Construction method of fabricated pool integrating anti-corrosion layer and prefabricated part

Abstract

The invention relates to the technical field of fabricated pools, in particular to a construction method of an anticorrosive coating and prefabricated part integrated fabricated pool, which comprises the following steps: S1, processing and manufacturing side wall prefabricated parts and top plate prefabricated parts in a factory, and completing the construction of glass fiber reinforced plastic layers in anticorrosive coatings on the surfaces of the prefabricated parts; s2, a bottom plate is constructed on site; s3, the side wall prefabricated parts are hoisted, and splicing of the side wall prefabricated parts is completed; s4, the top plate prefabricated parts are hoisted, and splicing of the top plate prefabricated parts is completed; s5, pouring of a cast-in-place laminated layer of the side wall and the top plate is completed; s6, the side walls and the top plate are subjected to joint filling treatment; s7, the bottom plate and other areas without the anti-corrosion layers are subjected to supplementary coating of glass fiber reinforced plastic layers in the anti-corrosion layers on site; and S8, construction of a finish paint layer in an anti-corrosion layer is conducted on the whole surface of the glass fiber reinforced plastic layer of the pool. The glass fiber reinforced plastic layer in the anti-corrosion layer is constructed on the surface of the prefabricated part in the factory prefabrication stage, only the finish paint layer in the anti-corrosion layer is constructed after field assembly is completed, and by optimizing the anti-corrosion layer construction technology, field anti-corrosion layer sealing work can be reduced, and the overall quality and construction efficiency of the anti-corrosion layer are improved.

Description

Technical Field

[0001] The present invention relates to the technical field of prefabricated water pools, and in particular to a construction method of a prefabricated water pool in which an anti-corrosion layer is integrated with prefabricated components. Background Art

[0002] Currently, anti-corrosion coatings are commonly applied on-site for water tank structures. Because water tanks are often confined spaces and the anti-corrosion materials contain volatile toxic substances, workers face occupational health risks and certain production safety risks. Furthermore, on-site temperature, humidity, and dust disturbances can easily cause defects such as pinholes and peeling in the anti-corrosion coating, making quality control difficult. Summary of the Invention

[0003] The purpose of the present invention is to provide a construction method for an assembled water pool in which an anti-corrosion layer is integrated with prefabricated components, which can effectively solve the problems of health hazards, quality defects and low construction efficiency caused by on-site construction of the anti-corrosion layer of a cast-in-place water pool.

[0004] To achieve the above-mentioned purpose, the technical solution of the present invention is a construction method of an assembled pool in which an anti-corrosion layer is integrated with prefabricated components, comprising the following steps:

[0005] S1. Processing and manufacturing side wall prefabricated components and top plate prefabricated components in a factory, and completing the construction of a fiberglass reinforced plastic layer in the anti-corrosion layer on the surface of the prefabricated components; the fiberglass reinforced plastic layer includes a bottom sealing layer, an intermediate layer, and a surface reinforcement layer constructed in sequence;

[0006] S2, on-site construction base plate;

[0007] S3. Hoist the side wall prefabricated components and complete the assembly between the side wall prefabricated components;

[0008] S4. Hoist the top plate prefabricated components and complete the assembly between the top plate prefabricated components;

[0009] S5. Complete the pouring of the cast-in-place superimposed layer of the side walls and top plate;

[0010] S6. Caulk the side walls and top plate;

[0011] S7. Re-coat the fiberglass layer in the anti-corrosion coating on the bottom plate and other areas where the anti-corrosion coating is not applied on site;

[0012] S8. Apply the topcoat layer of the anti-corrosion layer to the entire surface of the fiberglass layer of the pool.

[0013] As one of the implementation methods, in step S2, the sealing bottom layer, the middle layer, and the surface reinforcement layer are stepped at the surface edges of the prefabricated component; in step S7, the fiberglass layer applied on site is overlapped with the fiberglass layer constructed in the factory on the prefabricated component in layers.

[0014] As one of the implementation methods, the edge of each layer of the fiberglass reinforced plastic layer constructed in the factory on the prefabricated component is retracted inward by 25 to 50 mm, and the overlap width of the recoated intermediate layer, surface reinforcement layer and the corresponding layer of the fiberglass reinforced plastic layer constructed in the factory on the prefabricated component is 25 to 50 mm.

[0015] As one of the embodiments, the intermediate layer is formed by laminating glass chopped strands after being fully impregnated with resin, with a thickness of more than 2 mm and a resin content of 65-75%; the surface reinforcement layer is formed by laminating glass surface felt or polyester surface felt after being fully impregnated with resin, with a thickness of more than 2 mm and a resin content of more than 85%.

[0016] As one of the implementation methods, the following steps are also included before step S7 and step S8: fixing reinforcement plates on the surface of the surface reinforcement layer of the side wall and the top plate at a certain interval, and constructing a sealing bottom layer, an intermediate layer, and a surface reinforcement layer in sequence on the surface of the reinforcement plate and the overlapping area with the surface reinforcement layer.

