A shaped curved surface super large GRC plate back system, manufacturing method and installation process

Abstract

The present application relates to a kind of special-shaped curved surface super GRC plate block system, and the system includes: main frame, including cross keel and vertical keel, by the frame cross keel of horizontal parallel arrangement and vertical parallel arrangement vertical keel is formed close to the space frame structure of main structure, cross keel is fixed on vertical keel by vertical pick, and connecting steel is welded on cross keel at certain interval, connecting steel and GRC panel are bonded together, and finally super GRC plate block is fixed on main frame by multiple connecting steel;Upper hanging point, including hanging piece and support piece, is set in the position of upper frame cross keel, and is realized up and down, left and right, front and back three-dimensional adjustment capability by custom combination steel sheet and bolt;Lower hanging point, including round tube and U-shaped groove base, multiple U-shaped groove bases are fixed on main structure respectively, and round tube is clamped in U-shaped groove base;It also includes the manufacturing method and installation process of plate block and system.The system and method of the present application have the advantages of convenient construction, economy, practicality, safety and reliability.

Description

Technical Field

[0001] This invention relates to the field of construction, and in particular to a carrying system, manufacturing method and installation process for an irregularly shaped curved super-large GRC panel. Background Technology

[0002] Irregularly shaped curved surface extra-large GRC panel curtain walls are increasingly being used on building exteriors. Traditional backing systems cannot meet on-site requirements in terms of manufacturing, installation, and adjustment.

[0003] In existing technologies, for GRC (Glass Reinforced Concrete) panels used on exterior walls, a frame structure is typically used as the connecting component. The GRC panels are then connected and installed on the building's exterior wall via this frame. If the GRC panels are regular components, a regular frame structure is used for installation. The back of the frame is fixed to the main structure of the building, while the front is connected to the GRC panels or other panels via the frame. If the GRC panels have an irregular curved shape, the side of the frame closest to the GRC panels is adjusted accordingly. The main focus is on aligning one side of the frame with the curved shape of the back of the GRC panel. In practical applications, the advantages of using GRC panels are typically demonstrated for irregular curved surfaces.

[0004] Typically, depending on the building's design, the irregularly shaped curved surfaces that embody its form are exterior wall decorative structures composed of multiple extra-large GRC (Glass Reinforced Concrete) panels. These curved surfaces have horizontally recessed areas on their inner sides, within which connecting steel bars are fixed. These extra-large GRC panels and the supporting system are connected to the main structure of the building's exterior wall. However, the GRC panels and supporting frame assembled in this way can only be installed sequentially; adjustments are not possible or can not be made during installation. This makes the fabrication of GRC panels cumbersome and complex, requiring multiple disassemblies and adjustments to the supporting frame. During construction, the supporting frame is fixed to the main structure, making effective adjustment difficult and affecting installation quality. For large, wraparound GRC decorative strips, multiple extra-large curved GRC panel pieces need to be fabricated and then spliced ​​together one by one. If the original supporting frame is still used for fabrication and construction, it will significantly impact the construction period, and the smoothness of the joints and connections between adjacent GRC panels cannot be guaranteed, also affecting the overall construction quality. Based on this, we need to design a brand-new irregular curved surface super-large GRC panel and its corresponding carrying system, and also develop and design correspondingly for its manufacturing and installation, so as to achieve a more perfect decorative effect. Summary of the Invention

[0005] The purpose of this invention is to overcome the shortcomings of the existing technology and provide a carrying system, manufacturing method, and installation process for large, irregularly shaped curved GRC (Glass Reinforced Concrete) panels. The carrying system of this invention is capable of withstanding the weight and horizontal wind loads of large GRC panels, while also enabling rapid panel fabrication in factories and solving the problems of difficult on-site panel adjustment and installation.

[0006] To achieve the above-mentioned objectives, the technical solution provided by this invention patent is as follows:

[0007] A support system for extra-large GRC (Glass Reinforced Concrete) panels with irregular curved surfaces, wherein the irregular curved surfaces are exterior wall decorative structures composed of multiple extra-large GRC panels spliced ​​together. The irregular curved surfaces are presented by GRC panels, with horizontally oriented recesses on the inner side of the GRC panels. Reinforcing bars are fixedly connected within these recesses. The extra-large GRC panels are connected to the main structure of the building's exterior wall via the support system. The support system is characterized by comprising:

[0008] The main frame includes horizontal and vertical keels arranged using a spatial three-dimensional interlacing method. The horizontal keels include frame horizontal keels and connecting horizontal keels. The frame horizontal keels arranged in parallel horizontal directions and the vertical keels arranged in parallel vertical directions form a rectangular planar frame structure close to the main structure. Connecting horizontal keels are provided on the inner side of the rectangular planar frame structure, protruding towards the recessed part of the GRC panel. The connecting horizontal keels are fixed to the vertical keels by multiple vertical keels. The connecting steel bars are welded to the connecting horizontal keels. Each GRC panel is fixed to the main frame by multiple connecting steel bars.

[0009] The upper hanging point is set on the upper frame horizontal keel. This upper hanging point is a combination hanging point made of custom steel plate, which can move left and right and rotate. The height is adjusted by the upper and lower bolts at the connection, and the horizontal movement is locked by the left and right bolts.

