Prefabricated concrete wallboard based on ALC board and preparation method of prefabricated concrete wallboard

Abstract

The invention relates to a prefabricated concrete wallboard based on an ALC board and a preparation method thereof.The prefabricated concrete wallboard comprises the ALC board, a plurality of steel bars and a concrete layer, the steel bars are embedded into the ALC board and penetrate through the top and the bottom of the ALC board respectively, the top and the bottom of the ALC board are set to be rough surfaces, the left side face and the right side face of the ALC board are provided with a plurality of deep holes, and the steel bars are inserted into the deep holes; the left side face and the right side face of the ALC plate are provided with rabbets. And the concrete layer is arranged outside the ALC plate and wraps the ALC plate. The strength of the wallboard is effectively improved by arranging the reinforcing steel bars, the wallboard is effectively prevented from being damaged by external force through wrapping of the concrete layer, the durability and safety of the prefabricated concrete wallboard are improved, and the overall strength, impact resistance, bending resistance and durability of the wallboard are remarkably improved; the service life of the ALC board is prolonged; and the application range of the ALC board in engineering application is expanded.

Description

Technical Field

[0001] The invention relates to a prefabricated concrete wallboard based on an ALC board and a preparation method thereof, belonging to the technical field of building structures. Background Art

[0002] With the rapid development of prefabricated buildings around the world, prefabricated buildings are characterized by modular and standardized component production and rapid on-site assembly, requiring building materials to not only meet the precision requirements of industrialized production, but also have the comprehensive properties of light weight, high strength, fire resistance, heat insulation and environmental protection. As a lightweight and high-performance building material, Autoclaved Lightweight Aerated Concrete Panel (ALC Panel) has been widely used in prefabricated buildings due to its excellent mechanical properties, thermal insulation properties and convenient construction characteristics.

[0003] Traditional ALC boards are made of natural materials such as quartz sand, cement and quicklime through processes such as foaming and high-pressure steam curing. The material contains evenly distributed small pores, which give it superior properties such as light weight, sound insulation, heat insulation and fire resistance. Due to its environmental protection, light weight and high efficiency, it is widely used in building walls, roofs, floors and partitions.

[0004] The construction steps of the existing ALC board as a partition wall are as follows: (1) Clean the joints between the partition board and the top surface, ground wall; (2) According to the requirements of the construction drawings, pop out the horizontal lines and edge lines of the partition wall on the ground, wall and ceiling; (3) Apply a layer of interface mortar or interface agent on the concrete wall; (4) Apply bonding mortar on the bottom and side of the first ALC partition board; Install the ALC partition board on the wall and press it hard to ensure that it fits tightly with the wall; The upper node is fixed to the wall structure with a U-shaped steel clip and the lower end is fixed with a wooden wedge; (5) Apply bonding mortar on the bonding surface of the second and subsequent ALC boards and install them in the same way; (6) Apply special caulking glue or high-strength mortar to the joints between ALC boards to ensure that the gaps are filled and evenly flat; Use cement mortar to fill the gaps at the bottom of the wall panels to avoid hollowing; (7) After the caulking material hardens, grind the joints and surface to ensure that the wall is flat. The disadvantages of this method are:

[0005] (1) As a lightweight material, ALC wall panels have poor impact resistance. During transportation and installation, the panels are prone to cracking or corner damage.

[0006] (2) Since ALC wall panels are mainly made of cement and lime, their storage environment requirements are relatively strict. If the storage environment is too humid or too dry, it may cause deformation and cracking of the panels, thus affecting their performance.

[0007] (3) When constructing a wall, it is usually necessary to use a crowbar to adjust the verticality and installation position of the ALC wall panels. However, this construction method is prone to cause partial damage to the ALC wall panels, which in turn causes cracking of the ALC wall as a whole. In severe cases, the ALC wall panels cannot be used any longer. In addition, after the wall is built, its surface impact resistance is relatively weak, and an additional finishing layer or protective layer needs to be added to enhance durability. Summary of the invention

[0008] 1. Technical issues to be resolved

[0009] In order to solve the defects of ALC boards in the prior art, such as easy breakage during construction, transportation and use, insufficient impact resistance, moisture absorption and deformation, difficulty in joint treatment, and inability to meet high strength and special environmental requirements, the present invention provides a precast concrete wall panel based on ALC boards and a preparation method thereof.

