Punched steel plate shotcrete sandwich wall and construction method thereof

Abstract

The application relates to the field of building engineering, in particular to a punched steel plate jet concrete sandwich wall and a construction method thereof. The concrete sandwich wall comprises a core layer and two concrete surface layers; the core layer comprises heat preservation plates and concrete plate ribs which are alternately arranged along the length direction of the wall; the concrete surface layer comprises a concrete filling body and a plurality of first punched steel plates and second punched steel plates which are wrapped in the concrete filling body; the first punched steel plate comprises a first punched steel plate main body, a first punched steel plate upper wing, a first punched steel plate lower wing and a first punched steel plate side wing which are integrally formed; a first equilateral triangle punched hole array is formed on the first punched steel plate main body, and the upper edge of the first equilateral triangle punched hole is connected with a first equilateral triangle tongue piece; a second equilateral triangle hole array is formed on the first punched steel plate side wing; a third equilateral triangle punched hole array is formed on the second punched steel plate; the first equilateral triangle tongue piece is inserted into the inside of the third equilateral triangle punched hole to realize the overlapping fixing of the second punched steel plate and the first punched steel plate.

Description

Technical Field

[0001] This invention relates to the field of building engineering, and in particular to a perforated steel plate shotcrete sandwich wall and its construction method. Background Technology

[0002] Currently, common infill walls in construction projects can be divided into two main categories: one is masonry infill walls, including brick masonry, block masonry, and panel masonry; the other is cast-in-place concrete infill walls, including wire mesh polystyrene foam board (EPS) concrete sandwich walls, cast-in-place hollow concrete walls, and cast-in-place foamed concrete walls. Masonry infill walls are traditional, technologically mature, and widely used. Their disadvantages include the presence of numerous seams due to the discrete bricks, blocks, or panels, resulting in poor overall integrity, susceptibility to cracking, and poor thermal performance. This leads to poor seismic resistance, waterproofing, and self-insulating properties. In contrast, cast-in-place concrete infill walls typically incorporate reinforcing steel bars within the wall structure. The concrete is poured on-site to form the wall, and an insulation layer can be pre-embedded within the wall. Therefore, cast-in-place concrete infill walls offer advantages such as good integrity, strong seismic resistance, good crack resistance, and good self-insulating properties.

[0003] Taking a common steel wire mesh EPS concrete sandwich wall as an example, the cross-section of the wall is as follows: Figure 1 As shown. The wall has an EPS insulation layer in the middle, and steel mesh on both sides of the EPS insulation layer. The steel mesh on both sides is connected by welded steel bars that penetrate the EPS insulation layer to form an integral wire mesh frame. The wire mesh frame and EPS insulation layer are prefabricated in the factory. During on-site construction, the wire mesh frame and EPS insulation layer are installed first, then formwork is erected on both sides of the wire mesh frame, and the concrete surface layer is poured, or spraying or plastering methods are used to create the concrete surface layer. The wire mesh frame EPS concrete sandwich wall has good integrity and crack resistance. Due to the EPS insulation layer inside the wall, the wall also has good self-insulating properties. When used for exterior walls, it can eliminate the need for an external insulation layer. However, the wire mesh frame EPS concrete sandwich wall also has some drawbacks:

[0004] 1) The concrete surface layer of the EPS concrete sandwich wall with wire mesh is generally thin, and sprayed concrete is usually used to construct the concrete surface layer. Because the combined structure of the wire mesh and EPS insulation layer itself has very weak rigidity, the combined structure of the wire mesh and EPS insulation layer is prone to deformation and displacement under the pressure of sprayed concrete, which makes it impossible to accurately control the thickness of the concrete surface layer and results in large deviations in the wall dimensions;

[0005] 2) For larger infill walls, the combined structure of wire mesh and EPS insulation layer needs to be installed in sections. The steel mesh is broken at the joint. In order to prevent the concrete surface layer at the joint from cracking, another layer of steel mesh needs to be tied to the outside of the steel mesh at the joint. The steel mesh on both sides of the joint is overlapped and connected, which makes the construction complicated and inconvenient.

[0006] 3) The concrete surface layers on opposite sides of the wire mesh EPS concrete sandwich wall are connected only by diagonally inserted steel bars. The rigidity of the diagonally inserted steel bars is relatively weak, and the concrete surface layers on both sides of the wall are difficult to form a solid overall structure and share the load. Therefore, the overall rigidity of the wire mesh EPS concrete sandwich wall is relatively weak. Summary of the Invention

[0007] Technical issues:

[0008] A shotcrete sandwich wall is provided to improve the structural performance and construction convenience of existing wire mesh EPS concrete sandwich walls.

[0009] Technical solution:

