Composite wall with light steel keel having special-shaped cross-section structure and construction method

Abstract

The invention relates to a composite wall of a light steel keel with a special-shaped cross-section structure and a construction method. The wall is composited by a light steel keel with a special-shaped cross-section structure, a grid, and gypsum mortar spraying, wherein U-shaped upper and lower guide rails of the light steel keel with a special-shaped cross-section structure and a C-shaped column are fixed into a frame structure by screws or nails at a certain interval and arranged in the middle of the composite wall structure, the frame structure is installed and fixed with beams, plates and columns of building structures by bolts, and is integrated with the building structures; the grid is arranged on one side or both sides of the frame structure; the gypsum mortar is sprayed on the grid and wrapped and covered to form an integral seamless composite wall of solid wall, hollow wall, double wall or other structures.

Description

Technical Field

[0001] The invention relates to a spray-built composite wall in the technical field of building engineering, in particular to a composite wall with a light steel keel with a special-shaped cross-section structure and a construction method. Background Art

[0002] Gypsum, cement and lime are known as the three major cementitious materials. It is an excellent building material with the technical characteristics of early strength and fast hardening, fire resistance, energy saving, and harmless to the human body. Its production energy consumption is one-fourth of cement, and its carbon emissions are one-twentieth of cement. It is an environmentally friendly, low-carbon, green and environmentally friendly material. Sprayed gypsum composite wall is a new type of prefabricated building technology developed in recent years. It is composed of light steel keel, reinforced steel mesh and gypsum wall sprayed mortar. However, its cost is relatively high, and the anti-corrosion requirements of the steel mesh are also very high, which limits its large-scale promotion. How to solve the stability, safety, corrosion resistance and low cost of composite walls from a structural perspective is a problem that the industry peers are particularly concerned about today. Summary of the invention

[0003] The technical problem to be solved by the present invention is to provide a composite wall with a light steel keel with a special-shaped cross-section structure and a construction method, so as to realize a structural solution of a sprayed gypsum composite wall with stability, corrosion resistance and low cost.

[0004] To this end, the technical solution of the present invention to solve the problem is: a composite wall with a light steel keel with a special-shaped cross-section structure, wherein: the wall is composed of a light steel keel with a special-shaped cross-section structure, a grid, and gypsum mortar spraying; the cross-sectional structure of the light steel keel with a special-shaped cross-section structure is U-shaped and C-shaped, and a frame structure is formed by fixing U-shaped upper and lower guide rails and C-shaped columns with screws and is arranged in the middle of the composite wall; the frame structure is then installed and fixed with building structural members beams, plates and columns by bolts, and is integrated with the building structural members; the grid is arranged on one side or both sides of the frame structure; the gypsum mortar is sprayed on it and wraps and covers it to form a composite wall with an overall seamless solid wall or hollow wall or double-layer wall structure.

[0005] Furthermore: the solid wall of the composite wall is formed by spraying the gypsum mortar on the grid and the frame structure, and completely wrapping and covering the grid and the frame structure to form a fully filled solid structural composite wall; the hollow wall is formed by spraying the gypsum mortar on the grids on both sides of the frame structure and covering the grids on both sides of the frame structure, forming a hollow structural composite wall with the frame structure as hollow and both sides as solid; the double-layer wall is composed of a double-layer frame structure with a U-shaped or C-shaped structure and a corresponding grid, and the gypsum mortar is sprayed on the grid of the double-layer light steel keel respectively, and the skeleton and the grid of the frame structure are completely wrapped and covered, forming two solid wall structures composed of a single-layer frame structure, and then a composite wall composed of the two solid walls with a double-layer wall structure with a hollow surface between the layers.

[0006] Furthermore: the light steel keel with a special-shaped cross-section structure has a cross-sectional shape of U-type or C-type, wherein the U-shaped special-shaped cross-sectional structure facilitates the soft connection of the upper and lower guide rails with the beams and plates of the building structure and the fixation with the grid, and the C-shaped special-shaped cross-sectional structure facilitates the connection of the columns with the upper and lower guide rails, the fixation with the grid and the pre-embedding of water and electricity pipelines.

