3D printed shear wall structure and construction method

Abstract

The invention provides a 3D printed shear wall structure and a construction method, and relates to the technical field of building structures. The shear wall structure comprises outer molds arranged on the two sides and a framework arranged in the outer molds, and a pouring area is formed between the outer molds and the framework. Protruding units are arranged on the sides, facing the pouring area, of the outer mold and the framework at intervals. The outer mold and the framework are formed by ultra-high performance concrete through 3D printing; the cavity part of the framework is provided with a cavity used for being filled with materials with special functions. A first reinforcement cage is arranged in the pouring area, second reinforcement cages are connected to the two ends of the first reinforcement cage, and concrete is poured in the pouring area. The ultra-high-performance concrete is adopted as a formwork for pouring the shear wall through the 3D printed outer formwork and the framework, manual formwork erecting is not needed any more, and the problems that due to non-standard operation of constructors, the installation position of the formwork is inaccurate, and consequently slurry leakage of the root of the wall and unevenness of the wall face of the shear wall are caused are avoided.

Description

Technical Field

[0001] The present invention relates to the technical field of building structures, and in particular to a 3D printed shear wall and a construction method thereof. Background Art

[0002] Shear walls are also called wind-resistant walls, earthquake-resistant walls or structural walls. They are walls in houses or structures that mainly bear vertical loads (gravity) and horizontal loads caused by wind loads or earthquakes, and are generally made of reinforced concrete. Traditional cast-in-place concrete shear walls usually require tying a steel skeleton (steel cage) first, then fixing and gathering the concrete pouring area by supporting formwork and a support system, and then pouring concrete. Finally, after the concrete reaches the demolding strength, the formwork and support system are removed. The construction process of cast-in-place concrete shear walls requires a huge investment of manpower costs and will inevitably produce some quality problems.

[0003] In the process of manual loading and unloading of formwork, it is easy for construction workers to operate in an irregular manner, resulting in problems such as inaccurate formwork installation leading to leakage at the base of the wall, uneven shear wall surface, and concrete breakage when removing the formwork with tools such as crowbars.

[0004] Currently, common shear wall structures include "T" type, "L" type, "Z" type, "X" type, "I" type, broken line type, etc. Although these structural forms have the advantages of flexible arrangement and no conflict with the building's use function, for some special-shaped structural buildings with curved and arc-shaped designs, the shear wall structure is relatively complicated to construct.

[0005] Existing traditional shear walls have certain deficiencies in considering requirements such as thermal insulation, radiation protection, etc. Most of them meet the requirements by adding thermal insulation materials to the constructed concrete layer or increasing the thickness of the wall, which is bound to increase the manufacturing cost of the shear wall. Summary of the invention

[0006] The invention discloses a 3D printed shear wall structure and a construction method to solve the above problems.

[0007] The present invention adopts the following scheme: The present application provides a 3D-printed shear wall structure, comprising outer molds placed on both sides and a skeleton placed in the outer molds, wherein a casting area is formed between the outer molds and the skeleton; the outer molds and the skeleton are both provided with raised units at intervals on one side facing the casting area; the outer molds and the skeleton are formed by 3D printing using ultra-high performance concrete; a cavity for filling with special functional materials is provided in the middle of the skeleton; a first steel cage is provided in the casting area, and a second steel cage is connected to both ends of the first steel cage, and concrete is cast in the casting area.

[0008] Furthermore, first protrusion units arranged in a fishbone shape are arranged on both sides of the skeleton; and second protrusion units corresponding to the first protrusion units are arranged on the outer mold.

[0009] Furthermore, the cavity is filled with at least one material having the functions of thermal insulation, radiation protection, sound insulation and noise reduction.

[0010] Furthermore, the second steel cage is an annular columnar steel cage, and the first steel cage is a sheet-like grid steel cage.

[0011] Furthermore, two ends of the first steel cage are connected to the second steel cage, and the connection points are welded and reinforced.

[0012] Furthermore, the shear wall is D-shaped; the outer formwork includes two straight outer formworks in a straight line shape, and two arc-shaped outer formworks connected to the straight outer formworks; the frame includes a first frame arranged between the two straight outer formworks, and an arc-shaped second frame arranged between the two arc-shaped outer formworks; two annular columnar second steel cages are placed at both ends of the first frame; the first steel cage includes two first mesh steel cages placed between the first frame and the straight outer formwork, and two arc-shaped second mesh steel cages placed between the second frame and the arc-shaped outer formwork.