[0010] On one hand, a perforated steel plate shotcrete sandwich wall is provided, comprising a core layer and two concrete surface layers; the two concrete surface layers respectively cover the two sides of the core layer in the thickness direction; the core layer includes multiple insulation boards and multiple concrete ribs; the multiple insulation boards and multiple concrete ribs are arranged alternately in sequence along the length direction of the perforated steel plate shotcrete sandwich wall; the concrete ribs are perpendicular to the concrete surface layers; the concrete surface layers include: a concrete filler and multiple first perforated steel plates, multiple second perforated steel plates, and multiple pads encased inside the concrete filler; the concrete filler and the multiple concrete ribs are... The ribs are integrally formed; the first perforated steel plate includes an integrally formed first perforated steel plate body, a first perforated steel plate upper wing, a first perforated steel plate lower wing, and a first perforated steel plate side wing; multiple first perforated steel plates are arranged at a first preset interval along the length direction of the shotcrete sandwich wall, and the first perforated steel plate body is parallel to the concrete surface layer; the first perforated steel plate side wing is located on the left and right sides of the first perforated steel plate body, perpendicular to the concrete surface layer, and facing the core layer; the first perforated steel plate upper wing and the first perforated steel plate lower wing are respectively located on the upper and lower sides of the first perforated steel plate body, perpendicular to the concrete surface layer. A concrete surface layer, and is far from the core layer; a first equilateral triangular perforation array is formed on the first perforated steel plate body, and a first equilateral triangular tongue is connected to the upper edge of the first equilateral triangular perforation in the first equilateral triangular perforation array; the first equilateral triangular tongue protrudes from the surface of the first perforated steel plate body on the side away from the core layer; the first equilateral triangular tongue and the first equilateral triangular perforation are obtained by punching the first perforated steel plate body; a second equilateral triangular hole array is formed on the side wing of the first perforated steel plate; a third equilateral triangular perforation array is formed on the second perforated steel plate, and the arrangement and size of the third equilateral triangular perforation array are the same as those of the first perforated steel plate body. The first equilateral triangular perforated array cooperates with the second perforated steel plate to achieve overlapping and fixing of the second perforated steel plate and the first perforated steel plate when the first equilateral triangular tongue is inserted into the interior of the third equilateral triangular perforation and the second perforated steel plate is in close contact with the surface of the first perforated steel plate body away from the core layer; the first preset distance is maintained between two adjacent first perforated steel plates located on the same concrete surface layer, and they are respectively overlapped and fixed with the same second perforated steel plate to connect multiple first perforated steel plates into a whole structure; the first perforated steel plate and the insulation board are maintained at a second preset distance through multiple spacers.

[0011] In some embodiments, the insulation board is an EPS insulation board.

[0012] In some embodiments, the first perforated steel plate and the second perforated steel plate are integrally formed along the height direction of the shotcrete sandwich wall of the perforated steel plate.

[0013] In some embodiments, the insulation board is integrally formed along the height direction of the perforated steel plate sprayed concrete sandwich wall.

[0014] In other embodiments, the insulation board is formed by splicing multiple insulation boards along the height direction of the perforated steel plate shotcrete sandwich wall. This allows the insulation boards to be manufactured in sections and assembled on-site according to the height of the perforated steel plate shotcrete sandwich wall during construction.

[0015] In some embodiments, the first equilateral triangle punch array is a matrix with vertical and horizontal alignment; the shape of the first equilateral triangle punch is an inverted equilateral triangle; the top edge of the first equilateral triangle tongue is connected to the first equilateral triangle punch; the third equilateral triangle punch array is a matrix with vertical and horizontal alignment; the shape of the third equilateral triangle punch is an inverted equilateral triangle; the second punched steel plate has the same height as the first punched steel plate.

[0016] In some embodiments, the perforated steel plate shotcrete sandwich wall further includes a first connector; the side wing of the first perforated steel plate adjacent to the main structure of the wall is fixed to the main structure around the wall via the first connector.

[0017] In some embodiments, the perforated steel plate shotcrete sandwich wall further includes a second connector; the upper edge of the first perforated steel plate is fixed to the main structure surrounding the wall via the second connector.

[0018] In some embodiments, the perforated steel plate shotcrete sandwich wall further includes a third connector; the lower wing of the first perforated steel plate is fixed to the main structure surrounding the wall via the third connector.

[0019] In some embodiments, the first connector, the second connector, or the third connector is a nail.

[0020] In some embodiments, the width of the insulation board is smaller than the width of the first perforated steel plate body; wherein: the width of the insulation board refers to the dimension of the insulation board along the length direction of the perforated steel plate shotcrete sandwich wall; the width of the first perforated steel plate body refers to the dimension of the first perforated steel plate body along the length direction of the perforated steel plate shotcrete sandwich wall.

[0021] In some embodiments, the pad includes a connected support portion and a plug portion; the plug portion is in the shape of a triangular prism; the shape and size of the cross-section of the triangular prism are adapted to the first equilateral triangular punch hole, the plug portion is inserted into the first equilateral triangular punch hole, and the support portion is engaged outside the first equilateral triangular punch hole to fix the pad to the first punched steel plate body; the end of the support portion away from the plug portion abuts against the insulation board.

[0022] In some embodiments, the support portion is cylindrical; the cylinder is coaxially arranged with the triangular prism; the diameter of the cylinder is larger than the diameter of the circumcircle of the first equilateral triangular punch.

[0023] On the other hand, a construction method for the aforementioned perforated steel plate shotcrete sandwich wall is provided, which includes the following steps:

[0024] (1) Process the first perforated steel plate in the aforementioned perforated steel plate shotcrete sandwich wall;

[0025] (2) Process the second perforated steel plate in the aforementioned perforated steel plate shotcrete sandwich wall;

[0026] (3) Process the insulation board in the aforementioned perforated steel plate shotcrete sandwich wall;

[0027] (4) Process the pads in the aforementioned perforated steel plate shotcrete sandwich wall;

[0028] (5) Lay out and position the perforated steel plate shotcrete sandwich wall, and mark the installation position of the first perforated steel plate.

[0029] (6) Install the first pair of the first perforated steel plates and the insulation board from the first side of the column or wall along the length direction close to the wall: install the pad on the side of the first pair of the first perforated steel plates close to the core layer; fix the side wings of the first pair of the first perforated steel plates to the column or wall; then place the insulation board between the first pair of the first perforated steel plates, adjust the position, and make the first pair of the first perforated steel plates clamp the insulation board; then fix the upper wing of the first pair of the first perforated steel plates and the lower wing of the first perforated steel plates to the main structure around the wall.

[0030] (7) Referring to step (6), install the second pair of the first perforated steel plates and the insulation board from the second side of the column or wall near the length direction of the wall;

[0031] (8) Install the third pair of first perforated steel plates and the insulation board adjacent to the first pair of first perforated steel plates or the second pair of first perforated steel plates: install the pad on the side of the third pair of first perforated steel plates near the core layer; fix the upper wing and lower wing of the first perforated steel plate on one side to the main structure around the wall; then install the insulation board; then install the first perforated steel plate on the other side in the same way; finally, overlap and fix two adjacent first perforated steel plates on the same side of the wall to the same second perforated steel plate respectively.

