A 3D printed concrete shear wall structure with anchor points and construction method thereof

Abstract

The present invention provides a 3D-printed concrete shear wall structure with anchor points and a construction method thereof, comprising an outer formwork formed of ultra-high performance concrete by 3D printing, a pouring area for pouring concrete formed within the outer formwork, a steel cage group disposed within the pouring area, anchoring units protruding from both inner sides of the outer formwork in the x-axis direction toward the pouring area, the anchoring units being configured to have an engaging groove with a notch parallel to the x-axis direction; and a steel cage group comprising a first steel cage, a second steel cage, and a third steel cage, wherein the first steel cage is provided with a connecting unit, the connecting unit being configured to have a connecting portion parallel to the y-axis direction and engaging portions disposed at both ends of the connecting portion, the two engaging portions being capable of engaging with the engaging grooves on both sides, respectively, so that the connecting unit can be connected to both sides of the outer formwork in the x-axis direction. The structures are firmly combined, have good integrity and load-bearing capacity, save manpower and material resources, and meet actual engineering needs.

Description

Technical Field

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

[0002] When constructing traditional reinforced concrete shear walls, it's necessary to first set up formwork and supports, secure and gather the concrete pouring area, then pour the concrete. Finally, after the concrete reaches the demoulding strength, the formwork and support system are removed. This step not only consumes a huge amount of manpower, but also fails to precisely control the amount of concrete used, resulting in material waste. Furthermore, during the manual installation and removal of formwork, improper operation by construction workers can easily lead to problems such as inaccurate formwork installation leading to leakage at the base of the wall, uneven shear wall surfaces, and concrete damage when removing the formwork with tools such as crowbars.

[0003] 3D-printed concrete structures are an innovative approach to applying 3D printing technology to architecture and engineering, creating building components by stacking concrete materials layer by layer. However, current 3D-printed concrete structures are limited in structure, lacking a secure connection between the walls and the internal reinforcement, and their structural performance may not meet actual engineering requirements.

[0004] In view of this, the applicant filed this application after studying the existing technology. Summary of the Invention

[0005] The present invention provides a 3D printed concrete shear wall structure with anchor points and a construction method thereof, aiming to improve at least one of the above-mentioned technical problems.

[0006] In order to solve the above technical problems, the present invention provides a 3D printed concrete shear wall structure with an anchor point, comprising an outer formwork formed by 3D printing of ultra-high performance concrete, a pouring area for pouring concrete formed in the outer formwork, and a steel cage group is arranged in the pouring area; the outer formwork has anchor units protruding toward the pouring area on both inner sides in the x-axis direction, wherein the anchor units are constructed to form an engaging groove with a notch facing parallel to the x-axis direction; the steel cage group includes a first steel cage, and the first steel cage is provided with a connecting unit, and the connecting unit is constructed to form a connecting portion parallel to the y-axis direction and an engaging portion arranged at both ends of the connecting portion, and the two engaging portions can be respectively engaged with the engaging grooves on both sides, so that the connecting unit can be connected to both sides of the outer formwork in the x-axis direction.

[0007] As a further optimization, the anchoring unit includes a T-shaped formwork, and multiple T-shaped formworks are arranged at equal intervals and staggered on both sides of the outer formwork; the connecting unit includes a Z-shaped horizontal steel bar, and the two end engaging parts of the Z-shaped horizontal steel bar are respectively engaged and connected with the T-shaped formworks on both sides.

[0008] As a further optimization, the anchoring unit also includes an L-shaped formwork, which is staggered at both ends of the anchoring unit; the connecting unit also includes a C-shaped horizontal steel bar, and the interlocking parts at both ends of the C-shaped horizontal steel bar are respectively used to interlock and connect the L-shaped formwork on one side and the T-shaped formwork on the other side.

[0009] As a further optimization, the first steel cage is further provided with a first horizontal steel bar and a first vertical steel bar; the first horizontal steel bar is in a U-shaped structure and is arranged at equal intervals along the z-axis direction, and is located between the anchor units on both sides of the outer formwork; the first horizontal steel bar is respectively provided with a first connecting end intersecting with the Z-shaped horizontal steel bar, and a second connecting end intersecting with the C-shaped horizontal steel bar; the first vertical steel bar is respectively connected to the first connecting end and the second connecting end, and is located on the inner side of the first horizontal steel bar.

