Installation construction method of complex double-layer double-curved-surface aluminum plate carved composite curtain wall

Abstract

The application provides a complex structure double-layer double-curved-surface aluminum plate carving combined curtain wall installation construction method, which comprises the following steps: Faro scanning completed steel structure, deepening design and modeling, curtain wall keel positioning and line laying, glass and aluminum plate carving round pipe keel installation, fluorocarbon spraying, intermediate layer package box beam aluminum plate installation, glass installation and gluing, double-layer double-curved-surface aluminum plate carving installation, outermost package box beam aluminum plate installation and gluing, and the like. In the application, the installation sequence of the aluminum plate, the glass and the aluminum plate carving is reasonably organized, the installation precision and the integrity are improved, and it is ensured that all the processes can form a flow construction.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of combined curtain wall installation, in particular to a complex structure double-layer double-curved-surface aluminum plate carved combined curtain wall installation construction method. BACKGROUND

[0002] In the scheme design stage of large-scale stadium construction, in order to reflect the local human culture, take into account the local city development planning, distinguish from similar buildings and other factors, through the double-layer double-curved-surface carved curtain wall design, the different types of curtain walls are combined, and the display forms of the same type of curtain wall are created, finally forming the different style of the facade effect, which effectively sublimates the connotation of the building, strengthens the organic integration of the building and the environment, improves the image of city development, and promotes the convenience of residents' life.

[0003] However, the construction node of the glass, aluminum plate, double-layer double-curved-surface aluminum plate carved combined curtain wall is complex, especially each aluminum plate carving section is large and is a double-curved-surface, which has great difficulty in material processing and carving installation. SUMMARY

[0004] In view of the above prior art, the present application provides a complex structure double-layer double-curved-surface aluminum plate carved combined curtain wall installation construction method.

[0005] The complex structure double-layer double-curved-surface aluminum plate carved combined curtain wall installation construction method provided by the present application comprises the following steps:

[0006] S1, Faro scans the completed steel structure: after the settlement of the steel structure is completed, the Faro equipment is used to scan the steel structure in three dimensions, and the entity steel structure model is generated by reverse modeling, and then the Rhino modeling design is performed on the real steel structure;

[0007] S2, deepening design and modeling: when installing the round pipe keel shared by the double-layer double-curved-surface aluminum plate carving and the glass, one end of the round pipe keel is inserted and welded with the bent and twisted box beam core, and the other end is bolted with the bent and twisted box beam through the ear plate; when processing and installing the double-layer double-curved-surface aluminum plate carving, the double-layer double-curved-surface aluminum plate carving is symmetrically and uniformly divided into blocks in the height direction, the non-standard section is placed at the end in the height direction, the standard section is installed first, and then the non-standard section is installed;

[0008] S3, curtain wall keel positioning and line laying: parameterized processing is adopted, the Rhino software is used to extract the radius and length data, the materials are ordered and processed one by one, and are matched according to the construction plan requirements; the key temporary axis network is positioned on the floor by the total station, the vertical line is guided by the weather-resistant steel plate, and the relationship between each other is obtained by conversion, the spatial relationship is converted into the plane relationship, so as to position and measure the round pipe keel and check the size;

[0009] S4, package box beam aluminum plate keel installation: positioning and welding 200*200 square tubes on the bending and torsion box beam, and welding several 40*40 square tubes as package box beam aluminum plate keels on the bending and torsion box beam and the 200*200 square tubes;

[0010] S5, glass and aluminum plate carved round pipe keel installation: installation of the round pipe keel shared by the glass and the aluminum plate carving is performed, a sleeve pipe is installed first, then one end of the round pipe keel is connected to the bending and torsion box beam through a plug core and is welded and fixed, and the other end is connected to the bending and torsion box beam through a bolt and an ear plate and is fixed;

[0011] S6, fluorocarbon spraying: after the full welding of the connection of the round pipe keel is completed, unified treatment of rust and corrosion prevention and fluorocarbon paint spraying of the round pipe is performed;

[0012] S7, installation of the middle layer package box beam aluminum plate: installation of the middle layer package box beam aluminum plate is performed to create conditions for glass installation;

[0013] S8, glass installation and glue filling: installation of a cross beam is performed before glass installation, and the glass is installed through the cross beam; after the glass is installed, a foam rod is filled in a glass joint position, and then the joint is cleaned and glued;