[0007] Further: the light steel keel with a special-shaped cross-section structure has a C-shaped cross-section, wherein concave platforms (or platforms) are provided on the upper and lower sections along the vertical direction of the cross-section, and each of the two concave platforms (or platforms) is provided with a mounting hole; and a groove air vent intersecting with the vertical direction is provided on the section along the horizontal direction of the cross-section.

[0008] Furthermore: the light steel keel with a special-shaped cross-section structure has a U-shaped cross-section, wherein mounting holes are provided on the upper and lower sections along the vertical direction of the cross-section; and a convex groove intersecting with the vertical direction of the cross-section is provided on the section along the horizontal direction of the cross-section.

[0009] Preferably, the light steel keel is made of hot-dip galvanized steel strip, fireproof galvanized sheet, stainless steel, aluminum alloy and PVC plastic.

[0010] Preferably, the mesh includes non-metal meshes such as glass fiber mesh, nylon mesh, plastic mesh, etc.

[0011] In addition, a construction method of a sprayed composite wall with a light steel keel having a special-shaped cross-section structure is provided, the method comprising the steps of:

[0012] (1) Lay out the wall according to its designed position;

[0013] (2) Use expansion screws or chemical anchors to fix the upper and lower guide rails of the U-shaped special-shaped cross-section light steel keel to the top beam or slab and the floor;

[0014] (3) Use self-tapping screws to fix the C-shaped special-section light steel keel column to the U-shaped upper and lower guide rails, and use expansion screws or chemical anchor bolts to fix the C-shaped columns on both sides to the building structure columns or walls to form a frame structure;

[0015] (4) Insert elastic sealing materials such as foam strips into the convex grooves at the joints between the U-shaped upper and lower guide rails and the top beam or plate, and into the joints between the C-shaped columns on both sides and the walls or columns of the building structure;

[0016] (5) Lay the mesh on the upper and lower rails of the light steel keel and the sides of the columns, insert plastic rivets into the installation holes to fix them, and then use a spatula to apply gypsum mortar along the sides of the U-shaped upper and lower rails and C-shaped columns of the frame structure so that the mesh is attached to the frame structure to form a plane with the mesh laid on one or both sides;

[0017] Or add water to the pre-mixed gypsum mortar in the factory and stir it into slurry. Use a spatula to spread the gypsum mortar on the sides of the U-shaped upper and lower rails and C-shaped columns of the frame structure and squeeze it into the installation hole. Then lay the mesh on it and compact it with a spatula to make the mesh stick to the frame structure, forming a plane with all mesh laid on one side or both sides.

[0018] (6) After the above-mentioned gypsum mortar slurry hardens, use a special spraying machine to spray slurry horizontally into strips on the entire grid or manually plaster it into strips, and keep a certain distance between the strips. The thickness of the spraying cannot exceed the thickness of the wall;

[0019] (7) After the strip gypsum mortar has hardened, the first wall spraying or manual plastering is performed to form the wall;

[0020] (8) At the joints between the sprayed composite wall and the building structure, lay a 250mm wide mesh cloth to prevent cracking at the joints;

[0021] (9) Marking and punching the wall surface to form marking reinforcement that can ultimately control the wall thickness;

[0022] (10) After the reinforcement has hardened, spray the wall for the second time and scrape it along the reinforcement direction to form a wall surface that achieves the effect of plastering and leveling;

[0023] (11) Repair or polish the wall surface to acceptable standards.

[0024] Preferably: the U-shaped upper and lower guide rails and C-shaped columns, grids and gypsum mortar of the light steel keel with special cross-section structure are all manufactured in the factory and transported to the site for assembly; the gypsum mortar is transported to the site in bags, ton bags or in bulk, and is automatically fed and watered, stirred and sprayed in layers or manually plastered by a special spraying machine to form a wall, which becomes a non-load-bearing partition wall that does not require plastering after hardening and drying.

[0025] Preferably: the gypsum mortar is an inorganic gelling material made from industrial by-product gypsum as raw material, with quartz sand or vitrified microspheres, expanded perlite or other materials as aggregates, other mineral materials as fillers, and admixtures mixed in a certain ratio in a factory to produce a single-component dry powder material, which can be used when it is transported to the construction site to build a composite wall by simply adding water and stirring.

