A prefabricated modular wall structure

Abstract

This invention discloses a prefabricated formwork panel composite wall structure, comprising a concrete formwork panel 1, connecting steel members 2, insulation board 6, wire mesh 7, structural column reinforcement 8, shear wall reinforcement 9, and cast-in-place concrete 10. The concrete formwork panel 1 has a trapezoidal protrusion 4 on its top surface and a trapezoidal groove 5 on its bottom surface, within which a reinforcing steel mesh 3 is installed. The reinforcing steel mesh 3 is composed of transverse thick steel bars 30, vertical thick steel bars 31, transverse thin steel bars 32, and vertical thin steel bars 33. The wire mesh 7 is composed of transverse steel wires 70, vertical steel wires 71, and fixing steel plates 72. The concrete formwork panel 1 is vertically located at both ends of the connecting steel members 2. One large surface of the insulation board 6 has the wire mesh 7 inserted, and the other large surface is in close contact with the concrete formwork panel 1. The insulation board 6 and the wire mesh 7 are located between two concrete formwork panels 1. The structural column reinforcement 8, shear wall reinforcement 9, and cast-in-place concrete 10 are all located between two concrete formwork panels 1.

Description

Technical Field

[0001] This invention relates to a prefabricated modular wall structure, belonging to the field of construction. Background Technology

[0002] The main construction method for high-rise buildings in my country is a two-step process. The first step involves the construction of the reinforced concrete shear wall structure. This requires steel or bamboo formwork to support the inner and outer reinforced concrete shear walls. Steel formwork is expensive, heavy, inconvenient to assemble and disassemble, and incurs high costs for lifting, transportation, and maintenance. Bamboo formwork can generally only be reused 4-5 times before needing to be scrapped, and its cost is also high. Adding to this the labor costs for assembling and disassembling the formwork, and the cost of sealing the connecting holes created by the formwork connectors, all of these factors significantly increase construction costs. The second step, after the reinforced concrete shear wall exterior is completed, requires external wall insulation, primarily using a "polystyrene board thin-plaster external wall insulation system." This type of insulation system has revealed numerous problems in my country, mainly including: exterior wall cracking, insulation layer detachment, poor insulation layer durability, poor fire resistance, and a lifespan not matching that of the building. These two aspects contribute to poor building quality and high construction costs. To overcome the shortcomings of the traditional two-step construction technology for high-rise buildings, the inventors proposed to improve the above-mentioned two-step construction method of building shear wall main body and external wall insulation into a one-step construction method of building shear wall and external wall sandwich insulation. To this end, a prefabricated formwork panel combined wall structure was invented, which realizes the integration of insulation and main wall, the integration of insulation and structure, and the same lifespan of insulation material as building.

[0003] Engineering practice has proven that a prefabricated formwork composite wall structure can integrate insulation and formwork, eliminating the need for disassembly, maintenance, secondary external insulation, and plastering. This accelerates construction progress, significantly reduces construction costs, improves construction efficiency, and ensures building quality. It achieves integration of insulation and structure, with insulation materials having the same lifespan as the building. The main structure and external wall insulation are constructed in one step, achieving the 75% energy saving target for buildings. It meets the sandwich insulation requirements stipulated in the new version of the "Code for Fire Protection Design of Buildings" GB 50016-2014 and has extremely broad market prospects.

[0004] This invention aims to improve the current two-step construction method of building structure and external insulation into a one-step construction method of building structure and external wall sandwich insulation, so as to shorten the construction cycle, reduce construction costs and improve construction quality. Summary of the Invention

[0005] The purpose of this invention is to overcome the technical defects of the traditional two-step construction method for thermal insulation walls in high-rise buildings, and to provide a prefabricated formwork composite wall structure for realizing one-step construction of shear wall main body and sandwich insulation in high-rise buildings.

[0006] The technical solution of the present invention is implemented as follows: a prefabricated formwork panel combined wall structure, which consists of two concrete formwork panels 1, several connecting steel parts 2, insulation board 6, wire mesh 7, structural column reinforcement 8, shear wall reinforcement 9, and cast-in-place concrete 10.

[0007] The top surface of the concrete formwork plate 1 is provided with a trapezoidal protrusion 4, the bottom surface is provided with a trapezoidal groove 5, and a steel reinforcement mesh 3 is provided inside. The concrete formwork plate 1 is vertically located at both ends of the connecting steel part 2.