[0010] (II) Technical solution

[0011] In order to achieve the above object, the main technical solutions adopted by the present invention include:

[0012] A prefabricated concrete wall panel based on an ALC board comprises an ALC board, a plurality of steel bars and a concrete layer, wherein the steel bars are embedded in the interior of the ALC board and vertically penetrate the top and bottom of the ALC board respectively, the top and bottom of the ALC board are set as rough surfaces, the left side and the right side of the ALC board are respectively provided with a plurality of deep holes, and the steel bars are inserted into the deep holes; and the left side and the right side of the ALC board are also provided with tongue and groove; the concrete layer is arranged on the outside of the ALC board and wraps the ALC board.

[0013] As for the precast concrete wall panel as described above, preferably, both ends of the steel bars passing through the top and bottom of the ALC panel are exposed from the ALC panel surface, and further, the length of the steel bars exposed from the ALC panel surface is 20 to 30 mm.

[0014] As for the precast concrete wall panel as described above, preferably, all the steel bars penetrating the top and bottom of the ALC panel are arranged in parallel, and the steel bars in the deep holes are arranged in parallel; the depth of the deep holes is 80-150 mm, and the spacing is 180-220 mm.

[0015] As the precast concrete wall panels as described above, preferably, the ALC panels are provided with two or more pieces, and also include a plurality of connecting steel bars and a plurality of reinforcing steel bars, wherein the connecting steel bars are used to connect the left side and the right side of two adjacent ALC panels, and the reinforcing steel bars are connected to the connecting steel bars and are perpendicular to the connecting steel bars; at the same time, transverse reinforcing steel bars are tied to the exposed steel bars at the top and the bottom.

[0016] As for the prefabricated concrete wall panel as described above, preferably, alkali-resistant mesh cloths are hung on the front and rear panels of the ALC panel.

[0017] As for the precast concrete wall panel as described above, preferably, the thickness of the concrete layer wrapping the ALC board is 40-70 mm; the tongue and groove is a groove on one side of the left and right sides of the ALC board, and a raised edge matching the groove is provided on the other side, and the groove is snap-fitted with the raised edge.

[0018] A method for preparing a prefabricated concrete wall panel based on an ALC panel comprises the following steps:

[0019] S1. Drill vertical through holes on the top and bottom of the ALC board, and drill deep holes on the left and right sides of the ALC board;

[0020] S2. Roughen the top and bottom of the ALC board to form a rough surface;

[0021] S3. Hang alkali-resistant mesh cloth in front and behind the ALC board, scrape mortar on the wall to fix the mesh cloth, and apply interface agent on the surface of the ALC board;

[0022] S4, placing a concrete pad in the mold;

[0023] S5, placing the pretreated ALC board flat on the pad in the mold, and inserting the steel bars into the through holes and deep holes drilled in step S1 respectively;

[0024] S6. After closing the mold, pour concrete along the periphery of the ALC board and control the thickness of the concrete wrap to form a uniform protective layer;

[0025] S7. After construction is completed, maintenance should be carried out to reduce shrinkage and cracks of concrete and ensure the stability and durability of the structure.

[0026] In the preparation method as described above, preferably, a plurality of through holes are provided, and the plurality of through holes are provided in parallel; when the ALC plates are provided with two or more, the heights of the deep holes on the left side and the right side of each ALC plate are set to the same height, and the deep holes on the left side and the right side of two adjacent ALC plates in a straight line are inserted into connecting steel bars; and longitudinal reinforcing steel bars are tied to the connecting steel bars.

[0027] In the preparation method as described above, preferably, the depth of the deep hole is 80-150 mm; the thickness of the concrete wrap is controlled to 40-70 mm; the thickness of the ALC board is controlled to 100-120 mm to avoid the prefabricated wallboard being too thick.

[0028] In the preparation method as described above, preferably, the length of the steel bars in the through holes exposed on the ALC board surface is 20 to 30 mm; and transverse reinforcing steel bars are respectively tied to the steel bars exposed on the top and bottom.

[0029] (III) Beneficial effects

[0030] The beneficial effects of the present invention are:

[0031] The present invention provides a precast concrete wall panel based on an ALC board, which effectively improves the strength of the wall panel by arranging steel bars inside the ALC board, and effectively prevents the wall panel from being damaged by external forces by wrapping it with a concrete layer, thereby improving the durability and safety of the precast concrete wall.

