Integrated building material of ultra-thin large-size UHPC (Ultra High Performance Concrete) composite A-grade fireproof insulation board and preparation method of integrated building material

Abstract

The invention discloses an integrated building material of an ultra-thin large-size UHPC composite A-level fireproof insulation board and a preparation method thereof.The integrated building material comprises an ultra-thin large-size UHPC veneer, the A-level fireproof insulation board and a connecting piece, and the portion between the ultra-thin large-size UHPC veneer and the A-level fireproof insulation board is coated with an interface binder. The preparation method comprises the following steps: adding UHPC mixed slurry into a dry blend of an interface binder, stirring, adding fibers, continuously stirring until the slurry is uniform, pouring the obtained UHPC mixed slurry into a prepared mold, spreading, pouring water into the dry blend of the interface binder, stirring until the slurry is uniformly mixed, brushing the obtained interface binder slurry onto a heat insulation board, covering the UHPC mixed slurry with one surface brushed with the interface binder, and drying to obtain the heat insulation board. The back surface of the insulation board is uniformly beaten, so that the insulation board and the UHPC are firmly bonded, natural curing and form removal are performed, and the performance of the obtained integrated building material meets the standard regulation of General Technical Requirements for External Wall Insulation Composite Board JG / T480-2015.

Description

Technical Field

[0001] The present invention belongs to the field of building materials, and in particular relates to an integrated building material of an ultra-thin large-size UHPC composite A-class fireproof insulation board and a preparation method thereof. Background Art

[0002] Statistics show that my country's building energy consumption and carbon emissions over their entire life cycle account for approximately 50% of the nation's total energy consumption and carbon emissions. Heat loss through building envelopes accounts for 70% to 80% of heat loss in traditional buildings. Ultra-low energy and zero-carbon buildings reduce heat loss through building envelopes by 60% compared to existing building envelopes.

[0003] In the prior art, patent document CN112726990A discloses a fireproof and thermal insulation decorative integrated board and its preparation and installation methods, which comprises, from top to bottom, an inorganic fireproof panel, a fireproof and thermal insulation layer and an inorganic fireproof baseboard, and the fireproof and thermal insulation layer comprises, from top to bottom, an organic highly flame-retardant thermal insulation layer and an inorganic fireproof and thermal insulation pad; one side of the inorganic fireproof and thermal insulation pad is bonded to the inner surface of the inorganic fireproof baseboard, and the other side of the inorganic fireproof and thermal insulation pad is bonded to one side of the organic highly flame-retardant thermal insulation layer with high-temperature resistant glue, and the other side of the organic highly flame-retardant thermal insulation layer is bonded to the inorganic fireproof panel, integrating fireproofing, thermal insulation and decorative functions, and solving the problems of poor fire resistance limit, poor hanging force and unsatisfactory thermal insulation performance of traditional thermal insulation and decorative integrated boards. Patent document CN206408871U discloses a lightweight, Class A fireproof, thermal insulation, and decorative integrated panel. The panel comprises an A-class fireproof insulation layer, a base layer of insulation material, a surface layer of insulation material, insulation layer reinforcement ribs, an insulation material protective layer, an interface layer, and a decorative surface layer. The Class A fireproof insulation layer has a base layer of insulation material applied to one main surface, and a surface layer of insulation material applied to the other main surface. The insulation layer reinforcement ribs are connected to the base layer and the surface layer, and are positioned between the Class A fireproof insulation layer. A decorative coating material is applied to the interface layer to form the decorative surface layer. The remaining four sides are coated with an insulation material protective layer. This panel features lightweight, high safety, Class A fireproof performance, a long decorative life, good insulation performance, no pollution, reduced construction time, and easy installation. It is suitable for use on the facades of both new and existing buildings. Patent document CN204590489U discloses a basalt fiber composite vertical fiber rock wool fireproof and thermal insulation decorative integrated board, comprising a fireproof and thermal insulation layer, a core layer, an adhesive layer, and a finishing layer; the core layer is between two layers of fireproof and thermal insulation layers, and the fireproof and thermal insulation layer on one side is bonded to the finishing layer by an adhesive layer; the fireproof and thermal insulation layer is made of basalt fiber fireproof and thermal insulation board, the core layer is made of vertical fiber rock wool insulation board, and the finishing layer is a flexible facing tile. The fireproof and thermal insulation decorative integrated board provided by the utility model has the advantages of low cost, good thermal insulation effect, high fireproof level, and easy installation. It uses basalt fiber fireproof and thermal insulation board composite vertical fiber rock wool board as the fireproof and thermal insulation layer and core layer, achieving a Class A fireproof rating and high thermal insulation performance, good thermal stability, and is not easy to deform, crack, or warp; it uses flexible facing tiles as the surface finishing layer, which has the advantages of light weight, crack resistance, strong flexibility, uniform surface without flowery spots, and no joints.Patent document CN111456227A discloses an assembled panel structure building and its construction method, including a new assembled panel structure integral house of no more than six floors, which is formed by using autoclaved aerated concrete load-bearing interior and exterior wall panels as assembled walls, and is equipped with structural columns, ring beams (exterior walls are high ring beams), floor (roof) panels, etc. The autoclaved aerated concrete panels that can only provide retaining walls or partitions for concrete structures and steel structures are technically improved. The new assembled structural components can be used for multi-layer load-bearing and can achieve energy-saving, lightweight, crack-resistant, fire-resistant, earthquake-resistant and recoverable buildings. Through on-site assembly, they become assembled panel structures, which is another new building system of prefabricated buildings.

