ECP cladding panels are used in concrete retaining wall construction methods that require no formwork or decoration.

Abstract

This invention relates to the fields of interior and exterior wall decoration and concrete structure construction, specifically to a construction method for using ECP (Electronic Plasma) panels for concrete retaining walls without formwork or decoration. During the pouring of the concrete retaining wall foundation, the metal joists for installing the ECP panels are cast into the concrete foundation. Reinforcing steel bars are tied, and the horizontal metal joists for the ECP panels are installed and welded to fix the ECP concrete panels. Gaps in the ECP panels are treated to ensure a secure installation and guarantee the flatness and verticality of the panels. Finally, concrete is poured, and the ECP panels adhere firmly to the concrete. Once the concrete strength reaches 70%, the gaps in the ECP panels are grouted with silicone weather-resistant sealant. This integrates decoration and formwork, improving construction efficiency, saving time, and resulting in a smooth, simple, and elegant appearance.

Description

Technical Field

[0001] This invention relates to the fields of interior and exterior wall decoration and concrete structure construction, specifically to a construction method for concrete retaining walls using ECP hanging panels that requires no formwork or decoration. Background Technology

[0002] ECP (Extruded Cement Panel) is short for extruded cement cladding panel, also known as fair-faced concrete hollow panel. It is made primarily from silicate cement, fiber, and siliceous materials, formed through vacuum high-pressure extrusion, followed by a low-temperature steam curing process, and then a high-temperature, high-pressure steam curing process. ECP panels have the following characteristics:

[0003] a. High strength: The ECP board has undergone high temperature and high pressure curing, so it has very high strength, with a flexural strength of 17MPa and a solid compressive strength of 60MPa; in addition, its large-area feature meets the needs of today's most popular prefabricated development.

[0004] b. Green and environmentally friendly, green and low-carbon production process: Relying on steam curing (consuming less energy than terracotta panels, stone and clay bricks), a high-strength crystal called "Tobermori Stone" is generated. After hundreds of freeze-thaw cycles, the ECP board has extremely high durability.

[0005] c. Highly decorative, with surface treatments including clear water natural body color, fluorocarbon spraying, sandblasting, and custom embossing.

[0006] ECP panels possess both the understated elegance of flat panels and the rhythmic feel of stripes. They perfectly showcase the unique solidity, naturalness, and solemnity of exposed concrete.

[0007] d. High fire resistance rating, A1 fire resistance.

[0008] Regarding dimensions and specifications, ECP boards can be designed and manufactured according to the designer's requirements, or products designed by the designer can be produced. However, there are some limitations, as follows: the working width is no more than 600mm, and the thickness is within 120mm. The length depends on the use of the board and the thickness of the product, with a maximum processing length of 5000mm.

[0009] Traditional outdoor concrete retaining wall structures are prone to structural defects after construction, requiring subsequent grinding, repair, and finishing before the concrete surface can be decorated. This construction method not only increases project costs but also takes up a significant amount of time. Summary of the Invention

[0010] To avoid secondary repairs and concrete decoration caused by poor appearance of outdoor concrete retaining walls, and to avoid the technical problems of traditional wooden formwork such as scaffolding, formwork erection, formwork dismantling, scaffolding dismantling, and material transportation, this invention provides a construction method for concrete retaining walls using ECP hanging panels that eliminates the need for formwork and decoration.

[0011] This invention first involves casting the metal keel for installing the ECP hanging panels into the concrete foundation during the pouring of the concrete retaining wall foundation. Then, the retaining wall reinforcement is tied, and the horizontal metal keel for the ECP hanging panels is installed and welded to fix the ECP concrete hanging panels. Gaps in the ECP hanging panels are treated to ensure a secure installation and guarantee the flatness and verticality of the ECP hanging panels. Finally, concrete is poured, and the ECP hanging panels are firmly bonded to the concrete. Once the concrete strength reaches 70%, the gaps in the ECP hanging panels are grouted with silicone weather-resistant sealant. This achieves integrated decoration and formwork support, improving construction efficiency, saving time, and resulting in a smooth, simple, and elegant appearance.

[0012] To solve the above-mentioned technical problems, the technical solution adopted by the present invention is as follows: a construction method for ECP hanging panels for concrete retaining walls that requires no formwork or decoration, comprising the following steps:

[0013] (1) Lay out the foundation of the retaining wall according to the location in the drawings and excavate and backfill, and pour the retaining wall cushion layer;

[0014] (2) Based on the wall width, mark the inner edge line of the ECP concrete cladding on the concrete retaining wall pad, and mark the axis of the vertical metal keel based on the inner edge line of the ECP cladding; install the embedded parts of the vertical metal keel according to the axis position;

[0015] (3) Install two rows of vertical metal keels on the embedded parts and weld the embedded parts to the vertical metal keels firmly;

[0016] (4) Install horizontal and vertical reinforcing bars for the retaining wall between the two rows of vertical metal keels, and then tie the reinforcing bars;

[0017] (5) After the bottom slab reinforcement is tied, the bottom slab concrete is poured.