[0032] (9) Repeat step (8) until all the first perforated steel plates and the insulation plates are installed;

[0033] (10) Shotcrete construction: Shotcrete construction is carried out on the wall structure obtained in step (9) so that the concrete filler and the space corresponding to the concrete rib are filled with concrete. After the shotcrete construction is completed, the concrete surface is leveled with a scraper and the concrete is cured to the design strength to obtain the perforated steel plate shotcrete sandwich wall; wherein, the particle size of the shotcrete coarse aggregate is less than 2 / 5 of the side length of the first equilateral triangular perforation.

[0034] Beneficial effects:

[0035] The perforated steel plate shotcrete sandwich wall of this invention uses a first perforated steel plate instead of a wire mesh frame as the skeleton of the cast-in-place concrete sandwich wall and the reinforcement of the concrete surface layer. It can overcome many technical defects of the wire mesh frame EPS concrete sandwich wall and has certain improvements in terms of structural reliability, excellent performance, convenient construction and low cost.

[0036] (1) The perforated steel plate shotcrete sandwich wall of the present invention uses a first perforated steel plate instead of a wire mesh frame as the skeleton of the concrete sandwich wall. By setting the upper wing, lower wing and side wing of the first perforated steel plate, not only is the rigidity and strength of the first perforated steel plate guaranteed, but the upper wing, lower wing and side wing of the first perforated steel plate can also be conveniently fixed to the main structure around the wall by means of connectors such as nails, so that the wall and the main structure around the wall form a reliable connection and cooperate in bearing the force. This can overcome the technical problem that the existing combination structure of wire mesh frame and EPS insulation layer is easy to deform and easy to shift.

[0037] (2) The perforated steel plate shotcrete sandwich wall of the present invention adopts the idea of ​​splicing steel plates to realize the overlap between adjacent first perforated steel plates on the same side. Since the second perforated steel plate is connected to the first perforated steel plate by tongue-and-patch connection, the installation of spliced ​​steel plates is very convenient and quick, avoiding the problem that a large amount of steel mesh binding work is required when the existing steel wire mesh EPS board is overlapped, which is complicated and inconvenient in construction.

[0038] (3) The perforated steel plate shotcrete sandwich wall of the present invention has a certain gap between two adjacent first perforated steel plates on the same side. Based on this, after the shotcrete is sprayed, concrete ribs perpendicular to the wall surface are formed between the adjacent insulation boards, so that the two concrete surface layers form an integral structure and cooperate to bear the force. Therefore, the perforated steel plate shotcrete sandwich wall of the present invention has a large out-of-plane stiffness.

[0039] (4) When encountering non-standard width dimensions, the perforated steel plate shotcrete sandwich wall of the present invention only requires cutting the first perforated steel plate and the insulation board in the width direction, which makes construction more convenient.

[0040] (5) The main components of the perforated steel plate shotcrete sandwich wall of the present invention, the first perforated steel plate and the insulation board, are manufactured and installed separately. The manufacturing, transportation and installation of the components are more convenient than the existing steel wire mesh EPS concrete sandwich wall scheme. Attached Figure Description

[0041] To more clearly illustrate the technical solutions of this invention, the accompanying drawings used in some embodiments of this invention will be briefly described below. However, the drawings described below are merely drawings of some embodiments of this invention, and those skilled in the art can obtain other drawings based on these drawings. Furthermore, the drawings described below can be regarded as schematic diagrams and are not intended to limit the actual size of the product, the actual flow of the method, the actual timing of the signals, etc., involved in the embodiments of this invention.

[0042] Figure 1 Cross-sectional view of an existing steel wire mesh EPS concrete sandwich wall;

[0043] Figure 2 Elevation view of a perforated steel plate shotcrete sandwich wall according to some embodiments;

[0044] Figure 3 for Figure 2 AA section view in the middle;

[0045] Figure 4 for Figure 2 BB cross-section diagram in the middle;

[0046] Figure 5 for Figure 2 Exploded view of the BB section in the image;

[0047] Figure 6 Elevation view of the first perforated steel plate in some embodiments;

[0048] Figure 7 for Figure 6 CC cross-section view in the middle;

[0049] Figure 8 for Figure 6 DD cross-section view in the middle;

[0050] Figure 9 for Figure 6 EE cross-section diagram;

[0051] Figure 10 Elevation view of the second perforated steel plate in some embodiments;

[0052] Figure 11 Elevation views of the pad block in some embodiments;

[0053] Figure 12 This is a plan view of the pad in some embodiments. Detailed Implementation

[0054] The technical solutions in some embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. All other embodiments obtained by those skilled in the art based on the embodiments provided by the present invention are within the scope of protection of the present invention.

[0055] Unless the context otherwise requires, throughout the specification and claims, the term "comprising" is interpreted as open-ended and encompassing, meaning "including, but not limited to." In the description, terms such as "one embodiment," "some embodiments," "exemplary embodiment," "example," "specific example," or "some examples" are intended to indicate that a particular feature, structure, material, or characteristic associated with that embodiment or example is included in at least one embodiment or example of the invention. The illustrative representations of the above terms do not necessarily refer to the same embodiment or example. Furthermore, the specific feature, structure, material, or characteristic may be included in any suitable manner in any one or more embodiments or examples.

[0056] Hereinafter, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Thus, a feature defined as "first" or "second" may explicitly or implicitly include one or more of that feature. In the description of embodiments of the present invention, unless otherwise stated, "a plurality of" means two or more.

[0057] In describing some embodiments, the terms "coupled" and "connected," and their derivative expressions, may be used. The term "connected" should be interpreted broadly; for example, a "connection" can be a fixed connection, a detachable connection, or an integral part; it can be a direct connection or an indirect connection via an intermediate medium. The term "coupled" indicates that two or more components have direct physical or electrical contact. The term "coupled" or "communication coupling" may also refer to two or more components that do not have direct contact with each other but still cooperate or interact with each other. The embodiments invented herein are not necessarily limited to the content of this document.