[0017] As one of the implementation methods, the following steps are also included before step S1: first, a three-dimensional structural model of the water pool is established, and the design information of the equipment and pipelines is integrated into the three-dimensional structural model; then, the spatial layout of the equipment and pipelines is optimized through three-dimensional collaborative design and collision detection, and the positions of embedded parts and holes are determined; then, the side walls and top plate of the water pool are respectively split into multiple side wall prefabricated components and multiple top plate prefabricated components.

[0018] As one of the implementation methods, in step S3, after the assembly of the side wall prefabricated components is completed, PE rods are filled in the side wall joints, and then polyurethane foam glue is applied to the outside of the PE rods to seal them; in step S6, the polyurethane foam glue is first removed and then the joints are filled.

[0019] As one of the implementation methods, in step S4, after completing the assembly between the top plate prefabricated components, first stick masking tape on the bottom surface of the top plate prefabricated components at the position corresponding to the top plate joint, and then use polyurethane sealing paste to fill the top plate joint downward; in step S6, first remove the masking tape and then perform the caulking process.

[0020] As one of the implementation methods, in step S3 and step S4, after the prefabricated components are assembled, sleeves are installed in the corresponding reserved holes. In step S6, the method of caulking is: first, the interface sealing material is applied to the joints between the prefabricated components, the reserved joints around the sleeves, and the inner surfaces of other holes, and then the joints between the prefabricated components, the reserved joints around the sleeves, and other holes are filled with anti-seepage putty.

[0021] As one of the implementation methods, in step S5, before pouring the cast-in-place superimposed layer of the side wall and the top plate, the joints between the prefabricated components of the side wall and the prefabricated components of the top plate are sealed in stages. Narrow joints with a width less than or equal to 10 mm are sealed by applying polyurethane foaming agent; for wide joints with a width greater than 10 mm, PE rods are first used to fill the joints on the free side of the prefabricated plate, and then polyurethane sealant is used to seal them tightly.

[0022] Compared with the prior art, the present invention has the following beneficial effects:

[0023] (1) The present invention applies the bottom seal layer, the middle layer, and the surface reinforcement layer in the anti-corrosion layer to the surface of the prefabricated component during the prefabrication stage in the factory, and only the topcoat layer is applied after the on-site assembly is completed. By optimizing the anti-corrosion layer construction process, the on-site anti-corrosion layer sealing work can be reduced, and the overall quality and construction efficiency of the anti-corrosion layer can be improved. It is particularly suitable for the construction of reinforced concrete water tank structures that require an inner lining of an anti-corrosion layer, such as wastewater treatment tanks;

[0024] (2) The present invention adopts a stepped edge finishing method at the edges of the bottom layer, middle layer and surface reinforcement layer on the surface of the prefabricated component, and after the prefabricated components of the side wall and the top plate are spliced, the reapplied middle layer and surface reinforcement layer are overlapped with the middle layer and surface reinforcement layer on the surface of the prefabricated component respectively, to ensure the integrity of the anti-corrosion layer constructed on site and in the factory, and to improve the overall protective performance of the anti-corrosion layer;

[0025] (3) The present invention reinforces the base anti-corrosion layer through a reinforcement plate, thereby enhancing the overall protective effect of the anti-corrosion layer and prolonging its service life;

[0026] (4) The present invention first establishes a three-dimensional structural model of the pool and integrates the design information of the equipment and pipelines into the three-dimensional structural model. Then, the spatial layout of the equipment and pipelines is optimized through three-dimensional collaborative design and collision detection, and the positions of embedded parts and holes are determined, providing an accurate benchmark for the disassembly of prefabricated components. The side walls and top plates are modularly disassembled to reduce the limitations of on-site transportation and hoisting capabilities. The joints are closely spliced to reduce the joint width, simplify the construction process, and reduce on-site wet work.

[0027] (5) The present invention performs caulking treatment on the joints, reserved joints and holes before pouring the cast-in-situ superimposed layers of the side walls and the top plate, and prevents contamination and loss of the anti-corrosion layer on the surface of the component during the concrete pouring period by controlling the concrete pouring speed. BRIEF DESCRIPTION OF THE DRAWINGS

[0028] In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the following briefly introduces the drawings required for use in the embodiments or the description of the prior art. Obviously, the drawings described below are only some embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying any creative work.

[0029] Figure 1 A flowchart of a construction method for an assembled pool provided in an embodiment of the present invention;

[0030] Figure 2 A schematic diagram of a fiberglass reinforced plastic layer on a prefabricated side wall component provided by an embodiment of the present invention;

[0031] Figure 3 A schematic diagram of a fiberglass reinforced plastic layer on a prefabricated roof member provided by an embodiment of the present invention;

[0032] Figure 4 A schematic diagram of a fiberglass reinforced plastic layer on a prefabricated component provided by an embodiment of the present invention;

[0033] Figure 5 A schematic diagram of temporary sealing of joints of prefabricated side wall components provided by an embodiment of the present invention;

[0034] Figure 6 A schematic diagram of sealing the joints of the prefabricated roof components provided in an embodiment of the present invention;

[0035] Figure 7 A schematic diagram of the caulking of the upper sleeve of the side wall prefabricated component provided by an embodiment of the present invention;

[0036] Figure 8 A schematic diagram of the caulking of the upper sleeve of the top wall prefabricated component provided by an embodiment of the present invention;