[0026] Compared with the prior art, the technical solution of the present invention highlights the three structural forms of the sprayed gypsum composite wall and utilizes the structural characteristics of the light steel keel with a special-shaped cross-section structure to improve the anti-twisting, firmness, stability and durability of the sprayed gypsum composite wall. In particular, it further improves the corrosion resistance of the wall under the premise of making full use of energy-saving and environmentally friendly gypsum mortar, while greatly reducing the project cost. BRIEF DESCRIPTION OF THE DRAWINGS

[0027] Figure 1 It is a schematic diagram of the composite wall structure of the present invention;

[0028] Figure 2 It is a schematic diagram of the main view of the special-shaped (C-shaped) cross-section structure of the light steel keel in the composite wall;

[0029] Figure 3 About Figure 2 A side view schematic diagram of

[0030] Figure 4 About Figure 2 A rotation diagram of a top view schematic diagram of;

[0031] Figure 5 It is a schematic diagram of the main view of the special-shaped (C-shaped) cross-section structure of the light steel keel in the composite wall;

[0032] Figure 6 About Figure 5 A side view schematic diagram of

[0033] Figure 7 About Figure 5 A rotation diagram of a top view schematic diagram of ;

[0034] Figure 8 It is a schematic diagram of the main view of the special-shaped (U-shaped) cross-section structure of the light steel keel in the composite wall;

[0035] Fig. 9 About Figure 8 A side view schematic diagram of

[0036] Fig.10 About Figure 8 Rotated diagram of a top view schematic diagram of .

[0037] In the figure: 1-inner layer of the composite wall, 2-light steel keel with special-shaped cross-section structure, 3-hollow layer of the composite wall, 4-outer layer of the composite wall, 5-C-type light steel keel cross-section concave platform (or platform), 6-C-type light steel keel cross-section concave platform (or platform) mounting hole, 7-C-type light steel keel cross-section groove ventilation hole, 8-U-type light steel keel cross-section convex groove, 9-U-type light steel keel cross-section platform mounting hole, 10-U-type light steel keel cross-section platform. DETAILED DESCRIPTION

[0038] See attached Figure 1-10 The following embodiments provide a description of a composite wall with a light steel keel having a special-shaped cross-section. It is a hollow double-layer composite wall consisting of an inner layer 1 of a composite wall, a light steel keel 2 having a special-shaped cross-section, a hollow layer 3 of a composite wall, an outer layer 4 of a composite wall and a corresponding grid. Figure 2-9 As shown, considering the stability of the wall, the cross-sectional structure of the light steel keel in practice is specially designed into a special-shaped structure, which is called a light steel keel with a special-shaped cross-sectional structure in this example. The special-shaped cross-sectional structure refers to the cross-sectional shape of the keel being a U-shaped body or a C-shaped body. Figure 1 What is shown is a light steel keel with a special-shaped cross-section structure, which is arranged inside the inner and outer layers of the composite wall and is at the same height as the wall.

[0039] In practice, the upper and lower rails and columns of the light steel keel (omitted in the drawings) with a special-shaped cross-section are fixed to a frame structure at a certain interval by screws or nails (omitted in the drawings) and the frame is set in the middle of the composite wall. The frame structure is then installed and fixed with the building structure beams, plates and columns by bolts (omitted in the drawings) to form a whole with the building structure. Sealing materials such as rubber strips, polystyrene foam strips, and foam strips are filled in the joints between the upper and lower rails of the light steel keel (omitted in the drawings), the columns on both sides, and the building structure beams, plates and columns. The grid is fixed to the mounting holes 6 and 9 with plastic rivets, and the gypsum mortar is applied to the sides of the U-shaped upper and lower rails and the C-shaped columns of the frame structure with a spatula, so that the grid is attached to the frame structure to form a plane with the grid laid on one side or both sides; or the gypsum mortar is applied to the sides of the U-shaped upper and lower rails and the C-shaped columns of the frame structure with a spatula and squeezed into the mounting holes 6 and 9, and then the grid is laid thereon and compacted with a spatula, so that the grid is attached to the frame structure to form a plane with the grid laid on one side or both sides; and the gypsum mortar is sprayed thereon and wrapped and covered to form an overall seamless solid wall or hollow wall or a composite wall with a double-layer wall structure.

