of the reinforcing keel 62. Finally, a second fastener 64 is used to pass through the mounting hole 104 to tighten and fix the reinforcing main keel 63, the reinforcing keel 62, and the formwork mesh 3 together onto the modular precast wall panel 1. This multi-layer keel fixing method can provide greater clamping force and overall stability. When installing the reinforcing keel 62 and the reinforcing main keel 63, cable ties or clips can be used for reinforcement to ensure their firmness. The reinforcing keel 62, the reinforcing main keel 63, and the second fastener 64 can all be reused. After the pouring is completed and the demolding standard is met, they need to be removed (the removed second fastener 64, the reinforcing keel 62, and the reinforcing main keel 63 can be reused), but the formwork mesh 3 does not need to be removed.

[0038] In actual engineering design, the width of the formwork mesh 3 can be selected according to the size requirements of the cast-in-place wall panel 2. As a standardized preferred solution, the width of the formwork mesh 3 can be made in specifications such as 200mm and 300mm, which cover the size requirements of most edge components and connection areas. The width of the modular precast wall panel 1 can be designed to be 600mm, 900mm, or 1200mm to form a modularly coordinated composite wall. By setting the width of the formwork mesh 3 to two modules of 200mm and 300mm, the height can be cut as needed; and setting the width of the precast wall panel to three modules of 600mm (M1), 900mm (M2), and 1200mm (M3), it is possible to facilitate factory mold-making and production, unify or semi-unify the size of precast shear walls produced in the factory, that is, to make modular shear wall formwork, which is suitable for the production of shear walls in different projects, reduces the production cost of precast shear walls, changes the current waste of making molds for each project and each wall panel, and shortens the production cycle. By combining the above-mentioned modular units, almost all shear wall width requirements can be met.

[0039] This embodiment provides a detailed construction method for the above-mentioned shear wall, including the following steps: S1. Determine the combination of modular precast wall panels and formwork mesh based on the required shear wall dimensions. Before construction, technicians should carefully study the construction drawings to understand the design requirements and dimensional parameters of the building structure. The combination of shear walls should be determined based on the wall's length, thickness, height, and the form of the joints. The combination form is determined according to the pattern of "2 end cast-in-place wall panels 2 (referring to the ends of the wall segments and intersections, which must be cast in place to improve the overall shear wall support strength), n modular precast wall panels 1, and n-1 cast-in-place wall panels 2 between the wall panels (cast-in-place sections are set between the two precast wall panels to achieve continuous reinforcement lap (the precast wall panel's reserved reinforcement is tied to the reinforcement of the cast-in-place section), transferring tensile, compressive, and shear forces, avoiding "stress disconnection" when combining multiple precast blocks, and meeting the requirement of "continuous force transmission" in the "Technical Standard for Precast Concrete Structures" (GB 50231-2016)). Where n≥1, and when n=1, there is no cast-in-place section between the wall panels. Figure 8 , Figure 9 , Figure 10 The diagram shows common combinations for n=1, n=2, and n=3. During combined construction, while ensuring the overall structural strength, the prefabrication rate of the shear wall can be increased by minimizing the amount of cast-in-place sections through design. During assembly, the width of the cast-in-place sections at the ends of the shear wall limbs and at the connections of the modular prefabricated wall panels 1 should not be less than the wall limb thickness; for example, the width of each cast-in-place section should not be less than 200mm for a 200mm thick wall panel.

[0040] For example, in a certain project, the wall length is 1800mm and the wall thickness is 200mm. After calculation, a combination of n=2 can be used: end cast-in-place wall panel (200mm), modular precast wall panel (600mm), cast-in-place wall panel between wall panels (200mm), modular precast wall panel (600mm), and cast-in-place wall panel at the top (200mm), with a total length of 200+600+200+600+200=1800mm.

[0041] S2. Determine the required quantity of prefabricated wall panels and formwork mesh of each size according to the combination method.

[0042] Based on the determined combination, calculate the required quantity and specifications of modular precast wall panels 1, as well as the quantity and specifications of template mesh 3. The preferred widths of the precast wall panels 1 are 600mm, 900mm, and 1200mm, and the preferred widths of the template mesh 3 are 200mm and 300mm. Simultaneously, it is also necessary to calculate the required quantities of reinforcing steel frame 4 and connectors (bolts 13, first fasteners 52, second fasteners 64, clamping plates 53, reinforcing keel 62, reinforcing main keel 63, etc.).