[0037] Figure 9 A schematic diagram of a fiberglass reinforced plastic layer constructed on site according to an embodiment of the present invention;

[0038] Figure 10 A schematic diagram of the layer of glass fiber reinforced plastic coating at the joints of the side wall prefabricated components provided by an embodiment of the present invention;

[0039] Figure 11 A schematic diagram of the layer of glass fiber reinforced plastics applied to the joints of the top plate prefabricated components provided by an embodiment of the present invention;

[0040] Figure 12 A schematic diagram of the installation of a reinforcement plate provided in an embodiment of the present invention;

[0041] In the figure: 1. Prefabricated side wall components; 2. Prefabricated top plate components; 3. Sealing layer; 4. Middle layer; 5. Surface reinforcement layer; 6. PE rods; 7. Polyurethane foam; 8. Masking tape; 9. Polyurethane sealant; 10. Factory-applied fiberglass layer; 11. On-site repainted fiberglass layer; 12. Casing; 13. Water-resistant putty; 14. Base plate; 15. Reinforcement plate; 16. Insulation nails. DETAILED DESCRIPTION

[0042] The following will clearly and completely describe the technical solutions in the embodiments of the present invention in conjunction with the accompanying drawings. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making creative efforts are within the scope of protection of the present invention.

[0043] In the description of the present invention, it should be understood that the terms "center", "up", "down", "front", "back", "left", "right", "vertical", "horizontal", "top", "bottom", "inside", "outside", etc., indicating the orientation or position relationship, are based on the orientation or position relationship shown in the accompanying drawings, and are only for the convenience of describing the present invention and simplifying the description, rather than indicating or implying that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and therefore cannot be understood as limiting the present invention.

[0044] The terms "first" and "second" are used for descriptive purposes only and should not be understood to indicate or imply relative importance or implicitly specify the number of the technical features indicated. Therefore, features specified as "first" or "second" may explicitly or implicitly include one or more of such features; and in the description of the present invention, unless otherwise specified, "plurality" means two or more.

[0045] like Figure 1-Figure 2 As shown, this embodiment provides a construction method for an assembled pool in which an anti-corrosion layer is integrated with prefabricated components, comprising the following steps:

[0046] S1. Processing and manufacturing side wall prefabricated components 1 and top plate prefabricated components 2 in a factory, and completing the construction of a fiberglass reinforced plastic layer in the anti-corrosion layer on the surface of the prefabricated components; the fiberglass reinforced plastic layer includes a bottom sealing layer 3, an intermediate layer 4, and a surface reinforcement layer 5 constructed in sequence;

[0047] S2, on-site construction base plate 14;

[0048] S3, hoisting the side wall prefabricated component 1 and completing the assembly of the side wall prefabricated components 1;

[0049] S4, hoisting the top plate prefabricated component 2 and completing the assembly of the top plate prefabricated components 2;

[0050] S5. Complete the pouring of the cast-in-place superimposed layer of the side walls and top plate;

[0051] S6. Caulk the side walls and top plate;

[0052] S7. Re-coat the fiberglass layer in the anti-corrosion coating on the bottom plate 14 and other areas where the anti-corrosion coating is not applied on site;

[0053] S8. Apply the topcoat layer of the anti-corrosion layer to the entire surface of the fiberglass layer of the pool.

[0054] In this embodiment, the anti-corrosion layer includes a sealing bottom layer 3, an intermediate layer 4, a surface reinforcement layer 5 and a topcoat layer, and the sealing bottom layer 3, the intermediate layer 4 and the surface reinforcement layer 5 are applied to the surface of the prefabricated component during the prefabrication stage in the factory, and only the topcoat layer is applied after the on-site assembly is completed. By integrating the pool structure with the anti-corrosion layer for prefabricated construction, the on-site sealing work of the anti-corrosion layer can be reduced, and the overall quality and construction efficiency of the anti-corrosion layer can be improved.

[0055] The above embodiment is optimized. In step S2, the bottom sealing layer 3, the middle layer 4, and the surface reinforcement layer 5 are trimmed in a stepped manner at the surface edge of the prefabricated component. In step S7, the fiberglass reinforced plastic layer 11 applied on site is overlapped in layers with the fiberglass reinforced plastic layer 10 applied in the factory on the prefabricated component. By adopting a stepped trimming method at the edges of the bottom sealing layer 3, the middle layer 4, and the surface reinforcement layer 5 on the surface of the prefabricated component, a width is reserved for the subsequent overlap of the anti-corrosion layer applied on site. After the side walls and the top plate are spliced, the bottom sealing layer 3, the middle layer 4, and the surface reinforcement layer 5 are applied to the area where the anti-corrosion layer is not applied. The middle layer 4 and the surface reinforcement layer 5 applied on site are overlapped in layers with the middle layer 4 and the surface reinforcement layer 5 applied in the factory on the surface of the prefabricated component, respectively. This ensures the integrity of the anti-corrosion layer constructed on site and in the factory, and improves the overall protective performance.