[0010] The lower hanging point includes a round tube and a U-shaped groove base. Multiple U-shaped groove bases are fixed on the vertical keel of the frame. The round tube is inserted into the U-shaped groove base, and the round tube can move up, down, left, right, forward and backward through the U-shaped groove base.

[0011] In the irregular curved surface ultra-large GRC panel carrying system of the present invention, the main structure is provided with a support for the upper hanging point and a U-shaped groove base for the lower hanging point. The upper hanging point and the lower hanging point are connected to the main structure of the building. Usually, the main structure is provided with a connector to connect with the upper hanging point and the lower hanging point, so as to install the ultra-large GRC panel on the exterior wall of the building.

[0012] In the irregular curved surface ultra-large GRC plate carrying system of the present invention, in the structure of the upper hanging point, the cross-section of the support is L-shaped, and two parallel triangular ribs are provided on the support. The bottom of the support is connected to the main structure. The hanging member includes two parallel vertical plates on both sides and a horizontal plate on the top. The two sides of the horizontal plate are respectively connected to the top of the vertical plate to form an inverted U-shaped structure. A slot is provided in the middle of the bottom of the vertical plate. The two parallel vertical plates are locked to the top of the support through the slot at the bottom. The adjusting bolts include upper and lower bolts and left and right bolts. One of the upper and lower bolts passes through the middle of the horizontal plate and abuts against the middle position of the top of the support. The two left and right bolts pass through the triangular ribs on the support respectively and abut against the vertical plates of the hanging member respectively.

[0013] In the irregular curved surface ultra-large GRC plate carrying system of the present invention, the main body of the support is an L-shaped folded plate, and two triangular ribs are provided on the inner side of the L-shaped folded plate. The straight edges of the two sides of the triangular ribs are welded and fixed to the inner side of the L-shaped folded plate.

[0014] In the irregular curved surface ultra-large GRC plate carrying system of the present invention, the U-shaped groove base of the lower hanging point is a U-shaped steel plate integrally pressed. The bottom of the U-shaped steel plate is fixed to the main structure by adjusting bolts, and the nut of the adjusting bolt is located at the bottom. The outer diameter of the round tube that is locked in the U-shaped groove base is equal to the opening width of the U-shaped groove base, and a flared large mouth is provided at the upper end of the opening of the U-shaped groove base.

[0015] In the irregular curved surface ultra-large GRC panel carrying system of the present invention, the lower part of the vertical keel on the main frame extends and protrudes from the lower frame horizontal keel, and a connecting steel bar is also provided at the end of the extension part. The connecting steel bar extends and is fixed to the bottom inner side of the GRC panel.

[0016] In the irregular curved surface super large GRC panel backing system of the present invention, the horizontal and vertical keels arranged by the spatial three-dimensional interlacing method are as follows: between the super GRC panel, which serves as the skin of the irregular building, and the main structure, a typical cross section is extracted according to the position of the vertical keel. The vertical keel maintains a fixed distance from the main structure. The horizontal direction is arranged with connecting horizontal keels at the intersection points of the plane offset inward from the GRC panel at a spacing of 600-800mm. Vertical cantilever pieces are fixed between the connecting horizontal keels and the vertical keels to serve as vertical keels.

[0017] The present invention also includes a method for manufacturing an extra-large GRC panel with irregular curved surface. The method includes a manufacturing process for a GRC panel with irregular curved surface, a manufacturing process for a carrying system, and an overall composite process, specifically including the following steps.

[0018] The manufacturing process of the irregularly shaped curved GRC panel includes:

[0019] The first step is to divide the irregular decorative surface of the building exterior into multiple irregular curved surfaces according to the design drawings. The outer layer of the irregular decorative surface is a GRC panel. The divided irregular curved surfaces are numbered, the shape and size of the GRC panel are determined, and each GRC panel to be made is assigned a number.

[0020] The second step is the preparation of GRC panels. The process includes making a mold based on the building skin, spraying GRC material onto the mold to form the panel, and then rolling and curing it after forming. Through the above process, multiple numbered GRC panels are made using GRC material. The curved surface of the GRC panel is an irregular curved surface. Based on the building's facade design standards, with a length of 4-5 meters and a height of 2 meters, each GRC panel is an extra-large GRC slab.

[0021] The manufacturing process of the carrying system includes:

[0022] The third step is to design the corresponding carrying system according to the specifications of each irregular curved surface. The carrying system is designed and manufactured using a spatial three-dimensional interweaving method. The spatial frame structure of the carrying system includes horizontally parallel frame keels and vertically parallel frame keels, with the lower part of the vertical keels extending outwards.

[0023] The fourth step is to set up a connecting horizontal keel on one side of the completed spatial frame structure, based on the vertical concave and convex lines of the curved surface on the GRC plate and the design distribution of the connecting steel bars. The connecting horizontal keel is connected to the vertical keel through the vertical keel. Multiple connecting steel bars are set on the connecting horizontal keel, and connecting steel bars are also welded to the ends of the partially extended vertical keel.

