Shear wall structure and construction method thereof

Abstract

The invention belongs to the technical field of shear wall structures, and particularly discloses a shear wall structure and a construction method thereof, and a shear wall block stone embedding structure comprises a reinforcement cage system, an embedding body, a 3D printing template and a concrete layer. The reinforcement cage system comprises a first metal mesh, a second metal mesh and tie bars. The inlay comprises a plurality of block stone layers, and each block stone layer comprises a plurality of block stones. The 3D printing template is provided with a cavity, and the cavity is used for containing a reinforcement cage system. And the concrete layer is formed by pouring concrete in the cavity. The 3D printing template serves as a structural component to participate in stress, the embedded block stone is stabilized through the reinforcement cage system, the block stone, the reinforcing steel bars and the concrete form a tight synergistic effect, and therefore the shear strength and the crack resistance of the wall are remarkably improved, a template-reinforcing steel bar-block stone-concrete four-in-one synergistic stress system is formed, and the construction efficiency is improved. And efficient cooperation of block stone embedding, steel bar arrangement and formwork forming is achieved.

Description

Technical Field

[0001] The present invention belongs to the technical field of shear wall structures, and in particular relates to a shear wall structure and a construction method thereof. Background Art

[0002] Current shear wall construction generally utilizes traditional cast-in-place reinforced concrete techniques, which involve erecting formwork, tying longitudinal and transverse reinforcement and tie bars, and finally pouring and curing the concrete. To improve the structure's ductility and crack resistance, some projects incorporate steel fiber or other reinforcing materials into the concrete. However, the overall structure remains primarily based on fine-aggregate concrete, without the use of larger aggregates or embedded stone systems.

[0003] In other large structures, such as rockfill concrete dams and stone-embedded gravity walls, natural stone blocks have been embedded in concrete. These structures typically utilize stone blocks in an "embedded-wrapped" structure, which not only improves the concrete's crack resistance but also reduces cement usage. However, this technology is primarily applied to large horizontal or gravity structures. A mature and controllable construction method has yet to be developed for tall, vertically loaded components like shear walls. In particular, a systematic solution for coordinated construction with reinforcement layout and formwork formation is lacking.

[0004] There are many problems with the application of existing technologies. First, the traditional construction method uses step-by-step operations such as template installation, steel bar binding, and concrete pouring. As a result, the construction period is long and the integration is low, making it difficult to adapt to the efficient construction needs of complex structures. If stone blocks are introduced, the process will be further complicated and the construction quality will be difficult to guarantee. Secondly, the existing stone embedding technology lacks a coordinated coordination mechanism with the steel structure. Stone blocks are usually passively embedded in the concrete, making it difficult to form a stable connection with the steel grid. Quality problems such as debonding and displacement are prone to occur, affecting the integrity of the structure. At the same time, the versatility and reuse requirements of traditional templates determine their strong rigidity and single structure. They are not suitable for the complex interface morphology after the stone blocks are arranged, and may even damage the structural molding quality during the demolding process.

[0005] In summary, existing shear wall construction technology is unable to achieve efficient coordination between stone embedding, reinforcement arrangement, and formwork formation. Its main technical shortcomings are low construction integration, poor stone positioning accuracy, weak structural coordination, and insufficient formwork versatility. Summary of the Invention

[0006] In view of the above problems, the purpose of the present invention is to provide a shear wall structure and a construction method thereof.

[0007] The technical solution of the present invention is: a shear wall structure, including: a steel cage system, an inlay, a 3D printing template and a concrete layer.

[0008] The steel cage system includes a first metal mesh, a second metal mesh, and tie bars. There are two sets of first metal mesh, spaced longitudinally and parallel to each other. There are multiple sets of second metal mesh, spaced from top to bottom between the two sets of first metal mesh, and connected to the first metal mesh. There are multiple tie bars, each secured to the two sets of first metal mesh at both ends.

[0009] The inlay comprises a plurality of groups of stone layers, which are distributed on a plurality of groups of second metal meshes in a one-to-one correspondence, and each group of stone layers comprises a plurality of stone blocks.

[0010] The 3D printed template is formed on-site by stacking layer by layer and has a cavity for placing a steel cage system.

[0011] The concrete layer is formed by pouring concrete into the cavity, enclosing the steel cage system and stone blocks.