[0008] Several connecting steel parts 2 are perpendicular to the insulation board 6 and the wire mesh 7, and pass through the fixing holes 73 of the wire mesh 7 and the insulation board 6, and are welded to the steel reinforcement mesh 3 inside the concrete formwork plate 1.

[0009] The reinforcing steel mesh 3 is composed of several transverse thick steel bars 30, several vertical thick steel bars 31, several transverse thin steel bars 32, and several vertical thin steel bars 33. The transverse thick steel bars 30 in the reinforcing steel mesh 3 are of the same length as the concrete formwork plate 1 and are evenly and parallel to each other. The vertical thick steel bars 31 are evenly arranged and perpendicular to the transverse thick steel bars 30 and are welded together. The transverse thin steel bars 32 and the vertical thin steel bars 33 are evenly arranged, perpendicular to each other, and welded together, and are located on one side of the transverse thick steel bars 30 and the vertical thick steel bars 31, forming a rigid skeleton.

[0010] The wire mesh 7 is composed of horizontal wires (70), vertical wires 71, and fixing plates 72. The length of several horizontal wires 70 of the wire mesh 7 is less than the length of the insulation board 6, and the length of several vertical wires 71 is less than the width of the insulation board 6. Several horizontal wires 70 and vertical wires 71 are perpendicular to each other and welded together. Several fixing plates 72 with two fixing holes 73 are evenly welded onto the wire mesh 7.

[0011] A wire mesh 7 is inserted into one large side of the insulation board 6, and the other large side is in close contact with the concrete formwork plate 1. The insulation board 6 and the wire mesh 7 are located between the two concrete formwork plates 1. The size of the large side of the insulation board 6 is exactly the same as the size of the large side of the concrete formwork plate 1.

[0012] The structural column reinforcement 8 and the shear wall reinforcement 9 are both vertically located between the two concrete formwork plates 1 and are parallel to the concrete formwork plates 1 on both sides. The cast-in-place concrete 10 is located in the cavity formed by the insulation board 6 and the concrete formwork plate 1.

[0013] The steel reinforcement mesh 3 and steel wire mesh 7 in a prefabricated modular wall structure need to be treated with anti-corrosion measures. Attached image description:

[0014] Figure 1This is a three-dimensional schematic diagram of the structural positions of the concrete formwork plate 1, connecting steel parts 2, steel reinforcement mesh 3, insulation board 6, and wire mesh 7 of the present invention.

[0015] Figure 2 This is a front view schematic diagram of the structural positions of the concrete formwork plate 1, connecting steel parts 2, steel reinforcement mesh 3, insulation board 6, and wire mesh 7 of the present invention.

[0016] Figure 3 This is a top view schematic diagram of the structural positions of the concrete formwork plate 1, connecting steel parts 2, insulation board 6, and wire mesh 7 of the present invention.

[0017] Figure 4 This is a left-view AA-section schematic diagram showing the structural positions of the concrete formwork plate 1, connecting steel parts 2, insulation board 6, and wire mesh 7 of the present invention.

[0018] Figure 5 This is a front view schematic diagram of the structural composition of the steel reinforcement mesh 3 of the present invention;

[0019] Figure 6 This is a front view schematic diagram of the structural composition of the wire mesh 7 of the present invention;

[0020] Figure 7 This is a top view of the construction site installation of the composite wall structure consisting of the concrete formwork plate 1, connecting steel parts 2, insulation board 6, structural column reinforcement 8, and shear wall reinforcement 9 of the present invention.

[0021] Figure 8 This is a top view of the construction site installation of the composite wall structure of the present invention, consisting of concrete formwork plate 1, connecting steel parts 2, insulation board 6, structural column reinforcement 8, shear wall reinforcement 9, and cast-in-place concrete 10.

[0022] Figure 9 This is a three-dimensional schematic diagram of the structural positions of the concrete formwork plate 1, connecting steel parts 2, and steel reinforcement mesh 3 of the present invention.

[0023] Figure 10 This is a top view of the construction site installation of the composite wall structure consisting of the concrete formwork plate 1, connecting steel parts 2, structural column reinforcement 8, and shear wall reinforcement 9 of the present invention.

[0024] Figure 11 This is a top-view diagram of the construction site installation of the composite wall structure of the present invention, consisting of concrete formwork plate 1, connecting steel parts 2, structural column reinforcement 8, shear wall reinforcement 9, and cast-in-place concrete 10.

[0025] In the diagram: 1 represents the concrete formwork slab.

[0026] 2 is the connecting steel component

[0027] 3 is a steel reinforcement mesh.

[0028] 30 is a transverse thick steel bar.