[0058] "At least one of A, B and C" has the same meaning as "at least one of A, B or C", both including the following combinations of A, B and C: only A, only B, only C, combinations of A and B, combinations of A and C, combinations of B and C, and combinations of A, B and C.

[0059] "A and / or B" includes the following three combinations: A only, B only, and a combination of A and B.

[0060] As used herein, depending on the context, the term “if” may optionally be interpreted as meaning “when”, “in the event of”, “in response to determination”, or “in response to detection”. Similarly, depending on the context, the phrase “if it is determined that…” or “if [the stated condition or event] is detected” may optionally be interpreted as meaning “in the event of determination that…”, “in response to determination that…”, “when [the stated condition or event] is detected”, or “in response to the detection of [the stated condition or event]”.

[0061] The use of “applies to” or “configured to” in this article implies an open and inclusive language that does not preclude applicability to or configuration to devices that perform additional tasks or steps.

[0062] In addition, the use of “based on” implies openness and inclusivity, because processes, steps, calculations or other actions “based on” one or more of the stated conditions or values ​​may in practice be based on additional conditions or values ​​beyond those stated.

[0063] As used herein, “about,” “approximately,” or “approximately” includes the stated value and the average value within an acceptable range of deviation from the given value, wherein the acceptable range of deviation is determined by a person skilled in the art taking into account the measurement under discussion and the error associated with the measurement of the given quantity (i.e., the limitations of the measurement system).

[0064] As used herein, “parallel,” “perpendicular,” and “equal” include the described situation and situations that are similar to the described situation, within an acceptable range of deviation, which is determined by those skilled in the art taking into account the measurement under discussion and the error associated with the measurement of a particular quantity (i.e., the limitations of the measurement system). For example, “parallel” includes absolute parallelism and approximate parallelism, where an acceptable range of deviation for approximate parallelism may be, for example, within 5°; “perpendicular” includes absolute perpendicularity and approximate perpendicularity, where an acceptable range of deviation for approximate perpendicularity may also be, for example, within 5°; “equal” includes absolute equality and approximate equality, where an acceptable range of deviation for approximate equality may be, for example, a difference between the two equals being less than or equal to 5% of either one.

[0065] This document describes exemplary embodiments with reference to cross-sectional views and / or plan views, which are idealized exemplary drawings. In the drawings, the thickness of layers and regions is enlarged for clarity. Therefore, variations in shape relative to the drawings are contemplated due to, for example, manufacturing techniques and / or tolerances. Thus, exemplary embodiments should not be construed as limited to the shapes of the regions shown herein, but rather include shape deviations due to, for example, manufacturing processes. For example, etched regions shown as rectangular would typically have curved features. Therefore, the regions shown in the drawings are schematic in nature, and their shapes are not intended to show the actual shapes of the regions of the device, nor are they intended to limit the scope of the exemplary embodiments.

[0066] In some embodiments, a perforated steel plate shotcrete sandwich wall is provided, such as Figures 2-5 As shown, it includes a core layer and two concrete surface layers 7; the two concrete surface layers 7 respectively cover the two sides of the core layer in the thickness direction; the core layer includes multiple insulation boards 8 and multiple concrete ribs; the multiple insulation boards 8 and multiple concrete ribs are arranged alternately in sequence along the length direction of the perforated steel plate shotcrete sandwich wall; the concrete ribs are perpendicular to the concrete surface layers 7; the concrete surface layer 7 includes: a concrete filler and multiple first perforated steel plates 4, multiple second perforated steel plates 5 and multiple pads 9 wrapped inside the concrete filler; the concrete filler and the multiple concrete ribs are integrally formed structures. Figures 6-9As shown, the first perforated steel plate 4 includes an integrally formed first perforated steel plate body, an upper wing 11 of the first perforated steel plate, a lower wing 12 of the first perforated steel plate, and side wings 10 of the first perforated steel plate; multiple first perforated steel plates 4 are arranged at a first preset interval along the length direction of the perforated steel plate shotcrete sandwich wall, and the first perforated steel plate body is parallel to the concrete surface layer 7; the side wings 10 of the first perforated steel plate are located on the left and right sides of the first perforated steel plate body, perpendicular to the concrete surface layer 7, and facing the core layer; the upper wing 11 and the lower wing 12 of the first perforated steel plate are respectively located at the first... The upper and lower sides of a perforated steel plate body are perpendicular to the concrete surface layer 7 and far from the core layer; a first equilateral triangular perforation array is formed on the first perforated steel plate body, and the upper edge of the first equilateral triangular perforation 131 in the first equilateral triangular perforation array is connected to a first equilateral triangular tongue 14; the first equilateral triangular tongue 14 protrudes from the surface of the first perforated steel plate body on the side far from the core layer; the first equilateral triangular tongue 14 and the first equilateral triangular perforation 131 are obtained by punching the first perforated steel plate body; a second equilateral triangular perforation array is formed on the side wing 10 of the first perforated steel plate. Figure 10 As shown, a third equilateral triangular perforation array is formed on the second perforated steel plate 5. The arrangement and size of the third equilateral triangular perforation array are matched with the first equilateral triangular perforation array so that when the first equilateral triangular tongue 14 is inserted into the interior of the third equilateral triangular perforation 133 and the second perforated steel plate 5 is in close contact with the surface of the first perforated steel plate body away from the core layer, the second perforated steel plate 5 and the first perforated steel plate 4 can be overlapped and fixed. Two adjacent first perforated steel plates 4 located on the same concrete surface layer 7 maintain a first preset distance and are overlapped and fixed with the same second perforated steel plate 5 respectively, so as to connect multiple first perforated steel plates 4 into a whole structure (see Figure 4 and Figure 5 The first perforated steel plate 4 and the insulation plate 8 are separated by multiple spacers 9 to maintain a second preset distance (see...). Figure 3 and Figure 4 ).