[0012] Furthermore, the size of the stone blocks is 50 mm to 90 mm.

[0013] Furthermore, the first metal mesh includes longitudinal stress-bearing steel bars and transverse distribution steel bars. There are multiple longitudinal stress-bearing steel bars, which are spaced apart. There are multiple transverse distribution steel bars, which are spaced apart. The transverse distribution steel bars are fixed to the longitudinal stress-bearing steel bars, and the transverse distribution steel bars on the two sets of the first metal mesh are connected by the tie bars.

[0014] Furthermore, the 3D printing template is provided with an anchor, one end of the anchor is located in the cavity and connected to the transverse distribution steel bars, and the other end is located in the cavity for connection to an external component.

[0015] Furthermore, the anchoring piece includes a steel sleeve and an anchor plate.

[0016] The steel sleeve is inserted into the 3D printed template, with one end of the steel sleeve located in the cavity and the other end located outside the 3D printed template; the anchor plate is arranged at the end of the steel sleeve located in the cavity, and the anchor plate is provided with a connecting hole, which is connected to the end of the transversely distributed steel bars.

[0017] Furthermore, the concrete is fiber-reinforced self-compacting concrete.

[0018] A method for constructing a shear wall, comprising constructing a shear wall block stone embedded structure, and specifically comprising the following steps: Two groups of first metal meshes are placed vertically at intervals, and the second metal mesh and tie bars are fixed between the two groups of first metal meshes to prepare a steel cage system.

[0019] Hoist the steel cage system to the designated location.

[0020] Place blocks of stone on the second metal mesh at the bottom to form a block stone layer, prepare a 3D printing template based on concrete on the periphery of the steel cage system, and when the height of the 3D printing template approaches the height of the next second metal mesh, stop printing until the layers are bonded, lay blocks of stone on the next second metal mesh to form a block stone layer, and continue printing until the height of the 3D printing template approaches the height of the next second metal mesh; repeat the steps until the block stone layer is laid and the 3D printing template reaches the preset height.

[0021] Pour the concrete layer.

[0022] Furthermore, construction preparations were carried out before construction, and the steps of the construction preparations were: structural modeling of the shear wall block stone embedded structure, and three-dimensional parametric design based on the design dimensions, steel bar arrangement and block stone dimensions of the shear wall block stone embedded structure.

[0023] The steel cage system is prepared according to the designed dimensions and steel bar arrangement.

[0024] The arrangement of the blocks is based on a layout diagram generated by three-dimensional parameters of the structural modeling, which controls the particle size distribution, layout density and spacing.

[0025] Furthermore, the 3D printed formwork needs to be cured for 3 to 7 days before pouring the concrete layer.

[0026] Compared with the existing technology, the beneficial effect of the present invention is that the present invention uses 3D printed formwork as a structural component to participate in the load-bearing process, and stabilizes the embedded stone blocks through a steel cage system, so that the stone blocks form a close synergistic effect with the steel bars and concrete, thereby significantly improving the shear strength and crack resistance of the wall, forming a four-in-one synergistic load-bearing system of "formwork-steel bars-stone blocks-concrete", and realizing efficient synergy of stone block embedding, steel bar arrangement and formwork forming. Among them, stone blocks, as high-strength coarse aggregates, not only disperse the internal stress concentration, but also improve the structural ductility and energy consumption capacity through the "embedding-constraint-wrapping" mechanism, and are particularly suitable for high-rise building structures with high requirements for earthquake resistance and wind resistance. In addition, the introduction of stone blocks has outstanding performance in reducing material costs and carbon emissions. Replacing part of the concrete volume with stone blocks can save about 15%-30% of cement, significantly reduce carbon dioxide emissions, and conform to the development direction of green buildings.

[0027] Furthermore, during the construction process, 3D printing was performed simultaneously with the layered stone layout, and concrete was used as an integral filling, effectively achieving an integrated construction process of formwork construction, reinforcement placement, stone block positioning, and concrete pouring. This integrated construction method, combining 3D printed formwork with local prefabrication, not only saves on the use of traditional wooden and steel formwork, but also reduces labor input and on-site wet work, promoting the industrialization, intelligence, and greenness of structural construction. More importantly, stone blocks can be sourced locally, making them particularly suitable for mountainous and remote areas with abundant local resources but limited access, as well as for temporary disaster relief projects. They possess excellent regional adaptability and economic value. BRIEF DESCRIPTION OF THE DRAWINGS

[0028] Figure 1 It is a schematic diagram of the overall structure of the present invention; Figure 2 is a top view of the present invention; Figure 3 It is a schematic diagram of the partial structure of the steel cage system of the present invention; Figure 4 It is a structural schematic diagram of the 3D printing template of the present invention; Figure 5 yes Figure 2 A magnified view of the structure at point A; Figure 6 It is a structural schematic diagram of the anchoring piece of the present invention.

