Construction method of structural top plate with mold-foam composite insulation board combined with reinforcing mesh

Abstract

The invention discloses a construction method of a structural top plate with a mold-foam composite insulation board combined with a reinforcing mesh, and relates to the technical field of building construction, and the construction method comprises the following steps: (a) the mold-foam composite insulation board is laid as a permanent non-dismantling formwork, the core material of the insulation board is high-density EPS or XPS, the core material of the insulation board is a double-sided composite cement-based reinforcing layer, and the thickness is 80-100 mm; (b) a reinforcing mesh is embedded in a preset groove of the insulation board to form a bidirectional stress structure; (c) a grout leakage prevention adhesive tape is pasted to the abutted seam of the heat preservation plate, and a positioning clamping piece is installed on the plate face to fix the reinforcing mesh; the method has the core advantages that the construction period is remarkably shortened, and the links of formwork disassembly and assembly and later-stage thermal insulation layer additional links in the traditional process are eliminated; the interface bonding reliability of the thermal insulation layer and the structural layer is improved, and the hidden danger of hollowing and falling is effectively solved; and meanwhile, the building energy-saving standard and the structural safety requirement are met, and environmental protection benefits are considered.

Description

Technical Field

[0001] The invention relates to the technical field of building construction, in particular to a construction method for a structural top plate of a molded foam composite insulation board combined with a steel mesh. Background Art

[0002] In current construction projects, reinforced concrete cast-in-place flat roofs still generally adopt a step-by-step construction model of "structure first, insulation later". Its core process includes:

[0003] Structural layer construction: erecting wooden formwork / steel formwork support system → tying steel mesh → pouring concrete → curing for 28 days → removing formwork;

[0004] Additional insulation layer: laying loose insulation materials (slag, perlite) or pasting rigid insulation boards (XPS / EPS) on the surface of the structural layer;

[0005] Waterproofing and finishing: leveling layer, waterproofing layer and finishing layer are applied on the insulation layer.

[0006] The existing construction has the following problems:

[0007] Long construction period: The structural layer maintenance period (7 to 28 days) is completely separated from the insulation layer construction. The construction period of a single roof project is as long as 30 to 45 days, delaying the overall progress.

[0008] Formwork waste: The turnover of wooden formwork is ≤5 times, with an amortized cost of 35-40 yuan per square meter. Construction waste generated after dismantling accounts for 38% of the solid waste on the construction site.

[0009] Hollowing and falling off: Due to the poor physical properties of the insulation layer and the concrete structure layer, the interface peels off under the temperature difference stress; Thermal insulation performance degradation: The thermal conductivity coefficient of traditional loose thermal insulation materials increases sharply with the increase of humidity, and the energy saving efficiency decreases by 40%.

[0010] To this end, an integrated method was designed to solve the above-mentioned technical problems by using molded foam composite insulation board as permanent formwork and embedding steel mesh into the overall cast-in-situ concrete. Summary of the Invention

[0011] In view of the deficiencies in the prior art, the present invention provides a construction method for a structural top plate of a molded foam composite insulation board combined with a steel mesh, which solves the technical problems raised in the above-mentioned background technology.

[0012] To achieve the above objectives, the present invention is implemented through the following technical solutions: A construction method for a structural top plate of a molded foam composite insulation board combined with a steel mesh, comprising the following steps:

[0013] (a) Laying molded foam composite insulation board as a permanent non-disassembly formwork, wherein the core material of the insulation board is high-density EPS or XPS, and the double-sided composite cement-based reinforcement layer has a thickness of 80 to 100 mm;

[0014] (b) embedding a steel mesh into a preset groove of the insulation board to form a bidirectional force-bearing structure;

[0015] (c) Paste anti-leakage tape at the joints of the insulation board and install positioning clips to fix the steel mesh on the board surface;

[0016] (d) Casting concrete on the surface of the insulation board as a whole to simultaneously form an integrated top plate of the structural load-bearing layer and the insulation layer;

[0017] (e) After the concrete is cured and solidified, the roof finishing layer can be constructed directly.

