A production and construction method for multi-layer thermally broken composite steel-framed exterior wall panels

Abstract

This invention discloses a production and construction method for a multi-layer thermally broken composite steel-framed exterior wall panel, belonging to the field of prefabricated steel structure building technology. The method includes the following steps: S1, pre-pressing radiant cooling ceramic decorative panels and vacuum insulation panels into an integrated decorative and thermal insulation panel; S2, setting inner steel ribs within a C-shaped steel frame; S3, setting embedded connectors at the upper part of the steel ribs and embedded load-bearing components at the lower part; S4, laying steel mesh at the C-shaped steel frame; S5, setting a composite insulation board and FRP connectors within a double-layer steel wire mesh in the C-shaped steel frame; S6, setting clamping plate and hook-reinforcement connectors within the joints of the integrated decorative and thermal insulation panel; S7, laying fiberglass mesh in the upper layer of microporous lightweight concrete of the exterior wall panel; S8, welding the root reinforcing bars of the threaded sleeve to the inner steel ribs. The steel frame and steel mesh-reinforced microporous concrete composite structure provided by this invention achieves high rigidity, integrity, and easy connectivity of the exterior wall panel.

Description

Technical Field

[0001] This invention relates to the field of prefabricated steel structure building technology, specifically to a method for producing and constructing a multi-layer thermally broken composite steel frame exterior wall panel. Background Technology

[0002] Prefabricated steel structure buildings have become an important form of prefabricated construction due to their inherent prefabrication advantages. However, there is a lack of mature, stable, economical, environmentally friendly, and multifunctional integrated exterior wall cladding materials and products to match prefabricated steel structure buildings, which has become a key factor restricting the development of steel structure buildings in my country. Current exterior wall cladding materials for steel structure buildings generally use lightweight aerated concrete blocks, panels, hollow blocks, glass fiber reinforced cement boards, and other concrete slab products. These wall materials are heavy, have poor thermal insulation performance and seismic performance, require secondary insulation, and have low construction efficiency, failing to meet the requirements of multifunctional integrated walls for prefabricated steel structure buildings.

[0003] Therefore, there is an urgent need for a new type of prefabricated exterior wall panel product that integrates thermal insulation and structure, is lightweight and high-strength, provides thermal insulation, and allows for modular construction. Summary of the Invention

[0004] To achieve the above objectives, the present invention adopts the following technical solution:

[0005] A method for producing a multi-layer thermally broken composite steel-framed exterior wall panel includes the following steps:

[0006] S1, pre-pressing radiant cooling ceramic decorative panels and vacuum insulation panels into an integrated decorative and thermal insulation panel;

[0007] S2, an inner steel rib is set inside the C-shaped steel frame and welded to the C-shaped steel frame to form a steel-reinforced frame;

[0008] S3, with embedded connectors at the top of the inner steel ribs and embedded load-bearing components at the bottom, serves as the connection node between the outer wall panel and the main structure;

[0009] S4. Steel mesh is laid at the bends of the upper and lower frames of the C-shaped steel frame and welded to the C-shaped steel frame to form a double-layer steel wire mesh.

[0010] S5, an aerogel polystyrene particle composite insulation board and FRP connectors are set inside the double-layer steel wire mesh of the C-shaped steel frame; microporous lightweight concrete is poured on the upper and lower layers of the exterior wall panel, and the aerogel polystyrene particle composite insulation board is combined with the decorative insulation integrated board to form a microporous lightweight concrete composite sandwich structure.

[0011] S6, a card plate hook bar connector is installed in the joint of the decorative insulation integrated panel, and the tail of the card plate hook bar connector extends into the steel mesh at the bottom of the C-shaped steel frame and is tied with tie wire.

[0012] S7, fiberglass mesh is laid in the upper layer of microporous lightweight concrete of the exterior wall slab;

[0013] S8 has an opening on the C-shaped steel frame to weld the root steel bar of the threaded sleeve to the inner steel rib, and is used with lifting rings as lifting components during hoisting.

