A construction method for cast-in-place reverse-laying integrated molding of exterior wall stone

Abstract

This invention discloses a method for the integrated casting and reverse-casting construction of exterior wall stone, comprising the following steps: S1, detailed design, including: detailed design of the template, detailed design of the stone, and detailed design of stone repair, to obtain detailed design drawings; S2, based on the detailed design drawings, to prepare for construction; S3, to install the template; S4, to lay the stone on the outer steel formwork; S5, to install stainless steel hooks and grouting on the stone; S6, to perform alkali-proofing and waterproofing treatment on the stone; S7, to install the outer steel reinforcement of the wall using the integrated stone template; S8, to install the inner steel reinforcement of the wall after hoisting the outer steel formwork; S9, to hoist the inner steel formwork and pour concrete.

Description

Technical Field

[0001] This invention relates to the field of exterior wall decorative stone construction technology, specifically to a method for the integrated molding of exterior wall stone by cast-in-place reverse pouring. Background Technology

[0002] Traditional construction techniques for exterior wall decorative stone include wet installation and dry hanging. When using wet installation, excessive temperature changes can affect the adhesion between the stone and the substrate. Thermal expansion and contraction can weaken the bond between the adhesive or bonding material and the stone, thus affecting the stone's stability and durability. When using dry hanging, corrosive substances such as chlorides in salt spray can cause corrosion on the surface of metal profiles. This corrosion can lead to rust and other damage, and may even cause partial damage and gradual loss of strength in the metal profiles, weakening the structural performance of the metal fittings and reducing their load-bearing capacity and durability. The bonding strength of the stone is a key indicator of its impact resistance. Both existing techniques suffer from drawbacks such as difficulty in quality control, high safety risks associated with working at heights, long construction periods, and high costs. Summary of the Invention

[0003] The purpose of this invention is to provide a method for the integrated molding of cast-in-place exterior wall stone, in order to solve the problems mentioned in the background art.

[0004] To achieve the above objectives, the present invention provides a method for the integrated construction of cast-in-place reverse-cast exterior wall stone, comprising the following steps:

[0005] S1. Detailed design, including: detailed design of template, detailed design of stone and detailed design of stone repair, to obtain detailed design drawings;

[0006] S2. Based on the detailed design drawings, prepare for construction;

[0007] S3. Install the pre-formed template;

[0008] S4. Stone is laid on the outer steel formwork;

[0009] S5. Stainless steel hooks and grouting for stone installation;

[0010] S6, stone anti-alkali and waterproof treatment;

[0011] S7. Install the outer steel reinforcement of the wall using integrated stone formwork;

[0012] S8. Install the inner wall reinforcement after hoisting the outer steel formwork;

[0013] S9. Hoist the inner steel formwork and pour concrete.

[0014] In a preferred embodiment, step S1, the detailed design of the template, includes:

[0015] S11. Detailed Design of Large Steel Formwork: S111. Formwork Design: The large steel formwork includes inner and outer steel formwork. The outer steel formwork adopts a steel plate with an external back rib structure. The outer steel formwork surface is anchored with ribs according to the stone design to install the stone. S112. Based on the shape and size of the formwork design, the weight of the exterior wall stone, and the lateral pressure of the cast-in-place concrete, a comprehensive calculation is performed to confirm the formwork material, steel plate thickness, back rib position and size, and the number of bolts and fasteners for formwork connection. S113. The rib width of the outer steel formwork is determined according to the exterior wall stone design and the joint width. The rib height is 1 / 2 the stone thickness. S114. Based on the weight of the stone, the anchoring method of the ribs is determined after calculation.

[0016] S12. Detailed design of door and window openings and exterior wall corners: Door and window opening templates are designed with custom-sized frames according to the design dimensions. The frames are supported by steel sections, and multiple sets of horizontal supports are designed inside the frames. Door and window frame templates are bolted to the large steel formwork. When designing the outer steel formwork, reinforcing steel beams should be installed at the door and window openings for bolting and fixing the door and window frame templates. The door and window frame templates are set at the center of the entire large steel formwork. The inside and outside corner templates are designed as an integral structure with the large steel formwork. The corner length is greater than the length of the entire stone, and the back of the outside corner template is supported by triangular steel sections.