[0024] The overall composite process includes:

[0025] The fifth step is to cover the oversized GRC panel with the steel frame of the carrying space, so that the connecting steel bars of the carrying system are as close as possible to the inner curved surface of the GRC panel. GRC material is sprayed to form a protrusion at the position where the connecting steel bars are close to the inner curved surface of the GRC panel. The protrusion covers the end of the connecting steel bar, and the protrusion is rolled to protect the side, so that the carrying system is connected to the curved GRC panel as a whole.

[0026] The sixth step is to install the hanging brackets for the upper and lower hanging points and the round tubes for the lower hanging points on the corresponding positions on the carrying system, thus completing the composite into an extra-large GRC plate with an irregular curved surface.

[0027] The above-mentioned method for manufacturing irregularly shaped curved super-large GRC panels also includes a seventh step: splicing multiple finished irregularly shaped curved super-large GRC panels together, checking the gaps and surface transitions at the joints, and adjusting and correcting any differences in a timely manner. Each finished super-large GRC panel must be trial-spliced ​​with adjacent super-large GRC panels to ensure uniform gaps and smooth surface transitions, thereby meeting the design requirements. If the requirements are not met, corrections and adjustments must be made during the manufacturing stage.

[0028] It also involves an installation process for extra-large irregularly shaped curved GRC panels. This process involves attaching the completed extra-large irregularly shaped curved GRC panels to the main structure of the building's exterior wall to form an extra-large decorative surface made of GRC material. The installation method includes the following steps:

[0029] The first step is to pre-assemble and verify the extra-large GRC panels produced in the factory. The extra-large GRC panels with irregular curved surfaces that have been pre-assembled are packaged separately and transported to the construction site, where they are placed according to their numbers.

[0030] The second step is to determine the installation location of the GRC panels of the main structure on the exterior wall of the building, as well as the corresponding number of the large irregular curved GRC panels at that installation location, and then hoist the large irregular curved GRC panels to the ground at the installation location.

[0031] The third step involves pre-setting connectors at the installation positions on the main structure, welding and fixing the upper hanging point brackets to the connectors, and using adjusting bolts to install the U-shaped groove base of the lower hanging point. The positions of the brackets and the U-shaped groove base are then adjusted so that the upper and lower hanging points on the irregular curved surface of the large GRC plate correspond to each other.

[0032] The fourth step involves using multiple hoisting devices to simultaneously hoist the extra-large GRC panels with irregular curved surfaces at multiple points on the exterior wall of the building. The upper part of each extra-large GRC panel with irregular curved surfaces is connected to the main structure through an upper hanging point, and the lower part is connected to the main structure through a lower hanging point, so as to install the individual extra-large GRC panels on the exterior wall of the building.

[0033] The fifth step is to hoist the adjacent extra-large GRC panels. During hoisting, the extra-large GRC panels to be installed and the completed extra-large GRC panels need to be adjusted simultaneously. The upper and lower hanging points are used to adjust the three-dimensional direction of the extra-large GRC panels. After the three-dimensional adjustment is completed, the backing system is fixed to make the joints at the splicing position uniform, consistent in size, and the transition of irregular curved surfaces smooth.

[0034] The sixth step is to inspect the overall surface condition and transition after all the irregular curved surface oversized GRC panels have been hoisted and adjusted, so that the overall irregular curved surface is complete and natural. This completes the installation of all the irregular curved surface oversized GRC panels, thus forming the GRC cladding decoration on the building into an irregular curved surface shape that meets the design requirements.

[0035] Based on the above technical solutions, the carrying system, manufacturing method, and installation process for an irregularly shaped curved surface ultra-large GRC plate of the present invention have achieved the following technical effects through practical application:

[0036] 1. The support system for irregularly shaped, curved, extra-large GRC panels of this invention is designed and manufactured using a spatial three-dimensional interlacing method. It can withstand the weight of the large GRC panels and horizontal wind loads, while meeting the requirements for rapid factory fabrication. During installation, it allows for three-dimensional adjustment on-site, meeting installation accuracy requirements. The "spatial three-dimensional interlacing method" is used to arrange the specific form of the horizontal and vertical joists, effectively supporting the irregularly shaped GRC modules. Combined with customized three-dimensional adjustable hangers, this forms a dedicated support system for irregularly shaped, curved, extra-large GRC panels, enabling rapid factory fabrication and solving the difficulties of on-site panel adjustment and installation.

[0037] 2. In the manufacturing process of the irregular curved surface extra-large GRC panel of the present invention, a template is used to make the outer shell of GRC material into a GRC panel. Connecting steel bars are designed and installed on the inner curved surface of the outer shell. One end of the connecting steel bar is installed in the recessed part and the edge part, and the other end is connected to the spatial keel frame, so that it can be effectively connected with the carrying system set in the space. Moreover, the frame setting of the carrying system is convenient to be quickly completed in the factory. After being manufactured according to the number, it is pre-assembled in the factory to ensure the docking accuracy of adjacent GRC panels.