[0056] Furthermore, except for a 50~100mm wide range reserved at both ends of the top plate prefabricated component 2 and the edges of the side wall prefabricated component 1, the bottom sealing layer 3, the middle layer 4, and the surface reinforcement layer 5 on the surface of the top plate prefabricated component 2 and the side wall prefabricated component 1 are all constructed in the factory, thereby improving the anti-corrosion layer application ratio in the factory prefabrication link, and achieving the completion of the bottom sealing layer 3, the middle layer 4, and the surface reinforcement layer 5 in the anti-corrosion layer of more than 90% of the prefabricated component surface in a standardized workshop, effectively reducing the on-site workload of workers.

[0057] Furthermore, the edge of each layer of the fiberglass reinforced plastic layer 10 constructed in the factory on the prefabricated component is retracted inward by 25 to 50 mm, and the overlap width of the intermediate layer 4 and surface reinforcement layer 5 applied on site and the corresponding layer of the fiberglass reinforced plastic layer 10 constructed in the factory on the prefabricated component is 25 to 50 mm, ensuring that the overlap has sufficient thickness and good bonding strength, effectively preventing the intrusion of moisture, corrosive media, etc., thereby ensuring the anti-corrosion performance of the overlap and further improving the protection effect of the entire anti-corrosion system.

[0058] In this embodiment, the intermediate layer 4 is formed by laminating glass chopped strands that have been fully impregnated with resin. It has a thickness of at least 2 mm and a resin content of 65-75%, preferably approximately 70%. The surface reinforcement layer 5 is formed by laminating glass or polyester surface mats that have been fully impregnated with resin. It has a thickness of at least 2 mm and a resin content of at least 85%. During the construction of the intermediate layer 4 and surface reinforcement layer 5, bubbles and pinholes can significantly reduce the corrosion resistance. Therefore, careful degassing with a defoaming roller or other tool is necessary to ensure that the resin completely impregnates the fibers and that the layers are dense and free of visible defects.

[0059] In some embodiments, the following steps are further included before step S7 and step S8: reinforcing plates 15 are fixed to the surface reinforcement layer 5 of the side walls and the top plate at a predetermined interval, and a sealing layer 3, an intermediate layer 4, and a surface reinforcement layer 5 are sequentially constructed on the surface of the reinforcing plates 15 and in the overlapping areas with the surface reinforcement layer 5. In this embodiment, the reinforcing plates 15 are used to reinforce the base anti-corrosion layer, thereby enhancing the overall protective effect of the anti-corrosion layer and effectively extending its service life.

[0060] Among them, the reinforcement plate 15 can be a rectangular cross-section strip reinforcement plate 15 made of FRP material, which is evenly arranged on the surface reinforcement layer 5 of the side wall and the top plate according to the rule of spacing not more than 1500mm, and is anchored to the concrete structure base with insulation nails 16. The spacing between the insulation nails should be no more than 500mm, and the distance from the center of the insulation nails 16 near the free edge of the reinforcement plate 15 to the edge of the plate should be less than 100mm. The cross-sectional dimensions of the reinforcement plate 15 are 50mm (width) × 6mm (thickness), and the specifications of the insulation nails 16 are φ6mm × 65mm (rod diameter × rod length). After the reinforcement plate 15 is installed and fixed, the anti-corrosion layer must be stacked on its surface and in the overlap area with the base anti-corrosion layer. The thickness of the new stacking layer should be consistent with the design thickness of the existing anti-corrosion layer in the surrounding area.

[0061] In some embodiments, step S1 is preceded by the following steps: first, a three-dimensional structural model of the pool is created, and the design information of the equipment and pipelines is integrated into the three-dimensional structural model. Then, through three-dimensional collaborative design and collision detection, the spatial layout of the equipment and pipelines is optimized, and the locations of embedded parts and holes are determined. The side walls and roof of the pool are then divided into multiple side wall prefabricated components 1 and multiple roof prefabricated components 2, respectively. Specifically, based on the pool structural drawings, a three-dimensional structural model of the pool is created using Autodesk Revit 3D simulation software. After the design information of various specialized equipment and pipelines is input and integrated, the spatial layout of the equipment and pipelines is optimized through three-dimensional collaborative design and collision detection, and spatial conflicts are identified and resolved. Based on the coordinated and confirmed model, the location, size, and elevation of all metal parts (such as casing 12, anchor bolts, steel plates, etc.) and reserved holes that need to be embedded before the structural concrete is poured are precisely located, providing an accurate benchmark for the division of the prefabricated components. Furthermore, detailed design of nodes such as prefabricated component joints and structural casing 12 in the three-dimensional structural model is performed to ensure the overall protective performance of the anti-corrosion layer in weak or key areas.

[0062] In this embodiment, the prefabricated components of the pool structure are finely divided and optimized according to the optimized three-dimensional structural model. Among them, the side walls are in the form of double-layer prefabricated concrete composite walls, and the top plate is in the form of prefabricated concrete composite plates, which reduce the limitations on transportation and lifting capacity. The prefabricated components of the side walls and the top plate are modularly divided, and the joints of the prefabricated components avoid stress concentration areas, including the corners of the pool, openings, edges of pipe openings, and other areas where stress is significantly concentrated; the splicing between the prefabricated components adopts a close splicing form without post-casting strips, which can simplify the construction process, speed up the installation speed, reduce on-site wet work, and ensure the flatness of the board surface. Furthermore, the joint width of the side wall prefabricated component 1 is not more than 20 mm, and the joint width of the top plate prefabricated component 2 is not more than 5 mm. The use of narrow joints is conducive to reducing leakage, ensuring effective connection between components, and providing favorable conditions for reinforcement and sealing at the joints.