[0014] S9, installation of double-layer double-curved surface aluminum plate carving: after the glass installation is completed, the remaining middle layer package box beam aluminum plate is promptly constructed, and after the construction is completed, curtain wall water test is performed, and after the test is qualified, installation of the double-layer double-curved surface aluminum plate carving is formally started;

[0015] S10, installation and glue filling of the outermost package box beam aluminum plate: after the installation of the double-layer double-curved surface aluminum plate carving is completed, installation and glue filling of the outermost package box beam aluminum plate are performed, and finally the installation of the entire double-layer double-curved surface aluminum plate carving composite curtain wall is completed.

[0016] Preferably, in S2, for the large-section double-layer double-curved surface aluminum plate carving, the double-layer double-curved surface aluminum plate carving is segmented according to the 7m segmentation principle in the width direction.

[0017] Preferably, in S2, after the segmentation, each layer of the solid aluminum plate carving of each piece of the double-layer double-curved surface aluminum plate carving is directly completed in the factory, and then the pieces are welded and connected to form the double-layer aluminum plate carving, and all the aluminum plate carving pieces are separately bent on both sides, and the aluminum plate carving pieces are connected by stainless steel sleeve screws.

[0018] Preferably, in S5, the round pipe keel is made of galvanized steel pipe.

[0019] Preferably, in S8, the cross beam is an aluminum alloy cross beam.

[0020] Preferably, in S8, when installing the glass, the lower end of the glass panel is pressed on the pad frame of the crossbeam, and the left and right ends are fixed to the crossbeam by screws and pressure plates. During installation, the glass panel is lifted upward so that the lower end of the glass panel makes smooth contact with the rubber pad on the support plate of the crossbeam, and then the position of the glass panel is adjusted left and right.

[0021] Compared with the prior art, the beneficial effects of the present invention are as follows:

[0022] 1. This invention uses Faro laser scanning equipment to reverse engineer a complete steel structure into a precise skin model of the Rhino curtain wall using a three-dimensional scan. The precise coordinates of the keel are obtained through the newly created model, ensuring that the layout on the curved and twisted steel structure box beam is completed in one go.

[0023] 2. In this invention, through in-depth design, the bolt connection at both ends of the main keel shared by aluminum plate carving and glass is adjusted to a connection with a core at one end and a bolt connection at the other end, which simplifies the connection method, greatly reduces the error rate of round tube keel cutting and installation, and facilitates cutting and installation in one go.

[0024] 3. This invention utilizes a symmetrical and uniform block division with a 1.5m module in the height direction and a 7m segmentation principle in the width direction to divide the double-layer hyperboloid aluminum plate into blocks for carving. Non-standard segments in the height direction are placed at the ends. All carving blocks are individually double-sided bent, and the carving blocks are connected with stainless steel sleeve screws. The inner and outer carving pieces of each double-layer aluminum plate are processed first. After carving and bending each piece, aluminum alloy round tubes are welded to form each carved aluminum plate. Each aluminum single plate and aluminum plate carving are made in the factory and installed on site, which solves the problem of difficulty in overall installation in spatial curved diamond-shaped openings.

[0025] 4. By rationally organizing the installation sequence of aluminum plates, glass, and aluminum plate carvings, this invention improves installation accuracy and integrity, ensuring that all processes can be carried out in a continuous flow. Attached Figure Description

[0026] Figure 1 This is a flowchart of an installation and construction method for a complex double-layer hyperboloid aluminum plate carved combination curtain wall according to an embodiment of the present invention.

[0027] Figure 2 This is a schematic diagram of glass installation in an embodiment of the present invention.

[0028] Figure 3 This is a schematic diagram of the installation of the double-layer hyperboloid aluminum plate carving in an embodiment of the present invention.

