A method for manufacturing a gypsum nog

Abstract

The present application relates to a kind of preparation methods of gypsum keel, the method is in the scheduling, monitoring of joint operation center with two production lines according to different technical routes to produce the gypsum keel of same quality.Solve the problem of the easy rust corrosion of light steel keel, steel plate rib web, the difficulty of marking bar, the insufficient strength, pressure resistance and impact resistance of column body in the spray construction type composite wall.

Description

Technical Field

[0001] This invention relates to a method for preparing a wall support device in the field of building engineering technology, and more particularly to a method for preparing a gypsum board keel. Background Technology

[0002] my country produces approximately 184 million tons of industrial by-product gypsum annually, with a cumulative stockpile exceeding 1 billion tons. Most of this industrial by-product gypsum is discarded as waste. The stockpiling of waste not only occupies a large amount of land but also pollutes the surrounding environment, including air, water, and the ground. Therefore, developing and utilizing industrial by-product gypsum to turn waste into treasure is one of the high-tech industries that the country has consistently encouraged.

[0003] Sprayed gypsum composite walls are a rapidly developing new building technology in recent years. This includes various techniques that use light steel keel, PVC, or metal panels as the framework, steel mesh, fiberglass mesh, or plastic mesh as the adhesive layer, and gypsum mortar as the sprayed mortar to form the wall. Among these, the combination of light steel keel + steel mesh + sprayed gypsum mortar within the wall is the most mature technology. However, in production practice, the high demand for light steel keel and steel mesh, as well as the stringent corrosion resistance requirements for metal building materials, leads to high manufacturing costs for this new type of building, limiting its large-scale promotion. Furthermore, during the construction of sprayed gypsum composite walls, it is necessary to manually create standard lines (commonly known as guide lines) to control the flatness of the wall surface. Creating these guide lines requires skilled workers, which is not only time-consuming and labor-intensive but also results in high labor costs, hindering the development of this technology. How to address the drawbacks of the above-mentioned problems while developing industrial gypsum as the main material for spray-cast composite wall support columns, expanding the production capacity of gypsum keel, and solving the shortcomings of current technologies is a particularly important issue for building material options that can replace and surpass light steel keel, PVC, or metal panels as the framework. Summary of the Invention

[0004] The technical problem to be solved by the present invention is to provide a method for preparing gypsum keel. Through the two paths of this method, light steel keel that replaces the supporting columns in spray-cast composite walls can be prepared, completely solving the problems of easy corrosion of metal components, difficulty in marking reinforcement, uneven wall surface, and high cost of non-load-bearing walls.

[0005] Therefore, the technical solution of the present invention to solve the aforementioned problem is: a method for preparing gypsum keel, comprising the steps of: producing gypsum keels of the same quality under the control of a joint operation center, using either a casting method or a carving method:

[0006] The first step is for the joint operation center to determine the structural form of the plaster keel column A+B or A+B1+B2, where A and B or B1 and B2 are individual plaster keels, and B1+B2=B.

[0007] The second step is to produce gypsum keel columns of the same quality on two separate production lines, and then, using the carving method and under the control of the joint operation center, produce gypsum keel columns with mortise and tenon structures, such as A+B or A+B1+B2, by using CNC technology for processing.

[0008] Alternatively, using the casting method, under the control of the joint operation center, molds A and B, or molds B1 and B2 with ventilation holes are first set up, and then cast separately to obtain the plaster keel. The plaster keel is then assembled into plaster keel columns using mortise and tenon joints.

[0009] Furthermore, according to the carving method, the joint operation center uses a carving machine to process paper-faced gypsum board or paperless gypsum board according to the pre-set instruction program. The carved boards are arranged in pairs and connected to each other by mortise and tenon to form a column shape. The joint operation center tests the impact resistance and compressive strength of the column and reserves work position holes or openings until the gypsum keel is completed.