[0018] Preferably, the molded foam composite insulation board is spliced ​​in step (a) by tongue-and-groove lap joint or flat-jointed joint, and the gaps between the boards are filled with polymer mortar.

[0019] Preferably, the steel mesh in step (b) is a welded steel mesh prefabricated in a factory, formed by resistance welding at the intersections of the longitudinal and transverse steel bars, and the mesh spacing is ≤150mm.

[0020] Preferably, the positioning clip in step (c) is made of plastic or metal, is U-shaped or I-shaped, is clamped to the edge of the insulation board and presses the steel mesh.

[0021] Preferably, the cast-in-situ concrete in step (d) is fine stone concrete, the slump is controlled at 160-180 mm, and the casting thickness is ≥60 mm.

[0022] Preferably, before laying the insulation board in step (a), an L-shaped anchor is provided on the top of the base wall, and the insulation board is mechanically connected to the anchor by bolts or pins.

[0023] Preferably, the construction method is applicable to the renovation of existing buildings, and specifically includes:

[0024] Remove the original top plate finishing layer to the structural layer;

[0025] Implant short steel bars on the surface of the structural layer as connectors;

[0026] Bond the molded foam composite insulation board with mortar and sleeve it onto the short steel bars;

[0027] Complete the integrated roof construction according to steps (b)-(e).

[0028] Preferably, the cement-based reinforcement layer is mixed with polypropylene fiber or glass fiber mesh cloth, and has a compressive strength of ≥15 MPa and a bonding strength with concrete of ≥1.0 MPa.

[0029] Beneficial effects

[0030] This invention provides a construction method for a structural roof slab made of molded foam composite insulation panels combined with steel mesh. By using molded foam composite insulation panels as a permanent, removable formwork and integrating the steel mesh for simultaneous construction with cast-in-place concrete, this method achieves the integrated formation of the structural load-bearing layer and the insulation functional layer. Its core advantages include significantly shortening the construction cycle, eliminating the traditional process of formwork assembly and disassembly and subsequent addition of the insulation layer; improving the interfacial bonding reliability between the insulation layer and the structural layer, effectively addressing the risk of hollowing and shedding; and reducing overall construction costs while meeting building energy-saving standards and structural safety requirements, while also addressing environmental benefits. DETAILED DESCRIPTION

[0031] 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 part of the embodiments of the present invention, not all of them. All other embodiments obtained by ordinary technicians in this field based on the embodiments of the present invention without making any creative efforts are within the scope of protection of the present invention.

[0032] The present invention provides a technical solution: a construction method for a structural top plate of a molded foam composite insulation board combined with a steel mesh, comprising the following steps:

[0033] (a) Laying molded foam composite insulation board as a permanent non-disassembly formwork, wherein the core material of the insulation board is high-density EPS or XPS, and the double-sided composite cement-based reinforcement layer has a thickness of 80 to 100 mm;

[0034] (b) embedding a steel mesh into a preset groove of the insulation board to form a bidirectional force-bearing structure;

[0035] (c) Paste anti-leakage tape at the joints of the insulation board and install positioning clips to fix the steel mesh on the board surface;

[0036] (d) Casting concrete on the surface of the insulation board as a whole to simultaneously form an integrated top plate of the structural load-bearing layer and the insulation layer;

[0037] (e) After the concrete is cured and solidified, the roof finishing layer can be constructed directly.

[0038] This embodiment is further configured such that the molded foam composite insulation board in step (a) is spliced ​​by tongue-and-groove lap joint or flat-jointed joint, and the gaps between the boards are filled with polymer mortar.

[0039] This embodiment is further configured such that the steel mesh in step (b) is a welded steel mesh prefabricated in a factory, formed by resistance welding at the intersections of the longitudinal and transverse steel bars, and the mesh spacing is ≤150mm.

[0040] This embodiment is further configured such that the positioning clip in step (c) is made of plastic or metal, is U-shaped or I-shaped, is clamped to the edge of the insulation board and presses the steel mesh.

[0041] This embodiment is further configured such that the cast-in-situ concrete in step (d) is fine stone concrete, the slump is controlled at 160-180 mm, and the casting thickness is ≥60 mm.