[0063] Furthermore, in step S1, when making prefabricated components, embedded parts and reserved holes are embedded at corresponding positions of the prefabricated components, and after the prefabricated components are cured to 100% of the design strength, the moisture content of the component surface is measured. If the moisture content within 20 mm of the prefabricated component surface is below 6%, the anti-corrosion layer is then constructed on one or both sides of the prefabricated component.

[0064] Before applying the anti-corrosion coating to the surface of a prefabricated component, the component should be positioned for the application surface. Depending on the coating requirements (single-sided or double-sided), the following flipping methods should be used: A. Single-sided coating (applicable to sidewall prefabricated components 1 and roof prefabricated components 2): Use dedicated flipping equipment to flip the component so that the surface to be coated faces upward. Once the component is positioned horizontally, apply the sealant layer 3, intermediate layer 4, and surface reinforcement layer 5 in sequence. B. Double-sided coating (applicable to sidewall prefabricated components 1): Use dedicated flipping equipment to flip the component so that one surface to be coated faces upward. Once the component is positioned horizontally, apply the sealant layer 3, intermediate layer 4, and surface reinforcement layer 5 in sequence. Then, lift the component from its top as the lifting point. Once vertically suspended, rotate it 180° so that the other surface to be coated faces upward. Lower it to a horizontal position at a constant speed. Once the surface to be coated is flipped and positioned, apply the sealant layer 3, intermediate layer 4, and surface reinforcement layer 5 in sequence.

[0065] When applying the anti-corrosion layer on the surface of prefabricated components, first use putty to fill and level the holes, unevenness and weld defects on the surface of the concrete base of the prefabricated components to ensure that the base is flat and solid; then, based on the detailed design drawings, draw lines on the surface of the prefabricated components to mark the construction scope of the anti-corrosion layer in the factory, and then according to the design requirements, carry out the layer-by-layer construction of the sealing bottom layer 3, the intermediate layer 4, and the surface reinforcement layer 5.

[0066] Furthermore, in step S3, after the assembly of the side wall prefabricated components 1 is completed, PE rods 6 are filled in the side wall joints, and then polyurethane foam glue 7 is applied to the outside of the PE rods 6 to seal them; in step S6, the polyurethane foam glue 7 is first removed, and then the joints are filled. The side walls of the pool in this embodiment adopt a double-layer laminated structure. PE rods 6 are filled as pads in the joints of the inner side wall prefabricated components 1 near the inside of the pool, and PE rods 6 are filled as pads in the joints of the outer side wall prefabricated components 1 near the outside of the pool. The PE rods 6 can specifically be φ28mm PE rods 6. Polyurethane foam glue 7 is then applied to the side of the PE rods 6 facing away from the cast-in-place laminated layer to seal it as a temporary sealing measure to prevent leakage during the side wall concrete pouring stage. The polyurethane foam glue 7 needs to be fully and densely injected, and its effective sealing depth should be no less than 15mm.

[0067] In this embodiment, after the side wall prefabricated component 1 is hoisted and fixed, its plane position, installation elevation, verticality and flatness deviation between adjacent prefabricated components are checked to ensure that various parameters meet the requirements of the design drawings and relevant construction acceptance specifications.

[0068] Furthermore, in step S4, after the assembly of the top plate prefabricated components 2 is completed, a masking tape 8 is first pasted on the bottom surface of the top plate prefabricated component 2 at the position corresponding to the top plate joint, and then the top plate joint is filled downward with polyurethane sealing paste 9; in step S6, the masking tape 8 is first removed, and then the joint is filled. In this embodiment, the joint between the top plate prefabricated components 2 is sealed after the top plate prefabricated components 2 are hoisted to prevent leakage during concrete pouring. Specifically, the two ends of the masking tape 8 are respectively pasted and fixed on the bottom surface of the top plate prefabricated components 2 on both sides of the joint to prevent the polyurethane sealing paste 9 from flowing and contaminating the anti-corrosion layer on the surface of the top plate prefabricated component 2. A material with high fluidity such as grouting material can also be used instead of the polyurethane sealing paste 9 to seal the joint downward from the top of the top plate prefabricated component 2.

[0069] In this embodiment, after the top plate prefabricated component 2 is hoisted and fixed, its plane position, installation elevation, verticality and flatness deviation between adjacent prefabricated components are checked to ensure that various parameters meet the requirements of the design documents and relevant construction acceptance specifications.