[0038] 3. During the installation of the irregular curved surface super-large GRC panels of the present invention, due to the large construction site and the large number of panels, multiple installations are carried out simultaneously according to their number and location, and then connected and installed. Three-dimensional adjustable components are used for three-dimensional adjustment to meet the requirements of construction progress and construction accuracy, and the frame structure is fully utilized to ensure safety. Attached Figure Description

[0039] Figure 1 This is a three-dimensional structural schematic diagram of a non-circular curved surface ultra-large GRC plate carrying system according to the present invention.

[0040] Figure 2 This is a structural schematic diagram from the perspective of the main frame in the irregular curved surface ultra-large GRC plate back support system of the present invention.

[0041] Figure 3 This is a side view structural diagram of an irregular curved surface ultra-large GRC plate carrying system according to the present invention.

[0042] Figure 4 This is a side view of the upper hanging point in the irregular curved surface ultra-large GRC plate carrying system of the present invention.

[0043] Figure 5 This is a top view schematic diagram of the upper hanging point in the irregular curved surface ultra-large GRC plate carrying system of the present invention.

[0044] Figure 6 This is a cross-sectional schematic diagram of the lower hanging point in the irregular curved surface ultra-large GRC plate carrying system of the present invention.

[0045] Figure 7 This is a top view schematic diagram of the undercarriage point in a non-circular curved surface ultra-large GRC plate carrying system of the present invention.

[0046] Figure 8 This is a flowchart illustrating the manufacturing method of the irregular curved surface ultra-large GRC plate containing a carrying system according to the present invention.

[0047] Figure 9 This is a schematic diagram of the installation process of the irregular curved surface ultra-large GRC plate containing the carrying system of the present invention.

[0048] Among them, 1—extra-large GRC panel, 2—main frame, 21—horizontal frame joists, 22—vertical joists, 23—connecting horizontal joists, 24—vertical cantilever, 3—upper hanging point, 31—support piece, 32—hanging piece, 33—upper and lower bolts, 34—left and right bolts, 4—lower hanging point, 41—round pipe, 42—U-shaped groove base, 43—adjusting bolt, 5—connecting steel bar, A—main structure, B—GRC panel. Detailed Implementation

[0049] The following detailed description, in conjunction with the accompanying drawings and specific embodiments, further elaborates on the present invention's irregular curved surface ultra-large GRC plate carrying system, manufacturing method, and installation process. The purpose is to more clearly understand the structural composition and manufacturing process of the carrying system and to clarify its application in engineering construction.

[0050] like Figure 1 , Figure 2 and Figure 3 As shown, this invention first provides a support system for extra-large irregularly shaped curved GRC panels. Its function is to install extra-large GRC panels on the exterior walls of buildings, thereby forming an irregularly shaped curved decorative surface with a designed pattern. The irregularly shaped curved surface is an exterior wall decorative structure composed of multiple extra-large GRC panels spliced ​​together. Each block-shaped GRC material irregularly shaped curved surface is assembled into a large irregularly shaped curved decorative surface, with horizontally oriented recesses on each GRC panel B. Each individual GRC panel B is connected into a single extra-large GRC panel 1 through a dedicated support system, and then spliced ​​and installed onto the main structure of the building's exterior wall.

[0051] Structurally, the carrying system mainly includes a main frame 2, upper mounting points 3, and lower mounting points 4. The GRC panels are fixed to the main frame 2, and then secured to the main structure A of the building using the upper mounting points 3 and lower mounting points 4.

[0052] The main frame 2 includes horizontal and vertical keels 22 arranged using a spatial three-dimensional interwoven method. The horizontal keels include frame horizontal keels 21 and connecting horizontal keels 23, forming a rectangular planar frame structure close to the main structure. Connecting horizontal keels 23 are provided on the inner side of the rectangular planar frame structure, protruding towards the recessed portion of the GRC panel. These connecting horizontal keels 23 are fixed to the vertical keels 22 by multiple vertical keels, where the vertical keels are vertical cantilever members 24, with one end vertically fixed to the rectangular planar frame structure and the other end vertically fixed to the connecting horizontal keel 23. One end of the connecting steel bar 5 is welded to the connecting horizontal keel 23, and the other end of the connecting steel bar 5 is recessed near the inner side of the GRC panel and embedded in the connection point on the back of the GRC panel. The GRC panel is fixed to the main frame 2 by multiple connecting steel bars 5.

[0053] The upper hanging point 3 is set on the frame horizontal keel 21 on the upper part of the main frame 2. The upper hanging point 3 is a combination hanging point made of customized steel plate, which can move left and right and rotate. The height is adjusted by the upper and lower bolts 33 at the connection, and the horizontal movement is locked by the left and right bolts 34.

[0054] The lower hanging point 4 includes a circular tube 41 and a U-shaped groove base 42, and multiple U-shaped groove bases 42 are fixed on the main structure A. The circular tube 41 is engaged in the U-shaped groove base 42, and the circular tube 41 can move in the up, down, left, right, forward and backward directions through the U-shaped groove base 42.

[0055] In order to achieve stable fixing of the super-large GRC panel 1 on the main structure A of the building, multiple connectors are provided on the main structure A. The support 31 of the upper hanging point 3 and the U-shaped groove base 42 of the lower hanging point 4 are respectively connected to the corresponding connectors. One end of the connector is prefabricated on the main structure A.