[0017] S13. Detailed design of supports and anchors: At least two external supports shall 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 corner of the internal corner formwork should be set as Y-shaped. Lifting rings shall be designed and installed on the top of the large steel formwork. The size and number of through-wall bolts 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.

[0018] In a preferred embodiment, the detailed design of the stone includes: according to the requirements of the exterior wall cladding stone decoration and the fixed template, detailed design of the stone in different locations and colors, including the facade layout of the 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 the stone at the inside and outside corners, and the connection position and number of stainless steel hooks; the detailed design of stone repair includes: detailed design of the position and number of anchor holes on the stone, the strength of the stone, and the suspension force of the stainless steel bolts, wherein the position and number of anchor holes on the stone are determined according to the ultimate pull-out bearing capacity of the test section.

[0019] In a preferred embodiment, step S3, installing the shaping template, includes the following steps:

[0020] S31. Pre-lay and pre-assemble the large steel formwork according to the designed template size. Among them, multiple vertical beams are evenly spaced on one side of the outer steel formwork surface, and multiple horizontal beams perpendicular to the vertical beams are set on one side of the vertical beams. Multiple ribs are spaced on the other side of the outer steel formwork surface.

[0021] S32. Installation of connecting bolts, clips, and external supports between large steel formwork units;

[0022] S33. Level the large steel mold, reinforcing it while leveling, until it is horizontally and vertically straight and secure.

[0023] S34. Install door and window opening templates and level the door and window opening templates;

[0024] S35. Install triangular steel supports on the back of the external corner formwork, and set Y-shaped external supports at the corners of the internal corner formwork.

[0025] In a preferred embodiment, step S4, laying stone on the outer steel formwork, includes: numbering the stone on the detailed design drawings according to the size and design style of the stone and the size of the template; temporarily placing the stone on the ribs of the outer steel formwork according to the layout number of the detailed design drawings; the width of the ribs is consistent with the horizontal design joint width of the stone; and the vertical joint width is controlled according to the design requirements when placing the stone.

[0026] In a preferred embodiment, step S5, which involves installing stainless steel hooks and grouting on the stone, includes: using weather-resistant structural adhesive to install the stainless steel hooks one by one into the pre-reserved holes in the stone, ensuring that the adjacent stainless steel hooks on each stone are bent in a Y-shape, temporarily sealing the pre-reserved holes on the stone ribs with foam columns, and then grouting. Before the grout solidifies, the foam columns are removed, and stainless steel wire is passed through the pre-reserved holes on the ribs to tie the reinforcing mesh. Each stone within 20cm in width is provided with at least one pair of stainless steel hooks, and each stone wider than 20cm is provided with at least two pairs of stainless steel hooks. The stainless steel hooks are positioned 5cm from the edge of the stone.

[0027] In a preferred embodiment, step S6, the stone anti-alkali and waterproof treatment includes: applying an anti-alkali back coating and a waterproof coating to the back of the stone after the grout dries; in step S7, the installation of the outer wall reinforcement of the integrated stone template includes: removing the foam columns filling the through-wall holes before the waterproof coating and anti-alkali back coating dry, and after drying, installing protective layer pads and the outer wall reinforcement mesh to temporarily fix the stone through the holes reserved on the ribs. When binding the outer wall reinforcement mesh, the position of the reinforcement should avoid the through-wall bolt holes reserved on the large steel mold, and the binding points should be firmly bound point by point.

[0028] In a preferred embodiment, step S8, after hoisting the outer steel formwork, involves installing the inner wall reinforcement bars, including: cleaning the upper surface of the lower layer of stone and attaching sponge strips to prevent the leakage of cast-in-place concrete slurry and contamination of the lower layer of stone. The sponge strips are at least 2cm thick. The integrated stone formwork is hoisted to the construction position and fixed with support legs. After the outer steel formwork is temporarily fixed, the inner wall reinforcement mesh and protective layer pads are installed, and the inner reinforcement mesh is fixed with temporary supports. After fixing, pre-embedded pipelines are reserved on the inner wall reinforcement mesh.

[0029] In a preferred embodiment, step S9, which involves hoisting the inner steel formwork and pouring concrete, includes:

[0030] S91. Hoisting the inner steel formwork: Hoist the inner steel formwork to the construction position, use jacks to adjust the verticality of the formwork and install the inner support and final fixed support feet of the formwork. Install through-wall bolts and connect the inner and outer steel formworks through the through-wall bolts to complete the formwork assembly.