[0013] A construction method of the 3D printed shear wall structure comprises the following steps: Step 1: Use ultra-high performance concrete to print a straight outer mold, an arc-shaped outer mold, a first frame and a second frame through a 3D printer; Step 2: Make a first mesh steel cage, an arc-shaped second mesh steel cage, and a ring-shaped second steel cage; and weld the first mesh steel cage, the second mesh steel cage and the second steel cage to form a D-shaped integral steel cage; Step 3: hoist and position the D-shaped integral steel cage formed in step 2 into the casting area formed between the outer form and the frame; Step 4: Fill the cavity of the frame with materials having special functions, and pour concrete in the pouring area.

[0014] Furthermore, in step 2, the annular columnar second steel cage includes a plurality of first vertical steel bars equidistantly arranged along the annular circumference, and annular stirrups equidistantly arranged along the axial direction on the outside of the first vertical steel bars; the grid steel cage includes a plurality of second vertical steel bars equidistantly arranged along the horizontal direction and close to one side of the skeleton, and a plurality of transverse steel bars equidistantly arranged along the vertical direction and connected to the second vertical steel bars and close to one side of the outer mold.

[0015] By adopting the above technical solution, the present invention can achieve the following technical effects: 1. Ultra-high performance concrete is used as the template for shear wall casting through 3D printing of external formwork and skeleton, eliminating the need for manual formwork, thus avoiding leakage at the root of the wall and uneven shear wall surface caused by inaccurate template installation due to non-standard operation of construction workers. At the same time, there is no need to remove the formwork later, thus avoiding problems such as concrete damage caused by traditional tools such as crowbars to remove the formwork, saving a lot of labor costs.

[0016] 2. The cavity between the first frame and the second frame can be filled with materials with special functions, such as thermal insulation materials; compared with the traditional method of adding thermal insulation materials to the constructed concrete layer or increasing the thickness of the wall to meet the requirements, the manufacturing cost of the shear wall is greatly reduced.

[0017] 3. For special-shaped shear walls, especially for some special-shaped structural buildings with curved and arc-shaped designs, the casting formwork of the shear wall is constructed by 3D printing, which is fast and convenient and can be applied to various complex arc-shaped shear walls. BRIEF DESCRIPTION OF THE DRAWINGS

[0018] Figure 1 This is a schematic diagram of a top view of a 3D printed shear wall structure according to an embodiment of the present invention; Figure 2 It is a structural schematic diagram of a 3D printed shear wall structure according to an embodiment of the present invention; Figure 3 This is a structural schematic diagram of a 3D printed shear wall structure without a steel cage placed in an embodiment of the present invention; Figure 4 It is a structural schematic diagram of a second steel cage of a 3D printed shear wall structure according to an embodiment of the present invention; Figure 5 It is a structural schematic diagram of a first mesh reinforcement cage of a 3D-printed shear wall structure according to an embodiment of the present invention; Figure 6 It is a structural schematic diagram of a second grid reinforcement cage of a 3D printed shear wall structure according to an embodiment of the present invention; Icons: straight outer formwork 1, arc-shaped outer formwork 2, first skeleton 3, second skeleton 4, first grid steel cage 5, second grid steel cage 6, first raised unit 7, second raised unit 8, second steel cage 9, cavity 10, first vertical steel bar 11, annular stirrups 12, second vertical steel bar 13, first transverse steel bar 14, third vertical steel bar 15, second transverse steel bar 16. DETAILED DESCRIPTION

[0019] Example Combination Figures 1 to 6As shown, this embodiment provides a 3D-printed shear wall structure, including outer molds placed on both sides and a skeleton placed in the outer mold, and a casting area is formed between the outer mold and the skeleton; the outer mold and the skeleton are both provided with raised units at intervals on one side facing the casting area; the outer mold and the skeleton are formed by 3D printing using ultra-high performance concrete; a cavity 10 for filling with special functional materials is provided in the middle of the skeleton; a first steel cage is provided in the casting area, and a second steel cage 9 is connected to both ends of the first steel cage, and concrete is cast in the casting area.

[0020] The use of ultra-high performance concrete through 3D printing of external molds and skeletons as the template for shear wall casting eliminates the need for manual formwork, avoiding leakage at the root of the wall and uneven shear wall surface caused by improper operation of construction workers, such as inaccurate template installation. At the same time, there is no need to remove the mold later, avoiding problems such as concrete damage when removing the template with tools such as crowbars, saving a lot of labor costs. The setting of cavity 10 can be filled with special functional materials, such as thermal insulation materials. Compared with the traditional method of adding thermal insulation materials to the constructed concrete layer or increasing the thickness of the wall to meet the requirements, the manufacturing cost of the shear wall is greatly reduced. For special-shaped shear walls, especially for some special-shaped structural buildings with curved and arc-shaped designs, the casting template of the shear wall is constructed by 3D printing, which is fast and convenient and can be applied to various complex curved shear walls.

