Template-free multi-layer composite structure self-compacting light fireproof inner wall and preparation method thereof

Abstract

The invention relates to the field of building materials, in particular to a template-free multi-layer composite structure self-compacting light fireproof inner wall which is characterized by comprising a self-compacting light concrete layer, a fireproof heat insulation layer, a damp-proof sound insulation layer and a decorative surface layer. The self-compacting lightweight concrete layer is composed of cement, fly ash, pottery sand, expanded perlite, polypropylene fiber, vermiculite powder, chlorinated paraffin, zinc borate, ammonium polyphosphate melamine salt (PPAM), nano magnesium hydroxide, titanate melamine salt (TMS) and a zinc borate melamine compound (ZBMC). And the construction process is greatly simplified and the construction time and the labor cost are reduced due to the construction mode without a template. The self-leveling performance of the self-compacting lightweight concrete ensures the stability and consistency of the construction quality. By adopting the lightweight aggregate and optimizing the mix proportion, the self weight of the wall body is effectively reduced, meanwhile, sufficient strength and stability are ensured, and the load of a building is reduced.

Description

Technical Field

[0001] The invention relates to the technical field of building materials, in particular to a template-free multi-layer composite structure self-compacting lightweight fireproof inner wall and a preparation method thereof. Background Art

[0002] In modern buildings, the performance and quality of interior walls have a vital impact on the overall quality, safety and living comfort of the building. However, traditional interior wall structures and preparation methods often have many problems, such as complex construction, difficult quality control, poor lightweight effect, and insufficient fireproof performance. Traditional interior wall construction usually requires the construction of formwork, which not only increases the construction process and cost, but also easily leads to problems such as loose template installation and leakage, thus affecting the quality and appearance of the wall. In addition, traditional construction methods require high technical levels of workers, and human factors during the construction process are prone to quality fluctuations. In order to reduce the weight of the building, the interior wall needs to have lightweight characteristics. However, traditional interior wall materials are often dense, which increases the load on the building and has an adverse effect on structural design and safety. In the event of a fire, the fireproof performance of the interior wall is crucial. Traditional interior wall materials often have defects in fire prevention, are easy to burn, spread fire, and cannot effectively prevent the spread of fire, posing a huge threat to the safety of life and property. Summary of the invention

[0003] The present invention aims to provide a multi-layer composite structure interior wall which does not require a template, is easy to construct, is lightweight and has excellent fireproof performance, and a preparation method thereof, so as to solve the above problems existing in traditional interior walls. The structure of the wall is composed of: a self-compacting lightweight concrete layer: composed of cement, fly ash, ceramic sand, expanded perlite, polypropylene fiber, vermiculite powder, chlorinated paraffin, zinc borate, polyammonium phosphate melamine salt (PPAM), nano magnesium hydroxide, titanate melamine salt (TMS) and zinc borate melamine complex (ZBMC). The proportions of each component are as follows: fly ash accounts for 15-25 parts of cement mass, pottery sand accounts for 30-40 parts of the total volume of aggregate, expanded perlite accounts for 10-20 parts of the total volume of aggregate, polypropylene fiber accounts for 0.1-0.3 parts of concrete volume, vermiculite powder accounts for 5-10 parts of concrete mass, chlorinated paraffin accounts for 2-5 parts of concrete mass, zinc borate accounts for 3-6 parts of concrete mass, polyammonium phosphate melamine salt (PPAM) accounts for 5-10 parts of concrete mass, nano magnesium hydroxide accounts for 2-5 parts of concrete mass, titanate melamine salt (TMS) accounts for 1-3 parts of concrete mass, and zinc borate melamine complex (ZBMC) accounts for 2-4 parts of concrete mass.