[0042] This embodiment is further configured such that, before laying the insulation board in step (a), an L-shaped anchor is provided on the top of the base wall, and the insulation board is mechanically connected to the anchor by bolts or pins.

[0043] This embodiment is further configured such that the construction method is applicable to the renovation of existing buildings, and specifically includes:

[0044] Remove the original top plate finishing layer to the structural layer;

[0045] Implant short steel bars on the surface of the structural layer as connectors;

[0046] Bond the molded foam composite insulation board with mortar and sleeve it onto the short steel bars;

[0047] Complete the integrated roof construction according to steps (b)-(e).

[0048] This embodiment is further configured such that the cement-based reinforcement layer is mixed with polypropylene fiber or glass fiber mesh cloth, has a compressive strength of ≥15 MPa, and a bonding strength with concrete of ≥1.0 MPa.

[0049] The detailed connection means are well-known technologies in this field. The following mainly introduces the working principle and process. The specific operations are as follows.

[0050] Example:

[0051] Example 1: Construction of roof slab of new residential structure

[0052] Step 1: Base preparation and anchor installation (corresponding to right 6)

[0053] Clean the top surface of the base wall to ensure there is no dust or oil stains;

[0054] L-shaped stainless steel anchors (specifications: L50×50×5mm) are implanted at intervals of 600mm along the top of the wall. The anchoring depth is ≥50mm, and bolt holes are reserved at the exposed ends.

[0055] Step 2: Laying molded foam composite insulation board (corresponding to rights 1a, 2, and 8)

[0056] Use 60mm thick molded foam composite insulation board:

[0057] Core material: high density XPS (density ≥35kg / m 3 , thermal conductivity ≤ 0.030W / (m·K));

[0058] Reinforcement layer: double-sided composite 3mm thick cement base (mixed with 0.9kg / m 3 Polypropylene fiber, compressive strength 18MPa);

[0059] The board should be laid in tongue-and-groove joint, and the board seam bite width should be ≥20mm;

[0060] The insulation boards are mechanically connected to L-shaped anchors by latch bolts (no less than 4 connection points per board).

[0061] Step 3: Installation and fixing of steel mesh (corresponding to weight 1b, weight 3, weight 4)

[0062] Embed the factory-prefabricated welded steel mesh (CRB550 cold-rolled ribbed steel bars, mesh spacing 100×100mm) in the preset grooves (15mm deep and 10mm wide) of the insulation board;

[0063] The cross steel bars at the plate joints are fixed with "I" shaped plastic clips with a clip spacing of ≤400mm to press the steel bars tightly to prevent displacement.

[0064] Step 4: Anti-leakage treatment (corresponding to right 1c)

[0065] All insulation board joints should be affixed with 20mm wide butyl rubber anti-leakage tape;

[0066] The joints between the board edge and the wall are filled with polymer mortar (bonding strength ≥ 0.8MPa).

[0067] Step 5: Cast-in-place concrete integrated molding (corresponding to weights 1d and 5)

[0068] Pour C25 fine stone concrete (stone particle size 5-10mm, slump 170mm), one-time pouring thickness 70mm;

[0069] Use a flat vibrator to vibrate, focusing on controlling the density of the joints;

[0070] Polish the surface of concrete before final setting.

[0071] Step 6: Maintenance and finishing (corresponding to right 1e)

[0072] Cover with plastic film and maintain for 7 days;

[0073] Directly apply polymer cement-based waterproof coating (thickness 1.5mm) + lay ceramic tile finishing layer.

[0074] Effect: The construction period is shortened by 40%, the comprehensive cost is reduced by 45%, and the bonding strength between the insulation layer and the structural layer reaches 1.5MPa.

[0075] Example 2: Renovation of existing industrial plant roof

[0076] Step 1: Original top plate processing (corresponding to right 7)

[0077] Remove the original asphalt waterproof layer and mortar leveling layer to expose the concrete structure layer;

[0078] The cracks were repaired by injecting epoxy resin and the surface was polished smooth.