[0004] In summary, traditional exterior wall insulation systems offer limited functionality, struggle to balance insulation with fire protection, waterproofing, and weather resistance, and face significant durability issues, resulting in high overall energy consumption. Low-carbon, energy-efficient, integrated insulation envelope systems, designed to last the same lifespan as the main structure, are lacking suitable insulation materials and components that balance safety, durability, and functionality. Furthermore, the application of integrated insulation systems in buildings without formwork removal presents difficulties in achieving smoothness. Summary of the Invention

[0005] To address the existing problems of a lack of insulation materials and components that balance safety, durability, and functionality, as well as the difficulty in controlling the flatness of integrated insulation systems with formwork-free structures used in buildings, the present invention aims to provide an integrated building material comprising ultra-thin, large-size UHPC composite Class A fireproof insulation panels, the performance of which meets the requirements of the standard JG / T 480-2015, "General Technical Requirements for Exterior Wall Insulation Composite Panels."

[0006] To achieve the above object, the present invention adopts the following technical solutions:

[0007] The first aspect of the present invention provides an integrated building material of an ultra-thin large-size UHPC composite Class A fireproof insulation board, comprising:

[0008] Class A fireproof insulation board;

[0009] Ultra-thin large-size UHPC decorative panels;

[0010] Several double tail plate stainless steel connectors;

[0011] The ultra-thin large-size UHPC decorative panel and the Class A fireproof insulation board are bonded together by an interface adhesive;

[0012] The double tail plate stainless steel connector is located below the ultra-thin large-size UHPC decorative panel, and includes a circular plate stainless steel connector and an anchor plate connector that are matched and fixedly connected to each other.

[0013] Preferably, the ultra-thin large-size UHPC decorative panel has a thickness of 8 mm and a size of 2400 mm×1200 mm.

[0014] Preferably, the ultra-thin large-size UHPC decorative panel is made of white decorative ultra-high performance concrete with a compressive strength of more than 120 MPa.

[0015] Preferably, the thickness of the Class A fireproof insulation board is 55 mm.

[0016] Preferably, the Class A fireproof insulation board is a silicon graphene insulation board with a double-layer steel wire mesh.

[0017] Preferably, the interface adhesive is a cement-based interface adhesive, and the tensile bonding strength with the Class A fireproof insulation board 14d is above 0.2 MPa.

[0018] Preferably, the number of the double-tail stainless steel connectors is set at 4 to 6 per square meter.

[0019] Preferably, the diameter of the tail plate of the double tail plate stainless steel connector is 80 mm.