[0010] As a further optimization, a cavity is provided in the anchoring unit, and the cavity is used for pouring concrete.

[0011] As a further optimization, the steel cage group also includes a second steel cage, which is arranged between two T-shaped formwork shells; wherein, the second steel cage is provided with a second horizontal steel bar and a second vertical steel bar connected to each other, the second horizontal steel bars are arranged at equal intervals in the z-axis direction and in a U-shaped structure, and the second vertical steel bars are arranged at the four vertices on the inner side of the second horizontal steel bar.

[0012] As a further optimization, the steel cage group also includes a third steel cage, which is arranged at both side ends of the outer formwork in the x-axis direction; wherein, the third steel cage is provided with a third horizontal steel bar and a third vertical steel bar connected to each other, and the third horizontal steel bars are arranged at equal intervals in the z-axis direction and in a U-shaped structure, and the third vertical steel bars are arranged at the four vertices on the inner side of the third horizontal steel bar.

[0013] As a further optimization, the engaging portion is a circular structure.

[0014] The present invention also provides a construction method of a 3D printed concrete shear wall structure with anchor points as described in any one of the above, comprising the following steps:

[0015] Step S1: Printing an outer formwork using ultra-high performance concrete using a 3D printer;

[0016] Step S2: manufacturing a first steel cage, a second steel cage, and a third steel cage; hoisting and splicing a plurality of second steel cages on both sides of the long side of the first steel cage, hoisting and splicing two third steel cages on both sides of the short side of the first steel cage, and welding and reinforcing the intersection nodes of the steel cages to form a steel cage group;

[0017] Step S3: hoisting the steel cage assembly into the outer formwork;

[0018] Step S4: pouring concrete into the cavity and the pouring area and vibrating.

[0019] As a further optimization, in step S1, when encountering an anchor unit while printing the outer peripheral wall, the anchor unit is first printed inward at the intersection, and then the wall is printed, completing the printing along the four sides of the outer mold shell.

[0020] By adopting the above technical solution, the present application provides a 3D printed concrete shear wall structure with anchor points and a construction method thereof, which has the following beneficial effects:

[0021] The 3D printed shear wall structure in this application uses a 3D-printed ultra-high performance concrete outer formwork as a template for filling concrete. The outer formwork and the protruding anchoring units around the inner side of the outer formwork are combined with the placed steel cage group, and then concrete is poured. It is firmly combined, has good integrity and bearing capacity, and meets the actual needs of the project.

[0022] In addition, the anchoring units on the concrete outer formwork in the present invention can increase the equivalent thickness of the outer formwork to a certain extent, thereby increasing the lateral stability of the shear wall.

[0023] Compared with traditional reinforced concrete structure construction methods, this structure and its construction method are more precise, can reduce some of the human resources in the shear wall construction process, and can also reduce material waste and carbon footprint, achieving a more sustainable building model.

[0024] This structure and its construction method have good feasibility in construction technology. The steel cage group can be assembled and placed in the concrete outer formwork after 3D printing. The subsequent pouring work does not require the use of formwork, avoiding leakage problems, saving a lot of manpower and material resources, and improving the quality of shear wall construction. BRIEF DESCRIPTION OF THE DRAWINGS

[0025] In order to more clearly illustrate the technical solutions of the embodiments of the present invention, the following briefly introduces the drawings required for use in the embodiments. It should be understood that the following drawings only illustrate certain embodiments of the present invention and therefore should not be regarded as limiting the scope. For ordinary technicians in this field, other relevant drawings can be obtained based on these drawings without paying any creative work.