[0079] Step 2: Connector implantation and insulation board installation (corresponding to right 7)

[0080] Implant Φ8mm short steel bars (exposed length 50mm) at intervals of 500mm and inject anchoring glue for anchoring;

[0081] Apply polymer mortar (5mm thickness) to the old roof and paste 60mm thick foam composite insulation board;

[0082] Short steel bars are inserted into the preset holes in the insulation board, and the seams between the boards are filled with mortar.

[0083] Step 3: Steel mesh and concrete construction (Synchronous 1b-e)

[0084] Lay steel mesh in the groove of the insulation board (tied and connected with short steel bars);

[0085] Casting 60mm thick steel fiber concrete (fiber content 25kg / m 3 ), enhance crack resistance;

[0086] After curing, spray polyurea waterproof coating.

[0087] Effect: After the transformation, the heat transfer coefficient of the top plate increased from 1.8W / (m 2 K) is reduced to 0.4W / (m 2 ·K), the structural bearing capacity is increased by 30%.

[0088] Key process parameter verification table

[0089]

[0090] It should be noted that, in this document, relational terms such as first and second, etc. are merely used to distinguish one entity or operation from another entity or operation, and do not necessarily require or imply any actual relationship or order between these entities or operations.

Claims

1. A construction method for a structural top plate of a molded foam composite insulation board combined with a steel mesh, characterized in that: The following steps are involved: (a) Laying molded foam composite insulation board as a permanent non-disassembly formwork, wherein the core material of the insulation board is high-density EPS or XPS, and the double-sided composite cement-based reinforcement layer has a thickness of 80 to 100 mm; (b) embedding a steel mesh into a preset groove of the insulation board to form a bidirectional force-bearing structure; (c) Paste anti-leakage tape at the joints of the insulation board and install positioning clips to fix the steel mesh on the board surface; (d) Casting concrete on the surface of the insulation board as a whole to simultaneously form an integrated top plate of the structural load-bearing layer and the insulation layer; (e) After the concrete is cured and solidified, the roof finishing layer can be constructed directly.

2. The construction method of a molded foam composite insulation board combined with a steel mesh structural top plate according to claim 1, characterized in that The splicing method of the molded foam composite insulation board in step (a) is tongue-and-groove overlap or flat-end docking, and the gaps between the boards are filled with polymer mortar.

3. The construction method of a structural top plate of a molded foam composite insulation board combined with a steel mesh according to claim 1 is characterized in that The steel mesh in step (b) is a factory-prefabricated welded steel mesh, which is formed by resistance welding at the intersection of the longitudinal and transverse steel bars, and the mesh spacing is ≤150mm.

4. The construction method of a structural top plate of a molded foam composite insulation board combined with a steel mesh according to claim 1 is characterized in that The positioning clip in step (c) is made of plastic or metal, and is U-shaped or I-shaped. It is clamped to the edge of the insulation board and presses the steel mesh.

5. The construction method of a structural top plate of a molded foam composite insulation board combined with a steel mesh according to claim 1 is characterized in that The cast-in-place concrete in step (d) is fine stone concrete, the slump is controlled at 160-180 mm, and the casting thickness is ≥60 mm.

6. The construction method of a structural top plate of a molded foam composite insulation board combined with a steel mesh according to claim 1 is characterized in that ,Step (a) Before laying the insulation board, an L-shaped anchor is set on the top of the base wall, and the insulation board is mechanically connected to the anchor by bolts or pins.

7. The construction method of a structural top plate of a molded foam composite insulation board combined with a steel mesh according to claim 1 is characterized in that ,The construction method is applicable to the renovation of existing buildings, and specifically includes: Remove the original top plate finishing layer to the structural layer; Implant short steel bars on the surface of the structural layer as connectors; Bond the molded foam composite insulation board with mortar and sleeve it onto the short steel bars; Complete the integrated roof construction according to steps (b)-(e).

8. The construction method of a structural top plate of a molded foam composite insulation board combined with a steel mesh according to claim 1, characterized in that The cement-based reinforcement layer is mixed with polypropylene fiber or glass fiber mesh cloth, with a compressive strength of ≥15MPa and a bonding strength with concrete of ≥1.0MPa.

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