[0004] The fireproof and heat-insulating layer: adopts a composite structure of aluminum silicate fiberboard and glass micro-bead insulation mortar to effectively block heat transfer and improve fireproof performance. The moisture-proof and sound-insulating layer: consists of waterproof coiled material and sound-insulating sponge to prevent water vapor penetration and reduce noise transmission. The decorative surface layer: integrated wall panels, diatom mud or artistic paint can be selected to meet the needs of beauty and personalization. The preparation process of the wall is: prepare the raw materials required for the above layers and ensure that the material quality meets the requirements. Clean the construction base to ensure that the base is flat, clean, free of oil and loose objects. Cement, fly ash, pottery sand, expanded perlite, polypropylene fiber, vermiculite powder, chlorinated paraffin, zinc borate, polyphosphate ammonium melamine salt (PPAM), nano magnesium hydroxide, titanate melamine salt (TMS) and zinc borate melamine complex (ZBMC) are placed in a mixer according to the designed proportion, fully stirred and evenly mixed to make self-compacting lightweight concrete. Casting is carried out directly on the treated base without templates, and filling and molding is carried out relying on the self-leveling performance of concrete. After the self-compacting lightweight concrete layer is initially set, the aluminum silicate fiberboard is laid on its surface, and then the vitrified micro-bead insulation mortar is applied. The waterproof membrane is laid on the fireproof and heat-insulating layer, and then the sound insulation sponge is laid. According to the selected decorative surface material, the corresponding construction treatment is carried out, such as installing integrated wall panels, applying diatom mud or artistic paint, etc.

[0005] (III) Beneficial effects

[0006] The construction method without formwork greatly simplifies the construction process and reduces construction time and labor costs. The self-leveling performance of self-compacting lightweight concrete ensures the stability and consistency of construction quality. By using lightweight aggregates and optimizing the mix ratio, the deadweight of the wall is effectively reduced, while ensuring sufficient strength and stability, reducing the load on the building. Polyammonium phosphate melamine salt (PPAM) decomposes at high temperatures to produce ammonia and phosphoric acid, forming a covering layer to prevent combustion. Nano magnesium hydroxide decomposes and absorbs heat, and zinc borate synergistically plays a flame retardant role. Titanate in titanate melamine salt (TMS) can improve the compatibility of materials, and melamine plays a gas dilution and heat absorption role. Zinc borate in zinc borate melamine complex (ZBMC) can form a glassy substance at high temperature to cover the surface of the material, which plays a role in heat insulation and oxygen isolation, and melamine decomposes to produce non-flammable gas. The setting of the fireproof and heat-insulating layer further improves the fireproof performance of the wall and effectively delays the spread of fire. The moisture-proof and sound-insulating layer can effectively prevent water vapor penetration, keep the room dry, reduce noise transmission, and improve the comfort of the living environment. A variety of decorative surface materials are available to meet different decorative styles and personalized needs, and improve the beauty of the interior. DETAILED DESCRIPTION

[0007] Embodiment 1

[0008] The interior partition wall project of a commercial building has a total area of ​​about 6,000 square meters. The self-compacting lightweight concrete layer materials are: PO 42.5 cement, Class I fly ash, 0.5-5mm ceramic sand, 5-10mm expanded perlite, 12-19mm polypropylene fiber, 200 mesh vermiculite powder, chlorinated paraffin, zinc borate, polyphosphate ammonium melamine salt (PPAM), 50nm nano magnesium hydroxide, titanate melamine salt (TMS) and zinc borate melamine complex (ZBMC). The proportion of each component is: fly ash accounts for 20 parts of cement mass, pottery sand accounts for 35 parts of the total volume of aggregate, expanded perlite accounts for 15 parts of the total volume of aggregate, polypropylene fiber accounts for 0.2 parts of concrete volume, vermiculite powder accounts for 8 parts of concrete mass, chlorinated paraffin accounts for 3 parts of concrete mass, zinc borate accounts for 4 parts of concrete mass, polyphosphate ammonium melamine salt (PPAM) accounts for 8 parts of concrete mass, nano magnesium hydroxide accounts for 3 parts of concrete mass, titanate melamine salt (TMS) accounts for 2 parts of concrete mass, zinc borate melamine complex (ZBMC) accounts for 3 parts of concrete mass. Fireproof and heat insulation layer materials: aluminum silicate fiberboard, thickness of 30mm, vitrified microsphere insulation mortar. Moisture-proof and sound insulation layer materials: 2mm thick waterproof membrane, 50mm thick sound insulation sponge. Decorative surface material: integrated wallboard.

[0009] Construction process, construction preparation: clean the base, measure and lay out, and prepare the materials and equipment required for construction. Casting of self-compacting lightweight concrete layer: Mix self-compacting lightweight concrete according to the designed proportion and cast directly with a thickness of 120mm. Construction of fireproof and heat insulation layer: After the self-compacting lightweight concrete layer is initially set, lay aluminum silicate fiberboard and apply 20mm thick vitrified micro-bead insulation mortar. Construction of moisture-proof and sound insulation layer: Lay waterproof membrane and sound insulation sponge. Construction of decorative surface layer: Install integrated wall panels.