[0026] Figure 1 This is a structural schematic diagram of a 3D printed concrete shear wall structure with anchor points according to the present invention;

[0027] Figure 2 It is a cross-sectional schematic diagram of a 3D printed concrete shear wall structure with anchor points according to the present invention;

[0028] Figure 3 is a schematic structural diagram of a first steel cage in an embodiment of the present invention;

[0029] Figure 4 2 is a schematic structural diagram of a second steel cage according to an embodiment of the present invention;

[0030] Figure 5 2 is a schematic structural diagram of a third steel cage in an embodiment of the present invention;

[0031] Figure 6 2. It is a schematic structural diagram of the outer formwork in an embodiment of the present invention;

[0032] Markings in the figure: 1. Outer formwork; 2. Casting area; 3. First steel cage; 4. Second steel cage; 5. Third steel cage; 11. Wall; 12. T-shaped formwork; 13. L-shaped formwork; 14. Cavity; 15. Fitting groove; 31. Z-shaped horizontal reinforcement; 32. C-shaped horizontal reinforcement; 33. First horizontal reinforcement; 34. First vertical reinforcement; 35. Fitting part; 41. Second horizontal reinforcement; 42. Second vertical reinforcement; 51. Third horizontal reinforcement; 52. Third vertical reinforcement. DETAILED DESCRIPTION

[0033] In order to make the purpose, technical solutions and advantages of the embodiments of the present invention clearer, the technical solutions in the embodiments of the present invention will be clearly and completely described below in conjunction with the drawings in the embodiments of the present invention. Obviously, the described embodiments are part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making creative work are within the scope of protection of the present invention. Therefore, the following detailed description of the embodiments of the present invention provided in the drawings is not intended to limit the scope of the invention for which protection is sought, but merely represents selected embodiments of the present invention. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making creative work are within the scope of protection of the present invention.

[0034] Depend on Figures 1 to 6As shown, an embodiment of the present invention provides a 3D-printed concrete shear wall structure with anchor points, including an outer formwork 1 formed by ultra-high performance concrete (UHPC) through 3D printing, wherein conventional UHPC (without steel fiber) has ultra-high strength and high durability, and its compressive strength can generally reach 120-200 MPa, and it also has excellent crack resistance. Using it as a shear wall formwork can effectively give play to the advantages of UHPC, thereby reducing material waste and labor costs. Preferably, a pouring area 2 for pouring concrete is formed in the outer formwork 1, and a steel cage group is provided in the pouring area 2; the outer periphery of the outer formwork 1 is a rectangular wall 11, with the long side in the x-axis direction and the short side in the y-axis direction, and the inner sides of the long sides of the outer formwork 1 protrude toward the pouring area 2 to form an anchoring unit, wherein the anchoring unit is constructed to form an engaging groove 15 with a notch parallel to the x-axis direction; the steel cage group includes a first steel cage 3, and the first steel cage 3 is provided with a connecting unit, and the connecting unit is constructed to form a connecting groove parallel to the y-axis direction. The connecting portion and the interlocking portions 35 arranged at both ends of the connecting portion, the two interlocking portions 35 can be respectively engaged with the interlocking grooves 15 on both sides, so that the connecting unit can be connected to the two sides of the outer formwork 1 in the x-axis direction, so that the long side walls 11 on both sides that mainly bear the load in this embodiment establish a connection relationship through the connecting unit, and at the same time, the steel cage group itself is firmly engaged in the interlocking groove 15 through the interlocking portion 35 of the connecting unit, so as to realize the firm combination of the steel bars and the outer formwork 1 wall 11 in this embodiment, thereby improving the structural strength of the shear wall.

[0035] Furthermore, the use of ultra-high performance concrete through 3D printing of the outer formwork 1 as the formwork wall surface 11 for shear wall casting eliminates the need for manual formwork, thus avoiding problems such as inaccurate formwork installation, which can lead to leakage at the base of the wall and uneven shear wall surface 11 due to improper operation by construction workers. At the same time, there is no need for subsequent formwork removal, avoiding problems such as concrete damage caused by traditional tools such as crowbars when removing the formwork, thus saving a considerable amount of labor costs. The 3D printer is a six-axis multi-arm concrete 3D printer. The 3D printing method can precisely control the printing material, forming a standard-sized concrete outer formwork 1, avoiding unnecessary waste of concrete and significantly reducing the manufacturing cost of the shear wall.