[0067] In the above embodiment, a first perforated steel plate 4 replaces the steel mesh in the prior art as the skeleton of the concrete sandwich wall and the reinforcement of the concrete surface layer 7. The first perforated steel plate 4 can be made of a rectangular steel plate. The left and right sides of the first perforated steel plate 4 are bent into the wall to form the side wings 10 of the first perforated steel plate, thereby enhancing the bending stiffness of the first perforated steel plate 4. The upper and lower ends of the first perforated steel plate 4 are bent outward to form the upper wing 11 and the lower wing 12 of the first perforated steel plate, thereby enhancing the bending stiffness of the first perforated steel plate 4. A first equilateral triangular perforation array is formed on the main body of the first perforated steel plate. Thus, the shotcrete can reach the area between the first perforated steel plate 4 and the insulation board 8 through the first equilateral triangular perforation array on the main body of the first perforated steel plate. The numerous first equilateral triangular tongues 14 on the first perforated steel plate 4 have a good mortar adhesion effect on the shotcrete. A second equilateral triangular hole array is formed on the side wing 10 of the first perforated steel plate, but the second equilateral triangular holes in the second equilateral triangular hole array do not have protruding tongues. Therefore, the shotcrete can flow more smoothly through the second equilateral triangular hole array arranged on the side wing 10 of the first perforated steel plate, facilitating the formation of concrete ribs. Neither the upper wing 11 nor the lower wing 12 of the first perforated steel plate has perforations; they are used to fix the first perforated steel plate 4. Multiple spacers 9 maintain a second preset distance between the first perforated steel plate 4 and the insulation board 8, thereby improving the accuracy of the thickness of the concrete surface layer 7 formed during shotcrete construction. A first preset distance is maintained between two adjacent first perforated steel plates 4 located in the same concrete surface layer 7, so that concrete ribs perpendicular to the wall surface are formed during shotcrete construction, improving the out-of-plane stiffness and strength of the shotcrete sandwich wall with perforated steel plates. The surfaces of two adjacent first perforated steel plates 4 located on the same concrete surface layer 7, on the side away from the core layer, are respectively overlapped and fixed with the same second perforated steel plate 5. The second perforated steel plate 5 can be made of steel plate with a rectangular planar shape. The height of the second perforated steel plate 5 is equal to the height of the first perforated steel plate 4. A third equilateral triangular perforation array is formed on the second perforated steel plate 5 (the arrangement and size of the third equilateral triangular perforation array match the first equilateral triangular perforation array). When installing the second perforated steel plate 5, the first equilateral triangular tongue 14 of the first perforated steel plate 4 is inserted into the third equilateral triangular perforation 133 of the second perforated steel plate 5, and the second perforated steel plate 5 is tightly attached to the surface of the first perforated steel plate body on the side away from the core layer, thus achieving quick connection and installation. In this way, the second perforated steel plate 5 can achieve the effect of overlapping the adjacent first perforated steel plates 4 on the same side, which can effectively prevent cracks from appearing in the concrete surface layer 7 at the splicing of the first perforated steel plates 4.

[0068] In some embodiments, the height of the first perforated steel plate 4 is equal to the height of the wall, and the width is a standard width (e.g., 600mm).

[0069] In some embodiments, the width of the second perforated steel plate 5 is approximately 150 mm.

[0070] In some embodiments, the insulation board 8 is an EPS insulation board.

[0071] In some embodiments, the insulation board 8, the first perforated steel plate 4, and the second perforated steel plate 5 are integrally formed along the height direction of the shotcrete sandwich wall of the perforated steel plate.

[0072] In some embodiments, the height of the insulation board 8 is less than the height of the perforated steel plate shotcrete sandwich wall.

[0073] In some embodiments, the insulation board 8 is formed by splicing multiple insulation boards along the height direction of the perforated steel plate sprayed concrete sandwich wall.

[0074] In some embodiments, such as Figures 6 to 9 As shown, the first equilateral triangular perforation array is a matrix with vertical and horizontal alignment; the shape of the first equilateral triangular perforation 131 is an inverted equilateral triangle; the top edge of the first equilateral triangular tongue 14 is connected to the first equilateral triangular perforation 131 (i.e., the top edge of the first equilateral triangular perforation 131 is horizontal, and the pointed corner is downward; the two hypotenuses below the triangular steel plate inside the first equilateral triangular perforation 131 are cut off, while the top edge remains connected, and the triangular steel plate is bent outward toward the wall to form the first equilateral triangular tongue 14 protruding from the surface of the main body of the first perforated steel plate on the side away from the core layer). Figures 10-11 As shown, the third equilateral triangle punch array is a matrix with the vertical and horizontal lines aligned; the shape of the third equilateral triangle punch 133 is an inverted equilateral triangle; the second punched steel plate 5 has the same height as the first punched steel plate 4.

[0075] In some embodiments, such as Figures 2 to 5 As shown, the perforated steel plate shotcrete sandwich wall also includes a first connector; the first perforated steel plate side wing 10 adjacent to the main structure of the wall (e.g., side column 1 or wall) is fixed to the main structure of the wall (e.g., side column 1 or wall) through the first connector.

[0076] In some embodiments, such as Figures 2 to 5 As shown, the perforated steel plate shotcrete sandwich wall also includes a second connector; the upper flange 11 of the first perforated steel plate is fixed to the main structure around the wall (e.g., the upper beam 2) through the second connector.

[0077] In some embodiments, such as Figures 2 to 5 As shown, the perforated steel plate shotcrete sandwich wall also includes a third connector; the lower wing 12 of the first perforated steel plate is fixed to the main structure around the wall (e.g., the lower floor slab 3) through the third connector.

[0078] In some embodiments, such as Figures 2 to 5 As shown, the first connector, the second connector, or the third connector is a nail 6.