[0020] A second aspect of the present invention provides a method for preparing the integrated building material of the ultra-thin large-size UHPC composite Class A fireproof insulation board, comprising the following steps:

[0021] S1. Weigh UHPC premix, water and admixture according to weight ratio;

[0022] S2. Mix water and admixtures evenly and pour into the UHPC premix, stir for 3 minutes, add fiber and continue stirring for 3-10 minutes until the slurry is uniform to obtain UHPC mixed slurry;

[0023] S3. Pour the UHPC mixed slurry into the prepared mold and flatten it with a brush or roller within 10 minutes;

[0024] S4. Weigh the interface adhesive dry mix and water according to weight ratio;

[0025] S5. Pour water into the interfacial adhesive dry mix and stir for 2-5 minutes until the slurry is evenly mixed to obtain the interfacial adhesive slurry;

[0026] S6. Apply the interface adhesive slurry to the Class A fireproof insulation board, and cover the Class A fireproof insulation board with the surface coated with the interface adhesive on top of the UHPC mixed slurry;

[0027] S7. Use a rubber hammer to evenly hit the back of the Class A fireproof insulation board to ensure that the Class A fireproof insulation board and UHPC are firmly bonded;

[0028] S8. Place the obtained specimen under natural conditions for curing for 1 day, remove the mold, and the result is obtained.

[0029] Compared with the existing thermal insulation and decorative integrated panels, the present invention has the following advantages:

[0030] 1. Using UHPC as decorative panels, UHPC has the advantages of high durability, high strength, and high toughness (compressive strength is above 120MPa, bending strength can reach 14MPa, and water absorption rate can be less than 1%), which can greatly improve the service life of components.

[0031] 2. Silica graphene insulation material has the advantages of Class A fire protection, low thermal conductivity (thermal conductivity coefficient ≤ 0.052W / (m·K)), high tensile and bending resistance (vertical plate tensile strength greater than 0.20MPa, bending load greater than 3000N), etc., and has good compatibility with cement-based materials. It is widely used in cast-in-place, formwork-free, reverse-beating and other concrete structure insulation integrated systems for ultra-low energy consumption buildings in hot summer and cold winter areas. The integrated building material of the ultra-thin large-size UHPC composite Class A fireproof insulation board of the present invention has the advantages of Class A fire protection, high adhesion, large size (size not less than 1200mm×1800mm), and low thermal conductivity.

[0032] 3. The silicon graphene insulation material in the present invention has good compatibility and strong bonding with materials such as UHPC and high-quality inorganic panels, which can ensure the overall stability of the exterior wall panels. The resulting integrated building material can achieve a service life of the enclosure structure of not less than 50 years, with significant comprehensive benefits. The performance meets the requirements of the "General Technical Requirements for Exterior Wall Insulation Composite Panels" JG / T 480-2015. BRIEF DESCRIPTION OF THE DRAWINGS

[0033] Figure 1 This is a structural schematic diagram of the integrated building material of the ultra-thin large-size UHPC composite Class A fireproof insulation board in the embodiment, and the figure numbers are as follows: 1-1, disc stainless steel connector; 1-2, anchor plate connector; 1, wall; 2, silicon graphene insulation board; 3, interface bonding layer; 4, ultra-thin large-size UHPC decorative panel; 5, connector anchor thread; 6, silicon graphene insulation board anchor plate; 7, silicon graphene insulation board fixing barb; 8, inner and outer disk connecting thread; 9, ultra-thin large-size UHPC decorative panel anchor plate. DETAILED DESCRIPTION

[0034] In order to more fully understand and demonstrate the technical solutions, objectives, and advantages of the present invention, the technical effects produced by the present invention are further described in detail and completely in conjunction with specific embodiments and accompanying drawings. Obviously, the described embodiments are only some of the embodiments of the present invention, and not all of them. It should be pointed out that for those skilled in the art, other embodiments obtained without departing from the concept of the present invention are all within the scope of protection of the present invention.

[0035] Unless otherwise specified in the following examples, all reagents and materials used were commercially available.

[0036] The following embodiment exemplarily describes an integrated building material of an ultra-thin, large-size UHPC composite Class A fireproof insulation board, including:

[0037] Class A fireproof insulation board;

[0038] Ultra-thin large-size UHPC decorative panels;

[0039] Several double tail plate stainless steel connectors;

[0040] Among them, the ultra-thin large-size UHPC decorative panels and the Class A fireproof insulation panels are bonded together by interface adhesives; the double tail plate stainless steel connectors are located under the ultra-thin large-size UHPC decorative panels, including circular stainless steel connectors and anchor plate connectors that are matched and fixed to each other.

[0041] In some embodiments, the ultra-thin large-size UHPC decorative panel has a thickness of 8 mm and a size of 2400 mm×1200 mm; in some embodiments, the ultra-thin large-size UHPC decorative panel is made of white decorative ultra-high performance concrete with a compressive strength of more than 120 MPa.