[0056] like Figure 4 and Figure 5As shown, in the structure of the upper hanging point 3, the cross-section of the support 31 is L-shaped, and two parallel triangular ribs are provided on the support 31. The bottom of the support 31 is connected to the main structure A. The hanging member 32 includes two parallel vertical plates on both sides and a horizontal plate on the top. The two sides of the horizontal plate are respectively connected to the top of the vertical plate to form an inverted U-shaped structure. A slot is provided in the middle of the bottom of the vertical plate. The two parallel vertical plates are locked to the top of the support 31 through the slot at the bottom. The adjusting bolts include upper and lower bolts 33 and left and right bolts 34. One upper and lower bolt 33 passes through the middle of the horizontal plate and abuts against the middle position of the top of the support 31. The two left and right bolts 34 pass through the triangular ribs on the support 31 respectively and abut against the vertical plate of the hanging member 32 respectively.

[0057] The main body of the aforementioned support 31 is an L-shaped folded plate. Two triangular ribs are provided on the inner side of the L-shaped folded plate. The two straight edges of the triangular ribs are welded and fixed to the inner side of the L-shaped folded plate.

[0058] like Figure 6 and Figure 7 As shown, the U-shaped groove base 42 of the lower hanging point is a U-shaped steel plate integrally pressed. The bottom of the U-shaped steel plate is fixed to the main structure A by adjusting bolts 43, and the nut of the adjusting bolts 43 is located at the bottom. The outer diameter of the round tube 41 that is locked in the U-shaped groove base 42 is equal to the opening width of the U-shaped groove base 42, and a flared large opening is provided at the upper end of the opening of the U-shaped groove base 42.

[0059] The vertical keel 22 on the main frame 2 extends and protrudes from the lower frame horizontal keel 21. A connecting steel bar 5 is also provided at the end of the extension part. The connecting steel bar 5 extends and is fixed to the inner side of the bottom of the extra-large GRC plate 1.

[0060] In this invention, the horizontal and vertical keels arranged by the spatial three-dimensional interlacing method are as follows: between the GRC panel, which serves as the skin of the irregular building, and the main structure A, a typical cross-section is extracted according to the position of the vertical keel 22. The vertical keel 22 maintains a fixed distance from the main structure A. Horizontal keels 23 are arranged at the intersection points of the plane offset inward from the GRC panel at a spacing of 600-800mm. Vertical cantilever members 24 are fixed between the horizontal keel 23 and the vertical keel 22 to serve as vertical keels.

[0061] like Figure 8 As shown, the present invention also includes a method for manufacturing an irregularly shaped curved surface super-large GRC plate. The method includes a manufacturing step of the irregularly shaped curved surface super-large GRC plate, a carrying system manufacturing step, and an overall composite manufacturing step, specifically including the following steps;

[0062] The manufacturing process of the irregularly shaped curved GRC panel includes:

[0063] The first step is to divide the irregular decorative surface of the building exterior into multiple irregular curved surfaces according to the design drawings. The outer layer of the irregular decorative surface is a GRC panel. The divided irregular curved surfaces are numbered and each GRC panel is named to distinguish them.

[0064] The second step is the preparation of GRC panels. The preparation process of GRC panels includes making a mold according to the building skin, spraying GRC material onto the mold to form it, and performing rolling curing after forming. Through the above process, multiple GRC panels are made using GRC material and production number respectively. The curved surface of the GRC panel is an irregular curved surface. Each GRC panel is an extra-large GRC panel.

[0065] The manufacturing process of the carrying system includes:

[0066] The third step is to design the corresponding carrying system according to the specifications of each irregular curved GRC panel. The carrying system is designed and manufactured using a spatial three-dimensional interwoven method. The spatial frame structure of the carrying system includes horizontally parallel frame keels and vertically parallel frame keels. The lower part of the vertical keels extends outwards, and connecting steel bars are designed to connect the carrying system and the GRC panel.

[0067] The fourth step is to set a connecting horizontal keel 23 on one side of the space frame structure based on the vertical concave and convex lines of the GRC panel surface on the super large GRC plate 1 and the design distribution of the connecting steel bars. The connecting horizontal keel 23 is connected to the vertical keel 22 through the vertical keel. Multiple connecting steel bars 5 are set on the connecting horizontal keel 23, and connecting steel bars 5 are also welded to the ends of the partially extended vertical keel 22. Specifically, one end of the multiple connecting steel bars 5 is connected to the connecting horizontal keel 23 and the vertical keel 22.

[0068] The overall composite process includes:

[0069] The fifth step is to cover the GRC panel with the steel frame of the carrying space on top of the GRC panel. At this time, the inner curved surface of the GRC panel is facing upward to facilitate construction operations. The connecting steel bar 5 on the carrying system is brought as close as possible to the inner curved surface of the GRC panel. GRC material is sprayed at the position of the connecting steel bar 5 close to the inner curved surface of the GRC panel to form a protrusion. The protrusion covers the connection part of the connecting steel bar 5 and the GRC panel to connect the two into one. The protrusion part is then rolled to protect the side, so that the carrying system and the curved GRC panel are connected into one.

