Cast-in-place and reverse-hitting integrated forming construction method for outer wall stone

Abstract

The invention discloses an outer wall stone cast-in-place reverse-hitting integrated forming construction method which comprises the following steps: S1, deepening design: deepening design of a typified template, deepening design of stone and deepening design of stone repair to obtain a deepening design drawing; s2, performing construction preparation based on the deepened design drawing; s3, a shaping formwork is installed; S4, stone is laid on the outer side steel formwork; s5, stainless steel drag hooks and pointing joints are installed on the stone; s6, performing alkali-proof and waterproof treatment on the stone; s7, wall body outer side reinforcing steel bars are installed on the stone integrated formwork; s8, after the outer side steel mold is hoisted, wall body inner side steel bars are installed; and S9, the inner side steel mold is hoisted, and concrete is poured.

Description

Technical Field

[0001] The invention relates to the technical field of exterior wall decorative stone construction, and in particular to an exterior wall stone cast-in-place reverse-beating integrated molding construction method. Background Art

[0002] The construction process of traditional exterior wall decorative stone is divided into wet pasting and dry hanging. When wet pasting is used to paste stone, excessive temperature changes may affect the bonding strength between the stone and the substrate. Thermal expansion and thermal contraction may cause the bonding strength between the adhesive or adhesive material and the stone to weaken, thereby affecting the stability and durability of the stone. When dry hanging is used to hang stone, the corrosive substances such as chloride contained in the salt spray will cause corrosion on the surface of the metal profile. Corrosion will cause rust and corrosion on the metal surface, and may even cause partial damage to the metal profile and gradually lose a certain strength, thereby weakening the structural performance of the metal pendant and reducing its bearing capacity and durability. When the stone resists external impact or attack, its bonding strength is one of the key indicators of its impact resistance. Both processes of the prior art have the disadvantages of difficult quality control, high safety risks of high-altitude operations, long construction period, and high cost. Summary of the invention

[0003] The object of the present invention is to provide a construction method for cast-in-place counter-beating integrated molding of exterior wall stones to solve the problems raised in the above-mentioned background technology.

[0004] To achieve the above object, the present invention provides a method for cast-in-place integrated forming of exterior wall stone, comprising the following steps: S1. Deepening design, including: deepening design of finalized template, deepening design of stone and deepening design of stone repair, and obtaining deepening design drawings; S2. Carry out construction preparation based on the detailed design drawings; S3, installing the finalized template; S4, laying stone on the outer steel formwork; S5, stainless steel hooks and joints for stone installation; S6. Alkali and water-proof treatment of stone; S7, stone integrated formwork to install the outer wall reinforcement; S8. Install the inner steel bars of the wall after hoisting the outer steel formwork; S9. Hoist the inner steel formwork and pour concrete.

[0005] In a preferred embodiment, in step S1, the detailed design of the finalized template includes: S11. Deepening design of large steel formwork: S111. Formwork body design: The large steel formwork includes an inner steel formwork and an outer steel formwork. The outer steel formwork adopts a structure of steel plate plus backing ribs. Anchor ribs are provided on the outer steel formwork surface according to the designed pattern of the stone to install the stone; S112. Conduct comprehensive calculations based on the shape and size of the formwork body design, the weight of the exterior wall stone, and the lateral pressure of the cast-in-place concrete to confirm the formwork frame material, steel plate thickness, position and size of the backing ribs, and the number of bolts and fasteners for template connection; S113. Determine the rib width of the outer steel formwork according to the designed pattern of the exterior wall stone and the plate joint width. The rib height is 1 / 2 of the stone thickness; S114. Determine the anchoring method of the ribs according to the weight of the stone after calculation. S12. Deepening design of nodes such as door and window openings and exterior wall internal and external corners: The door and window opening formwork is designed with a fixed-size formwork frame according to the designed size. The formwork frame uses profiled steel as a support, and multiple groups of horizontal supports are designed inside the formwork frame. The door frame formwork and the window frame formwork are respectively bolted to the large steel formwork. When designing the outer steel formwork, a strengthening steel beam should be set at the door and window openings for bolted fixation of the door frame formwork and the window frame formwork. The door frame formwork and the window frame formwork are set at the center position of the whole large steel formwork; The internal corner formwork and the external corner formwork are designed as an integral structure with a corner length greater than the length of the whole stone, and a triangular profiled steel support is provided on the back of the external corner formwork. S13. Deepening design of supports and anchors: At least two external supports should be set on the outside of each large steel formwork. To prevent the external supports of the internal corner formwork from crossing and colliding, the external supports at the corners of the internal corner formwork should preferably be set in a Y shape, and lifting rings should be designed and installed at the top of the large steel formwork. Determine the size and number of through-wall screws according to the shape and size of the formwork body design, the weight of the exterior wall stone, and the lateral pressure of the cast-in-place concrete.