[0010] Furthermore, according to the casting method, the joint operation center pre-sets instructions and uses a robotic arm to cast the gypsum into a specific mold. The casting steps include the preparation, weighing, and mixing of the slurry before it enters the mold, laying fiberglass mesh in the mold, and the column forming, impact resistance and compressive strength testing, and reserving work position holes or openings after the slurry is poured into the mold, until the gypsum keel is completed. Then, the gypsum keel columns are assembled using mortise and tenon joints.

[0011] Furthermore, the casting method also includes the following steps: weighing 50-60 parts of gypsum powder, 30-40 parts of water, 4-9 parts of fiber material, and 2-8 parts of reinforcing agent by weight; adding the materials according to the weight proportions to a mixer controlled by the joint operation center and mixing them into a slurry; and introducing the slurry into a mold pre-set with glass fiber mesh in the joint operation center to form a gypsum keel column with an overall thickness d≥10mm.

[0012] Compared to existing technologies and building materials used in spray-cast composite walls, the positive effects of this preparation method are quite significant:

[0013] 1. The gypsum keel columns prepared by this method can completely replace the light steel keel columns in non-load-bearing walls in the existing technology, and replace the steel plate mesh with glass fiber mesh. It can eliminate the corrosion of wall support columns and wall reinforcement for life and reduce the overall construction material cost.

[0014] 2. Through the precise control of the joint operation center, gypsum keel of the same quality can be produced according to different technical paths according to the requirements of the construction site, thereby improving the construction efficiency of the products.

[0015] 3. The prepared gypsum board can serve as columns A and B of the spray-cast composite wall. The fiberglass mesh layer is fixed in the mesh gap between the gypsum keel columns composed of these two parts, and the outer side of the gypsum keel replaces the guide bar. This eliminates the tediousness of the guide bar and the waste of manpower in construction, and can greatly improve the smoothness and aesthetic effect of the wall surface.

[0016] 4. For spray-cast composite walls, the gypsum keel columns prepared by this method can not only position the wall but also improve the stability and seismic performance of the wall, thereby increasing the construction efficiency of the wall.

[0017] 5. For spray-cast composite walls, the gypsum columns A and B prepared by this method can be assembled into gypsum keel column bodies by their own and each other's mortise and tenon structures. This makes it easy to fix fiberglass mesh on the column bodies and control the spray thickness and verticality of the composite wall according to the thickness of the fiberglass mesh layer.

[0018] 6. For spray-cast composite walls, the gypsum column A prepared by this method can have holes pre-drilled in its body to facilitate the pre-embedding of water and electricity pipelines and the ventilation and drying of the hollow wall; when the composite wall is a solid wall, the wall thickness is column A + B; when the composite wall is a hollow wall, the wall thickness is column A + B1 + B2 (A is the cavity); when the composite wall is a double-layer wall, the wall thickness is column A + cavity + A.

[0019] 7. The plaster columns prepared by this method can have the layers and thickness of the fiberglass mesh determined by the joint operation center according to the reinforcement requirements of the construction wall. During construction, the fiberglass mesh can be laid between columns A and B and secured by the mesh gap between the two columns. When used for the construction of solid walls, the fiberglass mesh is laid on one side, and when used for the construction of double-layer walls, the fiberglass mesh is laid on both sides.

[0020] 8. For spray-cast composite walls, if U-shaped light steel keel is used as the upper and lower guide beams and the two side columns of the wall to fix the beams, slabs and columns of the main building structure, the gypsum keel columns prepared by this method can be positioned in the spray-cast composite wall, thereby improving the stability and seismic performance of the wall. Attached Figure Description

[0021] Figure 1 This is a schematic diagram of the process route for preparing plaster keel using the carving method according to the present invention;

[0022] Figure 2 This is a schematic diagram of the process route for preparing gypsum keel by casting method according to the present invention;

[0023] Figure 3 This is a schematic diagram of an embodiment of the plaster keel involved in the present invention;

[0024] Figure 4 This is a schematic diagram of another embodiment of the plaster keel involved in the present invention.