[0010] Embodiment 2

[0011] The interior partition wall project of a residential project has a total area of ​​about 8,000 square meters. The self-compacting lightweight concrete layer materials are: PO 52.5 cement, grade II fly ash, 1-4mm ceramic sand, 4-8mm expanded perlite, 10-15mm polypropylene fiber, 300 mesh vermiculite powder, chlorinated paraffin, zinc borate, polyphosphate ammonium melamine salt (PPAM), 80nm nano magnesium hydroxide, titanate melamine salt (TMS) and zinc borate melamine complex (ZBMC). The proportion of each component is: fly ash accounts for 22 parts of cement mass, pottery sand accounts for 32 parts of the total volume of aggregate, expanded perlite accounts for 18 parts of the total volume of aggregate, polypropylene fiber accounts for 0.25 parts of concrete volume, vermiculite powder accounts for 7 parts of concrete mass, chlorinated paraffin accounts for 4 parts of concrete mass, zinc borate accounts for 5 parts of concrete mass, polyphosphate ammonium melamine salt (PPAM) accounts for 7 parts of concrete mass, nano magnesium hydroxide accounts for 4 parts of concrete mass, titanate melamine salt (TMS) accounts for 1.5 parts of concrete mass, zinc borate melamine complex (ZBMC) accounts for 2.5 parts of concrete mass. Fireproof and heat insulation layer material: aluminum silicate fiberboard, thickness of 35mm, vitrified microsphere insulation mortar moisture-proof and sound insulation layer material: 3mm thick waterproof membrane, 60mm thick sound insulation sponge. Decorative surface material: diatom mud.

[0012] Construction process: Construction preparation: Same as Example 1. Casting of self-compacting lightweight concrete layer: Mix self-compacting lightweight concrete according to the designed ratio and cast directly with a thickness of 150mm. Construction of fireproof and heat-insulating layer: After the self-compacting lightweight concrete layer is initially set, lay aluminum silicate fiberboard and apply 25mm thick vitrified micro-bead insulation mortar. Construction of moisture-proof and sound-insulating layer: Lay waterproof membrane and sound-insulating sponge. Construction of decorative surface layer: Apply diatom mud.

[0013] Embodiment 3

[0014] (I) Comparison with traditional interior walls

[0015] 1. Construction time and cost comparison

[0016] Select building interior wall projects of the same area, use the traditional interior wall construction method and the multi-layer composite structure interior wall construction method of the present invention respectively, and record the construction time and the required manpower and material costs.

[0017] The results show that the multi-layer composite structure interior wall of the present invention does not require a template, is easy to construct, and greatly shortens the construction time. Compared with the traditional interior wall, the construction time is reduced by about 40%. At the same time, due to the reduction of the use of templates and installation procedures, the labor cost is reduced by about 30%, and the material cost is also reduced.

[0018] 2. Wall weight comparison

[0019] The weight per unit area of ​​the traditional interior wall and the interior wall of the multi-layer composite structure of the present invention were measured respectively.

[0020] Traditional interior walls use heavier materials and have a higher weight per unit area. The multi-layer composite structure interior wall of the present invention uses lightweight aggregates and optimized mix ratios, which effectively reduces the deadweight of the wall. Compared with traditional interior walls, the deadweight of the wall of the present invention is reduced by about 30%-40%, reducing the load on the building.

[0021] 3. Fire performance comparison

[0022] A vertical combustion test and a cone calorimeter test were performed to compare the fire resistance of the traditional interior wall and the interior wall of the multi-layer composite structure of the present invention.

[0023] In the vertical burning test, the traditional interior wall has a long burning time, the fire spreads quickly, and there is obvious dripping. However, the multi-layer composite structure interior wall of the present invention has a significantly shorter burning time due to the addition of multiple flame retardant components, the fire spread is effectively controlled, and there is no dripping.

[0024] In the cone calorimeter test, the heat release rate and total heat release of the multi-layer composite structure interior wall of the present invention are significantly lower than those of the traditional interior wall, which indicates that the wall of the present invention can release less heat when a fire occurs, reducing the risk of fire.

[0025] 4. Moisture-proof and sound-proof performance comparison

[0026] The conventional interior wall and the interior wall of the multi-layer composite structure of the present invention are placed in the same humid environment and noise environment respectively, and the moisture-proof performance and sound insulation performance of the wall are measured.

