Formula and production method of modified gypsum fabricated building component

Abstract

The invention provides a formula of a modified gypsum fabricated building component and a production method thereof, and relates to the technical field of building material preparation. The formula of the modified gypsum fabricated building component is prepared from the following components in percentage by mass: 40 to 65 percent of gypsum, 3 to 9 percent of basalt fiber, 20 to 35 percent of steel slag micro powder, 1 to 3 percent of nano Si O2 sol, 10 to 15 percent of aerogel, 0.5 to 1.2 percent of a water reducing agent, 2 to 15 percent of aluminum hydroxide and 3 to 11 percent of water, wherein the basalt fiber and the nano S O < 2 > sol have a synergistic effect, so that the compressive strength is greater than or equal to 58 MPa, and the fire endurance is greater than or equal to 3.5 h. According to the formula, through the synergistic effect of functional components, high-value utilization of solid waste and a dynamic production process, the problems of high pollution, high cost and low performance of a traditional building material are solved, the comprehensive performance of light weight, high strength, fire resistance, shock resistance, low carbon and environmental protection is achieved, the compressive strength exceeds that of C50 concrete by 16-26%, the self weight is reduced by 40%, the fire endurance is 3.5 h, and the comprehensive cost is 59% lower than that of concrete; and the construction period is shortened by 60%, the carbon emission is reduced by 47%, and more energy conservation and environmental protection are achieved.

Description

Technical Field

[0001] The present invention relates to the technical field of building material preparation, in particular to a formula of a modified gypsum assembled building component and a production method thereof. Background Art

[0002] Currently, China is vigorously promoting prefabricated buildings. Prefabricated buildings utilize industrialized production, with prefabricated construction and prefabricated decoration, primarily based on dry methods, becoming key development areas. This construction method offers numerous advantages, including rapid construction, easy quality control, energy conservation, and environmental protection. It effectively improves construction efficiency, reduces on-site wet work, and minimizes environmental impact, meeting the development requirements of the modern construction industry.

[0003] During the development of prefabricated buildings, some traditional building components have exposed numerous problems. For example, commonly used lightweight interior partitions, such as aerated concrete slats, foamed concrete slats, and ordinary gypsum slats, suffer from low bulk density, low strength, high porosity, and poor nail holding capacity. Furthermore, traditional concrete components are heavy, require long construction cycles, and have high carbon emissions. Ordinary gypsum-based materials have low strength, poor fire resistance, and are prone to moisture absorption and deformation, making them unable to meet the requirements of high-rise buildings. Existing prefabricated structures rely on steel reinforcement, which is costly and difficult to implement for outdoor insulation.

[0004] Therefore, those skilled in the art provide a formula of a modified gypsum prefabricated building component and a production method thereof to solve the problems raised in the above background technology. Summary of the Invention

[0005] (1) Technical problems solved

[0006] In response to the shortcomings of the existing technology, the present invention provides a formula for modified gypsum prefabricated building components and a production method thereof, which solve the problems of high cost, high pollution and low performance of traditional building materials. The components are suitable for beams / columns, wall panels, floor slabs and stairs in 1-10-story prefabricated buildings. It solves the problems that traditional concrete components have a large dead weight, a long construction period and high carbon emissions; ordinary gypsum-based materials have low construction strength, poor fire resistance, easy moisture absorption and deformation, and cannot meet the needs of high-rise buildings; existing prefabricated structures rely on steel reinforcement, which is costly and difficult to achieve outdoor insulation design.

[0007] (2) Technical solution

[0008] To achieve the above objectives, the present invention is implemented through the following technical solutions:

[0009] A formula for a modified gypsum prefabricated building component comprises the following components in percentage by mass: 40-65% gypsum, 3-9% basalt fiber, 20-35% steel slag powder, 1-3% nano-SiO2 sol, 10-15% aerogel, 0.5-1.2% water reducer, 2-15% aluminum hydroxide, and 3-11% water;

[0010] The basalt fiber and the nano-SiO2 sol work together to ensure a compressive strength of ≥58 MPa and a fire resistance of ≥3.5 h.

[0011] Preferably, the gypsum includes α-gypsum and β-gypsum.

[0012] Preferably, when the gypsum is α-gypsum, it is used for 7-10 layer components, and the basalt fiber content is ≥6%, and the aluminum hydroxide content is ≥10%.

[0013] Preferably, when the gypsum is β-gypsum, it is used for 1-6 layer components, with a basalt fiber content of ≥2%, an aluminum hydroxide content of ≥6%, a steel slag powder content of ≥20%, and an aerogel content of ≥10%.

[0014] Preferably, the formula of the prefabricated building components of the bottom 1-3 layers includes the following components in mass percentage: 55-65% beta gypsum, 2-4% basalt fiber, 20-30% steel slag powder, 1-1.5% nano-SiO2 sol, 0.5-1.2% water reducer, 2-15% aluminum hydroxide, and 3-11% water.