[0040] In practice, a solid wall is formed by first laying a grid on the frame structure of the composite wall, and then spraying gypsum mortar on the grid and the frame structure until the grid and the light steel keel are completely wrapped and covered to form a fully filled solid composite wall; or, if the composite wall in this example is made into a hollow wall, gypsum mortar is sprayed on the grids on both sides of the light steel keel of the frame structure until the grid is completely covered, forming a hollow composite wall with the light steel keel of the frame structure as the center and the walls on both sides as solid; or, as described in the previous example, a double-layer wall in practice is formed by first spraying gypsum mortar on the grids of the light steel keels on both sides of the wall (also referred to as inner and outer walls), completely wrapping and covering the light steel keel of the frame structure and the grid, until two solid walls consisting of single-layer frame structure light steel keels and grids are formed, and then a composite wall with a double-layer wall structure with a hollow space between the two layers is formed by the two solid walls.

[0041] As mentioned above, in order to improve the stability and security of the wall, this embodiment deliberately emphasizes the following Figure 2-9 The light steel keel shown is a U-shaped and C-shaped cross-sectional structure diagram; for example, C-shaped light steel keel cross-sectional concave platform (or platform) 5, C-shaped light steel keel cross-sectional concave platform (or platform) mounting hole 6, C-shaped light steel keel cross-sectional groove vent hole 7, U-shaped light steel keel cross-sectional convex groove 8, U-shaped light steel keel cross-sectional concave platform mounting hole 9, U-shaped light steel keel cross-sectional platform 10; these structural designs highlight the special structure of the U-shaped and C-shaped cross-sectional shapes of the light steel keel and the positions of the corresponding holes and grooves. Such a design can greatly improve the anti-twisting, stability and tight connection with various components of the wall frame structure.

[0042] According to the stress calculation and application occasions of the non-load-bearing walls of prefabricated buildings, the light steel keels described in practice are made of hot-dip galvanized steel strips, fireproof galvanized sheets, stainless steel, aluminum alloys and PVC plastics; at the same time, in order to fix the grids on the frame structure, plastic rivet accessories matching the mounting holes are designed in practice. The grids used in practice can be non-metallic meshes such as fiberglass mesh, nylon mesh, and plastic mesh.

[0043] For the composite wall described in the embodiment, the specific construction method also has specific implementation steps:

[0044] (1) Lay out the wall according to its designed position;

[0045] (2) Use expansion screws or chemical anchors to fix the upper and lower guide rails of the U-shaped special-shaped cross-section light steel keel to the top beam or slab and the floor;

[0046] (3) Use self-tapping screws to fix the C-shaped special-section light steel keel column to the U-shaped upper and lower guide rails, and use expansion screws or chemical anchor bolts to fix the C-shaped columns on both sides to the building structure columns or walls to form a frame structure;

[0047] (4) Insert elastic sealing materials such as foam strips into the convex grooves at the joints between the U-shaped upper and lower guide rails and the top beam or plate, and into the joints between the C-shaped columns on both sides and the walls or columns of the building structure;

[0048] (5) Lay the mesh on the upper and lower rails of the light steel keel and the sides of the columns, insert plastic rivets into the installation holes to fix them, and then use a spatula to apply gypsum mortar along the sides of the U-shaped upper and lower rails and C-shaped columns of the frame structure so that the mesh is attached to the frame structure to form a plane with the mesh laid on one or both sides;

[0049] Or add water to the pre-mixed gypsum mortar in the factory and stir it into slurry. Use a spatula to spread the gypsum mortar on the sides of the U-shaped upper and lower rails and C-shaped columns of the frame structure and squeeze it into the installation hole. Then lay the mesh on it and compact it with a spatula to make the mesh stick to the frame structure, forming a plane with all mesh laid on one side or both sides.

