Assembly Mould and Assembly Method for Prefabricated Composite Wall Panels with Expanded Metal Structure

Abstract

The present invention discloses an assembling mold and an assembling method for a steel plate reticulated prefabricated composite wallboard. The mold includes a type I template, a type II template, a corner connecting piece and a three-way connecting piece. On the left and right sides of the type I template, there are plug-in parts protruding outward along the height direction thereof; on the left and right sides of the type II template, there are grooves matching the plug-in parts; the end face of the corner connecting piece is of a square structure, and on the adjacent two sides of the square, there are plug-in parts protruding outward. The end face of the three-way connecting piece is of a square structure, and on the three sides of the square, there are plug-in parts protruding outward. The plug-in parts on the corner connecting piece and the three-way connecting piece are arranged along the height direction thereof and are matched with the grooves of the type II template. By using the assembling mold for the steel plate reticulated prefabricated composite wallboard of the present invention, during the prefabrication and installation process of the wallboard, modular design, standardized production, batch production and integral installation are realized, which can effectively shorten the construction period, save costs and improve the forming quality.

Description

Technical Field

[0001] The present invention relates to the technical field of building construction, and particularly relates to an assembly mold and an assembly method for a steel mesh structure prefabricated composite wall panel. Background Art

[0002] With the continuous progress of technology, the construction industry is gradually developing from a traditional labor-intensive industry towards modularization and integration. The construction of the main building structure is also gradually changing from the cast-in-place structure composed of traditional steel bars, formwork, and concrete to prefabricated buildings. A prefabricated building is a building assembled on-site with prefabricated components. Developing prefabricated buildings is a major change in the construction method, which is conducive to saving resources and energy, reducing construction pollution, and improving labor productivity and quality and safety levels.

[0003] Wall panels are important prefabricated components in prefabricated buildings. Using precast concrete wall panels to build prefabricated buildings can improve the efficiency of building construction, the degree of mechanized construction, reduce on-site wet operations, save on-site labor, overcome seasonal influences, and shorten the building construction period. Existing precast concrete wall panels can be divided into four types according to the production process: pedestal method, flat mold unit flow method, flat mold transfer flow method, and group or pair vertical mold method. In the pedestal method, the wall panel is formed and cured at a fixed location, and all materials and equipment required for procedures such as steel bar placement, forming, curing, and demolding are supplied to the wall panel forming location. In the flat mold unit flow method, the wall panel is manufactured at several workstations. After completing one or several procedures at one workstation, the wall panel is transported to the next workstation using a lifting and transportation device. In the flat mold transfer flow method, the production process is divided into several procedures, and each procedure is sequentially carried out at a fixed workstation on the production line. The wall panels to be processed move forward sequentially on the production line at a certain time rhythm. The group or pair vertical mold method is to produce wall panels in groups or pairs in a vertical position, vibrate and form through external mold equipment, and use heat conduction in the mold cavity for airtight heat curing. This method requires a short time, occupies a small area, and has high production efficiency, but can only produce wall panels of a single material.

[0004] When existing precast concrete wall panels are produced, generally only one wall panel can be poured at a time, and one set of molds is required for one wall panel. Different specifications of molds are needed to produce wall panels of different specifications. Therefore, a large number of molds and a large production site are required during the production process. The efficiency of mold assembly and demolding during the production of each wall panel is low and the cost is high. Summary of the Invention

[0005] The technical problem to be solved by the present invention is to provide an assembly mold and an assembly method for a steel mesh structure prefabricated composite wall panel, which can be applicable to wall panels of different specifications, can realize the simultaneous assembly and vertical pouring of multiple wall panels, improve the assembly efficiency, is conducive to cost savings, and completes the modular design, standardized production, and batch production of wall panel prefabrication.

[0006] To solve the above technical problems, the present invention adopts the following technical solutions:

[0007] Design an assembly mold for a steel mesh structure precast composite wall panel, including a type I template, a type II template, a corner connector, and a three-way connector. The left and right sides of the type I template are provided with outwardly protruding insertion parts along its height direction; the left and right sides of the type II template are provided with grooves matching the insertion parts.