[0070] The sixth step is to install the hanger 32 of the hanging point 3 and the round tube 41 of the lower hanging point 4 on the corresponding positions on the carrying system. After the GRC panel and the carrying system are combined, they become the super large GRC plate 1 with irregular curved surface. By analogy, all the super large GRC plates 1 are prepared.

[0071] The aforementioned method for manufacturing the irregularly shaped curved extra-large GRC panel 1 also includes a seventh step: splicing multiple finished extra-large GRC panels 1 together, checking the gaps and surface transitions at the joints, and adjusting and correcting any discrepancies promptly. Each finished extra-large GRC panel 1 must be trial-stitched with adjacent extra-large GRC panels 1 to ensure uniform gaps and smooth surface transitions, thereby meeting design requirements. If the requirements are not met, adjustments must be made during the manufacturing stage.

[0072] After the large GRC panels 1 required for the building's exterior walls and their supporting systems are prepared, inspected, and corrected, they can be transported to the construction site for on-site installation. To achieve better installation, we have specially designed an installation process for irregularly shaped, curved, extra-large GRC panels. This process involves hanging the completed irregularly shaped, curved, extra-large GRC panels onto the main structure of the building's exterior walls to form an extra-large decorative surface made of GRC material.

[0073] like Figure 9 As shown, the installation method includes the following steps:

[0074] The first step is to transport the large, irregularly shaped GRC panels 1, which are produced and pre-assembled in the factory, to the construction site and place them according to their numbering.

[0075] The second step is to determine the installation position of the super-large GRC panel 1 of the main structure A on the exterior wall of the building, as well as the super-large GRC panel 1 with the corresponding number of the irregular curved surface at the installation position, and hoist the super-large GRC panel 1 with the corresponding number of the irregular curved surface to the ground at the installation position.

[0076] The third step is to pre-install connectors at the installation positions on the main structure A. The connectors can be installed or pre-installed according to the site conditions. They are usually installed on-site as part of the main structure A. The support 31 of the upper hanging point 3 is welded and fixed on the connectors, and the U-shaped groove base 42 of the lower hanging point 4 is fixed using adjusting bolts. The position is adjusted so that the upper hanging point 3 and the lower hanging point 4 on the irregular curved surface super large GRC plate correspond to each other.

[0077] The fourth step involves using multiple hoisting devices to simultaneously hoist the extra-large GRC panels 1 with different irregular curved surfaces at multiple points on the exterior wall of the building. Each extra-large GRC panel 1 with an irregular curved surface is connected to the main structure A through the upper hanging point 3 and the lower hanging point 4, so as to install the individual extra-large GRC panel 1 on the exterior wall of the building.

[0078] The fifth step is to hoist the adjacent super-large GRC panel 1. After the super-large GRC panel 1 is hoisted into place, it needs to be adjusted simultaneously with the completed super-large GRC panel 1 before installation. The three-dimensional direction adjustment of the super-large GRC panel 1 is achieved by using the upper hanging point 3 and the lower hanging point 4. After the three-dimensional adjustment is completed, the backing system is fixed to make the splicing position joints uniform, consistent in size, and the transition of irregular curved surfaces smooth.

[0079] Step 6: After all the irregular curved surface extra-large GRC panels 1 have been hoisted and adjusted, check the overall surface condition and transition to ensure that the overall irregular curved surface is complete and natural, thus completing the installation of the irregular curved surface extra-large GRC panels.

[0080] Furthermore, in the process of arranging horizontal and vertical keels using the "spatial three-dimensional interlacing method": Between the irregular building skin and the main structure, typical cross-sections are extracted according to the positions of the vertical steel keels (based on structural calculations of spacing). The vertical steel keels maintain a fixed distance from the main structure. Horizontal keels are arranged at intervals of 600-800mm at the intersection points with the surfaces offset inwards from the skin by a fixed distance, thus perfecting the connection between the horizontal and vertical keels and meeting structural load requirements. The entire system can withstand the combined forces of large slab gravity and wind loads, and facilitates adjustment of slab flatness.

[0081] The horizontal and vertical keels are arranged using a "spatial three-dimensional interweaving method" to complete the main frame of the back keel. Custom steel plate hanging points are welded to the upper part of the back keel of the panel, and matching custom brackets for the upper hanging points are installed on the main structure. Round tubes are welded to the lower part of the back keel of the panel, and matching U-shaped grooves for the lower hanging points are installed on the main structure. The round tubes at the bottom of the panel are inserted into the U-shaped grooves first, and the upper hanging parts are pre-hung on the upper brackets. Three-dimensional adjustment is achieved by adjusting the screws up and down / left and right. After the panel is hoisted into place, the bracket positions are fully welded by adjusting the screws up and down / left and right.