[0021] Specifically, Figures 1 to 3 As shown, a D-shaped shear wall is taken as an example; the outer formwork includes two straight outer forms 1 in a straight line shape, and two arc-shaped outer forms 2 connected to the straight outer forms 1; the frame includes a first frame 3 arranged between the two straight outer forms 1, and an arc-shaped second frame 4 arranged between the two arc-shaped outer forms 2; two annular columnar second steel cages 9 are placed at both ends of the first frame 3; the first steel cage includes two sheet-shaped first mesh steel cages 5 placed between the first frame 3 and the straight outer form 1, and two arc-shaped second mesh steel cages 6 placed between the second frame 4 and the arc-shaped outer form 2. The two ends of the first steel cage are connected to the second steel cage 9, and the connection points are welded and reinforced to increase the overall stability of the arc-shaped shear wall and ensure the shear bearing capacity requirements of the shear wall section. The D-shaped shear wall is suitable for some walls with arc-shaped protruding designs, as well as walls where elevator shafts are located.

[0022] In this embodiment, the first skeleton 3 and the second skeleton 4 are provided with first protruding units 7 arranged in a fishbone shape on both sides close to the pouring area; and the outer mold is provided with a second protruding unit 8 corresponding to the first protruding unit 7. The provision of the first protruding unit 7 and the second protruding unit 8 increases the mechanical bite force between the steel cage and the 3D printed skeleton and the outer mold after pouring concrete. The cavity 10 is provided between the two first skeletons 3 and between the two second skeletons 4, and the cavity 10 is filled with at least one material such as thermal insulation, radiation protection, sound insulation and noise reduction, so that the shear wall has the corresponding thermal insulation, radiation protection or sound insulation and noise reduction functions. Compared with the traditional method of adding thermal insulation materials to the constructed concrete layer or increasing the thickness of the wall to meet the requirements, the manufacturing cost of the shear wall is greatly reduced.

[0023] like Figures 4 to 6 As shown, in this embodiment, the annular columnar second steel cage 9 includes a plurality of first vertical steel bars 11 arranged at equal intervals along the annular circumference, and annular stirrups 12 arranged at equal intervals along the axial direction and outside the first vertical steel bars 11; the first mesh steel cage 5 includes a plurality of second vertical steel bars 13 arranged at equal intervals along the horizontal direction and close to the frame side, and a plurality of first transverse steel bars 14 arranged at equal intervals along the vertical direction and connected to the second vertical steel bars 13 and close to the outer mold side; the second mesh steel cage 6 includes a plurality of third vertical steel bars 15 arranged at equal intervals along the arc direction and close to the frame side, and a plurality of arc-shaped second transverse steel bars 16 arranged at equal intervals along the vertical direction and connected to the third vertical steel bars 15 and close to the outer mold side. The arrangement of the positions of the vertical and transverse steel bars of the mesh steel cage enables the shear wall to have better bearing capacity when subjected to loads.

[0024] The present invention also provides a construction method of the 3D printed shear wall structure, comprising the following steps: Step 1: Use ultra-high performance concrete to print out a straight outer mold 1, an arc-shaped outer mold 2, a first skeleton 3 and a second skeleton 4 through a 3D printer; specifically, install and position a six-axis multi-arm 3D printer at the construction site, and then produce and transport ultra-high performance concrete to the 3D printer for printing the outer mold and the skeleton.

[0025] Step 2: Make a first mesh steel cage 5 and an arc-shaped second mesh steel cage 6, as well as an annular columnar second steel cage 9; and weld the first mesh steel cage 5 and the second mesh steel cage 6 and the second steel cage 9 together to form a D-shaped integral steel cage.

[0026] Specifically, a plurality of second vertical steel bars 13 are arranged at equal intervals in the horizontal direction close to the outer mold side, and then a plurality of first transverse steel bars 14 are tied to the second vertical steel bars 13 at equal intervals in the vertical direction close to the skeleton side to form the first grid steel cage 5.

[0027] A plurality of third vertical steel bars 15 are arranged at equal intervals in the arc direction close to the outer mold side, and then a plurality of second transverse steel bars 16 are tied to the third vertical steel bars 15 at equal intervals in the vertical direction close to the skeleton side to form the second grid steel cage 6.

[0028] A plurality of first vertical steel bars 11 are arranged at equal intervals to form an annular column, and then annular stirrups 12 are arranged at equal intervals along the axial direction on the outside of the first vertical steel bars 11 to form the second steel cage 9 in an annular column.