[0014] Furthermore, in step S6, the specific implementation steps are as follows:

[0015] S61, First, cut the prefabricated decorative insulation integrated panel according to the designed C-shaped steel frame size and the designed tongue and groove requirements;

[0016] S62, slots for fasteners are made on the four sides of the cut decorative insulation panel;

[0017] S63, lay the radiant cooling ceramic decorative panel face down on the fixed steel mold table, and at the same time assemble and lay the connector on the card plate hook rib connector with the tail facing up in the panel seam.

[0018] S64, use PC edge mold to fix the magnetic box and tightly fix the decorative and heat-insulating integrated panel;

[0019] S65, place the welded C-shaped steel frame on the laid decorative insulation integrated panel, so that it corresponds to the decorative insulation integrated panel;

[0020] S66, the tail of the clip-on hook connector set in the joint of the decorative insulation panel is tied to the lower steel mesh inside the C-shaped steel frame.

[0021] Furthermore, firstly, weld the C-shaped steel frame of the exterior wall panel according to the design requirements, and then weld the C-shaped steel frame, internal steel ribs, embedded connectors, embedded load-bearing components, threaded sleeves with reinforcing bars at the root, and the steel mesh at the bottom of the panel firmly to form a steel frame.

[0022] Furthermore, the thermal conductivity of the vacuum insulation panel is 0.05 W / (m·K).

[0023] Furthermore, the thermal conductivity of the aerogel polystyrene particle composite insulation board is 0.02 W / (m·K).

[0024] Furthermore, the thermal conductivity of microporous lightweight concrete is 0.14 W / (m·K).

[0025] Furthermore, a method for installing a multi-layer thermally broken composite steel-framed exterior wall panel includes the following steps:

[0026] S1, transport the prefabricated exterior wall panels to the main installation position of the H-beam using lifting rings;

[0027] S2, Install the connecting adjustment component at the pre-embedded connector location;

[0028] S3, weld one side of the first connecting plate in the connecting adjustment component to the lower part of the H-beam, and on the other side with a large square hole, pass the first bolt through the first pad and connect it to the first nut on the pre-embedded connecting component;

[0029] S4, weld the root of the load-bearing connection box to the pre-embedded load-bearing component, and insert the second bolt into the second nut at the top of the load-bearing connection box;

[0030] S5, weld the second connecting plate in the load-bearing adjustment component to the upper part of the H-beam, and on the other side with a large square hole, connect the third bolt through the sliding plate and the second pad to the third nut on the load-bearing connection box.

[0031] S6, remove the lifting ring, and place foamed polyethylene rods in the joint between the two large panels of the exterior wall. Seal the outer joint with silicone sealant, and fill the inner joint with fireproof rock wool strips.

[0032] The present invention has the following beneficial effects:

[0033] 1. The steel frame structure of the exterior wall panel of the present invention is scientifically and rationally designed. Its microporous lightweight concrete structural layer is reinforced by steel mesh and glass fiber mesh. Furthermore, the upper and lower steel meshes are welded to the C-shaped steel frame containing internal steel ribs, so that the steel frame and the steel mesh reinforced microporous concrete composite structure achieve high rigidity, integrity and easy connection of the exterior wall panel.

[0034] 2. The decorative and thermal insulation integrated panel used in this invention, composed of a radiation-cooled ceramic decorative panel and a vacuum insulation panel with a thermal conductivity of only 0.05 W / (m·k), reflects sunlight, resulting in a surface temperature lower than the air temperature and excellent thermal insulation performance. Furthermore, when combined with an aerogel polystyrene particle composite panel with a thermal conductivity of only 0.02 W / (m·k), it forms a double-layer composite thermal insulation structure inside and outside the wall. Through the seamless composite of the microporous lightweight concrete with a thermal conductivity of only 0.14 W / (m·k) used in the large panel, the exterior wall panel has good thermal insulation and thermal performance, meeting the requirements for ultra-low energy consumption.

[0035] 3. The molding process of this invention adopts a decorative insulation layer reverse composite molding process. Structurally, the card plate hook bar connector used in the decorative insulation integrated panel is tied to the steel mesh inside the large panel. After the concrete is poured, it is anchored to the inside of the large panel. Moreover, the back of the decorative insulation integrated panel is also seamlessly bonded to the poured microporous lightweight concrete. The whole panel is integrally molded, realizing the requirements of building energy conservation and structural integration. In addition, the whole panel is suspended as a whole, realizing rapid assembly, significantly shortening the construction period and reducing costs.