[0025] In the picture, Figure 3 , Figure 4 In the diagram: 1- Composite wall (gypsum mortar layer), 2- Fiberglass mesh layer, A, B, B1, and B2 are individual gypsum joists, B1+B2=B; 3- Gypsum joist groove, 4- Gypsum joist protrusion, 5- Gypsum joist ventilation hole, 6- Mesh joint between two adjacent gypsum joists. Detailed Implementation

[0026] The following examples illustrate the production of plaster keels of the same quality using either casting or carving methods under the control of a joint operations center.

[0027] The first step is for the joint operation center to determine the structural form of the plaster keel column A+B or A+B1+B2, where A and B or B1 and B2 are individual plaster keels, and B1+B2=B.

[0028] The second step is to produce gypsum keel columns of the same quality on two separate production lines, and then, using the carving method and under the control of the joint operation center, produce gypsum keel columns with mortise and tenon structures, such as A+B or A+B1+B2, by using CNC technology for processing.

[0029] Alternatively, using the casting method, under the control of the joint operation center, molds A and B, or molds B1 and B2 with ventilation holes are first set up, and then cast separately to obtain the plaster keel. The plaster keel is then assembled into plaster keel columns using mortise and tenon joints.

[0030] Furthermore, according to the carving method, the joint operation center pre-sets instructions and uses a carving machine to process paper-faced gypsum board or paperless gypsum board. The carved boards are arranged in pairs and connected to each other by mortise and tenon joints to form a column shape. The joint operation center tests the impact resistance and compressive strength of the column and reserves work position holes or openings until the gypsum keel is completed.

[0031] Furthermore, according to the casting method, the joint operation center pre-sets instructions and uses a robotic arm to cast the gypsum into a specific mold. The casting steps include the preparation, weighing, and mixing of the slurry before it enters the mold, laying fiberglass mesh in the mold, and the column forming, impact resistance and compressive strength testing, and reserving work position holes or openings after the slurry is poured into the mold, until the gypsum keel is completed. Then, the gypsum keel columns are assembled using mortise and tenon joints.

[0032] Furthermore, the casting method also includes the following steps: weighing 50-60 parts of gypsum powder, 30-40 parts of water, 4-9 parts of fiber material, and 2-8 parts of reinforcing agent by weight; adding the materials according to the weight proportions to a mixer controlled by the joint operation center and mixing them into a slurry; and introducing the slurry into a mold pre-set with glass fiber mesh in the joint operation center to form a gypsum keel column with an overall thickness d≥10mm.

[0033] In this embodiment, the carving method is used to process paper-faced gypsum board or paperless gypsum board using a carving machine according to the instruction program pre-set by the joint operation center. The carved boards are arranged in pairs and connected to each other by mortise and tenon joints to form a column shape. The joint operation center tests the impact resistance and compressive strength of the column and reserves work position holes or openings until the gypsum keel is completed.

[0034] In this embodiment, the gypsum board is formed in a specific mold by means of a casting method, according to the instruction program pre-set by the joint operation center. The casting steps include the preparation, weighing and mixing of the slurry before it is poured into the mold, the column forming, impact resistance and compressive strength testing, and the reservation of work station holes or openings after the slurry is poured into the mold, until the production of the gypsum board is completed. Then, the gypsum board column is assembled in the form of mortise and tenon structure.

[0035] In this embodiment, the casting method further includes the following steps: weighing 30-40 parts of gypsum powder, 50-60 parts of water, 4-9 parts of fiber material, and 2-8 parts of reinforcing agent by weight; adding the materials according to the weight proportions to a mixer controlled by a joint operation center and mixing them into a slurry; introducing the slurry into a mold with a glass fiber mesh to form a gypsum keel with an overall thickness d≥10mm; then conducting impact resistance and compressive strength tests; and finally assembling the gypsum keel columns using a mortise and tenon structure.

[0036] Another embodiment is a method for fabricating plaster keel by casting:

[0037] (1) Obtain gypsum powder, water, fiber material and reinforcing agent according to the building industry standard; the fiber material can be glass fiber, ball milled quartz microparticles or diatomaceous earth; the water can be greywater suitable for land irrigation; the reinforcing agent can be a building material coagulating reinforcing agent that meets national standards.