[0015] Preferably, the formula of the prefabricated building components of the middle 4-6 layers includes the following components in mass percentage: 45-55% beta gypsum, 5-7% basalt fiber, 20-35% steel slag powder, 1-3% nano-SiO2 sol, 10-15% aerogel, 0.5-1.2% water reducer, and 3-11% water.

[0016] Preferably, the formula of the prefabricated building components for high-rise buildings of 7-10 floors includes the following components in mass percentage: 48-55% α-gypsum, 7-9% basalt fiber, 20-35% steel slag powder, 10-15% aluminum hydroxide, 2-3% nano-SiO2 sol, 0.5-1.2% water reducer, and 3-11% water.

[0017] Preferably, a method for producing a modified gypsum assembled building component comprises the following steps:

[0018] Step S1. The dynamic proportioning system mixes the dry materials according to the proportions set in the raw materials;

[0019] Step S2. Add water to the mixed dry material and stir until the fluidity is 160-180 mm to obtain a mixed wet material;

[0020] Step S3. The mixed wet material is injected into the 3D printing mold to a layer thickness of 8 mm, vibrated and compacted, and then demolded;

[0021] Step S4: steam curing the demoulded product, and then performing microwave secondary curing after curing to obtain the building component.

[0022] Preferably, the steam curing temperature in step S4 is 80° C., the curing time is 12 h, the microwave secondary curing frequency is 2.45 GHz, and the microwave curing time is 30 min.

[0023] (3) Beneficial effects

[0024] The present invention provides a formula for a modified gypsum prefabricated building component and a production method thereof. It has the following beneficial effects:

[0025] 1. The present invention provides a formula for a modified gypsum prefabricated building component and a production method thereof. This formula solves the high pollution, high cost, and low performance problems of traditional building materials through the synergistic effect of functional components, high-value utilization of solid waste, and a dynamic production process, and achieves the comprehensive performance of light weight, high strength, fire resistance, earthquake resistance, low carbon, and environmental protection.

[0026] 2. The present invention provides a formula for a modified gypsum prefabricated building component and a production method thereof. The gypsum prefabricated building component prepared with this formula has a compressive strength 16-26% higher than that of C50 concrete, a deadweight reduced by 40%, a fire resistance limit of 3.5 hours, an overall cost 59% lower than that of concrete, and a construction period shortened by 60%. A single project can consume 18,000 tons of steel slag powder and waste gypsum board, reducing carbon emissions by 47%, making it more energy-efficient and environmentally friendly. DETAILED DESCRIPTION

[0027] The following is a clear and complete description of the technical solutions in the embodiments of the present invention. Obviously, the embodiments described are only some embodiments of the present invention, not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making any creative efforts are within the scope of protection of the present invention.

[0028] Example 1:

[0029] 7-10th floor beam / column components, including the following components by mass percentage: 50% alpha gypsum, 8% basalt fiber, 32% steel slag powder, 3% nano-SiO2 sol, 1.2% water reducer, 12% aluminum hydroxide, and 3.8% water;

[0030] The production method of the assembled building component comprises the following steps:

[0031] Step S1. The dynamic proportioning system mixes the dry materials according to the proportions set in the raw materials;

[0032] Step S2. Add water to the mixed dry material and stir until the fluidity is 160-180 mm to obtain a mixed wet material;

[0033] Step S3. The mixed wet material is injected into the 3D printing mold to a layer thickness of 8 mm, vibrated and compacted, and then demolded;

[0034] Step S4: steam curing the demoulded product, and then performing microwave secondary curing after curing to obtain the building component.

[0035] According to measurements, the performance indicators of the 7-10th floor beam / column components are: compressive strength 58MPa, bending strength 20MPa, fire resistance limit 3.5h, and seismic resistance 0.35g.

[0036] Example 2:

[0037] 4-6 layers of exterior wall panels, comprising the following components by mass percentage: 45% beta gypsum, 15% aerogel, 3% basalt fiber, 25% steel slag powder, 2% nano-SiO2 sol, and 10% water;

[0038] The production method of the assembled building component comprises the following steps:

[0039] Step S1. The dynamic proportioning system mixes the dry materials according to the proportions set in the raw materials;

[0040] Step S2. Add water to the mixed dry material and stir until the fluidity is 160-180 mm to obtain a mixed wet material;

[0041] Step S3. The mixed wet material is injected into the 3D printing mold to a layer thickness of 8 mm, vibrated and compacted, and then demolded;

[0042] Step S4: steam curing the demoulded product, and then performing microwave secondary curing after curing to obtain the building component.

[0043] The performance indicators of the 4-6 layer exterior wall panels are as follows: thermal conductivity 0.10W / (m·K), fire resistance limit 3.2h, wind pressure resistance 1.6kN / m 2 .

[0044] Example 3:

[0045] Floor slabs for floors 1-3, comprising the following components by mass percentage: 50% beta gypsum, 3% steel slag fiber, 25% ceramsite, 15% silica fume, and 7% water;

[0046] The production method of the assembled building component comprises the following steps:

[0047] Step S1. The dynamic proportioning system mixes the dry materials according to the proportions set in the raw materials;

[0048] Step S2. Add water to the mixed dry material and stir until the fluidity is 160-180 mm to obtain a mixed wet material;

[0049] Step S3. The mixed wet material is injected into the 3D printing mold to a layer thickness of 8 mm, vibrated and compacted, and then demolded;

[0050] Step S4: steam curing the demoulded product, and then performing microwave secondary curing after curing to obtain the building component.