[0043] Taking the aforementioned 1800mm wall as an example, two precast wall panels 1 (600mm wide) are required, along with three sections: the end cast-in-place section and the section between the wall panels. Each section is 200mm wide (excluding the overlap length with the precast wall panels). Each cast-in-place section requires formwork mesh 3 on both sides, therefore requiring a total of 3 sections × 2 sides = 6 pieces of formwork mesh 3, each 300mm wide. Additionally, the length of the formwork mesh 3 needs to be calculated based on the height of the cast-in-place section, typically the floor height minus the floor slab thickness.

[0044] S3. Hoist the precast wall panels to the corresponding positions and fix them in place.

[0045] Using lifting equipment, the modular prefabricated wall panels 1 are hoisted to the designated positions and placed sequentially according to their assembly form. During hoisting, care should be taken to protect the edges and corners of the prefabricated wall panels 1 to avoid collision damage. After placement, temporary support rods are used to fix the prefabricated wall panels 1 in stable positions, adjusting their verticality and horizontality to ensure they meet design requirements. Temporary support rods are generally installed on both sides of the wall panels, with a spacing not exceeding 3 meters, and the support points should be reliable.

[0046] S4. Place the steel reinforcement cage in the corresponding position and tie it in place.

[0047] The prefabricated steel reinforcement cage 4 or loose steel reinforcement is transported to the construction site and placed in the area of ​​the cast-in-place wall panel 2 according to the design requirements. The steel reinforcement cage 4 should be reliably connected to the connecting steel bars extending from the prefabricated wall panel 1. The steel bars at the ends, middle and intersections of the prefabricated wall panel 1 are tied, the upper part is tied to the steel bars of the beams and hidden beams, and the bottom is connected to the vertical steel bars, usually by tying.

[0048] S5. After the above steps have been accepted, the template mesh pre-configured in the factory (cut and connected to the appropriate size, and reinforced with keel if necessary) will be installed in the installation groove of the modular prefabricated wall panel.

[0049] Installation method: The first method, such as Figure 2 As shown, a pre-embedded sleeve 12 is used. The edge of the template mesh 3 is placed into the mounting groove 11 of the precast wall panel 1. Then, after passing the bolt 13 through the corresponding mesh of the template mesh 3, the bolt 13 is screwed into the pre-embedded sleeve 12 in the mounting groove 11, thereby fixing the template mesh 3. The bolts should be tightened, and the torque should meet the design requirements.

[0050] The second method, such as Figure 3As shown, a clamping plate 53 is used. After the edge of the template mesh 3 is placed into the mounting groove 11, the first fastener 52 is passed through the mounting hole 104, and the clamping plate 53 is installed and tightened on the outside of the template mesh 3, pressing the template mesh 3 into the mounting groove 11. If there are any gaps or incomplete clamping in some areas, the clamping force of the clamping plate 53 on the template mesh 3 can be increased by inserting wedge blocks between the clamping plate 53 and the template mesh 3.

[0051] The third method, such as Figure 4 As shown, a keel reinforcement connection method is adopted. First, the template mesh 3 is installed on the reinforcing keel 62. Then, the reinforcing keel 62 and the template mesh 3 are placed in the mounting groove 11. During this process, the template mesh 3 can be fixed to the reinforcing keel 62 using wire or similar materials to facilitate subsequent operations. Then, the reinforcing main keel 63 is placed on the outside of the reinforcing keel 62. Finally, the second fastener 64 is passed through the mounting hole 104 to tighten and fix all components to the modular precast wall panel 1. The reinforcing keel 62 is generally set longitudinally, and the reinforcing main keel 63 is generally set laterally. The reinforcing keel 62 can be a square steel pipe or a standardized reinforcement component commonly used in building construction. The reinforcing main keel 63 is generally a round steel pipe, and the second fastener 64 is generally an extended screw used in conjunction with a locking buckle. The template mesh 3 installed in the above manner should have reinforcing ribs 62 installed at least in the direction perpendicular to the template mesh 3. If necessary, reinforcing ribs 62 should be installed around the perimeter of the template mesh 3. When the area of ​​the template mesh 3 is large enough, reinforcing ribs 62 need to be installed at intervals to ensure the overall rigidity of the template mesh 3. The reinforcing ribs 62 can be made of square steel pipes, and can be connected by welding or connectors. The reinforcing ribs 62 and the template mesh 3 can be fixed by special connectors or thin iron wires. After the concrete is poured and the concrete strength reaches the design requirements, the reinforcing ribs 62 can be removed and reused.