[0079] In some embodiments, the width of the insulation board 8 is smaller than the width of the first perforated steel plate body; wherein: the width of the insulation board 8 refers to the dimension of the insulation board 8 along the length direction of the perforated steel plate sprayed concrete sandwich wall; the width of the first perforated steel plate body refers to the dimension of the first perforated steel plate body along the length direction of the perforated steel plate sprayed concrete sandwich wall.

[0080] In some embodiments, such as Figures 3 to 5 , Figure 11 and Figure 12 As shown, the pad 9 includes a connected support portion 15 and a plug portion 16; the plug portion 16 is in the shape of a triangular prism; the shape and size of the cross-section of the triangular prism are adapted to the first equilateral triangular punch 131, the plug portion 16 is inserted into the first equilateral triangular punch 131, and the support portion 15 is engaged outside the first equilateral triangular punch 131, so as to quickly and accurately fix the pad 9 to the first punched steel plate body; the end of the support portion 15 away from the plug portion 16 abuts against the insulation plate 8.

[0081] In some embodiments, such as Figure 11 and Figure 12 As shown, the support part 15 is cylindrical in shape; the cylinder is coaxial with the triangular prism; the diameter of the cylinder is larger than the diameter of the circumcircle of the first equilateral triangular punch 131.

[0082] In some embodiments, the height of the cylinder is equal to the distance between the first perforated steel plate 4 and the insulation plate 8.

[0083] In some embodiments, the pad 9 is made of plastic.

[0084] In some embodiments, a construction method for the aforementioned perforated steel plate shotcrete sandwich wall is provided, wherein the first perforated steel plate is installed in sequence from both sides adjacent to the main body towards the middle, including the following steps:

[0085] (1) Process the first perforated steel plate in the aforementioned perforated steel plate shotcrete sandwich wall;

[0086] (2) Process the second perforated steel plate in the aforementioned perforated steel plate shotcrete sandwich wall;

[0087] (3) Process the insulation board in the aforementioned perforated steel plate shotcrete sandwich wall;

[0088] (4) Process the pads in the aforementioned perforated steel plate shotcrete sandwich wall;

[0089] (5) Lay out and position the perforated steel plate shotcrete sandwich wall, and mark the installation position of the first perforated steel plate.

[0090] (6) Install the first pair of first perforated steel plates and insulation board from the first side of the column or wall along the length direction close to the wall: install the pad block on the side of the first pair of first perforated steel plates close to the core layer; fix the side wings of the first pair of first perforated steel plates to the column or wall; then place the insulation board between the first pair of first perforated steel plates, adjust the position, and make the first pair of first perforated steel plates clamp the insulation board; then fix the upper wing of the first pair of first perforated steel plates and the lower wing of the first perforated steel plates to the main structure around the wall.

[0091] (7) Referring to step (6), install the second pair of first perforated steel plates and insulation boards from the second side of the column or wall near the length of the wall;

[0092] (8) Install the third pair of first perforated steel plates and insulation board adjacent to the first pair of first perforated steel plates or the second pair of first perforated steel plates: install the pad block on the side of the third pair of first perforated steel plates near the core layer; fix the upper wing and lower wing of the first perforated steel plate on one side to the main structure around the wall; then install the insulation board; then install the first perforated steel plate on the other side in the same way; finally, overlap and fix the two adjacent first perforated steel plates on the same side of the wall to the same second perforated steel plate respectively.

[0093] (9) Repeat step (8) until all the first punched steel plates and insulation boards are installed;

[0094] (10) Shotcrete construction: Shotcrete construction is carried out on the wall structure obtained in step (9) so that the concrete fills the space corresponding to the concrete infill and the concrete rib. After the shotcrete construction is completed, the concrete surface is leveled with a scraper and the concrete is cured to the design strength to obtain a perforated steel plate shotcrete sandwich wall; wherein, the particle size of the shotcrete coarse aggregate is less than 2 / 5 of the side length of the first equilateral triangular perforation.

[0095] In some embodiments, if the remaining installation spacing is insufficient for the standard width of the first perforated steel plate when installing the last first perforated steel plate, the first perforated steel plate and the insulation board are cut to meet the installation spacing requirements.

[0096] In some embodiments, the side wing of the first perforated steel plate may be appropriately bent for ease of construction.

[0097] The following example illustrates the specific implementation method of perforated steel plate shotcrete sandwich wall using a particular infill wall project.

[0098] Given a project task: an infill wall with a height of 2800mm, a width of 4200mm, and a thickness of 200mm. It will be constructed using perforated steel plates and shotcrete.

[0099] The standard dimensions of the first perforated steel plate are: height 2800mm, width 600mm, and thickness 2.0mm. The width of the side wing of the first perforated steel plate is 63mm. The width of both the upper and lower wing of the first perforated steel plate is 50mm. The spacing between perforated steel plates on the same side is 20mm. The spacing between the first perforated steel plates on both sides is 150mm. The thickness of the EPS insulation board is 120mm. The thickness of the single-sided concrete surface layer is 40mm.

[0100] I. Component Fabrication

[0101] (1) The factory manufactures the first punched steel plate:

[0102] The first perforated steel plate is made of 2.0mm thick steel plate. The first perforated steel plate has a rectangular shape, with a height equal to the wall height (2800mm) and a standard width of 600mm. The left and right sides of the first perforated steel plate are bent inwards towards the wall to form side wings (63mm wide). The top and bottom ends of the first perforated steel plate are bent outwards towards the wall to form upper and lower wings (50mm wide). A matrix of first equilateral triangular perforations is formed on the main body of the first perforated steel plate. The side length of each first equilateral triangular perforation is 14mm, and the shape of each perforation is an inverted equilateral triangle (the top edge of the first equilateral triangular perforation is horizontal, and the apex points downwards). The two lower sloping sides of the triangular steel plate within the first equilateral triangular perforations are cut off, while the horizontal top edge remains connected. The triangular steel plate is then bent outwards towards the wall to form a first equilateral triangular tongue protruding from the surface of the main body of the first perforated steel plate, away from the core layer. The first perforated steel plate also has second equilateral triangular holes aligned longitudinally and laterally in a matrix arrangement on its side wing. The side length of the second equilateral triangular holes is 14mm, but the second equilateral triangular holes do not have protruding tongues. The upper and lower wings of the first perforated steel plate do not have punching holes for fixing the first perforated steel plate with nails.