[0031] S92. Concrete pouring: Use through-wall bolts 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 tremie method for pouring. Vibration time is 15-20s.

[0032] S93. Concrete formwork removal: Remove the formwork 24 hours after concrete pouring. After formwork removal, cut off the stainless steel wires that temporarily fix the stone and insulation materials and then carry out grouting.

[0033] S94. Waterproofing treatment of bolt holes in exterior walls: After demolding, use water-swellable sealing material to fill the center of the wall. The sealing material extends 5cm outward from the center line of the wall. Use waterproof cement mortar to seal the outer edge of the hole to the sealing material. After the hole for through-wall bolts is filled tightly, grouting treatment is performed.

[0034] In a preferred embodiment, the method further includes: step S10, repairing the exterior wall cladding stone: using a special adhesive for cladding stone to paste the repair stone to the repair position and cure it. After the adhesive reaches the design strength, holes are drilled perpendicular to the concrete base at the anchoring hole position of the cladding stone, and stainless steel expansion bolts are placed to fix the stone again. After the stainless steel expansion bolts are placed, the repair stone cover is pasted on the bolt cap to beautify the repair stone. The repair stone cover is a nut-shaped structure made of stone from the same batch as the cladding stone.

[0035] Compared with the prior art, the beneficial effects of the present invention are:

[0036] The integrated casting construction method for exterior wall decorative stone of this invention involves first laying the finished exterior wall stone on a prefabricated template. After fixing the stone, installing stainless steel hooks, and applying alkali-resistant and waterproof treatment, the outer steel mesh of the wall is directly fixed to the outer steel formwork. After acceptance, the outer steel formwork is hoisted to the work surface, and the inner steel mesh and inner steel formwork are installed. At this point, the integrated casting of the exterior wall decorative stone and structure is possible. This method allows the exterior wall decorative stone and outer steel reinforcement to be installed directly on the ground. The decorative stone is fixed to the concrete using stainless steel hooks, significantly reducing high-altitude work time, ensuring overall quality, and improving work efficiency. The stone is cast into shape with the concrete in one go using stainless steel hooks, thus reducing the risk of hollowing and detachment caused by temperature differences, reducing the corrosive damage of the profiles from salt spray, and enhancing the stone's impact resistance. Compared to the traditional dry-hanging method, it reduces construction costs and speeds up construction. Compared to the traditional wet-laying method, it completely solves the quality problem of hollowing and detachment, and also reduces construction costs and speeds up construction. The raw materials used in this invention are all produced in factories, reducing on-site secondary processing, enabling standardized construction and production, reducing construction noise, waste and dust generation, and thus reducing environmental pollution. Attached Figure Description

[0037] Figure 1 This is a schematic diagram of the construction method of the present invention;

[0038] Figure 2 This is a schematic diagram of the template for the present invention;

[0039] Figure 3A This is a schematic diagram of the outer steel mold structure of the present invention;

[0040] Figure 3B This is a schematic diagram of the cross-sectional node of the outer steel mold of the present invention;

[0041] Figure 4A This is a three-dimensional schematic diagram of the doorway template of the present invention;

[0042] Figure 4B This is a cross-sectional view of the door opening template of the present invention;

[0043] Figure 5A This is a three-dimensional schematic diagram of the window opening template of the present invention.

[0044] Figure 5B This is a cross-sectional view of the window opening template of the present invention;

[0045] Figure 6 This is a schematic diagram of the external corner template of the present invention;

[0046] Figure 7 This is a schematic diagram of the external support configuration of the present invention;

[0047] Figure 8 This is a schematic diagram of the through-wall bolt arrangement of the present invention;

[0048] Figure 9 This is a schematic diagram of stone paving on the outer steel formwork of the present invention;

[0049] Figure 10 This is a schematic diagram of the stainless steel hook for stone materials according to the present invention;

[0050] Figure 11 This is a schematic diagram of drilling holes in the stone for repair according to the present invention;

[0051] Figure 12 This is a schematic cross-sectional view of the stone repair material according to the present invention. Detailed Implementation

[0052] The technical solutions in the embodiments of the present invention will be clearly and completely described below. All other embodiments obtained by those skilled in the art without inventive effort are within the scope of protection of the present invention.