[0029] In the picture, 1. Curved box girder; 2. 200*200 square tube; 3. 40*40 square tube; 4. Round tube keel; 5. Aluminum plate covering the box girder; 6. Glass; 7. Double-layer double-curved aluminum plate with carvings. Detailed Implementation

[0030] In order to make the technical means, creative features, purposes and effects of the present application easy to understand, the present application is further described below in combination with specific drawings. Embodiments

[0031] A complex double-layer double-curved-surface aluminum plate carving combined curtain wall installation construction method, as shown in Figure 1 includes the following steps:

[0032] S1, Faro scans the completed steel structure: Generally, the steel structure of a stadium is elliptical in shape and arched in roof, and most of the outer facade is designed as a complex-shaped curtain wall, such as a bent and twisted steel box beam design, similar to a curved rhombic petal skeleton structure. The double-layer double-curved-surface combined aluminum plate carving combined curtain wall is "rooted" on the petal steel structure, and the positioning and measurement are difficult. At the same time, considering that the steel structure and the curtain wall project are generally constructed by two units, the actual completed steel structure generally has size, elevation, and spatial positioning deviations from the original steel structure model. Therefore, the most accurate actual completed steel structure model needs to be established to facilitate the subsequent keel positioning and a series of material cutting work of the curtain wall project.

[0033] The aluminum plate carving combined curtain wall has a complex structure, and the construction space limit is 40-200 mm. In the limited construction space, a series of installation, processing, and welding processes need to be completed, and the keel installation position precision is required to be high.

[0034] Therefore, the three-dimensional scanning technology is adopted. After the steel structure is settled, the Faro device is used to perform three-dimensional scanning on the steel structure, and a solid steel structure model is generated by reverse modeling. Then, the Rhino modeling design is performed again on the real steel structure.

[0035] S2, deepening design and modeling: Since the double-layer double-curved-surface aluminum plate carving combined curtain wall has a complex design node, such a curtain wall often presents a special-shaped structure, involves size gradient, and has different bending angles. Therefore, according to the Rhino accurate model and design drawings, the combined curtain wall processing cutting, installation method, and installation sequence are analyzed and researched to find a general processing and installation method. Taking the existing swimming pool and gymnasium projects as examples, the aluminum plate carving combined curtain wall has the following design profiles:

[0036] a. The swimming pool curtain wall is designed as a double-layer double-curved-surface aluminum plate carving. Each layer of the double-curved-surface aluminum plate carving is a solid pure aluminum plate with a thickness of 12 mm. A total of 88 curved rhombic aperture carvings are provided. Each carving has a length of 1.5-22 m, a width of 0.5-7.5 m, and a weight of 0.5-3 t. The glass and aluminum plate carvings share a horizontal circular tube keel. The circular tube has a specification of ø102-ø219. The two ends of the circular tube keel are welded to the ear plates, and then the two ends of the circular tube keel are bolted to the ear plates.

[0037] b. The stadium curtain wall design is double-layered double-curved aluminum plate carving. Each layer of double-curved carving is a solid pure aluminum plate. The standard section is 112*6mm, the petal section width is 130-239mm, and the total number of curved rhombic hole carvings is 72. Each carving is 12m-27m long and 5-11m wide, weighing 1.3-9.5t. The glass and aluminum plate carvings share a horizontal circular tube keel. The circular tube specification is ø102-ø219. The two ends of the bent and twisted box beam are welded to the ear plate, and then the two ends of the circular tube keel are bolted to the ear plate.

[0038] Due to the complex connection node between the circular tube keel and the bent and twisted box beam of the steel structure, and the gradual change in the size of the curved rhombic petal steel structure hole, the deviation in the cutting and installation of the circular tube keel will cause the circular tube keel to fail to be installed normally. In view of this situation, during the deepening design, one end of the circular tube keel shared by the double-layer double-curved aluminum plate carving and the glass is inserted into the bent and twisted box beam and welded, and the other end is bolted to the bent and twisted box beam through the ear plate. This simplifies the connection method, greatly reduces the fault tolerance of the cutting and installation of the circular tube keel, and ensures that the cutting and installation are done at one time.

[0039] Due to the different cross-sections of each double-layer double-curved aluminum plate carving and the double-curved surface, the overall cross-section is large and heavy, which cannot be bent and transported in whole, and the concrete structure platform is designed around each single body of the stadium, which cannot be lifted by heavy equipment such as cranes. The whole aluminum plate carving needs to be lifted by a long-arm crane, which is not economical. Therefore, the lifting scheme needs to be determined by considering the size, weight, processing equipment, transportation conditions, construction technology, lifting conditions and other requirements. The processing and on-site installation scheme of the double-layer double-curved aluminum plate carving can be developed according to the following ideas:

[0040] a. The double-layer double-curved aluminum plate carving is symmetrically and uniformly divided into blocks in the height direction at a modulus of 1.5m. The non-standard section is placed at the end in the height direction. The standard section is installed first, and then the non-standard section is installed.