[0006] In a preferred embodiment, the deepening design of the stone includes: According to the decorative requirements of the exterior wall facing stone and the situation of the fixed-form template, conduct deepening design on stones at different positions and colors, including the elevation layout of the stone, the horizontal and vertical joints within a single large steel formwork, the joint treatment at the junction of two large steel formworks, the treatment method of internal and external corner stones, and the position and number of stainless steel hook connections; The deepening design of stone repair includes: Conduct deepening design on the position and number of anchoring holes on the stone, the stone strength, and the hanging force of the stainless steel bolts. Among them, according to the ultimate pull-out bearing capacity of the test section, determine the position and number of anchoring holes on the stone.

[0007] In a preferred embodiment, in step S3, installing the fixed-form template includes the following steps: S31. Pre-lay and pre-assemble the large steel formwork according to the designed size of the fixed-form template. Among them, multiple vertical beams are evenly spaced on one side of the outer steel formwork surface, multiple cross beams perpendicular to the vertical beams are provided on one side of the vertical beams, and multiple ribs are spaced on the other side of the outer steel formwork surface. S32, installation of connecting bolts, buckles and external supports between large steel molds; S33. Level the large steel formwork and reinforce it while leveling until it is horizontal, vertical and tight; S34, install the door and window opening templates and level the door and window opening templates; S35. Install a triangular steel support on the back of the external angle formwork, and set a Y-shaped external support at the corner of the internal angle formwork.

[0008] In a preferred embodiment, in step S4, the outer steel mold is used to lay stones, including: numbering the stones on the detailed design drawings according to their size and design style and the size of the finalized template, temporarily placing the stones on the ribs of the outer steel mold according to the layout numbers of the detailed design drawings, the rib width being consistent with the horizontal design seam width of the stones, and controlling the vertical seam width according to the design requirements when placing the stones.

[0009] In a preferred embodiment, in step S5, stainless steel hooks and grouting are installed on the stone, including: using weather-resistant structural adhesive to install the stainless steel hooks one by one into the holes reserved in the stone, and making the upper and lower adjacent stainless steel hooks of each stone bend in a Y-shape, and temporarily blocking the holes reserved on the stone ribs with foam columns, and then grouting is performed, the foam columns are taken out before the grouting agent solidifies, and stainless steel wire is passed through the holes reserved on the ribs for tying the steel mesh, wherein at least one pair of stainless steel hooks is set for each stone within 20 cm in width, and at least two pairs of stainless steel hooks are set for each stone above 20 cm, and the stainless steel hooks are set at a distance of 5 cm from the edge of the stone.

[0010] In a preferred embodiment, in step S6, the stone is treated with alkali-proof and waterproof treatment, including: applying alkali-proof back coating and waterproof coating to the back of the stone after the grout is dried; in step S7, the stone integrated formwork is used to install the steel bars on the outside of the wall, including: removing the foam columns filling the through-wall holes before the waterproof coating and the alkali-proof back coating are dried, and after drying, the protective layer pads and the steel mesh on the outside of the wall are installed through the holes reserved on the ribs to temporarily fix the stone. When tying the steel mesh on the outside of the wall, the position of the steel bars should avoid the through-wall bolt holes reserved on the large steel formwork, and the tying points should be tied firmly point by point.

[0011] In a preferred embodiment, in step S8, after hoisting the outer steel formwork, the inner wall steel bars are installed, including: cleaning the upper surface of the lower stone, and pasting a sponge strip to prevent the cast-in-place concrete slurry from leaking and contaminating the lower stone, the thickness of the sponge strip is more than 2 cm, the stone integrated formwork is hoisted to the construction position, and fixed with a support leg, the inner wall steel mesh and protective layer pads are installed after the outer steel formwork is temporarily fixed, and the inner steel mesh is fixed with a temporary support, and after fixing, pre-buried pipelines are reserved to the inner wall steel mesh.