[0053] This invention uses a specific project as an example. The project comprises 10 high-rise residential buildings with a cast-in-place shear wall structure. The total building area is 52,610 square meters (7 floors above ground) and the building's eaves height is 31.5 meters. The exterior stone cladding area is 21,834 square meters. The thickness of the base concrete structure wall is no less than 150 mm, the thickness of the facing stone is no less than 25 mm, the flexural strength is no less than 8.0 MPa, and the design transverse gap is greater than 1 cm.

[0054] like Figures 1 to 12 As shown, the preferred embodiment of the present invention for the construction method of cast-in-place reverse-cast integrated molding of exterior wall stone includes the following steps:

[0055] Step S1, detailed design, including:

[0056] 1. Detailed Design of Standard Formwork: The standardized formwork will be detailed in accordance with the requirements for exterior stone decoration and structural construction organization. This detailed design will focus on the segmentation and joints of the exterior stone, the dimensions of the standardized steel formwork, the treatment of formwork at door and window openings, the treatment of internal and external corner formwork, anchors and connections, support and fixing, and the placement of through-wall bolts. Specifically, the detailed design of standardized formwork 201 includes:

[0057] Step S11, Detailed Design of Large Steel Mold: Step S111, Mold Design: The large steel mold includes an inner steel mold and an outer steel mold 301. The outer steel mold 301 adopts a steel plate with an external back rib structure. The outer steel mold surface 311 is anchored with ribs 312 according to the design style of the stone to install the stone. Multiple vertical beams 313 are installed on one side of the outer steel mold surface 311, and multiple horizontal beams 314 are installed on one side of the vertical beams 313. Multiple support legs 315 are set on one side of the vertical beams 313. The inner steel mold is the same as the ordinary steel mold; Step S 112. To prevent deformation of the large formwork, a comprehensive calculation is performed based on the shape and dimensions of the formwork design, the weight of the exterior wall stone, and the lateral pressure of the cast-in-place concrete to confirm the formwork material, steel plate thickness, back rib position and size, and the number of bolts and fasteners for formwork connections; Step S113. Determine the rib width of the outer steel formwork according to the design style of the exterior wall stone and the width of the joints. The rib height is 1 / 2 the stone thickness; Step S114. Based on the weight of the stone, the anchoring method of the ribs is determined after calculation, ensuring it can withstand the weight of the stone itself. Holes should be pre-drilled in the ribs for temporarily fixing the stone and placing through-wall bolts to allow stainless steel wires and through-wall bolts to pass through.

[0058] Step S12, Detailed Design of Door and Window Openings and External Wall Corners: Door opening template 401 and window opening template 402 are designed with custom-sized frames according to the design dimensions. The frames use steel sections for support, and the material should be calculated based on the lateral pressure of the cast-in-place concrete. Multiple sets of horizontal supports 411 are designed inside the frames. Door frame templates 412 and window frame templates 413 are connected to the large steel formwork 414 using bolts 415. When designing the outer steel formwork, reinforcing steel beams should be installed at the door and window openings for bolting and fixing the door and window frame templates. The door and window frame templates should be positioned at the center of the entire large steel formwork. To facilitate demolding, the angle between the opening templates and the large steel formwork should be greater than 5°. The internal and external corner templates are designed as an integrated structure with the large steel formwork. Their corner length is greater than the length of the entire stone slab. The external corner template has triangular steel supports 601 on its back, while the internal corner template is designed with reinforced external supports.

[0059] Step S13, Detailed Design of Supports and Anchors: When designing the support positions and fixing methods, the positions of planar supports, corner supports, and through-wall bolts should be considered based on the shape, size, and rigidity of the formwork. The support material should have sufficient rigidity and adjustable length, and the support positions should ensure the stability of the formwork system. At least two external supports should be installed on the outside of each large steel formwork. To prevent cross-collision of the external supports of the corner formwork, the external support 701 at the corner of the corner formwork should preferably be Y-shaped, and a lifting ring 416 should be designed and installed on the top of the large steel formwork 414. The design of the lifting ring 416 should consider the overall weight of the formwork and a certain safety redundancy. The size and number of through-wall bolts should be determined according to the shape and size of the formwork design, the weight of the exterior wall stone, and the lateral pressure of the cast-in-place concrete. The connection between steel formworks can be made using high-strength bolts or fasteners.