[0052] The fourth method, such as Figure 5 As shown, a reinforced connection is achieved using a reinforcing keel 62 and a clamping plate 53. Specifically, the template mesh 3 is first installed on the reinforcing keel 62, and then the reinforcing keel 62 and template mesh 3 are placed in the mounting groove 11. During this process, the template mesh 3 can be fixed to the reinforcing keel 62 using tie wires or similar materials to facilitate subsequent operations. Then, the clamping plate 53, along with the first fastener 52, is firmly pressed onto the reinforcing keel 62 through the mounting hole 104. At this point, the length of the reinforcing keel 62 is generally the same as or slightly shorter than the length of the template mesh 3 at the corresponding position. Adjacent reinforcing keels 62 can be clamped using the same clamping plate 53. Uneven areas can also be adjusted by inserting wedge blocks.

[0053] For complex areas such as corners and T-junctions, the formwork mesh 3 can be achieved by bending a single wide piece of mesh 3, or by splicing two narrow pieces of mesh 3 together. Multiple reinforcing joists 62 and main reinforcing joists 63 should be erected at the bends, and the mesh 3 should be tied to the reinforcing joists 62 with cable ties to enhance the strength at that point. Additionally, to further reinforce the mesh 3, cable ties can be used to tie it to the reinforcing steel frame 4 through its mesh 31. This is especially important for wider mesh 3s, where tying it to the reinforcing steel frame 4 at the middle position can enhance the load-bearing capacity in the center.

[0054] In actual construction, one or more of the above methods can be selected to fix the formwork mesh according to the specific circumstances of the project.

[0055] After installation, thoroughly inspect the verticality, flatness, and connection strength of all template mesh 3, especially the sealing and stability of the node areas. If any deviations are found, adjust them promptly.

[0056] S6. Pour concrete into the assembled shear wall.

[0057] After all the formwork mesh 3 has been installed and inspected, concrete pouring can begin. Before pouring, debris inside the formwork mesh 3 should be cleaned, and the joint surfaces of the precast wall panels 1 should be moistened with water. Concrete should be pumped or conveyed by hopper, and poured in layers, with each layer not exceeding 500mm in thickness. During pouring, a vibrator should be used to ensure the concrete is compacted, especially in joint areas and areas with dense reinforcement. Due to the mesh openings 31 on the formwork mesh 3, some cement slurry may seep out; this is normal and beneficial for the bonding between the formwork mesh 3 and the concrete.

[0058] Pouring should be carried out continuously to avoid the formation of cold joints. If an interruption is necessary, the interval should not exceed the initial setting time of the concrete.

[0059] S7. Once the concrete reaches the demolding strength, the installation fasteners can be removed.

[0060] After the concrete is poured, it is cured. Once the concrete strength reaches the demolding strength, the fasteners used to install the formwork mesh (such as bolts 13, first fastener 52, second fastener 64, and joists) can be removed. However, the formwork mesh itself is a permanent formwork and does not need to be removed; it becomes part of the structure. After removing the temporary fasteners, the wall surface is inspected. If there are any uneven areas or defects, they should be repaired promptly. Once the concrete reaches the design strength and the superstructure has been completed, the temporary support rods for the precast wall panels can be removed. At this point, the shear wall construction is complete.

[0061] After the concrete is poured and cured to a certain strength, the wall finishing process begins. Because the formwork mesh 3 has multiple mesh openings 31, during the concrete pouring process in step S6, some cement mortar seeps through the mesh openings 31 under vibration, forming uneven mortar spots or thin layers on the outer surface of the formwork mesh 3. This is a normal characteristic of the structural system of this invention and an important indicator of achieving a good bond between the formwork mesh 3 and the concrete. These seepage materials not only provide a naturally rough bonding surface for subsequent plastering but also require appropriate finishing to meet the requirements of architectural decoration and finishing.

[0062] The entire construction process is simple, straightforward, and easy to operate. Modular precast wall panels and modular formwork mesh can be freely combined to adapt to almost all shear wall sizes. When manufacturing precast wall panels, the factory only needs to produce a few modular sizes, and formwork tools can be reused. Precast wall panel production can be carried out in advance, saving significant costs and reducing the tedious steps of repeated formwork opening. Furthermore, compared to traditional construction methods, using formwork mesh 3 instead of traditional wooden formwork eliminates the cumbersome procedures of formwork erection and dismantling, significantly shortening the construction period and improving efficiency. Simultaneously, the presence of formwork mesh 3 effectively treats the interface between new and old concrete, ensuring the integrity and durability of the structure.