[0029] Finally, the first mesh steel cage 5, the second mesh steel cage 6 and the second steel cage 9 are welded to form a D-shaped integral steel cage.

[0030] Step 3: hoist and position the D-shaped integral steel cage formed in step 2 into the concrete pouring area formed between the outer formwork and the frame.

[0031] Step 4: Fill the cavity 10 with materials having special functions, and pour concrete in the pouring area.

[0032] Ultra-high performance concrete is used as the template for shear wall casting through 3D printing of external formwork and skeleton, which eliminates the need for manual formwork, thus avoiding leakage at the root of the wall and uneven shear wall surface caused by inaccurate template installation due to improper operation of construction workers. At the same time, there is no need to remove the formwork later, avoiding problems such as concrete breakage caused by traditional use of tools such as crowbars to remove the formwork, saving a lot of labor costs. At the same time, the construction is fast and convenient, and it can be applied to various complex curved or arc-shaped shear walls.

[0033] It should be understood that the above are only preferred implementations of the present invention, and the protection scope of the present invention is not limited to the above embodiments. All technical solutions under the concept of the present invention belong to the protection scope of the present invention.

[0034] The above description of the drawings used in the implementation manner only illustrates certain embodiments of the present invention and should not be regarded as limiting the scope. For ordinary technicians in this field, other related drawings can be obtained based on these drawings without paying creative work.

Claims

1. A 3D printed shear wall structure, characterized in that: It includes outer molds placed on both sides and a skeleton placed in the outer mold, and a casting area is formed between the outer mold and the skeleton; the outer mold and the skeleton are both provided with raised units at intervals on one side facing the casting area; the outer mold and the skeleton are formed by 3D printing using ultra-high performance concrete; a cavity for filling with special functional materials is provided in the middle of the skeleton; a first steel cage is provided in the casting area, and a second steel cage is connected to both ends of the first steel cage, and concrete is cast in the casting area.

2. The 3D printed shear wall structure according to claim 1, characterized in that: First protrusion units arranged in a fishbone shape are arranged on both sides of the skeleton; and second protrusion units corresponding to the first protrusion units are arranged on the outer mold.

3. The 3D printed shear wall structure according to claim 1, characterized in that: The cavity is filled with at least one material having the functions of thermal insulation, radiation protection, sound insulation and noise reduction.

4. The 3D printed shear wall structure according to claim 1, characterized in that: The second steel cage is an annular columnar steel cage, and the first steel cage is a sheet-like grid steel cage.

5. The 3D printed shear wall structure according to claim 1, characterized in that: The two ends of the first steel cage are connected to the second steel cage, and the connection points are welded and reinforced.

6. The 3D printed shear wall structure according to any one of claims 1 to 5, characterized in that: The shear wall is in a D shape; the outer formwork includes two straight outer formworks in a straight line shape, and two arc-shaped outer formworks connected to the straight outer formworks; the frame includes a first frame arranged between the two straight outer formworks, and an arc-shaped second frame arranged between the two arc-shaped outer formworks; two annular columnar second steel cages are placed at both ends of the first frame; the first steel cage includes two first mesh steel cages placed between the first frame and the straight outer formwork, and two arc-shaped second mesh steel cages placed between the second frame and the arc-shaped outer formwork.

7. A construction method of a 3D printed shear wall structure as claimed in claim 6, characterized in that: The following steps are involved: Step 1: Use ultra-high performance concrete to print straight outer molds and curved outer molds through 3D printer An outer mold and a first frame and a second frame; Step 2: making a first mesh steel cage, an arc-shaped second mesh steel cage, and an annular columnar second steel cage; and hoisting and welding the first mesh steel cage, the second mesh steel cage, and the second steel cage to form a D-shaped integral steel cage; Step 3: hoist and position the D-shaped integral steel cage formed in step 2 into the casting area formed between the outer form and the frame; Step 4: Fill the cavity with materials having special functions, and pour concrete in the pouring area.

8. The construction method of the 3D printed shear wall structure according to claim 7, characterized in that: In step 2, the annular columnar second steel cage includes a plurality of first vertical steel bars equidistantly arranged along the annular circumference, and annular stirrups equidistantly arranged along the axial direction on the outside of the first vertical steel bars; the grid steel cage includes a plurality of second vertical steel bars equidistantly arranged along the horizontal direction and close to one side of the skeleton, and a plurality of transverse steel bars equidistantly arranged along the vertical direction and connected to the second vertical steel bars and close to one side of the outer mold.

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