[0012] In a preferred embodiment, in step S9, hoist the inner steel formwork and pour concrete, including: S91. Hoist the inner steel formwork: Hoist the inner steel formwork to the construction position, use a jack to adjust the verticality of the formwork and install the inner support and final fixed feet of the formwork, install the wall-through screw rod, and connect the inner steel formwork and the outer steel formwork through the wall-through screw rod to complete the formwork closing; S92. Concrete pouring: Use the wall-through screw rod to temporarily fix the stone to the outer steel formwork, add air-entraining agent and pumping agent and other admixtures to the ready-mixed concrete, control the slump at 160±20mm, adopt the conduit method for pouring, and the vibration time is 15-20s; S93. Concrete formwork removal: Remove the formwork 24 hours after the concrete is poured. After the formwork is removed, cut off the stainless steel wires for temporarily fixing the stone and the thermal insulation material and then carry out the caulking operation; S94. Waterproof treatment of the wall bolt holes: After the formwork is removed, use a water-swellable leak stoppage material to fill it to the center of the wall. The leak stoppage material extends 5 cm outward from the center line of the wall. Use waterproof cement mortar to seal the outer edge of the hole to the leak stoppage material to densely fill the wall-through screw rod holes and then carry out the caulking treatment.

[0013] In a preferred embodiment, it further includes: step S10. Repair of the exterior wall facing stone: Use a special adhesive for the facing stone to paste the repair stone to the repair position and carry out maintenance. After the adhesive reaches the design strength, drill holes perpendicular to the concrete base at the position of the anchor holes of the facing stone and place stainless steel expansion bolts to fix the stone again. After the stainless steel expansion bolts are placed, paste the repair stone cover on the bolt cap to beautify the repair stone. The repair stone cover is a nut-shaped structure processed from the same batch of stone as the facing stone.

[0014] Compared with the prior art, the beneficial effects of the present invention are: The construction method of integrally casting the exterior wall decorative stone of the present invention is to first lay the finished exterior wall stone on the sizing template. After fixing the stone, installing stainless steel hooks on the stone, and performing alkali-resistant and waterproof treatment, the steel mesh on the outer side of the wall is directly fixed on the outer steel formwork. After passing the acceptance, the outer steel formwork is hoisted to the working surface and the steel mesh and the inner steel formwork on the inner side of the wall are installed. Thus, the conditions for integrally casting the exterior wall decorative stone and the structure are met. This method enables the exterior wall decorative stone and the steel bars on the outer side of the wall to be directly installed in place on the ground. The facing stone is fixed to the concrete through stainless steel hooks, greatly reducing the high-altitude operation time, ensuring the overall quality, and improving the operation efficiency. The stone is integrally cast with the concrete through stainless steel hooks, so the risks of hollowing and falling caused by temperature difference are reduced, the erosion damage of the salt spray environment to the profiles is reduced, and the anti-striking ability of the stone is enhanced. Compared with the traditional dry hanging method, it can reduce the construction cost and speed up the construction progress. Compared with the traditional wet pasting method, it can completely solve the quality problem of hollowing and falling, and can also reduce the construction cost and speed up the construction progress. The raw materials used in the present invention are all concentrated in the factory production, reducing the on-site secondary processing operations, realizing the standardization of construction production, reducing the construction noise, reducing the generation of waste and construction dust, and reducing the environmental pollution. BRIEF DESCRIPTION OF THE DRAWINGS

[0015] Figure 1 It is a schematic flow chart of the construction method of the present invention; Figure 2 It is a schematic diagram of the sizing template of the present invention; Figure 3A It is a schematic diagram of the structure of the outer steel formwork of the present invention; Figure 3B It is a schematic diagram of the cross-sectional node of the outer steel formwork of the present invention; Figure 4A It is a three-dimensional schematic diagram of the door opening template of the present invention; Figure 4B It is a sectional view of the door opening template of the present invention; Figure 5A It is a three-dimensional schematic diagram of the window opening template of the present invention Figure 5B It is a sectional view of the window opening template of the present invention; Figure 6 It is a schematic diagram of the external corner template of the present invention; Figure 7 It is a schematic diagram of the external support setting of the present invention; Figure 8 It is a schematic diagram of the arrangement of the wall-piercing screw rods of the present invention; Figure 9 It is a schematic diagram of laying the stone on the outer steel formwork of the present invention; Figure 10 It is a schematic diagram of setting the stainless steel hooks on the stone of the present invention; Figure 11 Schematic diagram of drilling holes in the repaired stone material of the present invention; Figure 12 Schematic sectional view of the repaired stone material of the present invention. Specific implementation manner

[0016] Next, the technical solutions in the embodiments of the present invention will be described clearly and completely. For the embodiments of the present invention, all other embodiments obtained by those of ordinary skill in the art without creative efforts shall fall within the protection scope of the present invention.