[0018] (6) The horizontal metal keel is welded to the vertical metal keel;

[0019] (7) Connect the multiple horizontal support columns to the two corresponding vertical metal keels to connect the structures on both sides;

[0020] (8) Install Z-shaped connectors at the junction of the vertical and horizontal metal keels;

[0021] (9) Install ECP concrete panels, install the concrete panels symmetrically, and install the ECP concrete panels from bottom to top; attach sponge strips between the ECP concrete panels;

[0022] (10) After each layer of ECP concrete cladding is installed, a layer of concrete is poured until the concrete retaining wall is constructed to the structural elevation.

[0023] (11) Correct the gaps in the ECP panel of the retaining wall and mark the gaps;

[0024] (12) Concrete retaining wall, the top of the wall is sealed with ECP board and the perimeter is sealed with sealant to prevent water leakage.

[0025] Furthermore, in step (2), the size of the embedded part is 300mm×200mm, the length direction of the embedded part is parallel to the wall, and it is fixed by using inverted conical anchor bolts. The embedded parts are set at 500mm intervals.

[0026] Furthermore, the vertical metal keel has a cross-sectional dimension of 100mm × 50mm, and the length of the cross-section is parallel to the direction of the wall.

[0027] Further, in step (4), according to the pop-up bar position line, first lay the lower layer of bars, with the short bars at the bottom and the long bars at the top; when binding the bars, bind each point of the intersection of the two outermost rows, and bind the intersection of the middle part in a quincunx pattern. For bars subjected to bidirectional force, all the bar intersections must be bound.

[0028] Furthermore, in step (6), the horizontal spacing between two adjacent horizontal metal keels is 1000mm.

[0029] Furthermore, the horizontal support structure column in step (7) is a galvanized keel of 50mm×50mm×2mm, and both the horizontal and vertical metal keels are galvanized keels.

[0030] Compared with the prior art, the present invention has the following beneficial effects:

[0031] This invention mainly utilizes the strength advantages and decorative properties of ECP concrete cladding panels; when pouring the concrete retaining wall foundation, the ECP cladding panel columns are poured into the foundation, which improves the flatness and verticality of the ECP cladding panel installation.

[0032] First, ECP panels are installed, and traditional wooden formwork is used instead of scaffolding, formwork, or timber. Similarly, there is no need to spend money on dismantling the scaffolding later. Also, there is no need to repair, chisel, or modify the concrete retaining wall later. Attached Figure Description

[0033] Figure 1 This is a cross-sectional view of a concrete retaining wall structure.

[0034] Figure 2 This is an enlarged view of the connection between the ECP mounting plate and the vertical metal keel.

[0035] Figure 3 This is a schematic diagram of the embedded parts.

[0036] Figure 4 This is a schematic diagram of an inverted cone-shaped anchor bolt.

[0037] Figure 5 This is a longitudinal section view of the concrete retaining wall structure.

[0038] Figure 6 This is a horizontal cross-sectional view of a concrete retaining wall structure.

[0039] The markings in the image are as follows:

[0040] 1-Z-shaped connector, 2-ECP concrete cladding, 3-vertical metal keel, 4-horizontal metal keel, 5-horizontal support structural column, 6-retaining wall horizontal reinforcement, 7-vertical reinforcement, 8-retaining wall foundation, 9-retaining wall pad, 10-embedded parts. Detailed Implementation

[0041] The present invention will be further described below with reference to specific embodiments.

[0042] Example 1

[0043] ECP cladding panels are used in a construction method for concrete retaining walls that requires no formwork or decoration. The specific steps include:

[0044] (1) Lay out the retaining wall foundation according to the location shown in the drawings, and excavate and backfill. Pour the retaining wall cushion layer 8, as shown in the drawings. Figure 1 As shown;

[0045] (2) Based on the wall width, mark the inner edge line of the ECP concrete cladding on the concrete retaining wall pad 8, and mark the axis of the vertical metal keel based on the inner edge line of the ECP cladding; install the embedded parts 10 of the vertical metal keel according to the axis position.

[0046] Embedded parts 10 Figure 3 The dimensions shown are 300mm × 200mm. The length of the embedded part 10 is parallel to the wall, using an inverted conical anchor (such as...). Figure 4 (As shown) Fix it, with one embedded plate spaced 500mm apart;

[0047] (3) Install vertical metal keel 3 on the embedded part 10, and weld the embedded part 10 to the vertical metal keel 3 firmly. The cross-sectional dimensions of the vertical metal keel 3 are 100mm×50mm, and the length direction of the cross-section is parallel to the wall direction.