[0050] (6) After the above-mentioned gypsum mortar slurry hardens, use a special spraying machine to spray slurry horizontally into strips on the entire grid or manually plaster it into strips, and keep a certain distance between the strips. The thickness of the spraying cannot exceed the thickness of the wall;

[0051] (7) After the strip gypsum mortar has hardened, the first wall spraying or manual plastering is performed to form the wall;

[0052] (8) At the joints between the sprayed composite wall and the building structure, lay a 250mm wide mesh cloth to prevent cracking at the joints;

[0053] (9) Marking and punching the wall surface to form marking reinforcement that can ultimately control the wall thickness;

[0054] (10) After the reinforcement has hardened, spray the wall for the second time and scrape it along the reinforcement direction to form a wall surface that achieves the effect of plastering and leveling;

[0055] (11) Repair or polish the wall surface to acceptable standards.

[0056] In practice, the U-shaped upper and lower guide rails and C-shaped columns, grids and gypsum mortar of the light steel keel with special cross-section structure described in the embodiments are all manufactured in the factory and transported to the site for assembly; the gypsum mortar is transported to the site in bags, ton bags or in bulk, and is automatically fed and watered by a special spraying machine, mixed and sprayed in layers or manually plastered to form a wall, which becomes a non-load-bearing partition wall that does not require plastering after hardening and drying.

[0057] In practice, the building materials mentioned in the preparation method of the composite wall, such as the guide rails and columns of the light steel keel with a special cross-section structure, the grid and the ingredients of the gypsum mortar can be standardized and customized in the factory and transported to the site for assembly; the gypsum mortar is transported to the site in bags, ton cans or bulk, and is automatically fed and watered by a special spraying machine, stirred and layered sprayed with mortar to form a wall or manually plastered to form a wall for hardening, and becomes a non-load-bearing partition wall without plastering after drying. In practice, gypsum mortar, one of the important building materials constituting the composite wall, is an inorganic gelling material made from industrial by-product gypsum as raw material, with quartz sand or vitrified microspheres, expanded perlite or other materials as aggregates, and other mineral materials as fillers and admixtures. It is mixed in a factory in a certain ratio to produce a single-component dry powder material, which can be transported to the construction site to build the composite wall, and only needs to be stirred with water before use. By limiting the production and preparation of gypsum mortar in this way, the production cost can be greatly reduced while ensuring environmental protection, while improving the project progress during on-site construction.

Claims

1. A composite wall with a light steel keel having a special-shaped cross-section structure, characterized in that: The wall is composed of a composite of a light steel keel with a special-shaped cross-section structure, a grid, and gypsum mortar spraying; the cross-sectional structure of the light steel keel with a special-shaped cross-section structure is a U-shaped body and a C-shaped body, and a frame structure is formed by fixing the upper and lower guide rails of the U-shaped body and the C-shaped body columns with screws and arranged in the middle of the composite wall; the frame structure is then installed and fixed with the beams, plates and columns of the building structure by bolts, and is integrated with the building structure; the grid is arranged on one side or both sides of the frame structure; the gypsum mortar is sprayed on it and wrapped and covered to form a A composite wall of a solid wall or a hollow wall or a double-layer wall structure without any gaps; wherein, the composite wall, in its solid wall, is a composite wall of a fully filled solid structure formed by spraying the gypsum mortar on the grid and the frame structure, and completely wrapping and covering the grid and the frame structure; the hollow wall is a composite wall of a hollow structure formed by spraying the gypsum mortar on the grids on both sides of the frame structure and covering the grids on both sides of the frame structure; the double-layer wall is a double-layer U-shaped or C-shaped composite wall. The gypsum mortar is sprayed on the grid of the double-layer light steel keel and completely wraps and covers the skeleton and grid of the frame structure, respectively forming two solid wall structures composed of a single-layer frame structure, and then a composite wall of a double-layer wall structure with a hollow surface between the two solid walls; wherein the U-shaped body special-shaped cross-section structure facilitates the soft connection of the upper and lower guide rails with the beams and plates of the building structure and the fixation with the grid, and the C-shaped body special-shaped cross-section structure facilitates the connection of the columns with the upper and lower guide rails, the fixation with the grid and the water The electrical pipelines are pre-buried; moreover, when the cross-sectional shape of the light steel keel with a special-shaped cross-sectional structure is a C-shaped body, concave platforms are provided on the upper and lower sections in the vertical direction of the cross-sectional structure, and mounting holes are provided on each of the two concave platforms; a groove vent hole intersecting with the vertical direction is provided on the section in the horizontal direction of the cross-sectional structure; when the cross-sectional shape of the light steel keel with a special-shaped cross-sectional structure is a U-shaped body, mounting holes are provided on the upper and lower sections in the vertical direction of the cross-sectional structure; a convex groove intersecting with the vertical direction of the cross-sectional structure is provided on the section in the horizontal direction of the cross-sectional structure; The light steel keel is made of hot-dip galvanized steel strip, fireproof galvanized sheet, stainless steel, aluminum alloy or PVC plastic.