[0017] Taking a certain actual project as an example, the project is 10 high-rise residential buildings with a cast-in-place shear wall structure. The total above-ground building area is 52,610 ㎡ on 7 floors, and the building eaves height is 31.5 meters. The construction area of the exterior wall stone is 21,834 ㎡. The thickness of the base concrete structure wall is not less than 150 mm, the thickness of the facing stone is not less than 25 mm, the flexural strength is not less than 8.0 MPa, and the designed horizontal joint is greater than 1 cm.

[0018] As Figures 1 to 12 shown, the construction method for integral casting-in-place and reverse casting of exterior wall stone in the preferred embodiment of the present invention includes the following steps: Step S1, detailed design, including: 1. Detailed design of the sizing formwork: The sizing formwork is deeply designed in combination with the decorative requirements of the exterior wall stone and the requirements of the structural construction organization. The detailed design needs to focus on the division, joint, size of the sizing steel formwork, treatment of the formwork at the door and window openings, treatment of the formwork at the internal and external corners, anchor and connection, support and fixation, layout of the through-wall screw rods, etc. Specifically, the detailed design of the sizing formwork 201 includes: Step S11. Deepening design of large steel formwork: Step S111. Formwork body design: The large steel formwork includes an inner steel formwork and an outer steel formwork 301. The outer steel formwork 301 adopts a structure of steel plate plus backing ribs. The outer steel formwork surface 311 is provided with anchoring rib ribs 312 for installing stone materials according to the designed pattern of the stone materials. A plurality of vertical beams 313 are installed on one side of the outer steel formwork surface 311, and a plurality of cross beams 314 are installed on one side of the vertical beams 313. Moreover, a plurality of supporting feet 315 are arranged on one side of the vertical beams 313. The inner steel formwork is the same as the ordinary steel formwork; Step S112. To prevent the large formwork from deforming, comprehensive calculations are carried out according to the shape and size of the formwork body design, the weight of the exterior wall stone materials, and the lateral pressure of the cast-in-place concrete to confirm the formwork frame material, steel plate thickness, position and size of the backing ribs, and the number of bolts and fasteners for formwork connection; Step S113. Determine the rib width of the outer steel formwork according to the designed pattern of the exterior wall stone materials and the joint width. The rib height is 1 / 2 of the stone material thickness; Step S114. Determine the anchoring method of the ribs according to the weight of the stone materials, which should be able to bear the self-weight of the stone materials. For temporarily fixing the stone materials and placing the through-wall screws, holes should be reserved on the ribs for passing through stainless steel wires and through-wall screws.

[0019] Step S12. Deepening design of nodes such as door and window openings and exterior wall internal and external corners: The door opening formwork 401 and the window opening formwork 402 are both designed with customized formwork frames according to the designed dimensions. The formwork frames use profiled steel as supports, and their materials should be calculated according to the lateral pressure of the cast-in-place concrete. Multiple groups of horizontal supports 411 are designed inside the formwork frames. The door frame formwork 412 and the window frame formwork 413 are respectively connected to the large steel formwork 414 by bolts 415. When designing the outer steel formwork, strengthening steel beams should be set at the door and window openings for bolt connection and fixing of the door frame formwork and the window frame formwork. Moreover, the door frame formwork and the window frame formwork are arranged at the center position of the whole large steel formwork. To facilitate formwork removal, the angle between the opening formwork and the large steel formwork should be greater than 5°. The internal corner formwork and the external corner formwork are designed as an integral structure with a corner length greater than the length of the whole stone material. Moreover, triangular profiled steel supports 601 are arranged on the back of the external corner formwork, and the internal corner formwork is designed with densified external supports.

[0020] Step S13: Detailed design of supports and anchors: When designing the support positions and fixing methods, the positions of the planar supports, the support positions at the internal and external corners, and the positions of the wall-through bolts should be considered according to the formwork shape, formwork size, and formwork body stiffness. The material of the support should have sufficient stiffness and adjustable length, and the support positions should ensure the stability of the formwork system. At least two external supports should be set on the outside of each large steel formwork. To prevent the external supports of the internal corner formwork from colliding with each other, the external support 701 at the internal corner of the formwork is preferably set in a Y shape, and a lifting ring 416 should be designed and installed at the top of the large steel formwork 414. When designing the lifting ring 416, the overall weight of the formwork should be considered, and a certain safety redundancy should be considered. Determine the size and quantity of the wall-through bolts according to the shape and size designed for the formwork body, the weight of the external wall stone, and the lateral pressure of the cast-in-place concrete. The connection between the steel formworks can adopt connection methods such as high-strength bolts or fastener connections.