[0082] This invention patent employs a "spatial three-dimensional interwoven method" to arrange horizontal and vertical keels to support irregularly shaped GRC modules, combined with a customized three-dimensional adjustable hanging system to form a backing system for irregularly shaped curved, ultra-large GRC panels. This structure can withstand the combined forces of the weight of large GRC panels and horizontal wind loads, allowing for rapid panel fabrication in factories while enabling on-site three-dimensional adjustment of the panels and accommodating the installation precision requirements of large panels. Furthermore, the solution implemented in this invention is convenient to construct, economical, safe, and reliable, making it beneficial for the promotion and use of similar projects.

Claims

1. A backing system for extra-large GRC panels with irregular curved surfaces, wherein the irregular curved surface is an exterior wall decoration structure spliced ​​from multiple extra-large GRC panels (1), the irregular curved surface includes a horizontal arc surface and a vertical concave-convex surface, the GRC panels are connected to the backing system by connecting steel bars, and the backing system is used to fix them to the main structure of the building exterior wall, characterized in that, The carrying system includes: The main frame (2) includes horizontal and vertical keels (22) arranged in a spatial three-dimensional interlacing method. The horizontal keel includes frame horizontal keel (21) and connecting horizontal keel (23). The frame horizontal keel (21) arranged horizontally parallel and the vertical keel (22) arranged vertically parallel form a spatial frame structure close to the main structure. The connecting horizontal keel (23) is fixed to the vertical keel (22) by multiple vertical cantilever pieces (24). Connecting steel bars (5) are provided on the GRC panel inside the spatial frame structure. One end of the connecting steel bar (5) is welded to the connecting horizontal keel (23), and the other end extends to the GRC panel and is connected. The GRC panel is fixed to the main frame (2) by multiple connecting steel bars (5). The upper hanging point (3) is set on the upper frame cross keel (21). The upper hanging point (3) is a combination hanging point made of custom steel plate. The combination hanging point includes a support (31), a hanging piece (32) and an adjusting bolt. The support (31) is connected to the main structure, and the hanging piece (32) is connected to the main frame (2). At the connection between the support (31) and the hanging piece (32), there are upper and lower bolts (33) for adjusting the height, and there are also left and right bolts (34) for locking the horizontal movement. The lower hanging point (4) includes a round tube (41) and a U-shaped groove base (42). Multiple U-shaped groove bases (42) are fixed on the main structure (A). The round tube (41) is inserted into the U-shaped groove base (42). The round tube (41) is connected to the main frame (2). The round tube (41) can move in the up, down, left, right, front and back directions within the U-shaped groove base (42).

2. The irregular curved surface ultra-large GRC plate carrying system according to claim 1, characterized in that, Multiple connectors are provided on the main structure (A). The support (31) of the upper hanging point (3) and the U-shaped groove base (42) of the lower hanging point (4) are respectively connected to the corresponding connectors. One end of the connector is prefabricated on the main structure.

3. The irregular curved surface ultra-large GRC plate carrying system according to claim 1, characterized in that, In the structure of the upper hanging point (3), the cross-section of the support (31) is L-shaped. Two parallel triangular ribs are provided on the support (31). The bottom of the support (31) is connected to the main structure (A). The hanging part (32) includes two parallel upright plates and a top horizontal plate. The two sides of the horizontal plate are respectively connected to the top of the upright plate to form an inverted U-shaped structure. The bottom of the upright plate is provided with a slot. The two parallel upright plates are locked to the top of the support (31) through the slot at the bottom. The adjusting bolts include upper and lower bolts (33) and left and right bolts (34). One upper and lower bolt (33) passes through the middle of the horizontal plate and abuts against the middle position of the top of the support (31). The two left and right bolts (34) pass through the triangular ribs on the support (31) respectively and abut against the upright plate of the hanging part (32).

4. The irregular curved surface ultra-large GRC plate carrying system according to claim 3, characterized in that, The main body of the support (31) is an L-shaped folded plate. Two triangular ribs are provided on the inner side of the L-shaped folded plate. The straight sides of the triangular ribs are welded and fixed to the inner side of the L-shaped folded plate.

5. The irregular curved surface ultra-large GRC plate carrying system according to claim 1, characterized in that, The U-shaped groove base (42) of the lower hanging point is a U-shaped steel plate integrally pressed. The bottom of the U-shaped steel plate is fixed to the main structure (A) by adjusting bolts (43), and the nut of the adjusting bolts (43) is located at the bottom. The outer diameter of the round tube (41) that is locked in the U-shaped groove base (42) is equal to the opening width of the U-shaped groove base (42), and a horn-shaped large mouth is provided at the upper end of the opening of the U-shaped groove base (42).

6. The irregular curved surface ultra-large GRC plate carrying system according to claim 1, characterized in that, The lower part of the vertical keel (22) on the main frame (2) extends out of the lower frame horizontal keel (21), and a connecting steel bar (5) is also provided at the end of the extension part. The connecting steel bar (5) extends and is fixed to the bottom inner side of the GRC panel.

7. The irregular curved surface ultra-large GRC plate carrying system according to claim 1, characterized in that, The horizontal and vertical keels arranged by the spatial three-dimensional interlacing method are as follows: between the GRC panel, which serves as the skin of the irregular building, and the main structure (A), a typical section is extracted according to the position of the vertical keel (22). The vertical keel (22) and the main structure (A) are kept at a fixed distance. The horizontal keel (23) is arranged at the intersection point of the plane offset inward from the GRC panel at a spacing of 600-800mm. A vertical cantilever (24) is fixed between the horizontal keel (23) and the vertical keel (22) to serve as a vertical keel.