[0048] (4) Reinforcing steel processing is carried out on the retaining wall; the reinforcing steel is processed and shaped in a centralized manner, and the semi-finished reinforcing steel must be stacked separately with labels to avoid confusion;

[0049] Check the material list: Before binding the steel bars, carefully review the drawings and check whether there are any discrepancies between the material list and the design drawings. Only after verifying that there are no errors can the steel bars be processed.

[0050] Finished product inspection: Check whether the specifications, shape and quantity of the processed steel bars are correct according to the design requirements, and check whether the finished product dimensions match the material list;

[0051] Reinforcing bar cleaning: The surface of the reinforcing bars should be clean, and any oil, dirt, or rust adhering to them must be cleaned before use;

[0052] Rebar straightening: Straighten the rebar with a straightening machine. After straightening, the rebar must not have bends, sharp bends, or small wavy shapes.

[0053] Rebar cutting: According to the diameter, length and quantity of the rebar, the lengths should be matched and the longer pieces should be cut first and then the shorter pieces, so as to minimize and shorten the short ends of the rebars and save steel.

[0054] Steel bar transportation: When transporting processed steel bars to the construction site, the steel bars should be properly numbered and the transportation management should be properly implemented to prevent the steel bars from deforming during transportation;

[0055] Reinforcing bar installation: Figure 1 6 is the horizontal reinforcement of the retaining wall. Figure 1 7 is a vertical reinforcing bar;

[0056] Measurement and layout: Layout to determine the edge lines of the base plate and mark them with ink;

[0057] Mark the rebar position lines: Calculate the actual number of rebars needed for the base slab according to the rebar spacing indicated on the drawings, and mark the rebar positions on the base slab;

[0058] Bottom slab reinforcement binding: According to the marked reinforcement position lines, first lay the lower layer of reinforcement. Shorter reinforcement bars at the bottom, and longer reinforcement bars at the top;

[0059] When tying reinforcing bars, tie each intersection point of the two outermost rows, tie the intersection points of the middle section in a quincunx pattern, and tie all intersection points of reinforcing bars subjected to bidirectional stress.

[0060] Place mortar spacers for the concrete protective layer of the base slab. The thickness of the spacers should be equal to the thickness of the protective layer. There should be no less than 4 spacers per square meter, arranged in a quincunx pattern.

[0061] Embedded reinforcement binding: According to the location of the wall, bind the reinforcing bars that extend into the foundation of the wall firmly, and the insertion depth into the foundation should meet the design requirements;

[0062] The hooks should be oriented correctly, and the lap joints should comply with the construction specifications, with lap lengths not less than the specified values. The angle of the hooks and the length of the straight sections should comply with the construction specifications. The hooks should hook onto the intersections of the reinforcing mesh and be securely tied.

[0063] (5) After the bottom slab reinforcement is tied, pour the bottom slab concrete; ensure that the bottom of the vertical metal keel is embedded in the retaining wall foundation 8;

[0064] (6) The horizontal metal keel 4 is welded to the vertical metal keel 3 with a horizontal spacing of 1000mm;

[0065] (7) The ECP concrete hanging plate 2 on both sides of the retaining wall steel bars is fixed to the keel structure and connected into a whole: multiple horizontal support structure columns 5 are respectively connected between two corresponding vertical metal keels 3 to connect the structures on both sides; the horizontal support structure columns 5 are galvanized keels of 50mm×50mm×2mm.

[0066] (8) Install Z-shaped connector 1 at the junction of vertical metal keel and horizontal metal keel: Install Z-shaped connector 1 on ECP concrete cladding 2, drill holes in ECP concrete cladding 2, take care to prevent damage to the cladding, use electric drill to drill holes, and connect the processed connecting piece to ECP concrete cladding 2 with screws, bolts and ECP concrete cladding 2.

[0067] (9) Install ECP concrete panels. Install the concrete panels symmetrically, from bottom to top. Place sponge strips between the ECP concrete panels to prevent concrete leakage and fill the gaps.

[0068] (10) After each layer of ECP concrete cladding is installed, a layer of concrete is poured until the concrete retaining wall is constructed to the structural elevation: The specific steps are as follows:

[0069] The installation of the first layer of horizontal ECP concrete cladding panels is complete; check the installation quality.

[0070] Check the flatness and verticality of the installation, whether the gaps are uniform, whether the screws are firmly and reliably connected, whether the sponge strips are firmly attached, and whether the position is accurate;

[0071] Concrete pouring: Concrete is centrally mixed at the batching plant, transported to the construction site by concrete mixer trucks, and pumped to the pouring surface using a truck-mounted pump.