[0021] 2. Detailed design of the stone materials, including: According to the decorative requirements of the external wall finishing stone materials and the situation of the fixed-form templates, conduct a detailed design of the stone materials in different positions and colors, including the vertical layout of the stone materials, the horizontal and vertical joints within a single large steel formwork, the joint treatment at the intersection of two large steel formworks, the treatment method of the internal and external corner stones, and the connection positions and quantities of the stainless steel hooks.

[0022] 3. Detailed design of stone repair, including: Conduct a detailed design of the positions and quantities of the anchoring holes on the stone materials, the strength of the stone materials, and the hanging force of the stainless steel bolts. Among them, determine the positions and quantities of the anchoring holes on the stone materials according to the ultimate pull-out bearing capacity of the test section. After pasting the finishing stone materials with a special stone adhesive, use stainless steel expansion bolts to penetrate the finishing stone materials and implant them into the concrete for secondary fixation. The anchoring holes are beautified with repair stone covers processed from the same batch of stone materials as the finishing stone materials and having the same size as the nuts. Through strengthening the detailed design, the present invention maximally adopts the fixed-form templates, sized stone materials, and sized steel bar meshes processed in the factory, greatly reducing the on-site secondary processing time, significantly improving the operation efficiency, and shortening the construction period.

[0023] Step S2: Based on the detailed design drawings, carry out construction preparations.

[0024] Step S3: Install the fixed-form templates: After the materials arrive at the site, install the templates according to the numbers in the detailed design drawings in the designated area of the site. During installation, it is necessary to ensure the surface flatness of the templates, the dimensions and positions of the ribs, the anchoring force, the anchoring and positions of the door and window opening templates, the tightening degree of the connection bolts, the adjustment distance and locking force of the support feet. Conduct acceptance one by one after installation, and only put them into use after passing the inspection.

[0025] Specifically, it includes the following steps: Step S30: Use concrete to harden and level the site, or directly operate on the lower-layer concrete roof slab, and draw a flatness control ink line on the site / lower-layer concrete roof slab; Step S31, pre-laying and pre-assembling a large steel formwork (laid flat on the ground) according to the designed size of the fixed formwork, wherein a plurality of vertical beams 313 are evenly spaced on one side of the outer steel formwork surface, a plurality of horizontal beams 314 perpendicular to the vertical beams are disposed on one side of the vertical beams, and a plurality of ribs are spaced on the other side of the outer steel formwork surface; Step S32, installing connecting bolts, buckles and external supports between large steel molds; Step S33, leveling the large steel mold, and reinforcing it while leveling until it is horizontal, vertical and tight; Step S34, installing the door and window opening templates and leveling the door and window opening templates; Step S35: install a triangular steel support on the back of the external angle template, and set a Y-shaped external support 701 at the corner of the internal angle template.

[0026] Step S4, laying stones on the outer steel formwork: number the stones on the detailed design drawing according to their size and design style as well as the size of the finalized formwork, and temporarily place the stones 801 on the ribs of the outer steel formwork 301 according to the layout number of the detailed design drawing. The rib width is consistent with the horizontal design seam width of the stones, and the vertical seam width is controlled according to the design requirements when placing the stones. If there are special grouting requirements in the design, they should be performed after the stainless steel hooks are installed.

[0027] Step S5, installing stainless steel hooks and grouting on the stone: Use weather-resistant structural adhesive to install stainless steel hooks 901 one by one into the reserved holes of the stone, and make the upper and lower adjacent stainless steel hooks of each stone bend in a Y-shape, and temporarily block the reserved holes on the stone ribs with foam columns, and then perform grouting. Take out the foam columns before the grouting agent solidifies, and use stainless steel wire to pass through the reserved holes on the ribs for tying the steel mesh, and do not process the holes for the through-wall screws. Preferably, at least one pair of stainless steel hooks 901 is set for each stone within 20 cm in width, and at least two pairs of stainless steel hooks 901 are set for each stone over 20 cm in width. The stainless steel hooks 901 are set at a distance of 5 cm from the edge of the stone, and the stainless steel hooks extend to the outer part of the stone in an L-shape. The diameter of the stainless steel hooks is 3 mm. The stone 801 is fixed to the concrete by the stainless steel hook 901, which greatly reduces the time of high-altitude operation and ensures the overall quality. The stone is cast and formed at one time by the stainless steel hook and concrete, which improves the operation efficiency.