[0036] 4. After the exterior wall decoration and insulation integrated panel of the present invention is reverse-molded, the exposed insulation layer on the four sides of the panel is sealed with waterproof flexible cement-based polymer slurry, which improves the durability of the wall panel decoration and insulation layer.

[0037] 5. The exterior wall panels of this invention use high-strength microporous lightweight concrete and thermal insulation materials, which makes the panels have high overall strength, low self-weight, and convenient hoisting. During construction, unique connectors enable quick connection with the main structure, making the panel connections safe and reliable, with good seismic performance. The connectors are also detachable, facilitating the later maintenance of the exterior wall panels. Attached Figure Description

[0038] Figure 1 A schematic diagram of a multi-layer thermally broken composite structure steel-framed exterior wall panel provided by the present invention, illustrating the production and construction method of the panel.

[0039] Figure 2 A schematic diagram of the steel frame of a multi-layer thermally broken composite structure steel-framed exterior wall panel, which is provided by the present invention for the production and construction method of the steel-framed exterior wall panel.

[0040] Figure 3 A schematic diagram of the AA cross-section structure of a multi-layer thermally broken composite steel-framed exterior wall panel provided by the present invention for the production and construction method of the panel.

[0041] Figure 4 A schematic diagram of the BB cross-section structure of a multi-layer thermally broken composite steel-framed exterior wall panel provided by the present invention for the production and construction method of the panel.

[0042] Figure 5 A schematic diagram showing the connection between the exterior wall panel and the main structure in a production and construction method of a multi-layer thermally broken composite steel-framed exterior wall panel provided by the present invention.

[0043] Figure 6 A schematic diagram of the card plate hook reinforcement connector for the production and construction method of a multi-layer thermally broken composite structure steel frame exterior wall panel provided by the present invention;

[0044] Figure 7 A schematic diagram of the pre-embedded connectors for the production and construction method of a multi-layer thermally broken composite steel-framed exterior wall panel provided by the present invention.

[0045] Figure 8 A schematic diagram of the connection adjustment component for the production and construction method of a multi-layer thermally broken composite steel-framed exterior wall panel provided by the present invention.

[0046] Figure 9 A schematic diagram of the embedded load-bearing components in the production and construction method of a multi-layer thermally broken composite steel-framed exterior wall panel provided by the present invention.

[0047] Figure 10 A schematic diagram of a load-bearing connection box for a production and construction method of a multi-layer thermally broken composite steel-framed exterior wall panel provided by the present invention.

[0048] Figure 11 This is a schematic diagram of a load-bearing adjustment component for a method of producing and constructing a multi-layer thermally broken composite steel-framed exterior wall panel provided by the present invention.

[0049] The components include: 1. H-shaped steel beams; 2. C-shaped steel frames; 3. Radiant cooling ceramic decorative panels; 4. Vacuum insulation panels; 5. Aerogel polystyrene particle composite insulation panels; 6. Steel mesh; 7. Clamping plate and hook reinforcement connectors; 8. Microporous lightweight concrete; 9. Internal steel ribs; 10. FRP connectors; 11. Fiberglass mesh; 12. Embedded connectors; 13. Embedded load-bearing components; 14. Threaded sleeves; 15. Connecting adjustment components; 16. Load-bearing connecting boxes; 17. Load-bearing adjustment components; 18. First nut; 19. First connecting plate; 20. First pad; 21. First bolt; 22. Second nut; 23. Third nut; 24. Sliding plate; 25. Second connecting plate; 26. Second pad; 27. Third bolt. Detailed Implementation

[0050] The technical solutions of the present invention will be clearly and completely described below with reference to the accompanying drawings in the embodiments of the present invention.