[0032] The precast concrete wall panel based on the ALC board provided by the present invention can further significantly improve the bending and shearing resistance of the precast wall panel by providing reinforcing steel bars, can better cope with the stress changes caused by construction loads and foundation settlement, and reduce structural deformation; by providing a concrete layer with a thickness of 40 to 70 mm, the water absorption rate of the ALC board is significantly reduced, and the strength reduction and expansion deformation caused by moisture absorption are effectively avoided; at the same time, it can resist the erosion of moisture, saline-alkali and acidic gases, and extend the service life of the wall; the fireproof performance of the ALC board is further enhanced, so that it can be used in places with high fire protection requirements, such as fire escapes and machine rooms; the sound insulation effect is also improved, so that the precast wall panel is very suitable for use in places requiring high sound insulation standards, such as residences and conference rooms; the wall wrapped with concrete has higher nailing performance and bearing capacity, which is convenient for the installation of equipment, pipelines or hangers; at the same time, the structural damage that may be caused by directly grooving or punching on the ALC board is avoided, so the precast concrete wall panel based on the ALC board provided by the present invention greatly expands its scope of application in engineering applications. BRIEF DESCRIPTION OF THE DRAWINGS

[0033] Figure 1 This is a schematic structural diagram of a prefabricated concrete wall panel preferably based on an ALC panel according to the present invention;

[0034] Figure 2 It is a schematic structural diagram of a preferred ALC board of the present invention.

[0035] Figure 3 This is a schematic structural diagram of a preferred embodiment of the present invention based on two ALC panels prefabricated concrete wall panels;

[0036] [Description of Reference Numerals]

[0037] 1: ALC board;

[0038] 2: Steel bars;

[0039] 3: Concrete layer;

[0040] 4: Alkali-resistant mesh cloth;

[0041] 11: Rough surface;

[0042] 12: Tongue and groove;

[0043] 21: penetrating steel bars;

[0044] 22: exposed steel bars;

[0045] 23: Connecting steel bars;

[0046] 24: Strengthen the steel bars. DETAILED DESCRIPTION

[0047] The present invention provides a prefabricated concrete wall panel based on an ALC board and a preparation method thereof, so that the ALC board maintains the advantages of light weight, sound insulation and fire prevention, and at the same time, through concrete wrapping and steel reinforcement, the overall strength, impact resistance, bending resistance and durability of the wall panel are significantly improved. The technical defects of the ALC board in the prior art, such as easy damage during construction, transportation and use, insufficient impact resistance, moisture absorption deformation, difficulty in joint treatment, and inability to meet high strength and special environmental requirements, are overcome, and its application scope in engineering applications is greatly expanded.

[0048] In order to better explain the present invention and facilitate understanding, the present invention is described in detail below through specific implementation modes in conjunction with the accompanying drawings.

[0049] Example 1

[0050] This embodiment provides a prefabricated concrete wall panel based on ALC board, such as Figure 1 As shown, it includes an ALC board 1, steel bars 2 and a concrete layer 3. Among them, the ALC board 1 can be provided with one or more pieces, and the steel bars 2 are embedded in the interior of the ALC board 1 and extend vertically through the top and bottom of the ALC board 1 respectively. The steel bars 2 vertically pass through the interior of the ALC board 1 and extend out of the ALC board from the top and bottom of the ALC board 1. The length of the steel bars 2 extending out of the ALC board can be set to 25mm, which is convenient for connection with the concrete exterior wall and strengthens the integrity of the ALC board 1 and the poured concrete. The left side and right side of the ALC board 1 are also provided with a plurality of deep holes preferably extending in the horizontal direction, and the steel bars 2 are inserted into the deep holes, and the length of the steel bars exposed from the ALC board 1 is 25mm. The number of steel bars in the deep holes can be set according to the area size of the ALC board 1.

[0051] When the ALC board is set as multiple ALC boards, the height positions of the inserted steel bars on the left and right sides of the ALC board are consistent, and the connecting steel bars 23 are inserted into the deep holes on the left and right sides of the two adjacent ALC boards to connect the two adjacent ALC boards; vertical reinforcing steel bars 24 are also tied to the connecting steel bars 23 between the two ALC boards 1, that is, the connecting steel bars 23 and the vertical reinforcing steel bars 24 are arranged vertically. Furthermore, horizontal reinforcing steel bars 24 are also tied to the exposed steel bars 2 at the top and bottom of the ALC board 1, and the arrangement of the reinforcing steel bars 24 makes the concrete more secure. Such an arrangement can be applied to modular integrated structures (MiC), which can reduce weight, ensure structural stability, and reduce other risks such as cracking.