[0027] Traditional interior walls easily absorb moisture in a humid environment, causing problems such as mold and deformation. The multi-layer composite structure interior wall of the present invention is equipped with a moisture-proof and sound-insulating layer, which can effectively prevent moisture penetration and keep the room dry. In terms of sound insulation performance, the wall of the present invention can significantly reduce noise transmission and improve the comfort of the living environment. Compared with traditional interior walls, the sound insulation effect is improved by about 20%-30%.

[0028] (II) Comparison of the synergy of different flame retardant ingredients

[0029] 1 Comparison between using flame retardant ingredients alone and using flame retardant ingredients in combination

[0030] Self-compacting lightweight concrete specimens with only a single flame retardant ingredient (such as ammonium polyphosphate melamine salt, nano magnesium hydroxide, zinc borate, etc.) and self-compacting lightweight concrete specimens with multiple flame retardant ingredients (ammonium polyphosphate melamine salt, nano magnesium hydroxide, titanate melamine salt, zinc borate melamine complex, etc.) added at the same time were prepared.

[0031] Vertical burning tests and cone calorimeter tests were performed to compare the fire performance of different specimens.

[0032] The results show that when a single flame retardant component is used alone, the fire resistance of the wall is improved to a certain extent, but the effect is not as good as when multiple flame retardant components are used in combination. When multiple flame retardant components are used in combination, the components work synergistically with each other, which can more effectively prevent combustion and improve the fire resistance of the wall. The heat release rate and total heat release are further reduced, the burning time is shortened, and the spread of fire is better controlled.

[0033] 2. Comparison of different flame retardant component ratios

[0034] The proportions of ammonium polyphosphate melamine salt, nano magnesium hydroxide, titanate melamine salt and zinc borate melamine complex were adjusted to prepare self-compacting lightweight concrete specimens with different proportions.

[0035] Carry out fire resistance test to observe the changes in fire resistance of walls at different proportions.

[0036] It is found through testing that when the ratio of each flame retardant component is within a certain range, the fire resistance of the wall is the best. For example, in Example 1, when fly ash accounts for 20 parts of cement mass, pottery sand accounts for 35 parts of aggregate total volume, expanded perlite accounts for 15 parts of aggregate total volume, polypropylene fiber accounts for 0.2 parts of concrete volume, vermiculite powder accounts for 8 parts of concrete mass, chlorinated paraffin accounts for 3 parts of concrete mass, zinc borate accounts for 4 parts of concrete mass, polyammonium phosphate melamine salt (PPAM) accounts for 8 parts of concrete mass, nano magnesium hydroxide accounts for 3 parts of concrete mass, titanate melamine salt (TMS) accounts for 2 parts of concrete mass, and zinc borate melamine complex (ZBMC) accounts for 3 parts of concrete mass, the fire resistance of the wall reaches a good level. If the ratio of the flame retardant component is too high or too low, the fire resistance of the wall will be affected.

[0037] It can be seen from the above comparative tests that the present invention is significantly superior to traditional interior wall technology in terms of construction efficiency, lightweight effect, fire resistance, sound insulation and moisture resistance, and has broad application prospects and market value.

[0038] In summary, the template-free multi-layer composite structure self-compacting lightweight fireproof interior wall and its preparation method of the present invention have the advantages of convenient construction, light weight and high strength, excellent fireproof, moisture-proof and sound insulation properties, and can effectively improve the quality and performance of the interior walls of buildings.

Claims

1. A template-free multi-layer composite structure self-compacting lightweight fireproof interior wall, characterized in that: It includes a self-compacting lightweight concrete layer, a fireproof and heat-insulating layer, a moisture-proof and sound-insulating layer, and a decorative surface layer, wherein the self-compacting lightweight concrete layer is composed of cement, fly ash, pottery sand, expanded perlite, polypropylene fiber, vermiculite powder, chlorinated paraffin, zinc borate, polyammonium phosphate melamine salt (PPAM), nano magnesium hydroxide, titanate melamine salt (TMS) and zinc borate melamine complex (ZBMC), and the proportion of each component is: fly ash accounts for 15-25 parts of the cement mass, pottery sand accounts for 30-40 parts of the total volume of aggregate, and expanded perlite accounts for 10-25 parts of the total volume of aggregate. The proportion of polypropylene fiber in concrete is 10-20 parts by volume, polypropylene fiber accounts for 0.1-0.3 parts by volume of concrete, vermiculite powder accounts for 5-10 parts by mass of concrete, chlorinated paraffin accounts for 2-5 parts by mass of concrete, zinc borate accounts for 3-6 parts by mass of concrete, polyammonium phosphate melamine salt (PPAM) accounts for 5-10 parts by mass of concrete, nano magnesium hydroxide accounts for 2-5 parts by mass of concrete, titanate melamine salt (TMS) accounts for 1-3 parts by mass of concrete, and zinc borate melamine complex (ZBMC) accounts for 2-4 parts by mass of concrete.