[0070] Furthermore, in step S5, before pouring the cast-in-place superimposed layer of the side walls and the top plate, the joints between the side wall prefabricated components 1 and the top plate prefabricated components 2 are sealed in stages. Narrow joints with a width less than or equal to 10 mm are sealed by injecting polyurethane foaming agent; wide joints with a width greater than 10 mm are first filled with PE rods 6 on the free side of the prefabricated plate, and then sealed tightly with polyurethane sealant 9. Before pouring the cast-in-place superimposed layer of the side walls and the top plate, check again whether the installation positions of all prefabricated components meet the design and specification requirements, and check whether the sealing status of the joints between the prefabricated components is intact. Due to the existence of installation tolerances, the actual width of the joints between the side wall prefabricated components 1 and the top plate prefabricated components 2 may be inconsistent. It is necessary to classify the joints according to the position and width of the prefabricated component joints for temporary filling or formal sealing to prevent pollution losses during concrete pouring. For narrow joints with a width less than or equal to 10 mm, polyurethane foam is applied on the joint surface of cast-in-place concrete for sealing; for wide joints with a width greater than 10 mm, since polyurethane foam is difficult to support the side pressure of cast-in-place concrete, PE rods 6 should be used to fill the joints on the free surface of the prefabricated component, i.e., the indoor side, and then polyurethane sealant 9 should be used to seal the outside of the PE rods 6 tightly.

[0071] Furthermore, the pouring of the cast-in-place superimposed layer of the side wall and the top plate is carried out in batches and layers, with the pouring height of each time being less than or equal to 4.2m and the pouring height per hour not exceeding 1m. By controlling the concrete pouring speed, the contamination loss of the anti-corrosion layer on the surface of the component during the concrete pouring period is prevented, and the upper layer of concrete should be covered and poured in time when the lower layer of concrete is close to initial setting but has not lost its plasticity, to ensure that the side pressure of the cast-in-place concrete acting on the side wall prefabricated component 1 is maintained at the lowest level, thereby avoiding deformation of the prefabricated component due to excessive side pressure, and further causing quality defects such as cracking and falling off of the surface anti-corrosion layer. In one embodiment, the cast-in-place superimposed layers of the side walls and roof are poured in three stages: first, the bottom of the double-layer precast side wall components 1, then the middle of the double-layer precast side wall components 1, and finally, the upper portion of the double-layer precast side wall components 1 and the top of the precast roof components 2. Before pouring concrete, debris should be removed, and the concrete joints should be pre-moistened with water. Before the next pour, any accumulated water in the wall should be cleared to ensure concrete strength. After pouring, the concrete should be promptly cured for at least seven days.

[0072] Furthermore, in steps S3 and S4, after the prefabricated components are assembled, sleeves 12 are installed in the corresponding reserved holes. In step S6, the method for caulking is as follows: first, an interface sealant is applied to the inner surface of the joints between the prefabricated components, the reserved joints around the sleeves 12, and other holes, and then the joints between the prefabricated components, the reserved joints around the sleeves 12, and other holes are filled with anti-seepage putty 13. This embodiment improves the anti-corrosion and anti-seepage properties of the concrete structure matrix by filling the gaps and holes in the matrix with anti-seepage putty 13.

[0073] Among them, after the wall sleeve 12 is installed and fixed to the reserved hole on the side wall prefabricated component 1, the hole is closed with a wooden formwork, and the wooden formwork is fastened using a high-strength tension screw with a water stop ring. Since the interface between the wall sleeve 12 and the cast-in-place concrete is prone to density defects, a PE sealing strip can be pre-arranged around the outside of the sleeve 12 to leave a 20mm×20mm cross-section of the embedded gap. Subsequently, anti-seepage putty 13 is used to seal and compact it to enhance the anti-seepage performance of the node. The anti-seepage putty 13 can be a putty with waterproof and anti-seepage properties, specifically FRP polymer putty, etc.

[0074] After the cast-in-situ concrete of the structure is poured and cured, the structural joints between the prefabricated components, the reserved joints around the sleeve 12, and other holes are filled and compacted with anti-seepage putty 13 to enhance the anti-seepage and anti-corrosion performance of this part. The joints of the side wall prefabricated components 1 are temporarily sealed with foam glue. When the joints are permanently filled, the PE rods 6 of the lining need to be retained. Only the polyurethane foaming agent used as a temporary sealing measure is removed. After the residual sealant and impurities on the surface of the concrete matrix in the joint are thoroughly cleaned, the anti-seepage putty 13 can be used for backfilling and compaction. Before the FRP polymer anti-seepage putty 13 is used for filling, the special interface sealing material supplied by the same manufacturer as the putty must be used to fully coat the inner surface of the joints or holes. The painting operation should strictly follow the order from the top of the joint to the bottom of the joint to ensure that all base surfaces to be filled are evenly painted and not missed.

[0075] In this embodiment, the bottom layer 3, the middle layer 4 and the surface reinforcement layer 5 of the anti-corrosion layer of the prefabricated component have been completed during the prefabrication stage in the factory. However, since there are still some areas on the surface of the prefabricated component where the anti-corrosion layer has not been applied, it is necessary to apply the anti-corrosion layer on site to these areas where the anti-corrosion layer has not been applied, such as the edges of the prefabricated components, the joints between the prefabricated components, and the installation locations of the casing 12.