[0051] Example 1

[0052] Reference Figure 1-4 In this embodiment, a method for producing a multi-layer thermally broken composite steel-framed exterior wall panel includes the following steps:

[0053] S1, pre-press the radiant cooling ceramic decorative panel 3 and the vacuum insulation panel 4 into a decorative and heat-insulating integrated panel;

[0054] S2, C80*3.0 inner steel rib 9 is set inside the C-shaped steel frame 2 and welded to the C-shaped steel frame 2 to form a steel-reinforced frame;

[0055] S3, an embedded connector 12 is set on the upper part of the steel rib 9 in C80 and an embedded load-bearing component 13 is set on the lower part, serving as a connection node between the exterior wall panel and the main structure.

[0056] S4, φ4@100 steel mesh 6 is laid at the bending part of the upper and lower frame of the C-shaped steel frame 2 and welded to the C-shaped steel frame 2 to form a double-layer steel wire mesh reinforcement;

[0057] S5, an aerogel polystyrene particle composite insulation board 5 and an FRP connector 10 are set in the double-layer steel wire mesh in the C-shaped steel frame 2. By pouring microporous lightweight concrete 8 on the upper and lower layers of the large board respectively, the aerogel polystyrene particle composite insulation board 5 is combined with the decorative insulation integrated board pre-pressed from the radiant cooling ceramic decorative board 3 and the vacuum insulation board 4 to form a microporous lightweight concrete 8 composite sandwich structure.

[0058] S6, a card plate hook bar connector 7 is set in the joint of the decorative and heat-insulating integrated panel pre-pressed by the radiant cooling ceramic decorative panel 3 and the vacuum insulation panel 4, and the tail of the card plate hook bar connector 7 extends into the steel mesh 6 at the bottom of the C-shaped steel frame 2 and is tied with tie wire.

[0059] S7, 11 glass fiber mesh is laid in the upper layer of microporous lightweight concrete of the exterior wall slab;

[0060] S8, an opening is set on the C-shaped steel frame 2, and the root steel bar of the threaded sleeve 14 is welded to the inner steel rib 9. During hoisting, it is used with a lifting ring as a hoisting component.

[0061] In this embodiment, the steel frame structure of the exterior wall panel is scientifically and rationally designed. The structural layer of its microporous lightweight concrete 8 is reinforced by steel mesh 6 and fiberglass mesh 11. Furthermore, the upper and lower steel mesh 6 are welded together with the C-shaped steel frame 2 containing internal steel ribs. This makes the steel frame and the steel mesh 6 reinforced microporous concrete composite structure achieve high rigidity, integrity and easy connection of the exterior wall panel.

[0062] In this embodiment, the decorative and thermal insulation integrated panel, composed of a radiation-cooled ceramic decorative panel 3 and a vacuum insulation panel 4 with a thermal conductivity of only 0.05 W / (m·k), reflects sunlight, resulting in a surface temperature lower than the air temperature and excellent thermal insulation performance. Furthermore, it is combined with an aerogel polystyrene particle composite panel with a thermal conductivity of only 0.02 W / (m·k) to form a double-layer composite thermal insulation structure inside and outside the wall. Through the seamless composite of the microporous lightweight concrete with a thermal conductivity of only 0.14 W / (m·k) used in the large panel, the exterior wall panel has good thermal insulation and thermal performance, meeting the requirements for ultra-low energy consumption.

[0063] In this embodiment, the molding process adopts a decorative insulation layer reverse composite molding process. Structurally, the card plate hook bar connector used in the decorative insulation integrated panel is tied to the steel mesh 6 inside the large panel. After the concrete is poured, it is anchored to the inside of the large panel. Moreover, the back of the decorative insulation integrated panel is also seamlessly bonded to the poured microporous lightweight concrete. The whole panel is integrally molded, realizing the requirements of building energy conservation and structural integration. Furthermore, the whole panel is suspended as a whole, realizing rapid assembly, significantly shortening the construction period and reducing costs.

[0064] In this embodiment, after the exterior wall decorative insulation integrated panel is reverse-molded, the exposed insulation layer on all four sides of the panel is sealed with waterproof flexible cement-based polymer slurry, which improves the durability of the wall panel decorative insulation layer.

[0065] In this embodiment, the exterior wall panel adopts high-strength microporous lightweight concrete and thermal insulation material, which makes the panel have high overall strength, low self-weight, and convenient hoisting. During construction, a unique connector is used to achieve rapid connection with the main structure, making the panel connection safe and reliable, with good seismic performance. The connector is also detachable, which facilitates the later maintenance of the exterior wall panel.