[0052] In order to precisely connect with the concrete, the top and bottom of the ALC board 1 are set as rough surfaces 11. Alkali-resistant mesh cloth 4 is hung on the front and back of the ALC board 1 and an interface agent is applied on the surface to enhance the adhesion and firmness of the ALC board 1 and the concrete. Figure 2 As shown, the top and bottom of the ALC board 1 are set as rough surfaces 11, and the length of the vertical through steel bars 21 on the top and bottom of the ALC board 1 exposed from the ALC board surface is 25 mm; the length of the exposed steel bars 22 on the left and right sides of the ALC board 1 exposed from the ALC board 1 is 25 mm. The left and right sides of the ALC board 1 are set as tongues and grooves 12; the tongue and groove 12 is specifically a groove on one side of the left and right sides of the ALC board 1, and a convex ridge adapted to the groove is provided on the other side, and the groove is clamped with the convex ridge. The tongue and groove 12 is used to strengthen the integrity between the ALC board 1 and the concrete.

[0053] The concrete layer is arranged outside the ALC board 1 to wrap the ALC board 1, and the thickness of the concrete layer can be set to 50 mm. The setting of the concrete layer plays a role in protecting the ALC board 1, enhancing the strength of the ALC board 1, and improving the durability. The thickness of the concrete layer of the prefabricated concrete wall panel based on the ALC board is set to 40 to 70 mm, so that the ALC board maintains the advantages of light weight, sound insulation and fire prevention, while significantly improving the overall strength, impact resistance, bending resistance and durability of the wall panel through the reinforcement of concrete and wrapped steel bars.

[0054] Example 2

[0055] This embodiment provides a method for preparing a prefabricated concrete wall panel based on an ALC panel, which comprises the following steps:

[0056] S1. Drill vertical through holes at the top and bottom of the ALC board, which are used to insert through steel bars; drill deep holes on the left and right sides of the ALC board to facilitate the insertion of steel bars and the pouring of concrete. When there are multiple ALC boards, the height of the deep holes on the left and right sides is set to the same height; they are used to insert connecting steel bars to firmly connect two adjacent ALC boards;

[0057] S2. The top and bottom of the ALC board are roughened to form a rough surface to enhance the bonding strength with the subsequent pouring of concrete;

[0058] S3. Alkali-resistant mesh cloth is hung in front and behind the ALC board, and mortar is scraped on the wall to fix the alkali-resistant mesh cloth. At the same time, an interface agent is applied on the surface of the ALC board to improve the bonding strength between the concrete and the ALC board; the interface agent can be a commercially available product;

[0059] S4. Place a concrete pad with a thickness of 50 mm in the mold; the concrete pad is used to support the ALC board to facilitate concrete pouring;

[0060] S5, such as Figure 2 and Figure 3 As shown, the pretreated ALC board is placed flat on the pad of the mold, and the through steel bars 21 are inserted into the through holes drilled at the top and bottom in step S1, and the exposed steel bars 22 on the left and right sides are inserted into the deep holes. The steel bars are used to strengthen the mechanical properties of the plate.

[0061] When multiple ALC panels are provided, a connecting steel bar 23 is inserted into the deep hole between two adjacent ALC panels, and two longitudinal steel bars are tied to the connecting steel bars as reinforcing steel bars 24, and transverse steel bars are tied to the exposed through steel bars at the top and bottom of the ALC panels as reinforcing steel bars 24; wherein the mold is such that after pouring concrete, the ALC panels are wrapped, and the thickness of the formed concrete layer is 50 mm; the length of the steel bars exposed from the ALC panel surface is 25 mm;

[0062] S6. After closing the mold, pour concrete around the ALC board and control the concrete wrapping thickness to 50mm to form a uniform protective layer;

[0063] S7. After the construction is completed, proper maintenance should be carried out, i.e. watering should be carried out every 4 to 6 hours and the maintenance period should be 7 days to reduce the shrinkage and cracks of the concrete and ensure the stability and durability of the structure.

[0064] Compared with the prior art, the prefabricated wallboard prepared in the above embodiment has the following advantages:

[0065] (1) Adding through steel bars inside the ALC slab can effectively improve the strength of the slab, while pouring concrete further improves the overall stability and bearing capacity of the wall, making it more adaptable to complex engineering environments.

[0066] (2) Concrete has high compressive and impact resistance. By wrapping the ALC board with concrete, it can effectively prevent it from being damaged by external forces, thereby improving the durability and safety of the wall.

[0067] (3) After pouring concrete, the bending and shear resistance of precast wall panels are significantly improved, which can better cope with the stress changes caused by construction loads and foundation settlement and reduce structural deformation.

[0068] (4) Concrete wrapping can significantly reduce the water absorption rate of ALC boards, effectively avoiding the strength loss and expansion deformation caused by moisture absorption. At the same time, concrete can resist the erosion of moisture, salinity and acidic gases, thereby extending the service life of the wall.

[0069] (5) The high fire resistance of concrete further enhances the fire resistance of ALC boards, making them particularly suitable for places with high fire protection requirements, such as fire passages and machine rooms, providing higher safety protection for the walls.