[0076] The quality of the concrete substrate surface treatment is crucial to the adhesion performance of the anti-corrosion coating. In step S7, the concrete substrate surface must be dry, clean, and free of contamination before construction. If moisture or condensed water droplets are present on the surface, the water must be thoroughly removed and the concrete substrate dried. Dust, oil, and other contaminants must also be thoroughly removed from the concrete substrate surface, and any defects must be repaired as necessary. The anti-corrosion coating should be applied layer by layer, following the bottom seal layer 3, the middle layer 4, and the surface reinforcement layer 5. A topcoat layer should not be applied for now. The fiberglass mat (e.g., chopped strand mat or surface mat) used in the middle layer 4 and the surface reinforcement layer 5 must overlap the prefabricated component factory-applied anti-corrosion layer 10 in layers. Each layer should overlap at least 50 mm, but the surface mat overlap should be limited to 100 mm. One or two additional layers of fiberglass mat should be applied to the middle layer 4 for localized reinforcement in areas of stress concentration or vulnerability, such as around the casing 12 and at component corners. In one embodiment, the surface reinforcement layer 5 is formed from a resin and surface mat, with a thickness of at least 0.2 mm and a resin content of at least 85%. The intermediate layer 4 is formed from the same resin as the surface layer and two or more layers of chopped strand mat (450 g / m*), with a thickness of at least 2 mm and a resin content of approximately 70%.

[0077] Furthermore, in step S8, after the anti-corrosion layer reinforcement plate 15 is completed, a topcoat layer is applied to the surface reinforcement layer 5 of the bottom plate 14, side walls, and top wall to achieve the final seal of the anti-corrosion system. The topcoat layer combines aesthetic enhancement, enhanced weather resistance, and accelerated resin curing. Liquid paraffin (also known as an air hardener) is typically added. Because the resin-air interface is prone to curing inhibition, the added liquid paraffin migrates to the coating surface during the curing process and forms a continuous barrier film, effectively isolating the resin from air and ensuring complete resin curing.

[0078] The construction method of the present invention is described in detail below through a specific embodiment.

[0079] A construction method for an assembled water pool with an integrated anti-corrosion layer and prefabricated components comprises the following steps:

[0080] 1) Build a 3D structural model of the pool and integrate the design information of equipment and pipelines into the 3D structural model. Then, optimize the spatial layout of the equipment and pipelines through 3D collaborative design and collision detection. Accurately locate the positions of embedded parts and holes based on the coordinated and confirmed model. Then, based on the optimized 3D structural model, split the pool's sidewalls and roof into multiple sidewall prefabricated components 1 and multiple roof prefabricated components 2, respectively.

[0081] 2) The side wall prefabricated components 1 and the top plate prefabricated components 2 are processed and manufactured in the factory. The anti-corrosion layer including the bottom seal layer 3, the middle layer 4, and the surface reinforcement layer 5 are sequentially constructed on the surface of the prefabricated components. The edges of the bottom seal layer 3, the middle layer 4, and the surface reinforcement layer 5 are finished in a stepped manner.

[0082] 3) On-site construction of base plate 14;

[0083] 4) Hoist the side wall prefabricated components 1, complete the assembly of the side wall prefabricated components 1, and install the sleeves 12 in the corresponding reserved holes. Then, fill the side wall joints with PE rods 6, and then apply polyurethane foam glue 7 on the outside of the PE rods 6 to seal them;

[0084] 5) Hoist the prefabricated roof components 2 and complete the assembly between the two prefabricated roof components. Install the sleeves 12 in the corresponding reserved holes. Then, apply masking tape 8 to the bottom surface of the prefabricated roof components 2 at the location corresponding to the roof joint. Then, use polyurethane sealant 9 to fill the roof joint downwards.

[0085] 6) First, perform graded sealing on the joints between the side wall prefabricated components 1 and the top plate prefabricated components 2. Narrow joints with a width of less than or equal to 10 mm are sealed by applying polyurethane foaming agent. For wide joints with a width greater than 10 mm, first fill the joints with PE rods 6 on the free-facing side of the prefabricated panels, then seal them tightly with polyurethane sealant 9. Subsequently, the cast-in-place superimposed layers of the side walls and top plate are cast in stages and layers.

[0086] 7) Apply interface sealing material to the inner surface of the joints between prefabricated components, the reserved joints around the casing 12, and other holes, and then use anti-seepage putty 13 to fill the joints between prefabricated components, the reserved joints around the casing 12, and other holes, completing the caulking treatment of the side walls and top plate;

[0087] 8) On site, the bottom plate 14 and other areas without anti-corrosion coating, such as the edges of prefabricated components, the joints between prefabricated components, and the installation locations of the casing 12, are sequentially re-coated with the anti-corrosion coating of the bottom seal layer 3, the middle layer 4, and the surface reinforcement layer 5;

[0088] 9) Fix reinforcement plates 15 at regular intervals on the surface of the surface reinforcement layer 5 of the side walls and top plate, and sequentially construct the bottom layer 3, the middle layer 4, and the surface reinforcement layer 5 on the surface of the reinforcement plates 15 and in the overlapping area with the surface reinforcement layer 5;

[0089] 10) Apply a topcoat layer to the surface of the surface reinforcement layer 5 of the bottom plate 14, side walls and top wall to achieve final sealing of the anti-corrosion system.

[0090] The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions, improvements, etc. made within the spirit and principles of the present invention should be included in the scope of protection of the present invention.