[0029] 31 is a vertical thick steel bar.

[0030] 32 is a transverse thin steel bar.

[0031] 33 is a vertical thin steel bar.

[0032] 4 is a trapezoidal boss

[0033] 5 is a trapezoidal groove

[0034] 6 is insulation board

[0035] 7 is a steel wire mesh.

[0036] 70 is a transverse steel wire

[0037] 71 is a vertical steel wire

[0038] 72 is a fixed steel plate

[0039] 73 is a fixing hole

[0040] 8 represents the reinforcing bars of the structural column.

[0041] 9 represents the shear wall reinforcement.

[0042] 10 is cast-in-place concrete. Detailed Implementation

[0043] The present invention is implemented as follows, in conjunction with the appendix. Figures 1 to 11 To further explain: The technical solution of the present invention is implemented as follows: A prefabricated formwork panel combined wall structure is composed of two concrete formwork panels 1, several connecting steel parts 2, insulation board 6, wire mesh 7, structural column reinforcement 8, shear wall reinforcement 9, and cast-in-place concrete 10.

[0044] The top surface of the concrete formwork plate 1 is provided with a trapezoidal protrusion 4, the bottom surface is provided with a trapezoidal groove 5, and a steel reinforcement mesh 3 is provided inside. The concrete formwork plate 1 is vertically located at both ends of the connecting steel part 2.

[0045] Several connecting steel parts 2 are perpendicular to the insulation board 6 and the wire mesh 7, and pass through the fixing holes 73 of the wire mesh 7 and the insulation board 6, and are welded to the steel reinforcement mesh 3 inside the concrete formwork plate 1.

[0046] The reinforcing steel mesh 3 is composed of several transverse thick steel bars 30, several vertical thick steel bars 31, several transverse thin steel bars 32, and several vertical thin steel bars 33. The transverse thick steel bars 30 in the reinforcing steel mesh 3 are of the same length as the concrete formwork plate 1 and are evenly and parallel to each other. The vertical thick steel bars 31 are evenly arranged and perpendicular to the transverse thick steel bars 30 and are welded together. The transverse thin steel bars 32 and the vertical thin steel bars 33 are evenly arranged, perpendicular to each other, and welded together, and are located on one side of the transverse thick steel bars 30 and the vertical thick steel bars 31, forming a rigid skeleton.

[0047] The wire mesh 7 is composed of horizontal wires (70), vertical wires 71, and fixing plates 72. The length of several horizontal wires 70 of the wire mesh 7 is less than the length of the insulation board 6, and the length of several vertical wires 71 is less than the width of the insulation board 6. Several horizontal wires 70 and vertical wires 71 are perpendicular to each other and welded together. Several fixing plates 72 with two fixing holes 73 are evenly welded onto the wire mesh 7.

[0048] A wire mesh 7 is inserted into one large side of the insulation board 6, and the other large side is in close contact with the concrete formwork plate 1. The insulation board 6 and the wire mesh 7 are located between the two concrete formwork plates 1. The size of the large side of the insulation board 6 is exactly the same as the size of the large side of the concrete formwork plate 1.

[0049] The structural column reinforcement 8 and the shear wall reinforcement 9 are both vertically located between the two concrete formwork plates 1 and are parallel to the concrete formwork plates 1 on both sides. The cast-in-place concrete 10 is located in the cavity formed by the insulation board 6 and the concrete formwork plate 1.

[0050] The steel reinforcement mesh 3 and steel wire mesh 7 in a prefabricated modular wall structure need to be treated with anti-corrosion measures.

[0051] The on-site construction of the prefabricated formwork panel combined wall structure of the present invention is achieved as follows:

[0052] 1) Clean up any remaining concrete on the ground beam and establish a level surface;

[0053] 2) Laying out lines and arranging boards;

[0054] 3) Tie the main structural column reinforcement 8 and the shear wall reinforcement 9;

[0055] 4) Install prefabricated formwork panels for interior and exterior walls using double-line mounting;

[0056] 5) After installing one layer of prefabricated formwork panels, it is necessary to check the dimensional error to ensure that the dimensions of the formwork panels meet the dimensional accuracy of the cast-in-place reinforced concrete wall. Then, install the second layer of prefabricated formwork panels, and continue until the height of one floor is reached.

[0057] 6) Check whether the joints of the prefabricated formwork are sealed tightly to prevent cement slurry from leaking out, and then pour the mixed cast-in-place concrete 10 and vibrate it to compact it.