[0008] The end face of the corner connector is of a square structure, and outwardly protruding insertion parts are provided on two adjacent sides of the square. The end face of the three-way connector is of a square structure, and outwardly protruding insertion parts are provided on three sides of the square. The insertion parts on the corner connector and the three-way connector are arranged along their height direction and match the grooves of the type II template.

[0009] Preferably, it further includes a bottom template and a top template. A plurality of pouring holes for pouring concrete are provided on the top template, and the interval between adjacent pouring holes is ≤ 1000 mm.

[0010] Preferably, it further includes a template support mechanism. The template support mechanism includes a horizontal support rod at the bottom, a vertical support rod provided at one end of the horizontal support rod, and an inclined support rod provided between the horizontal support rod and the vertical support rod.

[0011] Preferably, it further includes a transverse purlin for fixing the template. A plurality of fixing holes are provided along the height direction on the vertical support rod of the template support mechanism, and a plurality of transverse purlins are fixedly installed up and down in parallel on a plurality of equally spaced support mechanisms.

[0012] Preferably, the type I template and the type II template are of a hollow structure; the type I template, the type II template, the corner connector, and the three-way connector are all made of aluminum alloy. The width and height of the type I template and the type II template are customized according to requirements.

[0013] The present invention also relates to an assembly method for the assembly mold of the steel mesh structure precast composite wall panel based on the above, including the following steps:

[0014] (1) Select appropriate quantities and sizes of the type I template, the type II template, the corner connector, the three-way connector, the bottom template, and the top template according to the specifications of the precast composite wall panel;

[0015] (2) First, install and reinforce the template fixing frame and the template support mechanism, and correct the verticality deviation. After passing the acceptance, then fixedly install the transverse purlin;

[0016] (3) When assembling the wall formwork, first install the bottom formwork, then assemble the formwork on the side close to the formwork fixing frame. Insert and assemble the Type I formwork and Type II formwork in sequence. After vertical fixation, place the spliced and anchored wall panel frame close to the side formwork, and correct the position of the window frame and reinforce it;

[0017] (4) After the wall panel frame is vertically erected and fixed, the prefabricated pads are placed in a plum blossom shape; then the template on the other side is installed and reinforced, and the corners are connected with corner connectors; the two adjacent prefabricated wall panel side molds are connected with three-way connectors;

[0018] (5) Splice and fix the top formwork to support, correct and fix the rear formwork;

[0019] (6) Install all prefabricated formwork and wall panel frames in sequence, and bury the embedded parts; use square and round hoop fasteners to reinforce the fixed formwork as a whole, and then test the verticality, flatness and stability of the overall formwork. Only after passing the acceptance test can the next step of concrete pouring be carried out.

[0020] Preferably, there are multiple template support mechanisms in step (2), and the distance between adjacent support mechanisms is not less than 1.5 m.

[0021] Preferably, in step (4), the spacing between the spacers is no more than 500 mm, and the spacing between the prefabricated door and window frames and openings needs to be strengthened to be no more than 300 mm;

[0022] Preferably, the wall panel skeleton adopts a mortise and tenon steel frame with a built-in steel plate honeycomb structure.

[0023] The beneficial effects of the present invention are:

[0024] The assembly mold of the steel plate mesh prefabricated composite wall panel in the present invention can assemble multiple wall panels at the same time to achieve vertical casting, which can effectively improve the production efficiency of the wall panels. The width and height of the type I template and the type II template can be customized according to needs. Wall panels of different specifications can be assembled using templates of different numbers and widths, which can reduce the number of templates used and save production space. The template can be recycled and recast for repeated use, which can effectively save costs.