[0029] Among them, 1-rebar cage system, 11-first metal mesh, 111-longitudinal stress-bearing steel bars, 112-transverse distribution steel bars, 12-second metal mesh, 13-tie bars, 2-3D printing template, 20-anchor, 201-rebar sleeve, 202-anchor plate. DETAILED DESCRIPTION

[0030] The following combination Figures 1 to 6 , the specific embodiments of the present invention are described in detail. In the description of the present invention, it should be understood that the terms "center", "upper", "lower", "front", "back", "left", "right", "vertical", "horizontal", "top", "bottom", "inside", "outside", etc., indicating directions or positional relationships, are based on the directions or positional relationships shown in the accompanying drawings and are only used to facilitate the description of the present invention and simplify the description. They do not indicate or imply that the devices or components referred to must have a specific direction, be constructed or operate in a specific direction, and therefore should not be understood as limiting the present invention.

[0031] 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; in the description of the present invention, unless otherwise specified, "plurality" means two or more.

[0032] Example like Figure 1 、 Figure 2 A shear wall structure shown includes: a steel cage system 1, an inlay, a 3D printed template 2 and a concrete layer.

[0033] like Figure 2 、 Figure 3 As shown, the steel cage system 1 includes a first metal mesh 11, a second metal mesh 12, and tie bars 13. There are two groups of first metal meshes 11, which are spaced longitudinally and parallel to each other. There are multiple groups of second metal meshes 12, which are spaced from top to bottom between the two groups of first metal meshes 11 and connected to the first metal meshes 11. There are multiple tie bars 13, and the ends of the multiple tie bars 13 are respectively fixed to the two groups of first metal meshes 11.

[0034] The inlay includes multiple groups of stone layers, which are distributed one-to-one on multiple groups of second metal meshes 12, and each group of stone layers includes multiple stone blocks.

[0035] The 3D printing template 2 is formed by on-site printing in a layer-by-layer stacking manner, such as Figure 4 As shown, the 3D printing template 2 has a cavity, which is used to place the steel cage system 1.

[0036] The concrete layer is formed by pouring concrete into the cavity, enclosing the steel cage system 1 and the stone blocks.

[0037] Preferably, the size of the stone blocks is 50 mm to 90 mm.

[0038] Preferably, Figure 3 As shown, the first metal mesh 11 includes longitudinal stress-bearing steel bars 111 and transverse distribution steel bars 112. There are multiple longitudinal stress-bearing steel bars 111, which are spaced apart. There are multiple transverse distribution steel bars 112, which are spaced apart. The transverse distribution steel bars 112 are fixed to the longitudinal stress-bearing steel bars 111. The transverse distribution steel bars 112 on the two sets of first metal mesh 11 are connected by tie bars 13.

[0039] Preferably, Figure 2 、 Figure 5As shown, the 3D printing template 2 is provided with an anchor 20. One end of the anchor 20 is located in the cavity and connected to the transverse distribution steel bar 112. The other end is located in the cavity and is connected to the external member. The external member is a steel member connected to the shear wall, specifically the internal steel bar of the frame column or the internal steel bar of the frame beam.

[0040] Preferably, Figure 6 As shown, the anchor 20 includes a rebar sleeve 201 and an anchor plate 202. The rebar sleeve 201 is inserted into the 3D printing template 2, with one end of the rebar sleeve 201 located within the cavity and the other end located outside the 3D printing template 2. The anchor plate 202 is disposed at the end of the rebar sleeve 201 located within the cavity. The anchor plate 202 is provided with a connection hole, which is connected to the end of the transverse distribution rebar 112. The end of the transverse distribution rebar 112 is provided with an external thread, and the connection hole is provided with an internal thread that matches the external thread. The end of the transverse distribution rebar 112 is threadedly installed in the connection hole.