[0058] 7) Without disassembling the formwork and plastering the interior and exterior walls, proceed directly to the next process cycle.

[0059] The beneficial effects of this invention are:

[0060] 1) A prefabricated formwork composite wall structure, consisting of concrete formwork 1, connecting steel parts 2, insulation board 6, wire mesh 7, structural column reinforcement 8, shear wall reinforcement 9, and cast-in-place concrete 10. Such an extremely stable rigid integral wall structure upgrades the traditional two-step construction technology of high-rise buildings to a one-step construction method, improving construction efficiency and reducing construction labor intensity.

[0061] 2) Prefabricated formwork panels are manufactured in factories and constructed using standardized prefabricated methods on-site. This results in fast construction speed, high construction quality, no environmental pollution, reduced construction costs, and improved energy-efficient building quality.

[0062] 3) The concrete formwork panels 1 located on both sides serve as non-removable formwork. After construction, there is no need to dismantle the formwork again, which eliminates the procedures and costs of dismantling the formwork again, sealing the connection holes, and plastering the inner and outer walls, thus shortening the construction cycle.

[0063] 4) The application of a prefabricated formwork panel composite wall structure makes one-step construction technology a reality. Concrete formwork panels 1 are located on both sides and connected vertically by connecting steel components 2. Insulation panels 6 are located between the two concrete formwork panels 1, forming a cast-in-place concrete sandwich insulated wall. This significantly improves the building's thermal insulation and heat insulation standards, meeting the requirements of the new version of the "Code for Fire Protection Design of Buildings" GB 50016-2014. Compared with current external wall insulation, it greatly improves the thermal insulation and heat insulation effect, and reduces the building's operating costs in terms of energy-saving thermal insulation and heat insulation. It has multiple functions including thermal insulation, heat insulation, and fire resistance, is integrated with the building structure, and the insulation material has the same lifespan as the building.

Claims

1. A prefabricated formwork composite wall structure, consisting of two concrete formwork panels (1), several connecting steel parts (2), insulation board (6), wire mesh (7), structural column reinforcement (8), shear wall reinforcement (9), and cast-in-place concrete (10); The top surface of the concrete formwork plate (1) is provided with a trapezoidal boss (4), the bottom surface is provided with a trapezoidal groove (5), and a steel reinforcement mesh (3) is provided inside. The concrete formwork plate (1) is vertically located at both ends of the connecting steel parts (2). Several connecting steel parts (2) are perpendicular to the insulation board (6) and the wire mesh (7), and pass through the fixing holes (73) of the wire mesh (7) and the insulation board (6) to be welded to the steel reinforcement mesh (3) inside the concrete formwork plate (1); The steel reinforcement mesh (3) is composed of several horizontal thick steel bars (30), several vertical thick steel bars (31), several horizontal thin steel bars (32), and several vertical thin steel bars (33). The several horizontal thick steel bars (30) in the steel reinforcement mesh (3) are of the same length as the concrete formwork plate (1) and are evenly arranged in parallel. The several vertical thick steel bars (31) are evenly arranged and perpendicular to the horizontal thick steel bars (30) and welded together. The several horizontal thin steel bars (32) and several vertical thin steel bars (33) are evenly arranged, perpendicular to each other, welded together, and welded together to one side of the horizontal thick steel bars (30) and the vertical thick steel bars (31) to form a rigid skeleton. The wire mesh (7) is composed of horizontal wires (70), vertical wires (71), and fixing plates (72). The length of several horizontal wires (70) of the wire mesh (7) is less than the length of the insulation board (6), the length of several vertical wires (71) is less than the width of the insulation board (6), the several horizontal wires (70) and the vertical wires (71) are perpendicular to each other and welded together, and several fixing plates (72) with two fixing holes (73) are evenly welded onto the wire mesh (7). One large side of the insulation board (6) is fitted with a wire mesh (7), and the other large side is in close contact with the concrete formwork plate (1). The insulation board (6) and the wire mesh (7) are located between the two concrete formwork plates (1). The dimensions of the large side of the insulation board (6) are exactly the same as the dimensions of the large side of the concrete formwork plate (1). The structural column reinforcement (8) and shear wall reinforcement (9) are both vertically located between the two concrete formwork plates (1) and parallel to the concrete formwork plates (1) on both sides. The cast-in-place concrete (10) is located in the cavity formed by the insulation board (6) and the concrete formwork plate (1).

2. The prefabricated modular wall structure according to claim 1, characterized in that: The steel reinforcement mesh (3) and the wire mesh (7) need to be treated with anti-corrosion measures.

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