[0063] The above description is only a preferred embodiment of the present invention. It should be noted that for those skilled in the art, several improvements and modifications can be made without departing from the technical principles of the present invention, and these improvements and modifications should also be considered within the scope of protection of the present invention.

Claims

1. A modular prefabricated wall panel, characterized in that, The system includes a modular precast wall panel body (10), which is made of concrete and has horizontal steel bars (101) and vertical steel bars (102) arranged interlaced inside. The horizontal steel bars (101) and vertical steel bars (102) both pass through the modular precast wall panel body (10) and extend outward. The lower part of the modular precast wall panel body (10) is provided with a longitudinal steel bar lap splicing cast-in-place area (103). A concrete pouring hole is reserved above the longitudinal steel bar lap splicing cast-in-place area (103). An installation hole (104) and a bracket fixing hole (105) are provided through the modular precast wall panel body (10). The size of the modular precast wall panel body (10) is modular.

2. A modular prefabricated wall panel according to claim 1, characterized in that, The width of the modular prefabricated wall panel (1) is 600mm, 900mm, or 1200mm.

3. A shear wall combining modular prefabricated wall panels and a non-removable formwork mesh, characterized in that, It includes modular precast wall panels (1) and cast-in-place wall panels (2). The cast-in-place wall panels (2) include template mesh (3) located on both sides of the cast-in-place wall panels (2), concrete poured in the template mesh (3), and internal steel reinforcement skeleton (4). The template mesh (3) is installed on the steel reinforcement skeleton (4) and / or the modular precast wall panels (1). The template mesh (3) has multiple mesh openings (31).

4. A shear wall combining modular prefabricated wall panels and a non-removable formwork mesh as described in claim 3, characterized in that, The template mesh (3) is also provided with U-shaped ribs (32), and the mesh (31) is a dense mesh.

5. A shear wall combining modular prefabricated wall panels and a non-removable formwork mesh according to claim 3, characterized in that, The modular precast wall panel body (10) and the longitudinal steel reinforcement lap splice cast-in-place area (103) are provided with installation grooves (11) at their four edges. The installation holes (104) are spaced apart at the edges of the installation grooves (11). The depth of the installation grooves (11) is equal to the thickness of the template mesh (3). The edges of the template mesh (3) are fitted and fixed in the installation grooves (11).

6. A shear wall combining modular prefabricated wall panels and a non-removable formwork mesh according to claim 3, characterized in that, Multiple sleeves (12) with internal threads are pre-embedded in the mounting groove (11), and the template mesh (3) is fixed in the mounting groove (11) by bolts (13) that match the sleeves (12).

7. A shear wall comprising modular prefabricated wall panels and a formwork mesh according to claim 3, characterized in that, The template mesh (3) is fixed to the modular prefabricated wall panel (1) by a first fastener (52) passing through the mounting hole (104) and a clamping plate (53) located at both ends of the first fastener (52) and outside the template mesh (3).

8. A shear wall combining modular prefabricated wall panels and a non-removable formwork mesh according to claim 3, characterized in that, A reinforcing keel (62) is provided at the mounting groove (11), and the template mesh (3) is located between the reinforcing keel (62) and the mounting groove (11). A reinforcing main keel (63) is provided on the outside of the reinforcing keel (62), and the reinforcing main keel (63) is fixed to the modular prefabricated wall panel (1) by a second fastener (64) passing through the mounting hole (104).

9. A shear wall comprising modular prefabricated wall panels and a formwork mesh according to claim 1, characterized in that, The template mesh (3) is a steel plate mesh, and the width of the template mesh (3) is 200mm, 300mm, 400mm or 500mm.

10. The construction method of the shear wall according to any one of claims 3-9, characterized in that, Includes the following steps: S1. Determine the combination form of modular precast wall panels and formwork mesh according to the required shear wall size; the combination form is 2 end cast-in-place wall panels (2) located at both ends of the shear wall, n modular precast wall panels (1), and n-1 inter-wall cast-in-place wall panels (2) located between two adjacent modular precast wall panels (1), where n≥1, and there are no inter-wall cast-in-place wall panels (2) when n=1; S2. Determine the required quantity of modular prefabricated wall panel main body (1) and template mesh (3) of each size according to the combination form; S3. Hoist the modular prefabricated wall panel (1) to the corresponding position and fix it; S4. Place the steel reinforcement cage (4) in the corresponding position and tie it in place; S5. Cut the template mesh (3) to an appropriate length and fix it in the mounting groove (11) of the modular prefabricated wall panel (1); S6. Pour concrete into the assembled shear wall; S7. After the concrete reaches the demolding strength, remove the installed fasteners.

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