[0103] (2) Factory manufactures the second punched steel plate:

[0104] The second perforated steel plate is made of a 2.0mm thick rectangular steel plate. The height of the second perforated steel plate is equal to that of the first perforated steel plate (2800mm), and the width of the second perforated steel plate is 106mm. The second perforated steel plate forms a third equilateral triangular hole array (the arrangement and dimensions of the third equilateral triangular hole array correspond to those of the first equilateral triangular hole array), and the side length of the third equilateral triangular hole is 14mm.

[0105] (3) Factory manufactures EPS insulation boards

[0106] The EPS insulation board is 120mm thick, 2720mm high, and 560mm wide. (In some designs, the EPS insulation board can also be designed as multiple panels vertically (height direction), which are then spliced ​​together to form a whole.)

[0107] (4) Factory manufactures pad blocks

[0108] A spacer block is located between the first perforated steel plate and the EPS insulation board to control the distance between them. The spacer block is made of plastic and includes a connected support portion and a connector portion. The support portion is cylindrical (20mm in diameter, 15mm in height); the connector portion is triangular prism (14mm side length, 10mm in height). The cylinder and the triangular prism are coaxially aligned.

[0109] II. Construction of Perforated Steel Plate Shotcrete Sandwich Wall

[0110] (1) Lay out and position the perforated steel plate shotcrete sandwich wall, and mark the installation position of the first perforated steel plate.

[0111] (2) Start installing the first pair of perforated steel plates and insulation boards from the first column or wall on the first side along the length of the wall. First, install and fix the pads on the inside of the first perforated steel plates (insert the insert of the pad into the first equilateral triangular perforation of the first perforated steel plate to achieve pad installation). Use nails to fix the side wings of the first perforated steel plates to the adjacent main structural column or wall. For ease of construction, the side wings of the first perforated steel plates can be bent appropriately. Then place the EPS insulation board between the two first perforated steel plates. Adjust the position of the first perforated steel plates so that the first perforated steel plates clamp the EPS insulation board; use nails to fix the upper wing of the first perforated steel plate to the top beam, and use nails to fix the lower wing of the first perforated steel plate to the lower floor slab;

[0112] (3) Referring to step (6), install the second pair of first perforated steel plates and insulation boards from the second side of the column or wall near the length direction of the wall;

[0113] (4) Continue installing the adjacent first perforated steel plates. First, install the pads inside the first perforated steel plates, then install and fix one side of the first perforated steel plate and the insulation board; use nails to fix the upper wing of the first perforated steel plate to the top beam, and use nails to fix the lower wing of the first perforated steel plate to the lower floor slab; then install the EPS insulation board. Next, install the other side of the first perforated steel plate. Finally, install the second perforated steel plate between the adjacent first perforated steel plates on the same side, and insert the first equilateral triangular tongue of the first perforated steel plate into the third equilateral triangular hole of the second perforated steel plate to achieve overlapping installation;

[0114] (5) Repeat step (4) until all the first perforated steel plates and insulation boards are installed. If the installation spacing is less than the width of a standard first perforated steel plate (600mm) when installing the last first perforated steel plate, the first perforated steel plate and EPS insulation board can be cut to meet the installation spacing requirements. The installation method is the same as above.

[0115] (6) After all the first perforated steel plates and EPS insulation boards are installed, sprayed concrete is applied. During sprayed concrete application, pay attention to changing the spraying direction to ensure that the concrete fills the inner side of the first perforated steel plate and the gap between adjacent first perforated steel plates. After spraying, use a scraper to level the concrete surface and cure the concrete to the design strength; the particle size of the coarse aggregate in the sprayed concrete should be less than 2 / 5 of the side length of the first equilateral triangular perforation.

[0116] In the description of the above embodiments, specific features, structures, materials, or characteristics may be combined in any suitable manner in one or more embodiments or examples.

[0117] The above description is merely a specific embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any changes or substitutions conceived by those skilled in the art within the scope of the technology disclosed in the present invention should be included within the scope of protection of the present invention. Therefore, the scope of protection of the present invention should be determined by the scope of the claims.

Claims

1. A perforated steel plate shotcrete sandwich wall, characterized in that, It includes a core layer and two concrete surface layers; the two concrete surface layers respectively cover the two sides of the core layer in the thickness direction; The core layer includes multiple insulation boards and multiple concrete ribs; the multiple insulation boards and multiple concrete ribs are arranged alternately in sequence along the length of the perforated steel plate shotcrete sandwich wall; the concrete ribs are perpendicular to the concrete surface layer. The concrete surface layer includes: a concrete filler and a plurality of first perforated steel plates, a plurality of second perforated steel plates, and a plurality of pads encased within the concrete filler; the concrete filler and the plurality of concrete ribs are integrally formed. The first perforated steel plate includes an integrally formed first perforated steel plate body, a first perforated steel plate upper wing, a first perforated steel plate lower wing, and a first perforated steel plate side wing; a plurality of first perforated steel plates are arranged at a first preset interval along the length direction of the perforated steel plate shotcrete sandwich wall, and the first perforated steel plate body is parallel to the concrete surface layer; the first perforated steel plate side wing is located on the left and right sides of the first perforated steel plate body, perpendicular to the concrete surface layer, and facing the core layer; the first perforated steel plate upper wing and the first perforated steel plate lower wing are respectively located on the upper and lower sides of the first perforated steel plate body, perpendicular to the concrete surface layer, and away from the core layer; A first equilateral triangular perforation array is formed on the first perforated steel plate body. A first equilateral triangular tongue is connected to the upper edge of each perforated triangular perforation in the first equilateral triangular perforation array. The first equilateral triangular tongue protrudes from the surface of the first perforated steel plate body away from the core layer. The first equilateral triangular tongue and the first equilateral triangular perforation are obtained by punching the first perforated steel plate body. A second equilateral triangular perforation array is formed on the side wing of the first perforated steel plate. A third equilateral triangular perforation array is formed on the second perforated steel plate, and the arrangement and size of the third equilateral triangular perforation array are the same as those of the first equilateral triangular perforation array. The perforated array cooperates to enable the second perforated steel plate and the first perforated steel plate to overlap and fix when the first equilateral triangular tongue is inserted into the interior of the third equilateral triangular perforation and the second perforated steel plate is in close contact with the surface of the first perforated steel plate body away from the core layer; the first preset distance is maintained between two adjacent first perforated steel plates located on the same concrete surface layer, and they are respectively overlapped and fixed with the same second perforated steel plate to connect multiple first perforated steel plates into a whole structure; the first perforated steel plate and the insulation board are separated by multiple spacers to maintain a second preset distance.