[0028] Step S6, anti-alkali and waterproof treatment of stone: after the grout is dry, apply anti-alkali back coating and waterproof coating to the back of the stone.

[0029] Step S7. Install the outer wall steel bars of the stone integrated formwork: Remove the foam columns filling the through-wall holes before the waterproof coating and alkali-resistant back coating dry. After drying, install the protective layer pads and the outer wall steel bar mesh 802 through the holes reserved on the rib strips to temporarily fix the stone. When binding the outer wall steel bar mesh, the positions of the steel bars should avoid the through-wall bolt holes reserved on the large steel formwork, and the binding points should be firmly bound one by one.

[0030] Step S8. Install the inner wall steel bars after hoisting the outer steel formwork: Clean the upper surface of the lower layer of stone, and paste a sponge strip to prevent the leakage of cast-in-place concrete slurry from polluting the lower layer of stone. The thickness of the sponge strip is more than 2 cm. Hoist the stone integrated formwork to the construction position and fix it with a support foot. After temporarily fixing the outer steel formwork, install the inner wall steel bar mesh and the protective layer pads, and use temporary supports to fix the inner steel bar mesh. After fixing, reserve and embed the pipeline on the inner wall steel bar mesh.

[0031] Step S9. Hoist the inner steel formwork and pour concrete. Specifically, it includes: Step S91. Hoist the inner steel formwork: Hoist the inner steel formwork to the construction position, use a jack to adjust the verticality of the formwork and install the inner support of the formwork and the final fixed support foot. Install the through-wall screw 803, and connect the inner steel formwork and the outer steel formwork through the through-wall screw 803 to complete the formwork closing.

[0032] Step S92. Concrete pouring: Use the through-wall screw 803 to temporarily fix the stone 801 to the outer steel formwork. To prevent the deformation and falling off of the stone caused by excessive vibration during pouring, it is necessary to shorten the free fall height of the concrete, shorten the vibration time and vibration intensity. Add air-entraining agents and pumping agents and other admixtures to the ready-mixed concrete, control the slump at 160±20 mm, adopt the duct method for pouring, and the vibration time is 15-20 s.

[0033] Step S93. Concrete formwork removal: Remove the formwork 24 hours after concrete pouring. After formwork removal, cut off the stainless steel wires temporarily fixing the stone and the thermal insulation material and then carry out the caulking operation.

[0034] Step S94. Waterproof treatment of the outer wall bolt holes: After formwork removal, use water-swellable plugging materials to fill to the center of the wall, and the plugging materials extend 5 cm outward from the center line of the wall. Use waterproof cement mortar to seal the outer edge of the hole to the plugging materials to densely fill the through-wall screw holes and then carry out the caulking treatment.

[0035] Step S10: Remove the stones to be replaced. After cleaning the base concrete, perform waterproof and alkali-proof treatment. Conduct exterior wall facing stone repair: First, remove the stones to be replaced. After cleaning the base concrete, perform waterproof and alkali-proof treatment. Use a special adhesive for facing stones to paste the repair stone 1001 to the repair position and cure it. After the adhesive reaches the design strength, drill holes perpendicular to the concrete base at the position of the anchor holes 1002 of the repair stone 1001, and place stainless steel expansion bolts 1003 to fix the stone again. After placing the stainless steel expansion bolts 1003, paste the repair stone cover 1004 on the bolt cap of the stainless steel expansion bolt to beautify the repair stone. Among them, the repair stone cover 1004 is a nut-shaped structure processed from the same batch of stones as the facing stones.

[0036] The present invention can reduce the construction procedures, reduce the input of workers, lower the safety risks and reduce material waste, etc. under the premise of ensuring the construction quality. The integral pouring construction method for exterior wall stones is more suitable for large-area exterior wall stone paving projects because it requires customized large steel molds. Table 1 makes a comparative analysis of the costs of the traditional construction process and the construction method of the present invention. Taking the construction of 10,000 ㎡ according to the Beijing quota as an example, the conclusions are as follows: Table 1 Benefit Statistics Table Compared with the two traditional methods of wet pasting and dry hanging, the integral molding construction method of the present invention can save about 11% and 37% respectively for every 10,000 square meters, that is, save 255,686 yuan per 10,000 square meters and 1,327,421 yuan per 10,000 square meters respectively, which can significantly improve the economic benefits.