[0072] Before pouring concrete, a comprehensive inspection is carried out to confirm that the debris and water inside the ECP concrete slab have been cleaned.

[0073] The concrete for retaining walls must have the characteristics of slow setting and high fluidity to adapt to the pouring process and ensure quality; the concrete should be poured in layers, in sequence, and to the top in one go.

[0074] Pour the concrete to a position 5cm lower than the ECP concrete cladding installed on the first layer.

[0075] Install the second layer of ECP concrete cladding;

[0076] Inspect the installation quality of the second-layer ECP concrete cladding panels, and promptly adjust and reinstall any problems found.

[0077] Pour the second layer of concrete; continue until the concrete retaining wall is constructed to the structural elevation.

[0078] (11) Correct the gaps in the ECP panel of the retaining wall and mark the gaps: paste tape on both sides of the ECP panel; fill and grout the gaps with silicone weather-resistant sealant; clean the tape to complete the grouting work of the panel gaps;

[0079] (12) Concrete retaining wall, the top of the wall is sealed with ECP panels and the perimeter is sealed with sealant to prevent water leakage. The wall surface is cleaned and any contaminated areas are treated promptly.

[0080] This invention utilizes ECP concrete cladding panels as formwork for pouring concrete; galvanized metal keel serves as the supporting structure for installing the ECP cladding panels; the galvanized metal keel is cast into the retaining wall structure, improving the load-bearing capacity of the concrete retaining wall. This construction method integrates decoration and formwork, improving construction efficiency, saving time, and resulting in a smooth, simple, and elegant appearance.

Claims

1. A construction method of ECP hanging plate for concrete retaining wall without formwork and without decoration, characterized in that, The method comprises the following steps: (1) according to the drawing position, carry out the blocking wall foundation line and excavation replacement, and pour the blocking wall cushion; (2) according to the wall width, pop out the inner edge line of the ECP concrete hanging plate on the concrete blocking wall cushion, and then pop out the axis of the vertical metal keel according to the inner edge line of the ECP hanging plate; according to the axis position, install the embedded part of the vertical metal keel; (3) install two rows of vertical metal keels on the embedded part, and weld the embedded part and the vertical metal keel firmly; (4) install the horizontal steel and vertical steel between the two rows of vertical metal keels, and then bind the steel; (5) after the bottom plate steel is bound, pour the bottom plate concrete; (6) weld the horizontal metal keel on the vertical metal keel; (7) connect the multiple horizontal support structure columns between the two corresponding vertical metal keels to connect the two sides of the structure; (8) install the Z-shaped connecting piece at the intersection position of the vertical metal keel and the horizontal metal keel; (9) install the ECP concrete hanging plate, symmetrically install the concrete hanging plate, and install the ECP concrete hanging plate from the bottom to the top; paste the sponge strip between the ECP concrete hanging plates; (10) after installing one layer of ECP concrete hanging plate, pour one layer of concrete, until the concrete blocking wall is constructed to the structure elevation position; (11) correct the ECP hanging plate gap of the blocking wall, and hook out the gap; (12) the concrete blocking wall, the top of the wall is sealed by the ECP hanging plate, and the periphery is glued to prevent water leakage.

2. The construction method for concrete retaining wall free-forming and free-decorating using the ECP hanging plate according to claim 1, characterized in that, In step (2), the size of the embedded part is 300mm×200mm, the length direction of the embedded part is parallel to the wall body, and the embedded part is fixed by using the inverted cone anchor bolt, and one embedded part is arranged at an interval of 500mm.

3. The construction method of claim 1, wherein the ECP panel is used for the concrete retaining wall without formwork and without decoration. The cross-sectional size of the vertical metal keel is 100mm×50mm, and the cross-sectional length direction is parallel to the wall direction.

4. The construction method for concrete retaining wall free formwork and free decoration by using the ECP hanging plate according to claim 1, characterized in that, In step (4), according to the position line of the popped steel, first lay the lower layer of steel, and the short direction steel is below and the long direction steel is above; when binding the steel, the intersection points of the two rows near the periphery are bound, the intersection points of the middle part are bound in a quincunx shape, and the two-way stressed steel must be bound at all steel intersection points.

5. The construction method for concrete retaining wall free form, free decoration of ECP hanging plate according to claim 1, characterized in that, In step (6), the horizontal distance between the two adjacent horizontal metal keels is 1000mm.

6. The ECP hanging plate for the construction method of the concrete blocking wall without formwork and decoration according to claim 1, characterized in that: the horizontal support structure column in step (7) is a 50mm×50mm×2mm galvanized keel, and the horizontal metal keel and the vertical metal keel are both galvanized keels.

Images