[0036] Preferably, the anchoring unit includes a T-shaped formwork 12, and multiple T-shaped formworks 12 are arranged at equal intervals and staggered on both sides of the outer formwork 1. By providing the T-shaped formworks 12, the equivalent thickness of the wall surface 11 can be increased. Unlike ordinary flat wall surfaces 11, the shear wall in the 3D printed shear wall structure has better lateral stability. After pouring, the T-shaped formworks 12 can serve as anchor points extending into the concrete, thereby strengthening the connection between the outer formwork 1 and the poured concrete, making the shear wall more integrated and having higher structural strength.

[0037] Furthermore, the connection unit includes a Z-shaped horizontal steel bar 31, and the interlocking portions 35 at both ends of the Z-shaped horizontal steel bar 31 are respectively interlocked and connected with the T-shaped formwork 12 on both sides. Among them, the interlocking portion 35 at one end of the Z-shaped horizontal steel bar 31 is interlocked with the interlocking groove 15 of the T-shaped formwork 12 on one wall surface 11, and the other end is interlocked with the interlocking groove 15 of the T-shaped formwork 12 at an intersecting position on the other wall surface 11. At this time, the Z-shaped horizontal steel bar 31 can be limited by the T-shaped formwork 12 on both sides, thereby enhancing the stability of the connection.

[0038] Preferably, the anchoring unit also includes an L-shaped formwork 13, which is staggered at both ends of the anchoring unit. In this embodiment, since the T-shaped formwork 12 is staggered, the anchoring unit is missing a piece at the lower left corner and the upper right corner, and cannot connect to the Z-shaped horizontal reinforcement 31. At this time, by setting the L-shaped formwork 13 here to correspond to the T-shaped formwork 12 on the other side, the connection unit further includes a C-shaped horizontal reinforcement 32, and the interlocking portions 35 at both ends of the C-shaped horizontal reinforcement 32 are respectively used to interlock and connect the L-shaped formwork 13 on one side and the T-shaped formwork 12 on the other side. In this way, the C-shaped horizontal reinforcement 32 is used as the outermost connection structure of the connection unit to connect the interlocking L-shaped formwork 13 and the T-shaped formwork 12, so that the interlocking groove 15 of each anchoring unit has an interlocking interlocking portion 35, which further strengthens the connection relationship between the two side walls 11 and the overall strength of the shear wall is higher.

[0039] Among them, the first steel cage 3 is also provided with a first horizontal steel bar 33 and a first vertical steel bar 34; the first horizontal steel bar 33 is a ring-shaped structure and is arranged at equal intervals along the z-axis direction, and is located between the anchor units on both sides of the outer formwork 1; the first horizontal steel bar 33 is provided with a first connection end intersecting with the Z-shaped horizontal steel bar 31, and a second connection end intersecting with the C-shaped horizontal steel bar 32; the first vertical steel bar 34 is connected to the first connection end and the second connection end, and is located on the inner side of the first horizontal steel bar 33. In this way, the structure of the complete first steel cage 3 is formed. The first steel cage 3 serves as the core steel skeleton in this embodiment. The interlocking portion 35 of the Z-shaped horizontal steel bar 31 and the C-shaped horizontal steel bar 32 is interlocked and connected in the interlocking groove 15 of the anchor unit, which greatly strengthens the connection relationship between the wall surfaces 11 on both sides while also ensuring the shear wall section bearing capacity requirements.

[0040] Preferably, the interlocking portion 35 is a circular structure. By setting the interlocking portion 35 as a circular structure, not only the connection surface with the interlocking groove 15 is increased, but also after pouring, concrete can be placed inside the circular structure, thereby strengthening the connection strength between the interlocking portion 35 and the concrete.

[0041] Preferably, a cavity 14 is provided in the anchoring unit, and the cavity 14 is used for pouring concrete.