[0037] Although the embodiments of the present invention have been shown and described, for those of ordinary skill in the art, it can be understood that various changes, modifications, substitutions and variations can be made to these embodiments without departing from the principle and spirit of the present invention. The scope of the present invention is defined by the appended claims and their equivalents.

Claims

1. A method for cast-in-place counter-beating integrated molding of exterior wall stone, characterized in that: The steps include: S1. Deepening design, including: deepening design of finalized template, deepening design of stone and deepening design of stone repair, and obtaining deepening design drawings; S2. Carry out construction preparation based on the detailed design drawings; S3, installing the finalized template; S4, laying stone on the outer steel formwork; S5. Install stainless steel hooks and grouts on stone; S6. Alkali and water-proof treatment of stone; S7, stone integrated formwork to install the outer reinforcement of the wall; S8. Install the inner steel bars of the wall after hoisting the outer steel formwork; S9. Hoist the inner steel formwork and pour concrete.

2. The exterior wall stone cast-in-place integrated molding construction method according to claim 1 is characterized by: In step S1, the finalized template is further designed, including: S11. In-depth design of large steel formwork: S111. Formwork design: The large steel formwork includes inner steel formwork and outer steel formwork. The outer steel formwork adopts steel plate plus back rib structure. The outer steel formwork surface is anchored with ribs according to the design style of the stone to install the stone; S112. According to the shape and size of the formwork design, the weight of the external wall stone and the lateral pressure of cast-in-place concrete, comprehensive calculation is carried out to confirm the formwork material, steel plate thickness, back rib position and size, and the number of bolts and fasteners for formwork connection; S113. According to the design style of the external wall stone and the width of the plate seam, the rib width of the outer steel formwork is determined, and the rib height is 1 / 2 of the stone thickness; S114. According to the weight of the stone, the anchoring method of the rib is determined after calculation; S12. Detailed design of nodes such as door and window openings and external wall corners: The door and window opening templates are designed with fixed-size template frames according to the design dimensions. The template frames are supported by steel sections. Multiple sets of horizontal supports are designed inside the template frames. The door frame templates and window frame templates are bolted to the large steel templates. When designing the outer steel templates, reinforced steel beams should be set at the door and window openings to bolt and fix the door frame templates and window frame templates. The door frame templates and window frame templates are set at the center of the entire large steel template. The internal angle template and external angle template are designed as an integrated structure with the large steel template. The corner length is greater than the length of the entire stone, and a triangular steel support is set on the back of the external angle template. S13. In-depth design of supports and anchors: at least two external supports shall be set on the outside of each large steel formwork. To prevent cross-collision of the external supports of the internal angle formwork, the external supports at the corners of the internal angle formwork shall be set in a Y-shape, and a lifting ring shall be designed and installed on the top of the large steel formwork. The size and number of the through-wall screws shall be determined according to the shape and size of the formwork design, the weight of the external wall stone and the lateral pressure of the cast-in-place concrete.

3. The exterior wall stone cast-in-place integrated molding construction method according to claim 2 is characterized by: The in-depth design of stone includes: in-depth design of stones in different positions and colors according to the requirements of exterior wall facing stone decoration and the situation of finalized templates, including the facade layout of stone, the horizontal and vertical joints in a single large steel mold, the joint treatment at the junction of two large steel molds, the treatment of corner stones, and the position and number of stainless steel hook connections; the in-depth design of stone repair includes: in-depth design of the position and number of anchor holes on the stone, the strength of the stone, and the hanging strength of the stainless steel bolts, among which the position and number of anchor holes on the stone are determined according to the ultimate pull-out bearing capacity of the test section.

4. The exterior wall stone cast-in-place integrated molding construction method according to claim 3 is characterized by: In step S3, the finalized template is installed, including the following steps: S31. Pre-laying and pre-assembling a large steel formwork according to the designed size of the standard formwork, wherein a plurality of vertical beams are evenly spaced on one side of the outer steel formwork surface, a plurality of horizontal beams perpendicular to the vertical beams are arranged on one side of the vertical beams, and a plurality of ribs are spaced on the other side of the outer steel formwork surface; S32, installation of connecting bolts, buckles and external supports between large steel molds; S33. Level the large steel mold and reinforce it while leveling until it is horizontal, vertical and tight; S34, install the door and window opening templates and level the door and window opening templates; S35. Install a triangular steel support on the back of the external angle formwork, and set a Y-shaped external support at the corner of the internal angle formwork.