2. The composite wall with light steel keel having a special-shaped cross-section structure according to claim 1, characterized in that: The mesh comprises a glass fiber mesh, a nylon mesh or a plastic mesh.

3. A construction method of a composite wall with a light steel keel having a special-shaped cross-section structure as claimed in claim 1, characterized in that: The method comprises the steps of: (1) Lay out the wall according to its designed position; (2) Use expansion screws or chemical anchors to fix the upper and lower guide rails of the U-shaped special-section light steel keel to the top beam or plate; (3) Use self-tapping screws to fix the C-shaped special-section light steel keel columns to the upper and lower guide rails of the U-shaped body, and use expansion screws or chemical anchor bolts to fix the C-shaped columns on both sides to the building structure columns or walls to form a frame structure; (4) Insert foam strips into the convex grooves at the joints between the upper and lower guide rails of the U-shaped body and the top beam or plate, and at the joints between the C-shaped body columns on both sides and the wall or column of the building structure; (5) Lay the mesh on the upper and lower rails and the sides of the columns of the light steel keel, insert plastic rivets into the installation holes to fix them, and then use a spatula to apply gypsum mortar along the sides of the upper and lower rails of the U-shaped body and the C-shaped body columns of the frame structure, so that the mesh is attached to the frame structure to form a plane with mesh on one side or both sides; or add water to the pre-mixed gypsum mortar in the factory and stir it into slurry, use a spatula to apply the gypsum mortar on the sides of the upper and lower rails of the U-shaped body and the C-shaped body columns of the frame structure and squeeze it into the installation holes, then lay the mesh on it and compact it with a spatula, so that the mesh is attached to the frame structure to form a plane with mesh on one side or both sides; (6) After the above-mentioned gypsum mortar slurry hardens, use a special spraying machine to spray slurry horizontally into strips on the entire grid or manually plaster it into strips, and keep a certain distance between the strips. The thickness of the spraying cannot exceed the thickness of the wall; (7) After the strip gypsum mortar has hardened, the first wall spraying or manual plastering is performed to form the wall; (8) At the joints between the sprayed composite wall and the building structure, lay a 250mm wide mesh cloth to prevent cracking at the joints; (9) Marking points and ribs on the above-mentioned wall surface to form the final ribs for controlling the thickness of the wall surface; (10) After the reinforcement has hardened, spray the wall for the second time and scrape it along the reinforcement direction to form a wall surface that achieves the effect of plastering and leveling; (11) Repair or polish the wall surface to meet the acceptance standards.

4. The construction method of the composite wall with a light steel keel having a special-shaped cross-section structure according to claim 3 is characterized in that: The U-shaped upper and lower guide rails of the light steel keel with special cross-section structure, the C-shaped column, the grid and the gypsum mortar are all manufactured in the factory and transported to the site for assembly; the gypsum mortar is transported to the site in bags or in bulk, and is automatically fed and watered, stirred and sprayed in layers by a special spraying machine or manually plastered to form a wall, which becomes a non-load-bearing partition wall that does not require plastering after hardening and drying.

5. The construction method of the composite wall with light steel keel having a special-shaped cross-section structure according to claim 3 is characterized in that: The gypsum mortar is an inorganic gelling material made from industrial by-product gypsum as raw material, quartz sand or vitrified microspheres, expanded perlite or other materials as aggregates, other mineral materials as fillers, and admixtures in a certain ratio in the factory to produce a single-component dry powder material. When it is transported to the construction site for building composite walls, it only needs to be added with water and stirred for use.

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