[0041] b. Due to the high-temperature kiln space for aluminum plate painting, which is generally about 7m, the double-layer double-curved aluminum plate carving is divided into blocks in the width direction according to the 7m segmentation principle.

[0042] c. After the double-layer double-curved aluminum plate carving is divided into blocks, each layer of solid aluminum plate carving in each double-layer aluminum plate carving is completed in the factory, and then the pieces are welded to form a double-layer aluminum plate carving. This reduces the welding workload and construction difficulty of the aluminum carving installation on site. At the same time, all aluminum plate carvings are separately bent, and stainless steel sleeve screws are used to connect the blocks.

[0043] The aluminum plate curtain wall can be designed in combination with the position of the round pipe keel, and the aluminum single plate joint is set at an interval of 1.5 m to ensure consistent and beautiful lines. After the steel structure solid model is established, the Rhino curtain wall model is drawn according to the drawings and the deepening design scheme, which can be used for line laying and cutting.

[0044] S3, curtain wall keel positioning and laying: Since the double-layer double-curved aluminum plate carving curtain wall is rooted on the spatial twisted box girder, the twisted box girder is a spatial structure, and the angle of the box girder itself varies, and the closer to the top, the closer to the horizontal, there are many invisible surfaces to be measured, and the traditional method cannot quickly measure, and the installation position precision of the combined curtain wall for the keel is extremely high, so the measurement is extremely difficult. In view of this situation, the following two aspects can be dealt with:

[0045] a, parameterized processing is adopted, the radius and length data are extracted by Rhino software, the materials are ordered and processed one by one, and the materials are matched according to the construction plan requirements.

[0046] b, temporary ground coordinate method: through the total station instrument, the key temporary axis network is positioned on the floor (there is a spatial conversion relationship with the actual axis network), the plumb line is drawn through the weather-resistant steel plate, and the relationship between each other is obtained through conversion, the spatial relationship is converted into a plane relationship (auxiliary main elevation), which can quickly position and measure the round pipe keel and check the size.

[0047] S4, aluminum plate keel installation of box girder: Since the double-layer double-curved aluminum plate carving combined curtain wall involves aluminum plate, glass, and solid aluminum plate carving three forms of curtain wall, before construction, the installation sequence of various forms of curtain wall keel and curtain wall panel needs to be deduced combined with the design node of the drawings, to find the best installation scheme of the keel and the panel, to ensure that the keel and the panel are installed in place at one time, and to reduce the risk of rework.

[0048] As shown in Figure 2 , the 200*200 square tube 2 is positioned and welded on the twisted box girder 1, and several 40*40 square tubes 3 are welded on the twisted box girder 1 and the 200*200 square tube 2 as the aluminum plate keel of the box girder.

[0049] S5, glass and aluminum plate carving round pipe keel installation: as shown in 2, the 200*200 square tube 2 is used as a measurement reference to assist in the installation of the round pipe keel 4 commonly used by glass and aluminum plate carving, the sleeve pipe is installed first, then the round pipe keel 4 made of galvanized steel pipe is positioned and measured by the total station instrument, one end is connected and welded to the twisted box girder 1 through the plug core, and the other end is connected and fixed to the twisted box girder 1 through bolts and ear plates.

[0050] S6, fluorocarbon spraying: after the full welding of the connection of the round pipe keel 4 is completed, the weld is uniformly treated for rust and corrosion prevention, and the round pipe fluorocarbon paint is sprayed.

[0051] S7, installation of intermediate layer box beam aluminum plate: as shown in Figure 2 After the round pipe keel 4 and box beam aluminum plate keel installation are completed and the corrosion and rust prevention and finish painting are completed, the installation of the intermediate layer box beam aluminum plate 5 is performed to create conditions for glass installation, wherein the box beam aluminum plate 5 is divided into single aluminum plates in the width direction and is installed in blocks.