[0025] By adopting the assembly mold of the steel plate mesh prefabricated composite wall panel of the present invention, modular design, standardized production, batch production and integrated installation are realized during the prefabrication and installation process of the wall panel, which can effectively shorten the construction period, save costs, improve the molding quality, and save energy and protect the environment. When the prefabricated wall panel is installed, it is connected with the main structure through its own mortise and tenon parts and cast as a whole, which greatly improves the integrity of the construction, saves construction period and ensures quality, and has significant economic and social benefits. Description of the Drawings

[0026] Figure 1 It is a schematic end face structure diagram of a Type-I template;

[0027] Figure 2 It is a schematic end face structure diagram of a Type-II template;

[0028] Figure 3 It is a schematic end face structure diagram of another specification of Type-II template;

[0029] Figure 4 It is a schematic end face structure diagram of a corner connecting piece;

[0030] Figure 5 It is a schematic end face structure diagram of a three-way connecting piece;

[0031] Figure 6 It is an installation schematic diagram of a template support mechanism and a transverse back purlin;

[0032] Figure 7 It is a schematic structure diagram after the top template is installed;

[0033] Figure 8 It is a schematic structure diagram after one side template is installed;

[0034] Figure 9 For Figure 8 The enlarged view of part A in;

[0035] Figure 10 It is a schematic structure diagram after the template and the grid framework are installed;

[0036] Figure 11 For Figure 10 The enlarged view of part B in.

[0037] Reference numerals in the figure: 1 is a Type-I template, 2 is a Type-II template, 3 is a corner connecting piece, 4 is a three-way connecting piece, 5 is a plug-in part, 6 is a groove; 7 is a bottom template, 8 is a top template, 9 is a template support mechanism, 10 is a transverse back purlin, 11 is a pouring hole, 12 is a fixed frame, 13 is a grid framework. Detailed Embodiments

[0038] The following embodiments are used to illustrate the specific implementation manners of the present invention. However, the following embodiments are only used to illustrate the present invention in detail and do not limit the scope of the present invention in any way. In the following embodiments, the device elements involved are conventional device elements unless otherwise specified; the industrial raw materials involved are conventional industrial raw materials available on the market unless otherwise specified.

[0039] Embodiment 1: An assembling mold for a steel plate grid precast composite wallboard, see Figures 1 - 5, including a Type I template 1, a Type II template 2, a corner connector 3 and a three-way connector 4. On the left and right sides of the Type I template 1, there are plug-in parts 5 protruding outward along its height direction; on the left and right sides of the Type II template 2, there are grooves 6 matching the plug-in parts. The end face of the corner connector 3 is a square structure, and on the adjacent two sides of the square, there are plug-in parts 5 protruding outward. The end face of the three-way connector 4 is a square structure, and on the three sides of the square, there are plug-in parts 5 protruding outward. The plug-in parts on the corner connector 3 and the three-way connector 4 are arranged along their height direction and match the grooves 6 of the Type II template 2.

[0040] It also includes a bottom template 7 and a top template 8. On the top template 8, there are a plurality of pouring holes 11 for pouring concrete, and the interval between adjacent pouring holes 11 is ≤ 1000 mm.

[0041] It also includes a template support mechanism 9. The template support mechanism 9 includes a horizontal support rod at the bottom, a vertical support rod arranged at one end of the horizontal support rod, and an inclined support rod arranged between the horizontal support rod and the vertical support rod. It also includes a transverse purlin 10 for fixing the template. On the vertical support rod of the template support mechanism 9, there are a plurality of fixing holes along its height direction, and a plurality of transverse purlins 10 are fixedly installed up and down in parallel on a plurality of equally spaced support mechanisms 9.

[0042] The Type I template and the Type II template are of hollow structure; the Type I template, the Type II template, the corner connector and the three-way connector are all made of aluminum alloy. The width and height of the Type I template and the Type II template are customized according to requirements. The aluminum alloy mold is mechanically formed and does not require secondary processing. It can be spliced into walls of any specifications and sizes, and the template has a high reuse rate. 95% can be recycled and remolded again.

[0043] Embodiment 2: An assembling method for an assembling mold of a steel mesh structure prefabricated composite wallboard based on Embodiment 1 includes the following steps:

[0044] (1) Select appropriate quantities and sizes of Type I templates, Type II templates, corner connectors, three-way connectors, as well as bottom templates and top templates according to the specifications of the prefabricated composite wallboard; the customized aluminum alloy mold is used as a support mold for pouring wallboard concrete and can be freely assembled into wallboards with specifications and thicknesses such as 100 mm, 150 mm, 200 mm, 280 mm, 300 mm, etc. The profile purlin is used to fix the aluminum alloy mold horizontally to avoid mold swelling and mold leakage. Before assembling the mold, it must be cleaned. For the steel mold, rust, cement residue, stains, etc. on the surface of the mold should be removed. Before installing the mold, ensure that the surface of the mold is smooth and dry, and the lining board has no delamination.