[0042] Preferably, the reinforcement cage assembly further includes a second reinforcement cage 4, which is arranged between the two T-shaped formworks 12. The second reinforcement cage 4 is provided with interconnected second horizontal reinforcements 41 and second vertical reinforcements 42. The second horizontal reinforcements 41 are arranged at equal intervals along the z-axis and in a zigzag configuration. The second vertical reinforcements 42 are arranged at the four vertices inside the second horizontal reinforcements 41, thereby forming a complete second reinforcement cage 4. The second reinforcement cage 4 not only fills the space between two adjacent anchoring units, serving as a supporting structure between the two, but also connects with the first reinforcement cage 3 to form a larger reinforcement cage, thereby enhancing the integrity of the reinforcement structure within the casting area 2 and increasing the stability of the shear wall.

[0043] Preferably, the reinforcement cage assembly further includes a third reinforcement cage 5, which is arranged at both ends of the outer formwork 1 in the x-axis direction, i.e., in the space between the outermost anchoring unit and the short side wall 11. The third reinforcement cage 5 is provided with connected third horizontal reinforcements 51 and third vertical reinforcements 52. The third horizontal reinforcements 51 are arranged at equal intervals in the z-axis direction and in a zigzag structure. The third vertical reinforcements 52 are arranged at the four vertices inside the third horizontal reinforcements 51, thereby forming a complete third reinforcement cage 5. The third reinforcement cage 5 not only fills the unused space on both sides but also connects with the first reinforcement cage 3 to form a larger reinforcement cage, thereby improving the integrity of the reinforcement structure within the casting area 2 and increasing the stability of the shear wall.

[0044] The present invention also provides a construction method of a 3D printed concrete shear wall structure with anchor points as described in any one of the above, comprising the following steps:

[0045] Step S1: Use ultra-high performance concrete to print an outer formwork 1 through a six-axis multi-arm concrete 3D printer. The outer formwork 1 is composed of a rectangular outer wall 11 and an anchoring unit protruding from the inner side of the long side. When the printed outer wall 11 encounters the anchoring unit, it turns inward at the intersection to print the anchoring unit, and then prints the wall 11. The printing is completed along the four sides of the outer formwork 1, thereby ensuring the integrity of the outer wall 11 and the internal anchoring unit.

[0046] Step S2: Make the first steel cage 3, the second steel cage 4 and the third steel cage 5; specifically, place the prepared Z-shaped horizontal steel bars 31 at equal intervals on the first horizontal steel bars 33, and place the C-shaped horizontal steel bars 32 on both end sides, and then tie the first vertical steel bars 34 at the intersection of the above three, that is, the first connecting end and the second connecting end, and then tie the first horizontal steel bars 33, Z-shaped horizontal steel bars 31 and C-shaped horizontal steel bars 32 at equal intervals in the z-axis direction to complete the production of the first steel cage 3.

[0047] The second vertical steel bars 42 are arranged at the four vertices of the square-shaped second horizontal steel bars 41, and the second horizontal steel bars 41 are evenly spaced along the z-axis and tied to form a second steel cage 4. The third vertical steel bars 52 are arranged at the four vertices of the square-shaped third horizontal steel bars 51, and the third horizontal steel bars 51 are evenly spaced along the z-axis and tied to form a third steel cage 5.

[0048] Finally, multiple second steel cages 4 are hoisted and spliced ​​on both sides of the long side of the first steel cage 3, and two third steel cages 5 are hoisted and spliced ​​on both sides of the short side of the first steel cage 3, and the intersection nodes of the steel cages are welded and reinforced to form a complete steel cage group.

[0049] Step S3: hoisting the steel cage assembly into the outer formwork 1.

[0050] Step S4: pour concrete into the cavity 14 and the pouring area 2 and vibrate it. When the strength reaches the required level, the construction of the 3D printed concrete shear wall structure with anchor points is completed.

[0051] The foregoing description is merely a preferred embodiment of the present invention and is not intended to limit the present invention. Those skilled in the art will readily appreciate that various modifications and variations are possible. Any modifications, equivalent substitutions, or improvements made within the spirit and principles of the present invention are intended to be within the scope of protection of the present invention.