[0052] S8, glass installation and glueing: as shown in Figure 2 Before the glass 6 is installed, the installation of the aluminum alloy cross beam is performed, and during the installation process, it is necessary to check whether the cross beam has been damaged, whether the punching is according to the requirements, whether all the punched edges have deformation, and whether there are burr edges, etc. If similar situations are found, they are cleaned before installation to ensure the installation quality of the cross beam.

[0053] After the glass plate is processed in the processing factory, it is necessary to mark each glass according to the corresponding mark on the Rhino model grid chart. The lower end of the glass plate is pressed on the cushion frame of the cross beam, and the left and right ends are fixed on the cross beam by the pressing plate through the screws. When installing, the glass plate is lifted upward to make the lower end of the glass plate stably contact with the rubber pad on the supporting plate of the cross beam, and then the position of the glass plate is adjusted left and right.

[0054] After the glass 6 is installed, the foam rod is filled in the glass joint position, and then the joint is cleaned and glued. During the process, the “two-cloth wiping method” is adopted to clean the joint to be glued within half an hour before gluing.

[0055] S9, installation of double-layer double-curved surface aluminum plate carving: after the glass 6 is installed, the construction of the remaining intermediate layer box beam aluminum plate 5 is performed in time, and after the end of the construction, the curtain wall water test is performed first, as shown in Figure 3 After the test is qualified, the installation of the double-layer double-curved surface aluminum plate carving 7 is formally started. The following matters need to be paid attention to during the installation of the double-layer double-curved surface aluminum plate carving 7:

[0056] a. The installation sequence is from bottom to top. The standard block carving is installed first, and then the non-standard block carving at both ends is installed.

[0057] b. Before the carving is hoisted, the spacing of the round pipe keel 4 needs to be rechecked. The on-site construction management personnel can quickly position and measure and recheck the round pipe keel 4 by using the steel plate guide plumb line and by converting the space relationship of the carving on the Rhino model into a plane relationship.

[0058] After the size of the round pipe keel 4 is checked, the small car hoist can be used for single block three-point hoisting. For the double-layer double-curved surface aluminum plate carving which is segmented in the width direction, the on-site assembly is needed to ensure that the whole block is hoisted in the width direction.

[0059] S10, the outermost box beam aluminum plate installation and glue: after the installation of double-layer double-curved surface aluminum plate carving is completed, the installation of the outermost box beam aluminum plate 5 is carried out and glued, and finally the installation of the entire double-layer double-curved surface aluminum plate carving combined curtain wall is completed.

[0060] According to the design characteristics of the steel structure curved rhombic space opening and the double-layer double-curved surface aluminum plate carving combined curtain wall, the Rhino precise model is reversely established by using the Faro laser scanning equipment to scan the completed steel structure three-dimensionally, and then the curtain wall keel precise coordinates are exported, and finally the curtain wall keel coordinates are measured and placed on the bending and twisting box girder 1 by using the total station according to the coordinates. Meanwhile, according to the Rhino precise model and the design drawings, the analysis and research are carried out on the combined curtain wall processing blanking, installation mode and installation sequence, the bolt connection of the two ends of the main keel shared by the aluminum plate carving and the glass is adjusted to the "insert core" connection at one end and the bolt connection at one end, the connection mode is simplified, the fault tolerance of the round pipe keel blanking and installation is greatly reduced, and the one-time positioning of the blanking and installation is ensured.

[0061] In addition, the large-section double-layer double-curved surface aluminum single plate is divided into blocks in the width direction, the large-section double-layer double-curved surface solid aluminum plate carving is divided into blocks in the height and width directions, the one-time processing and installation problems of the large-section double-curved surface aluminum plate and the aluminum plate carving are solved, the factory processing of all aluminum single plates, glass and solid carvings is ensured, the on-site direct assembly and installation are realized, and the processing and installation precision is improved. The combined curtain wall keel is constructed on site, then the inner double-curved surface aluminum single plate, glass, middle aluminum single plate, double-layer double-curved surface aluminum plate carving and outermost double-curved surface aluminum single plate are constructed in sequence, and this installation mode can make the whole double-layer double-curved surface carving combined curtain wall form a continuous construction, effectively ensure the construction progress and quality of the carving combined curtain wall, and ensure the one-time qualification rate of the double-layer double-curved surface aluminum plate carving combined curtain wall installation.

[0062] The above is only an embodiment of the present application, and does not limit the patent scope of the present application, and any equivalent structure, direct or indirect application in other related technical fields according to the content of the present application specification and drawings, is also within the patent protection scope of the present application.