[0038] (2) Weigh out 30-40 parts of gypsum powder, 50-60 parts of water, 4-9 parts of fiber material, and 2-8 parts of reinforcing agent by weight.

[0039] (3) Add the materials, which are dispensed according to the weight percentage, to the mixer and mix them evenly to form a slurry;

[0040] (4) Pour the grout into a mold (with pre-drilled holes or openings for pipes, wires or pipes to facilitate wall construction) and after hardening, form a gypsum keel with a total thickness d≥10mm.

[0041] (5) Using light steel keel as the supporting column of sprayed composite wall as the comparison object, the impact resistance and compressive strength of the gypsum board prepared by the above steps were tested along the X, Y and Z axes using special testing equipment.

[0042] Inspect the mesh seams, protrusions and grooves pre-set on the keel. Take two or more randomly selected gypsum boards as a group and check the connection of the mortise and tenon structure of this group of boards. They should fit together tightly to form the body of the gypsum keel column.

[0043] In another embodiment, the gypsum board is still produced by casting. First, a portion of slurry is poured directly into the template groove. When the slurry forms the shape of a board and its surface is in a soft, pliable state, mesh seams, protrusions, and grooves are set on the board surface. Then, fiberglass mesh is laid on its surface. Next, another portion of slurry is poured into the template groove, and mesh seams, protrusions, and grooves are set on its surface again. After natural drying, gypsum board is formed. Then, at least one or more sets of gypsum boards are joined together with mortise and tenon joints to form a gypsum keel column body.

[0044] The following embodiments still involve the steps of producing gypsum board by casting: 36 parts by weight of gypsum powder, 50 parts of water, 6 parts of fiber material, and 8 parts of reinforcing agent are weighed and mixed into a slurry. The slurry is poured into a mold pre-laid with fiberglass mesh, the slurry board surface is leveled, fiberglass mesh is laid, and slurry that can form at least one layer of board surface is poured in again to form a gypsum board with an overall thickness d≥10mm. The board is then dried in a dryer to obtain gypsum board.

[0045] In another embodiment, 38 parts by weight of gypsum powder, 56 parts of water, 4 parts of fiber, and 2 parts of reinforcing agent are weighed and mixed into a slurry. The slurry is introduced into a board forming machine. After pre-setting the mesh seams on the board surface and the protrusions and grooves for the tenon and mortise connections between the boards, the slurry board surface is leveled, and a fiberglass mesh is laid. Slurry that can form at least one layer on the board surface is introduced again to form a gypsum board with an overall thickness d≥8mm. The board is then dried in a dryer to obtain a gypsum board.

[0046] Alternatively, 40 parts by weight of gypsum powder and 60 parts by weight of water can be mixed to form a slurry. The slurry is then poured into a mold pre-laid with fiberglass mesh. Another layer of slurry is poured in to form at least one layer of the board surface, thus creating a gypsum board with an overall thickness d≥7mm. The board is then dried in a dryer to obtain gypsum board.

[0047] In the above embodiments, the production of gypsum board is carried out under the control of the joint operation center, following a stepped operation procedure of pouring, laying mesh, pouring again, laying mesh again, and pouring again. Finally, protrusions, grooves, and mesh gaps are made on the gypsum board body to connect the boards with tenon and mortise joints.

[0048] In the above embodiments, in the process of making protrusions and grooves for the mortise and tenon joint between boards, the protrusions are made by the robot control device of the joint operation center using its own sensors to sense the overall hardness of the gypsum board, the control device extrudes the board surface, and the laser rangefinder probe of the control device measures the circumference, diameter, and thickness of the protrusion, wherein the taper of the protrusion head is ≤89°.