[0045] (2) First, install and reinforce the template fixing frame and the template support mechanism, and correct its verticality deviation. After passing the acceptance, then fix and install the transverse purlin. SeeFigure 6 ; The vertical steel back purlin support should be firmly fixed to the ground. When fixed with expansion bolts, the bolt diameter should not be less than Ф18 and the number should not be less than 3. When assembling the formwork, temporary diagonal braces should be added in real time according to the length of the assembly to prevent the formwork from tipping over. The spacing between temporary diagonal braces should not be less than 1.5m.

[0046] (3) When assembling the wall formwork, first install the bottom formwork, then assemble the formwork on the side close to the formwork fixing frame. Connect and assemble the Type I formwork and Type II formwork in sequence. Figures 8 - 9 After vertical fixation, place the spliced and anchored wall panel frame close to the side formwork, correct the position of the window frame and reinforce it. The wall panel frame adopts mortise and tenon steel frame with built-in steel plate honeycomb structure.

[0047] (4) After the wall panel skeleton is vertically erected and fixed, the prefabricated pads are placed in a plum blossom shape; then the template on the other side is installed and reinforced, and the corners are connected with corner connectors; the two adjacent prefabricated wall panel side molds are connected with three-way connectors; after the wall panel skeleton is vertically erected and fixed, the position, quantity, specifications, etc. of the embedded parts are checked and accepted according to the design drawings and detailed drawings. After the acceptance is completed, the prefabricated pads are placed in a plum blossom shape on the entire wall panel, and the spacing between the pads is not more than 500mm. The prefabricated door and window frames and openings need to be strengthened and placed with a spacing of no more than 300mm;

[0048] (5) Splice and fix the top formwork to support, correct and fix the rear formwork; set a circular pouring hole for concrete at intervals of no more than 1000mm on the top formwork to facilitate the pouring of composite insulation concrete, see Figure 7 .

[0049] (6) Install all the prefabricated templates and wall panel frames in sequence, and bury the embedded parts; the wall panels contain large embedded parts such as window frames. Cut the honeycomb mesh structure according to the design requirements of the window frames, and use a crawler-type flat cutter to cut it horizontally and vertically. Place the prefabricated window frames in the mesh structure, fix them, check and accept them, and finally seal them as a whole. Use square and round hoop fasteners to reinforce the fixed templates as a whole, see Figures 10 - 11 Then the verticality, flatness and stability of the overall formwork are tested, and the next step of concrete pouring can be carried out only after passing the acceptance.

[0050] When pouring with lightweight thermal insulation concrete, the free fall height of the concrete from the pouring hole shall not exceed 0.5 meters. If it exceeds 1 meter, measures must be taken. When pouring concrete, it shall be carried out continuously in sections and layers. The height of each layer of pouring shall be determined according to the structural characteristics of the wall panel, the size of embedded parts, etc. Generally, the maximum height of each layer does not exceed 50 centimeters. Use a vibrator to vibrate the outer wall of the formwork. The vibration points shall be arranged evenly, moved point by point, and carried out in sequence without omission, so as to achieve uniform compaction. When pouring concrete, the formwork, reserved holes, embedded parts, and cushion blocks shall be observed frequently for any movement, deformation, or blockage. If problems are found, pouring shall be stopped immediately, and corrections shall be made before the poured concrete sets.

[0051] After the strength of the wall panel reaches the design requirements, or reaches 75% of the design strength when there is no requirement, demolding and transportation can be carried out. When demolding, use special lifting tools to lift the precast components to achieve balanced lifting. When lifting, the lifting tools and wire ropes shall be kept vertical.