[0060] 2. Stone cladding detailed design, including: based on the requirements of exterior wall cladding stone decoration and the fixed template, detailed design of stone in different locations and colors, 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 inside and outside corner stone, and the location and quantity of stainless steel hooks.

[0061] 3. Detailed design of stone repair, including: detailed design of the location and number of anchor holes on the stone, stone strength, and suspension force of stainless steel bolts. Specifically, the location and number of anchor holes on the stone are determined based on the ultimate pull-out bearing capacity of the test section. After the facing stone is adhered using stone-specific adhesive, stainless steel expansion bolts are inserted through the facing stone and embedded in concrete for secondary fixation. The anchor holes are aesthetically pleasing using repair stone caps made from the same batch of stone as the facing stone, matching the size of the nuts. This invention, through enhanced detailed design, maximizes the use of factory-processed standardized templates, standard-length stone, and standard-length steel mesh, significantly reducing on-site secondary processing time, thereby significantly improving work efficiency and shortening the construction period.

[0062] Step S2: Based on the detailed design drawings, prepare for construction.

[0063] Step S3: Install the prefabricated templates: After the materials arrive on site, install the templates in the designated area according to the numbers on the detailed design drawings. During installation, ensure the flatness of the template surface, the size and position of the ribs and the anchoring strength, the anchoring and position of the templates for door and window openings, the tightness of the connecting bolts, and the adjustment distance and locking strength of the support legs. After installation, inspect each item one by one, and only put it into use after it passes the inspection.

[0064] Specifically, it includes the following steps:

[0065] Step S30: Harden and level the site using concrete, or operate directly on the lower concrete slab and mark flatness control lines on the site / lower concrete slab.

[0066] Step S31: Pre-lay and pre-assemble the large steel formwork according to the designed template size (lay it flat on the ground). Among them, multiple vertical beams 313 are evenly spaced on one side of the outer steel formwork surface, and multiple horizontal beams 314 perpendicular to the vertical beams are set on one side of the vertical beams. Multiple ribs are spaced on the other side of the outer steel formwork surface.

[0067] Step S32: Install connecting bolts, clips, and external supports between large steel formwork units;

[0068] Step S33: Level the large steel mold, reinforcing it as you level it, until it is horizontally and vertically straight and secure.

[0069] Step S34: Install door and window opening templates and level the door and window opening templates;

[0070] Step S35: Install triangular steel supports on the back of the external corner formwork, and set Y-shaped external supports 701 at the corner of the internal corner formwork.

[0071] Step S4: Laying stone on the outer steel formwork: According to the size and design style of the stone and the size of the template, number the stones on the detailed design drawings. Place the stone 801 temporarily on the ribs of the outer steel formwork 301 according to the layout number of the detailed design drawings. The width of the ribs should be consistent with the horizontal design joint width of the stone. When placing the stone, control the vertical joint width according to the design requirements. If there are special grouting requirements in the design, they should be carried out after the stainless steel hooks are installed.

[0072] Step S5: Install stainless steel hooks and grout on the stone: Use weather-resistant structural adhesive to install the stainless steel hooks 901 one by one into the pre-drilled holes in the stone, ensuring that the adjacent stainless steel hooks on each stone form a Y-shape. Temporarily seal the pre-drilled holes on the stone ribs with foam columns, then perform grouting. Remove the foam columns before the grout hardens, and use stainless steel wire to pass through the pre-drilled holes on the ribs for binding the reinforcing mesh. Holes for through-wall bolts are left untreated. Preferably, each stone within 20cm in width should have at least one pair of stainless steel hooks 901, and each stone wider than 20cm should have at least two pairs of stainless steel hooks 901. The stainless steel hooks 901 should be positioned 5cm from the edge of the stone, with the portion extending outwards in an L-shape, and the diameter of the stainless steel hooks should be 3mm. The 801 stone is fixed to the concrete using stainless steel hooks 901, which greatly reduces the time spent working at heights and ensures the overall quality. The stone is cast into shape in one go using stainless steel hooks and concrete, which improves work efficiency.

[0073] Step S6, Alkali-proof and Waterproof Treatment of Stone: After the grout dries, apply alkali-proof back coating and waterproof coating to the back of the stone.