Claims

1. A construction method for an assembled pool with an anti-corrosion layer integrated with prefabricated components, characterized in that: The steps include: S1. Processing and manufacturing side wall prefabricated components and top plate prefabricated components in a factory, and completing the construction of a fiberglass reinforced plastic layer in the anti-corrosion layer on the surface of the prefabricated components; the fiberglass reinforced plastic layer includes a bottom sealing layer, an intermediate layer, and a surface reinforcement layer constructed in sequence; S2, on-site construction base plate; S3. Hoist the side wall prefabricated components and complete the assembly between the side wall prefabricated components; S4. Hoist the top plate prefabricated components and complete the assembly between the top plate prefabricated components; S5. Complete the pouring of the cast-in-place superimposed layer of the side walls and top plate; S6. Caulk the side walls and top plate; S7. Re-coat the fiberglass layer in the anti-corrosion coating on the bottom plate and other areas where the anti-corrosion coating is not applied on site; S8. Apply the topcoat layer of the anti-corrosion layer to the entire surface of the fiberglass layer of the pool.

2. The construction method of the assembled pool with an integrated anti-corrosion layer and prefabricated components according to claim 1 is characterized in that: In step S2, the bottom sealing layer, the middle layer, and the surface reinforcement layer are stepped at the surface edges of the prefabricated component; in step S7, the fiberglass reinforced plastic layer applied on site is overlapped with the fiberglass reinforced plastic layer constructed in the factory on the prefabricated component in layers.

3. The construction method of the assembled pool with an integrated anti-corrosion layer and prefabricated components as claimed in claim 2, characterized in that: The edge of each layer of the fiberglass reinforced plastic layer constructed in the factory on the prefabricated component is retracted inward by 25~50 mm, and the overlap width of the intermediate layer and surface reinforcement layer applied on site and the corresponding layer of the fiberglass reinforced plastic layer constructed in the factory on the prefabricated component is 25~50 mm.

4. The construction method of the assembled pool with an integrated anti-corrosion layer and prefabricated components according to claim 1 is characterized in that: The intermediate layer is formed by laminating glass chopped strands after being fully impregnated with resin, with a thickness of more than 2 mm and a resin content of 65-75%; the surface reinforcement layer is formed by laminating glass surface felt or polyester surface felt after being fully impregnated with resin, with a thickness of more than 2 mm and a resin content of more than 85%.

5. The construction method of the assembled pool with the anti-corrosion layer integrated with the prefabricated components according to claim 1 is characterized in that: Before step S7 and step S8, the following steps are also included: fixing reinforcement plates on the surface reinforcement layers of the side walls and the top plate at a certain interval, and sequentially constructing a sealing bottom layer, an intermediate layer, and a surface reinforcement layer on the surface of the reinforcement plates and in the overlapping area with the surface reinforcement layer.

6. The construction method of the assembled pool with the anti-corrosion layer integrated with the prefabricated components according to claim 1, characterized in that: The following steps are also included before step S1: first, a three-dimensional structural model of the pool is established, and the design information of the equipment and pipelines is integrated into the three-dimensional structural model; then, the spatial layout of the equipment and pipelines is optimized through three-dimensional collaborative design and collision detection, and the positions of embedded parts and holes are determined; then, the side walls and top plate of the pool are split into multiple side wall prefabricated components and multiple top plate prefabricated components respectively.

7. The construction method of the assembled pool with an integrated anti-corrosion layer and prefabricated components as claimed in claim 2, characterized in that: In step S3, after the assembly of the side wall prefabricated components is completed, PE rods are stuffed in the side wall joints, and then polyurethane foam glue is applied to the outside of the PE rods to seal them; in step S6, the polyurethane foam glue is first removed, and then the joints are filled.

8. The construction method of the assembled pool with an integrated anti-corrosion layer and prefabricated components according to claim 1, characterized in that: In step S4, after the assembly of the top plate prefabricated components is completed, masking tape is first pasted on the bottom surface of the top plate prefabricated components at the position corresponding to the top plate joint, and then the top plate joint is filled downward with polyurethane sealing paste; in step S6, the masking tape is first removed, and then the joint is filled.

9. The construction method of the assembled pool with an integrated anti-corrosion layer and prefabricated components according to claim 1, characterized in that: In step S3 and step S4, after the prefabricated components are assembled, sleeves are installed in the corresponding reserved holes; in step S6, the method of caulking is: first, the interface sealing material is applied to the joints between the prefabricated components, the reserved joints around the sleeves, and the inner surfaces of other holes, and then the joints between the prefabricated components, the reserved joints around the sleeves, and other holes are filled with anti-seepage putty.

10. The construction method of the assembled pool with an integrated anti-corrosion layer and prefabricated components according to claim 1, characterized in that: In step S5, before pouring the cast-in-place superimposed layer of the side wall and the top plate, the joints between the prefabricated components of the side wall and the prefabricated components of the top plate are sealed in stages. Narrow joints with a width less than or equal to 10 mm are sealed by applying polyurethane foaming agent; for wide joints with a width greater than 10 mm, PE rods are first used to fill the joints on the free side of the prefabricated plate, and then polyurethane sealant is used to seal them tightly.

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