[0070] (6) After pouring concrete, the density of the precast wall panels increases, which can significantly reduce the propagation of airborne sound and improve the sound insulation effect. This makes precast wall panels very suitable for use in places that require high sound insulation standards, such as residences and conference rooms.

[0071] (7) The wall wrapped with concrete has higher nail hanging performance and bearing capacity, which is convenient for the installation of equipment, pipelines or hanging parts. At the same time, it avoids the structural damage that may be caused by directly grooving or drilling on the ALC board.

[0072] The above is only a preferred embodiment of the present invention, and does not limit the present invention in other forms. Any person skilled in the art can use the above disclosed technical content to change or modify it into an equivalent embodiment with equivalent changes. However, any simple modification, equivalent change and modification made to the above embodiment according to the technical essence of the present invention without departing from the technical solution of the present invention still belongs to the protection scope of the technical solution of the present invention.

Claims

1. A prefabricated concrete wall panel based on ALC board, characterized in that: It includes an ALC board, multiple steel bars and a concrete layer, wherein the steel bars are embedded in the interior of the ALC board and vertically penetrate the top and bottom of the ALC board respectively, the top and bottom of the ALC board are set as rough surfaces, the left side and right side of the ALC board are respectively provided with multiple deep holes, and the steel bars are inserted into the deep holes; and the left side and right side of the ALC board are also provided with tongue and groove; the concrete layer is arranged on the outside of the ALC board and wraps the ALC board.

2. The precast concrete wall panel according to claim 1, characterized in that: Both ends of the steel bars passing through the top and bottom of the ALC board are exposed from the ALC board surface, and the length of the steel bars exposed from the ALC board surface is 20 to 30 mm.

3. The precast concrete wall panel according to claim 1, characterized in that: All the steel bars penetrating the top and bottom of the ALC plate are arranged in parallel, and the steel bars in the deep holes are arranged in parallel; the depth of the deep holes is 80-150 mm, and the spacing is 180-220 mm.

4. The precast concrete wall panel according to claim 1, characterized in that: When the ALC board is provided with two or more pieces, it also includes connecting steel bars and reinforcing steel bars. The connecting steel bars are used to connect the left and right sides of two adjacent ALC boards, and the reinforcing steel bars are vertically connected to the connecting steel bars. At the same time, transverse reinforcing steel bars are tied to the exposed steel bars at the top and bottom.

5. The precast concrete wall panel according to claim 1, characterized in that: Alkali-resistant mesh cloths are hung on the front and rear panels of the ALC board.

6. The precast concrete wall panel according to claim 1, characterized in that: The thickness of the concrete layer wrapping the ALC board is 40-70 mm; the tongue and groove is a groove on one side of the left and right sides of the ALC board, and a raised edge matching the groove is provided on the other side, and the groove is snap-fitted with the raised edge.

7. A method for preparing a prefabricated concrete wall panel based on an ALC panel, comprising the following steps: S1. Drill vertical through holes on the top and bottom of the ALC board, and drill deep holes on the left and right sides of the ALC board; S2. Roughen the top and bottom of the ALC board to form a rough surface; S3. Hang alkali-resistant mesh cloth in front and behind the ALC board, scrape mortar on the wall to fix the mesh cloth, and apply interface agent on the surface of the ALC board; S4, placing a concrete pad in the mold; S5, placing the pretreated ALC board flat on the pad in the mold, and inserting the steel bars into the through holes and deep holes drilled in step S1 respectively; S6. After closing the mold, pour concrete along the periphery of the ALC board and control the thickness of the concrete wrap to form a uniform protective layer; S7. After construction is completed, maintenance should be carried out to reduce shrinkage and cracks of concrete and ensure the stability and durability of the structure.

8. The preparation method according to claim 7, characterized in that: A plurality of through holes are provided, and the plurality of through holes are provided in parallel; when two or more ALC plates are provided, the heights of the deep holes on the left side and the right side of each ALC plate are set to be the same height; connecting steel bars are inserted into the deep holes on the left side and the right side of two adjacent ALC plates in a straight line; and longitudinal reinforcing steel bars are tied to the connecting steel bars.

9. The preparation method according to claim 7, characterized in that: The depth of the deep hole is 80-150 mm; the thickness of the concrete wrapping is controlled to be 40-70 mm; and the thickness of the ALC board is controlled to be 100-120 mm.

10. The preparation method according to claim 7, characterized in that: The length of the steel bars in the through hole exposed on the ALC plate surface is 20 to 30 mm; and transverse reinforcing steel bars are respectively tied to the steel bars exposed on the top and bottom.

Images