[0074] Step S7: Install the outer wall reinforcement of the integrated stone formwork: Before the waterproof coating and alkali-proof back coating dry, remove the foam columns that fill the through-wall holes. After drying, install the protective layer pads and the outer wall reinforcement mesh 802 to temporarily fix the stone through the holes reserved on the ribs. When binding the outer wall reinforcement mesh, the position of the reinforcement should avoid the through-wall bolt holes reserved on the large steel formwork. Bind each binding point firmly.

[0075] Step S8: After hoisting the outer steel formwork, install the inner wall reinforcement: Clean the upper surface of the lower layer of stone and attach sponge strips to prevent leakage of cast-in-place concrete slurry and contamination of the lower layer of stone. The sponge strips should be at least 2cm thick. Hoist the integrated stone formwork to the construction position and fix it with supports. After temporarily fixing the outer steel formwork, install the inner wall reinforcement mesh and protective layer pads, and use temporary supports to fix the inner reinforcement mesh. After fixing, pre-embedded pipelines to the inner wall reinforcement mesh.

[0076] Step S9: Hoist the inner steel formwork and pour concrete. Specifically, this includes:

[0077] Step S91: Hoisting the inner steel formwork: Hoist the inner steel formwork to the construction position, use jacks to adjust the verticality of the formwork and install the inner support and final fixed support feet of the formwork. Install the through-wall bolts 803, and connect the inner and outer steel formwork through the through-wall bolts 803 to complete the mold closing.

[0078] Step S92, Concrete Pouring: Temporarily fix the stone 801 to the outer steel formwork using through-wall bolts 803. To prevent deformation and detachment of the stone due to excessive vibration during pouring, the free fall height of the concrete, vibration time, and vibration intensity need to be shortened. Add admixtures such as air-entraining agents and pumping agents to the ready-mixed concrete, control the slump at 160±20mm, use the tremie method for pouring, and vibrate for 15-20 seconds.

[0079] Step S93, Concrete formwork removal: Remove the formwork 24 hours after concrete pouring. After removal, cut off the stainless steel wires that temporarily fix the stone and insulation materials, and then perform grouting.

[0080] Step S94, Waterproofing treatment of external wall bolt holes: After demolding, use water-swellable sealing material to fill the center of the wall, extending 5cm outward from the center line of the wall. Use waterproof cement mortar to seal the outer edge of the hole up to the sealing material, and then grout the joints after completely filling the through-wall bolt holes.

[0081] Step S10: Remove the stone to be replaced, and clean the base concrete before applying waterproof and alkali-proof treatment. Repair the exterior wall cladding stone: First, remove the stone to be replaced, and clean the base concrete before applying waterproof and alkali-proof treatment. Use a special adhesive for cladding stone to attach the repair stone 1001 to the repair location and allow it to cure. After the adhesive reaches its designed strength, drill holes perpendicular to the concrete base at the anchoring holes 1002 of the repair stone 1001, and place stainless steel expansion bolts 1003 to further secure the stone. After placing the stainless steel expansion bolts 1003, attach the repair stone cap 1004 to the bolt cap to beautify the repair stone. The repair stone cap 1004 is a nut-shaped structure made from the same batch of cladding stone.

[0082] This invention, while ensuring construction quality, reduces construction steps, manpower input, safety risks, and material waste. The integrated casting method for exterior wall stone cladding requires custom-made large steel molds, making it more suitable for large-area exterior wall stone cladding projects. Table 1 compares the costs of traditional construction techniques and the method of this invention, using a 10,000㎡ construction quota in Beijing as an example. The conclusions are as follows:

[0083] Table 1. Benefit Statistics

[0084]

[0085] Compared to the two traditional methods of wet installation and dry hanging, the integrated molding construction method of the present invention saves approximately 11% and 37% of the cost per 10,000 square meters, respectively, which is RMB 255,686 / 10,000 square meters and RMB 1,327,421 / 10,000 square meters, respectively, thus significantly improving economic efficiency.

[0086] While embodiments of the present invention have been shown and described, it will be appreciated by those skilled in the art that various changes, modifications, substitutions, and variations may be made to these embodiments without departing from the principles and spirit of the invention, and that the scope of the invention is defined by the appended claims and their equivalents.