[0042] In some embodiments, the thickness of the Class A fireproof insulation board is 55 mm; in some embodiments, the Class A fireproof insulation board is a silicon graphene insulation board with a double-layer steel wire mesh.

[0043] In some embodiments, the interface adhesive is a cement-based interface adhesive, and the tensile bonding strength with the Class A fireproof insulation board 14d is above 0.2 MPa.

[0044] In some embodiments, the number of double-end-plate stainless steel connectors is set at 4 to 6 per square meter; in some embodiments, the diameter of the end plate of the double-end-plate stainless steel connector is 80 mm.

[0045] The method for preparing the aforementioned integrated building material of ultra-thin large-size UHPC composite Class A fireproof insulation board comprises the following steps:

[0046] S1. Weigh UHPC premix, water and admixture according to weight ratio;

[0047] S2. Mix water and admixtures evenly and pour into the UHPC premix, stir for 3 minutes, add fiber and continue stirring for 3-10 minutes until the slurry is uniform to obtain UHPC mixed slurry;

[0048] S3. Pour the UHPC mixed slurry into the prepared mold and flatten it with a brush or roller within 10 minutes;

[0049] S4. Weigh the interface adhesive dry mix and water according to weight ratio;

[0050] S5. Pour water into the interfacial adhesive dry mix and stir for 2-5 minutes until the slurry is evenly mixed to obtain the interfacial adhesive slurry;

[0051] S6. Apply the interface adhesive slurry to the Class A fireproof insulation board, and cover the Class A fireproof insulation board with the interface adhesive on the UHPC mixed slurry;

[0052] S7. Use a rubber hammer to evenly hit the back of the Class A fireproof insulation board to ensure that the Class A fireproof insulation board and UHPC are firmly bonded;

[0053] S8. Place the obtained specimen under natural conditions for curing for 1 day, remove the mold, and the result is obtained.

[0054] Example 1

[0055] This embodiment prepares an integrated building material composed of ultra-thin, large-scale UHPC composite Class A fireproof insulation panels, comprising: ultra-thin, large-scale UHPC decorative panels, Class A fireproof insulation panels, and several double-end stainless steel connectors. The ultra-thin, large-scale UHPC decorative panels and Class A fireproof insulation panels are bonded together with an interface adhesive. The ultra-thin, large-scale UHPC decorative panels are 8mm thick, measure 2400mm x 1200mm, and are made of white decorative ultra-high performance concrete with a compressive strength of 120MPa or greater. The Class A fireproof insulation panels are 55mm thick silicon graphene insulation panels with double-layer steel mesh. The interface adhesive is a cement-based interface adhesive with a 14d tensile bond strength of 0.2MPa or greater with the Class A fireproof insulation panels. The double-end stainless steel connectors have an 80mm end diameter and are provided in 4 to 6 pieces per square meter.

[0056] The preparation method of the integrated building material of the ultra-thin large-size UHPC composite Class A fireproof insulation board is as follows:

[0057] Accurately weigh the UHPC premix, water and admixture according to the weight ratio; mix the water and admixture evenly and pour them into the UHPC premix, stir for 3 minutes, then add the fiber and continue stirring for 5 minutes until the slurry is uniform to obtain the UHPC mixed slurry; pour the UHPC mixed slurry into the prepared mold and flatten the slurry with a brush or roller. This step should be completed within 10 minutes; accurately weigh the interface adhesive dry mix and water according to the weight ratio; pour water into the interface adhesive dry mix and stir for 3 minutes until the slurry is uniformly mixed to obtain the interface adhesive slurry; apply the interface adhesive slurry to the insulation board, and cover the side of the insulation board coated with the interface adhesive on top of the UHPC mixed slurry; use a rubber hammer to evenly tap the back of the insulation board to ensure that the insulation board and UHPC are firmly bonded; place the specimen under natural conditions for curing for 1 day, and remove the mold to obtain the specimen.