Claims

1. A 3D printed concrete shear wall structure with anchor points, characterized in that: It includes an outer formwork formed by ultra-high performance concrete through 3D printing, a pouring area for pouring concrete is formed in the outer formwork, and a steel cage group is arranged in the pouring area; the outer formwork has anchoring units protruding toward the pouring area on both inner sides in the x-axis direction, wherein the anchoring units are constructed to form an engaging groove with a notch parallel to the x-axis direction; the steel cage group includes a first steel cage, and the first steel cage is provided with a connecting unit, and the connecting unit is constructed to form a connecting portion parallel to the y-axis direction and an engaging portion arranged at both ends of the connecting portion, and the two engaging portions can be respectively engaged with the engaging grooves on both sides, so that the connecting unit can be connected to both sides of the outer formwork in the x-axis direction.

2. A 3D printed concrete shear wall structure with anchor points according to claim 1, characterized in that , the anchoring unit includes a T-shaped formwork, and a plurality of T-shaped formworks are arranged at equal intervals and staggered on both sides of the outer formwork; The connection unit includes a Z-shaped horizontal steel bar, and the engaging parts at both ends of the Z-shaped horizontal steel bar are respectively engaged and connected with the T-shaped formwork on both sides.

3. A 3D printed concrete shear wall structure with anchor points according to claim 2, characterized in that , the anchoring unit further includes an L-shaped formwork, and the L-shaped formwork is staggeredly arranged at both end sides of the anchoring unit; The connection unit also includes a C-shaped horizontal steel bar, and the engaging parts at both ends of the C-shaped horizontal steel bar are respectively used to engage and connect the L-shaped formwork on one side and the T-shaped formwork on the other side.

4. A 3D printed concrete shear wall structure with anchor points according to claim 3, characterized in that The first steel cage is also provided with a first horizontal steel bar and a first vertical steel bar; the first horizontal steel bar is in a U-shaped structure and is arranged at equal intervals along the z-axis direction, and is located between the anchor units on both sides of the outer formwork; the first horizontal steel bar is respectively provided with a first connecting end intersecting with the Z-shaped horizontal steel bar, and a second connecting end intersecting with the C-shaped horizontal steel bar; the first vertical steel bar is respectively connected to the first connecting end and the second connecting end, and is located on the inner side of the first horizontal steel bar.

5. A 3D printed concrete shear wall structure with anchor points according to claim 3, characterized in that A cavity is provided in the anchoring unit, and the cavity is used for pouring concrete.

6. A 3D printed concrete shear wall structure with anchor points according to claim 2, characterized in that The steel cage group also includes a second steel cage, which is arranged between two T-shaped formwork shells; wherein the second steel cage is provided with a second horizontal steel bar and a second vertical steel bar connected to each other, the second horizontal steel bars are arranged at equal intervals in the z-axis direction and in a circular structure, and the second vertical steel bars are arranged at the four vertices on the inner side of the second horizontal steel bar.

7. A 3D printed concrete shear wall structure with anchor points according to claim 1, characterized in that The steel cage group also includes a third steel cage, which is arranged at both side ends of the outer formwork in the x-axis direction; wherein the third steel cage is provided with a third horizontal steel bar and a third vertical steel bar connected to each other, and the third horizontal steel bars are arranged at equal intervals in the z-axis direction and in a U-shaped structure, and the third vertical steel bars are arranged at the four vertices on the inner side of the third horizontal steel bar.

8. A 3D printed concrete shear wall structure with anchor points according to claim 1, characterized in that , the engaging portion is a circular structure.

9. A construction method for a 3D printed concrete shear wall structure with anchor points according to any one of claims 1 to 8, characterized in that: The following steps are involved: Step S1: Printing an outer formwork using ultra-high performance concrete using a 3D printer; Step S2: manufacturing a first steel cage, a second steel cage, and a third steel cage; hoisting and splicing a plurality of second steel cages on both sides of the long side of the first steel cage, hoisting and splicing two third steel cages on both sides of the short side of the first steel cage, and welding and reinforcing the intersection nodes of the steel cages to form a steel cage group; Step S3: hoisting the steel cage assembly into the outer formwork; Step S4: pouring concrete into the cavity and the pouring area and vibrating.

10. The construction method according to claim 9, characterized in that In step S1, when encountering an anchor unit while printing the outer wall, turn inward at the junction to print the anchor unit first, then print the wall, and complete the printing along the four sides of the outer mold shell.

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