Claims

1. A method for integral molding of cast-in-place exterior wall stone, characterized in that: Includes the following steps: S1. Detailed design, including: detailed design of template, detailed design of stone and detailed design of stone repair, to obtain detailed design drawings; S2. Based on the detailed design drawings, prepare for construction; S3. Install the pre-formed template; S4. Stone is laid on the outer steel formwork; S5. Stainless steel hooks and grouting for stone installation; S6, stone anti-alkali and waterproof treatment; S7. Install the outer steel reinforcement of the wall using integrated stone formwork; S8. Install the inner wall reinforcement after hoisting the outer steel formwork; S9. Hoist the inner steel formwork and pour concrete; S10, Repair of exterior wall cladding stone; In step S1, the detailed design of the template includes: S11. Detailed Design of Large Steel Formwork: S111. Formwork Design: The large steel formwork includes inner and outer steel formwork. The outer steel formwork adopts a steel plate with an external back rib structure. The outer steel formwork surface is anchored with ribs according to the stone design to install the stone. S112. Based on the shape and size of the formwork design, the weight of the exterior wall stone, and the lateral pressure of the cast-in-place concrete, a comprehensive calculation is performed to confirm the formwork material, steel plate thickness, back rib position and size, and the number of bolts and fasteners for formwork connection. S113. The rib width of the outer steel formwork is determined according to the exterior wall stone design and the joint width. The rib height is 1 / 2 the stone thickness. S114. Based on the weight of the stone, the anchoring method of the ribs is determined after calculation. S12. Detailed design of door and window openings and internal and external wall corners; S13, Detailed design of supports and anchorages; In step S3, the shaping template is installed, including the following steps: S31. Pre-lay and pre-assemble the large steel formwork according to the designed template size. Among them, multiple vertical beams are evenly spaced on one side of the outer steel formwork surface, and multiple horizontal beams perpendicular to the vertical beams are set on one side of the vertical beams. Multiple ribs are spaced on the other side of the outer steel formwork surface. In step S4, the outer steel formwork is paved with stone, including: numbering the stone according to its size, design style and the size of the template on the detailed design drawings, temporarily placing the stone on the ribs of the outer steel formwork according to the layout number of the detailed design drawings, the width of the ribs being consistent with the horizontal design joint width of the stone, and controlling the vertical joint width according to the design requirements when placing the stone. In step S5, the installation of stainless steel hooks and grouting on the stone includes: using weather-resistant structural adhesive to install the stainless steel hooks one by one into the reserved holes in the stone, and making the bending direction of the adjacent stainless steel hooks on each stone Y-shaped. The reserved holes on the stone ribs are temporarily sealed with foam columns, and then grouting is performed. Before the grout solidifies, the foam columns are removed, and stainless steel wire is passed through the reserved holes on the ribs to tie the steel mesh. The stone is then cast into shape with the concrete in one go through the stainless steel hooks. Step S6, stone alkali and waterproof treatment, includes: applying alkali-resistant back coating and waterproof coating to the back of the stone after the grout has dried.

2. The construction method for cast-in-place reverse-cast integrated molding of exterior wall stone according to claim 1, characterized in that: Step S12, detailed design of door and window openings and exterior wall corners, including: door and window opening templates are designed with fixed-size frames according to the design dimensions. The templates are supported by steel profiles, and multiple sets of horizontal supports are designed inside the templates. The door frame templates and window frame templates are bolted to the large steel formwork. When designing the outer steel formwork, reinforcing steel beams should be set at the door and window openings for bolting and fixing 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 formwork. The inside corner templates and outside corner templates are designed as an integral structure with the large steel formwork. Their corner length is greater than the length of the entire stone, and the outside corner templates are supported by triangular steel profiles on the back. Step S13, detailed design of supports and anchors, including: setting at least two external supports on the outside of each large steel formwork; to prevent the external supports of the internal corner formwork from colliding, the external supports at the corner of the internal corner formwork are set as Y-shaped; and designing and installing lifting rings on the top of the large steel formwork; and determining the size and number of through-wall bolts 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 construction method for cast-in-place reverse-layout integrated molding of exterior wall stone according to claim 2, characterized in that: Stone cladding detailed design includes: based on the requirements for exterior wall cladding stone decoration and the availability of standardized templates, detailed design of stones in different locations and colors, including the stone facade layout, horizontal and vertical joints within a single large steel mold, joint treatment at the junction of two large steel molds, treatment of inside and outside corner stones, and the location and quantity of stainless steel hook connections; Stone repair detailed design includes: detailed design of the location and quantity of anchor holes on the stone, stone strength, and the suspension force of stainless steel bolts, wherein the location and quantity of anchor holes on the stone are determined based on the ultimate pull-out bearing capacity of the test section.