[0049] In the above embodiments, in the process of making protrusions and grooves for the mortise and tenon connection between boards, the grooves are made by the robot control device of the joint operation center using its own sensors to sense the overall hardness of the gypsum board, pressing it into the board surface, and then measuring the circumference, diameter, and thickness of the groove using the laser rangefinder probe of the control device. The taper of the groove tail is ≥90°.

[0050] The above embodiments are characterized by the use of molds in the casting method, with mortise and tenon structures in the molds. After casting, the gypsum columns can be assembled into A+B or A+B1+B2. Fiberglass mesh needs to be placed during casting. The gypsum keel column body is composed of two groups of gypsum boards joined by mortise and tenon joints. The thickness of each gypsum board in each group is not uniform.

[0051] The casting method is implemented by using molds with mortise and tenon structures. After casting, the gypsum columns can be assembled into A+B or A+B1+B2. Fiberglass mesh needs to be placed during casting.

[0052] In summary, the gypsum keel produced by the steps of two production lines producing gypsum keels of the same quality under the control of a joint operation center, according to the present invention, provides an innovative technical solution for leading the preparation of non-load-bearing wall support structures compared to the columns made of "light steel keel + steel mesh + gypsum sprayed mortar" and "light steel keel + fiberglass mesh + gypsum sprayed mortar" installed in sprayed composite walls.

[0053] The positive effects produced are compared as follows:

[0054] The first-generation composite wall support column, consisting of light steel keel, steel mesh, and gypsum sprayed mortar, has an impact resistance (MPa) of 10 impacts.

[0055] The second-generation composite wall support column, consisting of light steel keel, fiberglass mesh, and gypsum sprayed mortar, has an impact resistance (MPa) of 100 impacts.

[0056] The third-generation composite wall support column, consisting of gypsum keel, fiberglass mesh, and gypsum sprayed mortar, has an impact resistance (MPa) of over 200 blows.

Claims

1. A method for preparing gypsum keel, characterized in that, The method comprises the following steps: Under the control of a joint operation center, plaster keels of the same quality are produced using either a casting method or a carving method. The first step is for the joint operation center to determine the structural form of the plaster keel column A+B or A+B1+B2, where A and B or B1 and B2 are individual plaster keels, and B1+B2=B. The second step is to produce gypsum keel columns of the same quality on two separate production lines, and then, using the carving method and under the control of the joint operation center, produce gypsum keel columns with mortise and tenon structures, such as A+B or A+B1+B2, by using CNC technology for processing. Alternatively, using the casting method, under the control of the joint operation center, molds A and B, or molds B1 and B2 with ventilation holes are first set up, and then cast separately to obtain the plaster keel. The plaster keel is then assembled into plaster keel columns using mortise and tenon joints.

2. The method for preparing gypsum keel according to claim 1, characterized in that, According to the carving method, the joint operation center uses a carving machine to process paper-faced gypsum board or paperless gypsum board according to the pre-set instruction program. The carved boards are arranged in pairs and connected to each other by mortise and tenon to form a column shape. The joint operation center tests the impact resistance and compressive strength of the column and reserves work position holes or openings until the gypsum keel is completed.

3. The method for preparing gypsum keel according to claim 1, characterized in that, According to the casting method, the gypsum keel is formed in a specific mold by means of a robot casting method, according to the instructions and programs set in advance by the joint operation center. The casting steps include the preparation, weighing and mixing of slurry before entering the mold, laying fiberglass mesh in the mold, column forming after the slurry is poured into the mold, impact resistance and compressive strength testing, and reserving work position holes or openings until the production of gypsum keel is completed. Then, the gypsum keel column is assembled in the form of mortise and tenon structure.

4. The method for preparing gypsum keel according to claim 3, characterized in that, The casting method also includes the following steps: weighing 50-60 parts of gypsum powder, 30-40 parts of water, 4-9 parts of fiber material, and 2-8 parts of reinforcing agent by weight; adding the materials according to the weight proportions to a mixer controlled by the joint operation center and mixing them into a slurry; and introducing the slurry into a mold with a pre-set glass fiber mesh in the joint operation center to form a gypsum keel column with an overall thickness d≥10mm.

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