5. The exterior wall stone cast-in-place integrated molding construction method according to claim 4 is characterized by: In step S4, the outer steel formwork is used to lay stones, including: numbering the stones on the detailed design drawings according to their sizes and design styles as well as the sizes of the finalized templates, temporarily placing the stones on the ribs of the outer steel formwork according to the layout numbers of the detailed design drawings, the rib width being consistent with the horizontal design seam width of the stones, and the vertical seam width being controlled according to the design requirements when the stones are placed.

6. The exterior wall stone cast-in-place integrated molding construction method according to claim 5, characterized in that: In step S5, stainless steel hooks and grouting are installed on the stone, including: using weather-resistant structural adhesive to install the stainless steel hooks one by one into the holes reserved in the stone, and making the upper and lower adjacent stainless steel hooks of each stone bend in a Y-shape, and temporarily blocking the holes reserved on the stone ribs with foam columns, and then grouting is performed, the foam columns are taken out before the grouting agent solidifies, and stainless steel wire is passed through the holes reserved on the ribs for tying the steel mesh, wherein at least one pair of stainless steel hooks is set for each stone within 20 cm in width, and at least two pairs of stainless steel hooks are set for each stone above 20 cm, and the stainless steel hooks are set at a distance of 5 cm from the edge of the stone.

7. The exterior wall stone cast-in-place integrated molding construction method according to claim 6, characterized in that: In step S6, the stone is treated with alkali-proof and waterproof treatment, including: applying alkali-proof back coating and waterproof coating to the back of the stone after the grout is dried; in step S7, the stone integrated formwork is used to install the outer wall steel bars, including: removing the foam columns filling the through-wall holes before the waterproof coating and the alkali-proof back coating are dried, and after drying, the protective layer pads and the outer wall steel mesh are installed through the holes reserved on the ribs to temporarily fix the stone. When tying the outer wall steel mesh, the steel bars should be positioned away from the through-wall bolt holes reserved on the large steel formwork, and the tying points should be tied firmly point by point.

8. The exterior wall stone cast-in-place integrated molding construction method according to claim 7, characterized in that: In step S8, after hoisting the outer steel formwork, the inner steel bars of the wall are installed, including: cleaning the upper surface of the lower stone, and pasting a sponge strip to prevent the cast-in-place concrete slurry from leaking and contaminating the lower stone, the thickness of the sponge strip is more than 2 cm, the stone integrated formwork is hoisted to the construction position, and fixed with a support leg, the inner steel mesh and protective layer pads of the wall are installed after the outer steel formwork is temporarily fixed, and the inner steel mesh is fixed with a temporary support, and after fixing, the pre-buried pipeline is reserved to the inner steel mesh of the wall.

9. The exterior wall stone cast-in-place integrated molding construction method according to claim 8, characterized in that: In step S9, the inner steel form is hoisted and concrete is poured, including: S91. Hoist the inner steel formwork: hoist the inner steel formwork to the construction location, use the jack to adjust the verticality of the formwork, install the inner support of the formwork and the final fixed feet, install the through-wall screws, connect the inner steel formwork and the outer steel formwork through the through-wall screws, and complete the mold closing; S92, concrete pouring: Use through-wall screws to temporarily fix the stone to the outer steel formwork, add admixtures such as air entraining agent and pumping agent to the ready-mixed concrete, control the slump at 160±20mm, use the conduit method for pouring, and vibrate for 15-20s; S93, concrete formwork removal: the formwork is removed 24 hours after the concrete is poured. After the formwork is removed, the stainless steel wires that temporarily fix the stone and insulation materials are cut off and the jointing is carried out; S94. Waterproofing of bolt holes in exterior walls: After removing the formwork, use water-swellable plugging materials to embed into the center of the wall. The plugging materials should expand 5 cm from the center line of the wall. Use waterproof cement mortar to seal the outer edge of the hole to the plugging materials. Fill the holes for the through-wall screws densely and then perform grouting.

10. The exterior wall stone cast-in-place integrated molding construction method according to claim 1, characterized in that: Also includes: Step S10, exterior wall facing stone repair: Use a special adhesive for facing stone to stick the repair stone to the repair position and perform maintenance. After the adhesive reaches the designed strength, drill holes at the facing stone anchor hole position perpendicular to the concrete base, and place stainless steel expansion bolts to fix the stone again. After the stainless steel expansion bolts are placed, stick the repair stone cover on the bolt cap to beautify the repair stone, wherein the repair stone cover is a nut-type structure processed from the same batch of stones as the facing stone.

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