[0051] The performance index of the 1-3 floor slabs is: impact resistance 12kJ / m 2 , sound insulation ≥45dB, weight 1650kg / m 3 .

[0052] Basalt fiber provides three-dimensional network reinforcement, increasing the flexural strength of building components to ≥20MPa. Nano-SiO2 sol is used to fill pores, increasing the density by 15% and the compressive strength to ≥58MPa. Steel slag micropowder serves as an active filler, and the alkaline components react with gypsum to form ettringite, which improves durability by 30%. Polycarboxylate water reducer optimizes rheology and reduces the water-cement ratio to between 0.25-0.35.

[0053] The various indicators of the beam / column components of the 7th to 10th floors in Example 1 were experimentally measured, and the experimental data are shown in Table 1 below:

[0054] Table 17-10 Various indicators of beam / column components

[0055]

[0056]

[0057] In the present invention, the formula solves the high pollution, high cost and low performance problems of traditional building materials through the synergistic effect of functional components, high-value utilization of solid waste and dynamic production process, and achieves the comprehensive performance of light weight, high strength, fire resistance and earthquake resistance, low carbon and environmental protection;

[0058] In the present invention, the gypsum prefabricated building components prepared by this formula have a compressive strength that exceeds that of C50 concrete by 16-26%, a deadweight reduced by 40%, a fire resistance limit of 3.5 hours, an overall cost 59% lower than that of concrete, and a construction period shortened by 60%. A single project consumes 18,000 tons of steel slag powder and waste gypsum boards, reducing carbon emissions by 47%, making it more energy-saving and environmentally friendly.

[0059] 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 formula of modified gypsum assembled building components, characterized in that: The invention comprises the following components in percentage by mass: 40-65% gypsum, 3-9% basalt fiber, 20-35% steel slag powder, 1-3% nano-SiO2 sol, 10-15% aerogel, 0.5-1.2% water reducer, 2-15% aluminum hydroxide, and 3-11% water; The basalt fiber and the nano-SiO2 sol work together to ensure a compressive strength of ≥58 MPa and a fire resistance of ≥3.5 h.

2. The formula of the modified gypsum prefabricated building component according to claim 1, characterized in that: The gypsum includes α-gypsum and β-gypsum.

3. The formula of the modified gypsum prefabricated building component according to claim 2, characterized in that: When the gypsum is α-gypsum, it is used for 7-10 layer components, and the basalt fiber content is ≥6%, and the aluminum hydroxide content is ≥10%.

4. The formula of the modified gypsum prefabricated building component according to claim 2, characterized in that: When the gypsum is beta gypsum, it is used for 1-6 layer components, and the basalt fiber content is ≥2%, the aluminum hydroxide content is ≥6%, the steel slag powder content is ≥20%, and the aerogel content is ≥10%.

5. The formula of the modified gypsum prefabricated building component according to claim 4, characterized in that: The formula of the assembled building components of the bottom 1-3 layers includes the following components in mass percentage: 55-65% beta gypsum, 2-4% basalt fiber, 20-30% steel slag powder, 1-1.5% nano-SiO2 sol, 0.5-1.2% water reducer, 2-15% aluminum hydroxide, and 3-11% water.

6. The formula of the modified gypsum prefabricated building component according to claim 4, characterized in that: The formula of the assembled building components of the middle 4-6 layers includes the following components in percentage by mass: 45-55% beta gypsum, 5-7% basalt fiber, 20-35% steel slag powder, 1-3% nano-SiO2 sol, 10-15% aerogel, 0.5-1.2% water reducer, and 3-11% water.

7. The formula of the modified gypsum prefabricated building component according to claim 1, characterized in that: The formula of the assembled building components for high-rise buildings with 7 to 10 floors includes the following components in percentage by mass: 48-55% alpha gypsum, 7-9% basalt fiber, 20-35% steel slag powder, 10-15% aluminum hydroxide, 2-3% nano-SiO2 sol, 0.5-1.2% water reducer, and 3-11% water.

8. A method for producing a modified gypsum assembled building component, characterized in that: The following steps are involved: Step S1. The dynamic proportioning system mixes the dry materials according to the proportions set in the raw materials; Step S2. Add water to the mixed dry material and stir until the fluidity is 160-180 mm to obtain a mixed wet material; Step S3. The mixed wet material is injected into the 3D printing mold to a layer thickness of 8 mm, vibrated and compacted, and then demolded; Step S4: steam curing the demoulded product, and then performing microwave secondary curing after curing to obtain the building component.

9. The method for producing a modified gypsum assembled building component according to claim 8, characterized in that: The steam curing temperature in step S4 is 80° C., the curing time is 12 h, the microwave secondary curing frequency is 2.45 GHz, and the microwave curing time is 30 min.

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