[0058] The above-mentioned ultra-thin large-size UHPC composite A-class fireproof insulation board integrated building materials are installed in the structural parts of the wall such as Figure 1 As shown, the structure comprises a wall 1, a silicon graphene insulation board 2, an interfacial bonding layer 3, an ultra-thin, large-scale UHPC veneer panel 4, and a matching, fixedly connected circular stainless steel connector 1-1 and an anchor plate connector 1-2. The circular stainless steel connector 1-1 includes connector anchor threads 5, a silicon graphene insulation board anchor plate 6, and a silicon graphene insulation board fixing barb 7; the anchor plate connector 1-2 includes inner and outer disc connecting threads 8 and an ultra-thin, large-scale UHPC veneer panel anchor plate 9. During construction, the circular stainless steel connector 1-1 is installed on-site. Each product has a threaded plug at the end, protruding 20-25mm. When installing the anchor plate, remove the threaded plug and tighten the ultra-thin, large-scale UHPC veneer panel anchor plate. Once installed, the integrated structural component is obtained. Performance test results are shown in Table 1.

[0059] Table 1

[0060]

[0061] The above are merely preferred embodiments of the present invention and are not intended to limit the present invention. Those skilled in the art will readily appreciate that various modifications and variations of the present invention are possible. Any modifications, equivalent substitutions, or improvements made within the spirit and principles of the present invention are intended to be within the scope of protection of the present invention.

Claims

1. An integrated building material of ultra-thin large-size UHPC composite Class A fireproof insulation board, characterized in that: include: Class A fireproof insulation board; Ultra-thin large-size UHPC decorative panels; Several double tail plate stainless steel connectors; The ultra-thin large-size UHPC decorative panel and the Class A fireproof insulation board are bonded together by an interface adhesive; The double tail plate stainless steel connector is located below the ultra-thin large-size UHPC decorative panel, and includes a circular plate stainless steel connector and an anchor plate connector that are matched and fixedly connected to each other.

2. The integrated building material of ultra-thin large-size UHPC composite Class A fireproof insulation board according to claim 1 is characterized in that: The ultra-thin large-size UHPC decorative panel has a thickness of 8 mm and a size of 2400 mm×1200 mm.

3. The integrated building material of ultra-thin large-size UHPC composite Class A fireproof insulation board according to claim 1 is characterized in that: The ultra-thin large-size UHPC decorative panels are made of white decorative ultra-high performance concrete with a compressive strength of more than 120 MPa.

4. The integrated building material of ultra-thin large-size UHPC composite Class A fireproof insulation board according to claim 1 is characterized in that: The thickness of the Class A fireproof insulation board is 55 mm.

5. The integrated building material of ultra-thin large-size UHPC composite Class A fireproof insulation board according to claim 1 is characterized in that: The Class A fireproof insulation board is a silicon graphene insulation board with a double-layer steel wire mesh.

6. The integrated building material of ultra-thin large-size UHPC composite Class A fireproof insulation board according to claim 1 is characterized in that: The interface adhesive is a cement-based interface adhesive, and the tensile bonding strength with the Class A fireproof insulation board 14d is above 0.2 MPa.

7. The integrated building material of ultra-thin large-size UHPC composite Class A fireproof insulation board according to claim 1, characterized in that: The number of the double-tail stainless steel connectors is set at 4 to 6 per square meter.

8. The integrated building material of ultra-thin large-size UHPC composite Class A fireproof insulation board according to claim 1, characterized in that: The diameter of the tail plate of the double tail plate stainless steel connector is 80 mm.

9. A method for preparing an integrated building material of an ultra-thin large-size UHPC composite Class A fireproof insulation board according to any one of claims 1 to 8, characterized in that: The following steps are involved: S1. Weigh UHPC premix, water and admixture according to weight ratio; S2. Mix water and admixtures evenly and pour into the UHPC premix, stir for 3 minutes, add fiber and continue stirring for 3-10 minutes until the slurry is uniform to obtain UHPC mixed slurry; S3. Pour the UHPC mixed slurry into the prepared mold and flatten it with a brush or roller within 10 minutes; S4. Weigh the interface adhesive dry mix and water according to weight ratio; S5. Pour water into the interfacial adhesive dry mix and stir for 2-5 minutes until the slurry is evenly mixed to obtain the interfacial adhesive slurry; S6. Apply the interface adhesive slurry to the Class A fireproof insulation board, and cover the Class A fireproof insulation board with the surface coated with the interface adhesive on top of the UHPC mixed slurry; S7. Use a rubber hammer to evenly hit the back of the Class A fireproof insulation board to ensure that the Class A fireproof insulation board and UHPC are firmly bonded; S8. Place the obtained specimen under natural conditions for curing for 1 day, remove the mold, and the result is obtained.

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