8. A method for manufacturing an extra-large GRC (Glass Reinforced Concrete) plate with an irregular curved surface, characterized in that, The manufacturing method is based on the irregular curved surface ultra-large GRC panel carrying system described in claim 1. The manufacturing method includes the manufacturing process of the irregular curved surface ultra-large GRC panel, the manufacturing process of the space steel frame of the carrying system, and the overall composite process, specifically including the following steps; The manufacturing process of the aforementioned irregularly shaped curved extra-large GRC panel includes: The first step is to divide the irregular decorative surface of the building exterior into multiple irregular curved surfaces according to the design drawings. The outer layer of the irregular decorative surface is a GRC panel. The divided irregular curved surfaces are numbered. The second step is the preparation of GRC panels. The process includes making a mold based on the building skin, spraying GRC material onto the mold to form it, and then rolling and curing it after forming. Through the above process, multiple GRC panels with numbers are made using GRC material. The curved surface of the GRC panel is an irregular curved surface. Each GRC panel is an extra-large GRC panel. The fabrication process of the spatial steel frame for the carrying system includes: The third step is to design the carrying system according to the specifications of each irregular curved surface. The carrying system is designed and manufactured using a spatial three-dimensional interweaving method. The spatial frame structure of the carrying system includes horizontally parallel frame keels and vertically parallel frame keels, with the lower part of the vertical keels extending outwards. The fourth step is to set a connecting horizontal keel (23) on one side of the space frame structure according to the vertical concave and convex lines of the curved surface on the GRC panel and the design distribution of the connecting steel bars. The connecting horizontal keel (23) is connected to the vertical keel (22) through the vertical keel. Multiple connecting steel bars (5) are set on the connecting horizontal keel (23), and connecting steel bars (5) are also welded to the ends of the partially extended vertical keel (22) to form the space steel frame of the back system. The overall composite process includes: The fifth step is to cover the space steel frame on the GRC panel so that the connecting steel bars (5) of the carrying system are close to the inner curved surface of the GRC panel. GRC material is sprayed at the position where the connecting steel bars (5) are close to the inner curved surface of the GRC panel to form a protrusion, and the protrusion is protected by rolling to make the carrying system and the GRC panel integrated. The sixth step is to install the hanging parts (32) of the upper hanging point (3) and the round tube (41) of the lower hanging point (4) on the corresponding positions of the carrying system, and to complete the composite into an extra-large GRC plate (1) with an irregular curved surface.

9. The method for manufacturing an irregularly shaped curved surface ultra-large GRC plate according to claim 8, characterized in that, The seventh step involves joining multiple finished irregularly shaped, large GRC panels together, checking the gaps and transitions at the joints, and adjusting or correcting any discrepancies as needed.

10. An installation process for an irregularly shaped curved, extra-large GRC panel, characterized in that, This installation process is based on the irregular curved surface ultra-large GRC panel backing system described in claim 1. The completed irregular curved surface ultra-large GRC panels are hung onto the main structure of the building's exterior wall to form an ultra-large decorative surface made of GRC material. The installation process includes the following steps: The first step is to disassemble and package the irregularly shaped, curved, extra-large GRC panels that have been produced and pre-assembled in the factory, transport them to the construction site, and place them according to their numbers. The second step is to determine the installation position of the super-large GRC panel (1) on the main structure (A) of the building exterior wall, and the super-large GRC panel (1) with the corresponding number of the installation position, and hoist the determined super-large GRC panel (1) to the ground at the installation position. The third step is to pre-install a connector at the installation position on the main structure (A), weld and fix the support (31) of the upper hanging point (3) on the connector, and connect the U-shaped groove base (42) of the lower hanging point (4) with adjusting bolts, and adjust the position of the connector so that it corresponds to the upper hanging point (3) and the lower hanging point (4) on the super large GRC plate (1); The fourth step involves using multiple hoisting devices to simultaneously hoist different parts of the super-large GRC panels (1) at multiple points on the exterior wall of the building. Each super-large GRC panel (1) is connected to the main structure (A) through the upper hanging point (3) and at the same time to the main structure (A) through the lower hanging point (4) so ​​as to install the single super-large GRC panel (1) on the exterior wall of the building. The fifth step is to hoist the adjacent super-large GRC plate (1). The super-large GRC plate (1) to be hoisted and the super-large GRC plate (1) that has been completed are adjusted at the same time. The upper hanging point (3) and the lower hanging point (4) are used to realize the three-dimensional adjustment of the super-large GRC plate (1). After the three-dimensional adjustment is completed, the backing system is fixed so that the splicing position joints are uniform, the size is consistent, and the irregular curved surface transition is smooth. Step 6: After all the irregular curved surface super large GRC panels (1) have been hoisted and adjusted, check the overall curved surface condition and transition condition to make the overall irregular curved surface complete and natural, and complete the installation of the irregular curved surface super large GRC panels.

Images