[0066] Example 2

[0067] In this embodiment, the specific implementation steps of step S6 in the production method of a multi-layer thermally broken composite steel-framed exterior wall panel of Embodiment 1 are as follows:

[0068] S61, First, cut the prefabricated decorative insulation integrated panel according to the designed C-shaped steel frame 2 dimensions and the designed tongue and groove requirements;

[0069] S62, cut the decorative insulation integrated panel into slots on all four sides;

[0070] S63, the radiative cooling ceramic decorative panel is laid face down on the fixed steel mold table, and the end of the card plate hook rib connector 7 is assembled and laid with the end facing up in the panel seam.

[0071] S64, use PC edge mold to fix the magnetic box and tightly fix the decorative and heat-insulating integrated panel;

[0072] S65, place the welded C-shaped steel frame 2 on the laid decorative insulation integrated panel, so that it corresponds to the decorative insulation integrated panel;

[0073] S66, the tail of the card plate hook bar connector 7 set in the joint of the decorative insulation integrated panel is tied to the lower steel mesh 6 inside the C-shaped steel frame 2.

[0074] In this embodiment, the C-shaped steel frame 2 of the outer wall panel is first welded according to the design requirements. The C-shaped steel frame 2, the internal inner steel ribs 9, the embedded connectors 12, the embedded load-bearing components 13, the threaded sleeves with reinforcing bars at the root 14, and the steel mesh 6 at the bottom of the panel are then welded firmly to form a steel frame.

[0075] Example 3

[0076] Reference Figure 5 In this embodiment, including Embodiment 1 and Embodiment 2, and a method for installing a multi-layer thermally broken composite steel-framed exterior wall panel, the following steps are included:

[0077] S1, transport the prefabricated exterior wall panels to the main installation position of H-beam 1 using lifting rings;

[0078] S2, Install the connecting adjustment component 15 at the position of the pre-embedded connector 12;

[0079] S3, weld one side of the first connecting plate 19 in the connecting adjustment piece 15 to the lower part of the H-shaped steel beam 1, and on the other side with a large square hole, pass the first bolt 21 through the first pad 20 and connect it to the first nut 18 on the pre-embedded connecting piece 12.

[0080] S4, weld the base of the load-bearing connection box 16 to the pre-embedded load-bearing component 13, and insert the second bolt into the second nut 22 on the upper part of the load-bearing connection box 16;

[0081] S5, weld the second connecting plate 25 in the load-bearing adjustment component 17 to the upper part of the H-shaped steel beam 1, and on the other side with a large square hole, connect the third bolt 27 through the sliding plate 24 and the second pad 26 to the third nut 23 on the load-bearing connection box 16.

[0082] S6, remove the lifting ring, and place foamed polyethylene rods in the joint between the two large panels of the exterior wall. Seal the outer joint with silicone sealant, and fill the inner joint with fireproof rock wool strips.

[0083] The embodiments described above are merely preferred embodiments of the present invention and are not intended to limit the scope of the present invention. Various modifications and improvements made by those skilled in the art to the technical solutions of the present invention without departing from the spirit of the present invention should fall within the protection scope defined by the claims of the present invention.