4. The construction method for cast-in-place reverse-layout integrated molding of exterior wall stone according to claim 3, characterized in that: Step S3, installing the shaping template, also includes the following steps: S32. Installation of connecting bolts, clips, and external supports between large steel formwork units; S33. Level the large steel mold, reinforcing it while leveling, until it is horizontally and vertically straight and secure. S34. Install door and window opening templates and level the door and window opening templates; S35. Install triangular steel supports on the back of the external corner formwork, and set Y-shaped external supports at the corners of the internal corner formwork.

5. The construction method for cast-in-place reverse-layout integrated molding of exterior wall stone according to claim 4, characterized in that: In step S5, each stone piece within 20cm in width shall be equipped with at least one pair of stainless steel hooks, and each stone piece larger than 20cm shall be equipped with at least two pairs of stainless steel hooks. The stainless steel hooks shall be positioned 5cm away from the edge of the stone.

6. The construction method for cast-in-place reverse-layout integrated molding of exterior wall stone according to claim 5, characterized in that: In step S7, the outer wall reinforcement of the integrated stone formwork is installed, including: removing the foam columns that fill the through-wall holes before the waterproof coating and alkali-proof back coating dry; after drying, installing the protective layer pads and the outer wall reinforcement mesh through the holes reserved on the ribs to temporarily fix the stone; when binding the outer wall reinforcement mesh, the position of the reinforcement should avoid the through-wall bolt holes reserved on the large steel formwork, and the binding points should be firmly bound one by one.

7. The construction method for cast-in-place reverse-layout integrated molding of exterior wall stone according to claim 6, characterized in that: In step S8, after hoisting the outer steel formwork, the inner wall reinforcement is installed, including: cleaning the upper surface of the lower stone and attaching sponge strips to prevent the leakage of cast-in-place concrete slurry and contamination of the lower stone. The sponge strips are at least 2cm thick. The integrated stone formwork is hoisted to the construction position and fixed with support legs. After the outer steel formwork is temporarily fixed, the inner wall reinforcement mesh and protective layer pads are installed, and the inner reinforcement mesh is fixed with temporary supports. After fixing, the embedded pipelines are reserved on the inner wall reinforcement mesh.

8. The construction method for cast-in-place reverse-layout integrated molding of exterior wall stone according to claim 7, characterized in that: In step S9, the inner steel formwork is hoisted and concrete is poured, including: S91. Hoisting the inner steel formwork: Hoist the inner steel formwork to the construction position, use jacks to adjust the verticality of the formwork and install the inner support and final fixed support feet of the formwork. Install through-wall bolts and connect the inner and outer steel formworks through the through-wall bolts to complete the formwork assembly. S92. Concrete pouring: Use through-wall bolts to temporarily fix the stone to the outer steel formwork. Add air-entraining agent and pumping agent to the ready-mixed concrete. Control the slump at 160±20mm. Use the tremie method for pouring. Vibration time is 15-20s. S93. Concrete formwork removal: Remove the formwork 24 hours after concrete pouring. After formwork removal, cut off the stainless steel wires that temporarily fix the stone and insulation materials and then carry out grouting. S94. Waterproofing treatment of bolt holes in exterior walls: After demolding, use water-swellable sealing material to fill the center of the wall. The sealing material extends 5cm outward from the center line of the wall. Use waterproof cement mortar to seal the outer edge of the hole to the sealing material. After the hole for through-wall bolts is filled tightly, grouting treatment is performed.

9. The construction method for cast-in-place reverse-layout integrated molding of exterior wall stone according to claim 8, characterized in that: Use the decorative stone adhesive to attach the repair stone to the repair location and cure it. After the adhesive reaches the designed strength, drill holes perpendicular to the concrete base at the anchoring hole position of the decorative stone, and place stainless steel expansion bolts to fix the stone again. After the stainless steel expansion bolts are placed, attach the repair stone cap to the bolt cap to beautify the repair stone. The repair stone cap is a nut-shaped structure made of stone from the same batch as the decorative stone.

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