2. The perforated steel plate shotcrete sandwich wall according to claim 1, characterized in that, The first perforated steel plate and the second perforated steel plate are integrally formed along the height direction of the shotcrete sandwich wall of the perforated steel plate.

3. The perforated steel plate shotcrete sandwich wall according to claim 1, characterized in that: The first equilateral triangle punch array is a matrix with the columns and rows aligned; the shape of the first equilateral triangle punch is an inverted equilateral triangle; the top edge of the first equilateral triangle tongue is connected to the first equilateral triangle punch; The third equilateral triangle punch array is a matrix with the columns and rows aligned; the shape of the third equilateral triangle punch is an inverted equilateral triangle; The second perforated steel plate has the same height as the first perforated steel plate.

4. The perforated steel plate shotcrete sandwich wall according to claim 1, characterized in that, It also includes a first connector; the side wing of the first perforated steel plate adjacent to the main structure of the wall perimeter is fixed to the main structure of the wall perimeter through the first connector.

5. The perforated steel plate shotcrete sandwich wall according to claim 1, characterized in that, It also includes a second connector; the upper edge of the first perforated steel plate is fixed to the main structure around the wall via the second connector.

6. The perforated steel plate shotcrete sandwich wall according to claim 1, characterized in that, It also includes a third connector; the lower wing of the first perforated steel plate is fixed to the main structure around the wall through the third connector.

7. The perforated steel plate shotcrete sandwich wall according to claim 1, characterized in that, The width of the insulation board is smaller than the width of the first perforated steel plate body; wherein: The width of the insulation board refers to the dimension of the insulation board along the length of the perforated steel plate sprayed concrete sandwich wall. The width of the first perforated steel plate body refers to the dimension of the first perforated steel plate body along the length direction of the shotcrete sandwich wall of the perforated steel plate.

8. The perforated steel plate shotcrete sandwich wall according to claim 1, characterized in that, The pad includes a connected support portion and a plug portion; the plug portion is in the shape of a triangular prism; the shape and size of the cross-section of the triangular prism are adapted to the first equilateral triangular punch hole, the plug portion is inserted into the first equilateral triangular punch hole, and the support portion is engaged outside the first equilateral triangular punch hole to fix the pad to the first punched steel plate body; the end of the support portion away from the plug portion abuts against the insulation board.

9. The perforated steel plate shotcrete sandwich wall according to claim 8, characterized in that, The support part is cylindrical in shape; the cylinder is coaxial with the triangular prism; the diameter of the cylinder is larger than the diameter of the circumcircle of the first equilateral triangular punch.

10. A construction method for a perforated steel plate shotcrete sandwich wall according to any one of claims 1 to 9, characterized in that, Includes the following steps: (1) Processing the first perforated steel plate in the perforated steel plate shotcrete sandwich wall according to any one of claims 1 to 9; (2) Processing the second perforated steel plate in the perforated steel plate shotcrete sandwich wall according to any one of claims 1 to 9; (3) Processing the insulation board in the perforated steel plate shotcrete sandwich wall according to any one of claims 1 to 9; (4) Processing the pad block in the perforated steel plate shotcrete sandwich wall according to any one of claims 1 to 9; (5) Lay out and position the perforated steel plate shotcrete sandwich wall, and mark the installation position of the first perforated steel plate. (6) Install the first pair of the first perforated steel plates and the insulation board from the first side of the column or wall along the length direction close to the wall: install the pad on the side of the first pair of the first perforated steel plates close to the core layer; fix the side wings of the first pair of the first perforated steel plates to the column or wall; then place the insulation board between the first pair of the first perforated steel plates, adjust the position, and make the first pair of the first perforated steel plates clamp the insulation board; then fix the upper wing of the first pair of the first perforated steel plates and the lower wing of the first perforated steel plates to the main structure around the wall. (7) Referring to step (6), install the second pair of the first perforated steel plates and the insulation board from the second side of the column or wall near the length direction of the wall; (8) Install the third pair of first perforated steel plates and the insulation board adjacent to the first pair of first perforated steel plates or the second pair of first perforated steel plates: install the pad on the side of the third pair of first perforated steel plates near the core layer; fix the upper wing and lower wing of the first perforated steel plate on one side to the main structure around the wall; then install the insulation board; then install the first perforated steel plate on the other side in the same way; finally, overlap and fix two adjacent first perforated steel plates on the same side of the wall to the same second perforated steel plate respectively. (9) Repeat step (8) until all the first perforated steel plates and the insulation plates are installed; (10) Shotcrete construction: Shotcrete construction is carried out on the wall structure obtained in step (9) so that the concrete filler and the space corresponding to the concrete rib are filled with concrete. After the shotcrete construction is completed, the concrete surface is leveled with a scraper and the concrete is cured to the design strength to obtain the perforated steel plate shotcrete sandwich wall; wherein, the particle size of the shotcrete coarse aggregate is less than 2 / 5 of the side length of the first equilateral triangular perforation.

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