Claims

1. A method for installing a complex structure double-layer double-curved aluminum plate carved composite curtain wall, characterized in that, Includes the following steps: S1. Faro scan of completed steel structure: After the steel structure has settled, the Faro device is used to perform a three-dimensional scan of the steel structure and reverse model it to generate a solid steel structure model. Then, a new Rhino modeling design is carried out on the actual steel structure. S2. Detailed Design and Modeling: During the processing and on-site installation of double-layer hyperboloid aluminum plate carvings, the double-layer hyperboloid aluminum plate carvings are symmetrically and evenly divided into blocks with a 1.5m module in the height direction. Non-standard sections are placed at the ends in the height direction. Standard sections are installed first, followed by non-standard sections. After the blocks are divided, each layer of solid aluminum plate carvings in each double-layer hyperboloid aluminum plate carving is completed directly in the factory. Then, the pieces are joined together by welding to form a double-layer aluminum plate carving. At the same time, all aluminum plate carving blocks are individually bent on both sides, and stainless steel sleeve screws are used to connect the aluminum plate carving blocks. S3. Curtain wall keel positioning and layout: Parametric processing is adopted. The radius and length data of the structure are fully extracted by Rhino software. Material orders and processing are numbered and matched one by one, and materials are matched on site according to the construction plan requirements. The key temporary axis grid is positioned on the floor by a total station. The plumb line is drawn by weathering steel plate, and the relationship between them is calculated. The spatial relationship is converted into a planar relationship for positioning measurement and re-measurement of the round tube keel. S4. Installation of aluminum plate keel for box girder: Position and weld 200*200 square tubes on the curved and twisted box girder, and weld several 40*40 square tubes as aluminum plate keels for box girder to the curved and twisted box girder and 200*200 square tubes. S5. Installation of round tube keel for glass and aluminum plate carving: Install the round tube keel shared by glass and aluminum plate carving. First, install the sleeve, then connect one end of the round tube keel to the curved box beam through the insert and weld it in place. Connect the other end to the curved box beam through bolts and ear plates and fix it in place. S6. Fluorocarbon coating: After the joint of the round pipe keel is fully welded, the weld seam is uniformly treated with rust and corrosion prevention and the round pipe is treated with fluorocarbon coating topcoat. S7. Installation of aluminum panels for intermediate layer box girder: Install aluminum panels for intermediate layer box girder to create conditions for glass installation; S8. Glass installation and caulking: Before glass installation, install the crossbeams and install the glass through the crossbeams; after glass installation, fill the glass joints with foam rods, then clean and apply caulking sealant. S9. Installation of double-layer hyperboloid aluminum panel carvings: After the glass installation is completed, the construction of the remaining intermediate layer of box girder aluminum panels shall be carried out in a timely manner. After completion, a water spray test shall be carried out on the curtain wall. After passing the test, the installation of double-layer hyperboloid aluminum panel carvings shall be carried out. S10. Installation and caulking of the outermost box girder aluminum panel: After the double-layer hyperbolic aluminum panel carving is installed, the outermost box girder aluminum panel is installed and caulking is applied, thus completing the installation of the entire double-layer hyperbolic aluminum panel carving combination curtain wall.

2. The installation construction method of the complex double-layer double-curved-surface aluminum plate carved composite curtain wall according to claim 1, characterized in that, In S2, for large-section double-layer hyperboloid aluminum plate carvings, they are divided into blocks according to the 7m segmentation principle in the width direction.

3. The installation construction method of the complex double-layer double-curved-surface aluminum plate carved composite curtain wall according to claim 1 or 2, characterized in that, In S5, the round tube keel is made of galvanized steel pipe.

4. The method according to claim 1 or 2, wherein the method is characterized by, In S8, the crossbeam is an aluminum alloy crossbeam.

5. The method according to claim 1 or 2, wherein the method is characterized by, In S8, when installing glass, the lower end of the glass panel is pressed on the pad frame of the crossbeam, and the left and right ends are fixed to the crossbeam with screws and pressure plates. During installation, lift the glass panel upward so that the lower end of the glass panel makes smooth contact with the rubber pad on the support plate of the crossbeam, and then adjust the position of the glass panel left and right.

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