Claims

1. A method for producing a multi-layer thermally broken composite steel-framed exterior wall panel, characterized in that, Includes the following steps: S1, the radiant cooling ceramic decorative panel (3) and the vacuum insulation panel (4) are pre-pressed into a decorative and heat-insulating integrated panel; S2, an inner steel rib (9) is set inside the C-shaped steel frame (2) and welded to the C-shaped steel frame (2) to form a steel-reinforced frame; S3, an embedded connector (12) is set on the upper part of the inner steel rib (9), and an embedded load-bearing component (13) is set on the lower part, serving as a connection node between the outer wall panel and the main structure; S4, steel mesh (6) is laid at the upper and lower bends of the C-shaped steel frame (2) and welded to the C-shaped steel frame (2) to form a double-layer steel wire mesh; S5, set aerogel polystyrene particle composite insulation board (5) and FRP connector (10) in the double-layer steel wire mesh of C-shaped steel frame (2); pour microporous lightweight concrete (8) on the upper and lower layers of the outer wall panel respectively, and combine the aerogel polystyrene particle composite insulation board (5) with the decorative insulation integrated board to form a microporous lightweight concrete composite sandwich structure. S6, a card plate hook bar connector (7) is installed in the joint of the decorative insulation integrated panel, and the tail of the card plate hook bar connector (7) extends into the steel mesh (6) at the bottom of the C-shaped steel frame (2) and is tied with tie wire; S7, glass fiber mesh cloth is laid in the upper microporous lightweight concrete of the outer wall slab (11); S8, an opening is set on the C-shaped steel frame (2), and the root steel bar of the threaded sleeve (14) is welded to the inner steel rib (9), and a lifting ring is used as a lifting component during hoisting.

2. The method for producing a multi-layer thermally broken composite steel-framed exterior wall panel according to claim 1, characterized in that, In step S6, the specific implementation steps are as follows: S61, cut the prefabricated decorative insulation integrated panel according to the designed C-shaped steel frame (2) size and the designed tongue and groove requirements; S62, slots for fasteners are made on the four sides of the cut decorative insulation panel; S63, lay the radiative cooling ceramic decorative panel (3) face down on the fixed steel mold table, and at the same time assemble and lay the connector on the card plate hook rib connector (7) with the tail facing up in the panel seam. S64, use PC edge mold to fix the magnetic box and tightly fix the decorative and heat-insulating integrated panel; S65, place the welded C-shaped steel frame (2) on the opposite side of the laid decorative insulation integrated board; S66, the tail of the card plate hook bar connector (7) set in the joint of the decorative insulation integrated panel is tied to the lower steel mesh (6) in the C-shaped steel frame (2).

3. The production method of a multi-layer thermally broken composite steel-framed exterior wall panel according to claim 1, characterized in that, Weld the C-shaped steel frame (2) of the exterior wall panel according to the design requirements, and weld the C-shaped steel frame (2) and the internal steel ribs (9), embedded connectors (12), embedded load-bearing components (13), embedded threaded sleeves with reinforcing bars at the root (14) and the steel mesh (6) at the bottom of the panel firmly to form a steel frame.

4. The production method of a multi-layer thermally broken composite steel-framed exterior wall panel according to claim 1, characterized in that, The thermal conductivity of the vacuum insulation panel (4) is 0.05 W / (m·K).

5. The method for producing a multi-layer thermally broken composite steel-framed exterior wall panel according to claim 1, characterized in that, The thermal conductivity of the aerogel polystyrene particle composite insulation board (5) is 0.02 W / (m·k).

6. The method for producing a multi-layer thermally broken composite steel-framed exterior wall panel according to claim 1, characterized in that, The thermal conductivity of microporous lightweight concrete (8) is 0.14 W / (m·K).

7. The installation and construction method of a multi-layer thermally broken composite steel-framed exterior wall panel according to claim 1, characterized in that, Includes the following steps: S1, transport the prefabricated exterior wall panels to the main installation position of the H-beam (1) using lifting rings; S2, at the location of the pre-embedded connector (12), install the connecting adjustment component (15); S3, weld one side of the first connecting plate (19) in the connecting adjustment piece (15) to the lower part of the H-beam (1), and on the other side with a large square hole, connect the first bolt (21) through the first pad (20) to the first nut (18) on the pre-embedded connecting piece (12); S4, weld the root of the load-bearing connection box (16) to the pre-embedded load-bearing component (13), and insert the second bolt into the second nut (22) on the upper part of the load-bearing connection box (16); S5, weld the second connecting plate (25) in the load-bearing adjustment component (17) to the upper part of the H-beam (1), and on the other side with a large square hole, connect the third bolt (27) through the sliding plate (24) and the second pad (26) to the third nut (23) on the load-bearing connection box (16); S6, remove the lifting ring, and place foamed polyethylene rods in the joint between the two large panels of the exterior wall. Seal the outer joint with silicone sealant and fill the inner joint with fireproof rock wool strips.

Images