[0052] Use the assembling mold of the steel mesh structure precast composite wall panel of the present invention to prepare precast wall panels. The whole is poured with lightweight thermal insulation concrete, and its thermal conductivity meets the specification requirements. There is no need to carry out thermal insulation construction later, and it can be constructed synchronously with the main frame structure, saving the construction period. Before the construction of the precast wall panel, the drawings shall be deeply designed to clarify the positional relationship of the outer wall door and window frames, embedded parts, and various pipeline wires. According to the deeply designed drawings, precast the outer wall panels. First, position the tenon and mortise parts and the steel plate honeycomb structure on the steel framework, make the reservations for the door and window frames, embedded parts, and water and electricity pipeline wires according to the deeply designed drawings, and after passing the acceptance, use high-strength aluminum formwork for formwork closing and reinforcement. The whole is poured and formed with lightweight thermal insulation concrete. After meeting the design strength, the installation of the wall panel can be carried out. The precast wall panel is fixed by welding the tie bars between the tenon and mortise parts and the main structure beam and column steel bars. The tenon and mortise parts and the main structure beam and slab are reinforced and concreted at the same time. After demolding, fill the joint part of the wall panel with micro-expansion grouting material to do a good job in leakage prevention treatment.

[0053] The above has described the present invention in detail in combination with the embodiments. However, those skilled in the art can understand that without departing from the purpose of the present invention, various specific parameters in the above embodiments can be changed to form multiple specific embodiments, which are all within the common change range of the present invention and will not be elaborated one by one here.

Claims

1. A method for assembling a prefabricated composite wall panel with a steel mesh structure, characterized in that, The method comprises the following steps: (1) selecting the appropriate number and size of type I formwork, type II formwork, corner connectors, three-way connectors, bottom formwork and top formwork according to the specifications of the prefabricated composite wall panels; (2) first installing and reinforcing the formwork fixing frame and the formwork supporting mechanism, and correcting the verticality deviation, and then fixing and installing the horizontal back purlin after acceptance; (3) assembling the wall formwork, first installing the bottom formwork, and then assembling the formwork close to the side of the formwork fixing frame after completing the bottom formwork, plugging and assembling the type I formwork and type II formwork in sequence, and vertically fixing the spliced and anchored wall panel frame close to the side formwork and placing it upright, correcting the position of the window frame and reinforcing and fixing it; (4) after the wall panel frame is vertically erected and fixed, placing the prefabricated pads in a plum blossom shape; then installing and reinforcing the formwork on the other side, and connecting the corners with corner connectors; and connecting the two adjacent prefabricated wall panel side formworks with three-way connectors; (5) splicing and fixing the top formwork to provide support for the rear formwork The functions of support, correction and fixation; (6) all the templates and wall panel frames that need to be prefabricated are installed in sequence, and the embedded parts are buried well; the fixed templates are reinforced with square and round hoop fasteners as a whole, and then the verticality, flatness and stability of the overall template are tested. Only after acceptance can the next step of concrete pouring be carried out; the assembly mold of the steel plate mesh prefabricated composite wall panel includes: type I template, type II template, corner connector and three-way connector, the left and right sides of the type I template are provided with outwardly protruding plug-in parts along its height direction; the left and right sides of the type II template are provided with grooves matching the plug-in parts; the end face of the corner connector is a square structure, and outwardly protruding plug-in parts are provided on the adjacent two sides of the square; the end face of the three-way connector is a square structure, and outwardly protruding plug-in parts are provided on the three sides of the square; the plug-in parts on the corner connector and the three-way connector are arranged along their height direction and match the grooves of the type II template.

2. The assembling method of the assembling mold for the steel mesh structure prefabricated composite wall panel according to claim 1, characterized in that, In the step (2), there are multiple formwork support mechanisms, and the distance between adjacent formwork support mechanisms is not less than 1.5 m.

3. The assembling method of the assembling die for the prefabricated composite wall panel with steel mesh structure according to claim 1, characterized in that, In step (4), the spacing between the spacers is no more than 500 mm, and the spacing between the prefabricated door and window frames and openings needs to be strengthened to be no more than 300 mm.

4. The assembling method of the assembling mold for the prefabricated composite wall panel with steel mesh structure according to claim 1, characterized in that The wall panel frame adopts a mortise and tenon steel frame and a built-in steel plate honeycomb network structure.

Images