2. The template-free multi-layer composite structure self-compacting lightweight fireproof interior wall according to claim 1, characterized in that: The fireproof and heat-insulating layer is a composite structure of aluminum silicate fiberboard and vitrified microsphere insulation mortar.

3. The template-free multi-layer composite structure self-compacting lightweight fireproof interior wall according to claim 1, characterized in that: The moisture-proof and sound-insulating layer is composed of a waterproof coiled material and a sound-insulating sponge.

4. The template-free multi-layer composite structure self-compacting lightweight fireproof interior wall according to claim 1, characterized in that: The decorative surface layer is one of integrated wall panels, diatom mud or artistic paint.

5. A method for preparing a template-free multi-layer composite structure self-compacting lightweight fireproof interior wall as claimed in any one of claims 1 to 4, characterized in that: The following steps are involved: S1 Prepare the raw materials required for each layer to ensure that the quality meets the requirements; S2 Base treatment: Clean the construction base to make it flat, clean, free of oil and loose objects; S3 Material mixing: Put cement, fly ash, pottery sand, expanded perlite, polypropylene fiber, vermiculite powder, chlorinated paraffin, zinc borate, polyphosphate ammonium melamine salt (PPAM), nano magnesium hydroxide, titanate melamine salt (TMS) and zinc borate melamine complex (ZBMC) into a mixer in proportion and mix evenly to make self-compacting lightweight concrete; S4 Directly pour the self-compacting lightweight concrete on the treated base, and fill and shape it based on its self-leveling performance; S5 Fireproof and heat-insulating layer construction: After the self-compacting lightweight concrete layer is initially set, the aluminum silicate fiberboard is laid on its surface, and then the glass bead insulation mortar is applied; S6 Moisture-proof and sound-insulating layer construction: Waterproof membrane is laid on the fireproof and heat-insulating layer, and then the sound insulation sponge is laid; S7 Decorative surface layer construction: Carry out corresponding construction treatment according to the selected decorative surface layer material.

6. The preparation method according to claim 5, characterized in that: When mixing the self-compacting lightweight concrete layer materials, first add cement, fly ash, pottery sand, and expanded perlite and stir for 3-5 minutes, then add polypropylene fiber, vermiculite powder, chlorinated paraffin, zinc borate, polyammonium phosphate melamine salt (PPAM), nano magnesium hydroxide, titanate melamine salt (TMS) and zinc borate melamine complex (ZBMC) and continue stirring for 5-8 minutes until uniform.

7. The preparation method according to claim 5, characterized in that: When pouring the self-compacting lightweight concrete layer, the pouring speed is controlled at 0.5-1.0 cubic meters per hour, the pouring height does not exceed 1.5 meters, and a vibrating rod is used for auxiliary vibration during the pouring process. The vibration time is 5-10 seconds per point, and the spacing between vibration points is 30-50 centimeters.

8. The preparation method according to claim 5, characterized in that: During the construction of the fireproof and heat-insulating layer, the aluminum silicate fiberboard should be laid flat and tightly, the gap between adjacent boards should not exceed 2 mm, the thickness of the glass bead insulation mortar should be evenly applied, and the error should be controlled within the range of ±2 mm.

9. The preparation method according to claim 5, characterized in that: During the construction of the moisture-proof and sound-insulating layer, the waterproof membrane should be laid flat and without bubbles, the overlap width of the membrane should be no less than 100 mm, and the sound insulation sponge should be laid continuously and without gaps.

10. The preparation method according to claim 5, characterized in that: During the construction of the decorative surface layer, if integrated wall panels are used, they should be fixed with special hangers during installation, and the joint gap between adjacent wall panels should not exceed 1 mm; if diatom mud is used, the thickness of the application should be 1-3 mm, and it should be applied twice, with an interval of 12-24 hours between each application; If you choose artistic paint, you should apply primer first, and then apply topcoat after it dries. Apply the topcoat 2-3 times, with 4-6 hours between each coat.