[0041] Preferably, the concrete is fiber-reinforced self-compacting concrete.

[0042] The shear wall construction method proposed in this embodiment specifically includes the following steps: Two groups of first metal meshes 11 are placed vertically at intervals, and the second metal mesh 12 and tie bars 13 are fixed between the two groups of first metal meshes 11 to prepare a steel cage system 1.

[0043] Hoist the steel cage system 1 to the designated location.

[0044] Blocks are placed on the bottom second metal mesh 12 to form a block stone layer, and a 3D printing template 2 is prepared based on fiber-reinforced cement-based composite mortar on the periphery of the steel cage system 1. When the height of the 3D printing template 2 is close to the height of the next second metal mesh 12, printing is stopped until the layers are bonded, and blocks are laid on the next second metal mesh 12 to form a block stone layer. Printing is continued until the height of the 3D printing template 2 is close to the height of the next second metal mesh 12; the steps are repeated until the block stone layer is laid and the 3D printing template 2 reaches the preset height.

[0045] Pour the concrete layer.

[0046] Preferably, construction preparation is also carried out before construction, and the steps of construction preparation are: structural modeling of the shear wall block stone embedded structure, and three-dimensional parametric design according to the design size, steel bar arrangement and block stone size of the shear wall block stone embedded structure.

[0047] The reinforcement cage system 1 is prepared according to the designed dimensions and reinforcement arrangement.

[0048] The arrangement of the blocks is based on the three-dimensional parameters of the structural modeling to generate a layout diagram, which controls the particle size distribution, layout density and spacing.

[0049] Preferably, the stone arrangement method is robot embedding + automatic recognition auxiliary system. This embodiment adopts the 6-axis fully automatic manipulator of Hefei Mingde Optoelectronics Technology Co., Ltd. and the supporting deep learning control platform.

[0050] Preferably, the 3D printed template 2 needs to be cured for 3 to 7 days before pouring the concrete layer.

[0051] Application Examples According to the embodiment, a shear wall construction method is proposed to prepare a shear wall, which specifically includes the following steps: Step 1. Printing preparation: Draw a three-dimensional model in CAD, that is, the 3D printing concrete template, then convert it into STL file format, and then use the printer's built-in slicing software to save it in Gcode format for printing.

[0052] Prepare printing materials and printing equipment; the printing material is fiber-reinforced cement-based composite mortar, and the printing equipment uses an industrial-grade concrete (mortar) 3D printer model GL-3DPRT-C3.

[0053] Synchronously prefabricate the steel cage system 1 and the anchor 20. All steel bars in the steel cage system 1 are connected by straight thread sleeves and welding to ensure structural continuity.

[0054] Step 2: 3D print a 10mm base layer of concrete at the bottom, with an interval of 40min~60min.

[0055] Step 3: Place the steel cage system 1: hoist the steel cage system 1 to the designated location and place the first layer of blocks.

[0056] Step 4, print the 3D printed template 2: Start printing from the base layer, layer by layer, and reserve the penetration point of the anchor 20. Pause every 0.2m of printing to ensure inter-layer adhesion and prevent collapse. During the time interval of pausing every 0.2m of printing, natural blocks of stone of suitable size are embedded on top of the second metal mesh 12. The block arrangement is based on the layout diagram generated by the three-dimensional parameter model to control the particle size distribution, layout density and spacing. The stone layout method is robot embedding + automatic recognition auxiliary system to ensure uniform embedding and non-contact with the template, which can reduce the risk of block dislocation caused by human embedding deviation; the interface treatment agent is sprayed on the surface of the block to improve the bonding strength.

[0057] Repeat the process of "print one layer → stop for 40 minutes to 60 minutes and place stones in the interval" until the wall template is printed and cured for 3 days to 7 days.

[0058] Step 7: Pump fiber-reinforced self-compacting concrete (FRC) from top to bottom into the cavity of 3D-printed template 2. No vibration is required during the pouring process, relying on its self-compacting properties to complete the filling. The pouring speed is strictly controlled to no more than 2 m / h to prevent the stones from floating or shifting. The FRC is poured entirely. FRC has a typical fluidity of 650-750 mm, good cohesion, and high static stability, making it suitable for filling complex spaces. The concrete encapsulates the stones and bonds with the steel bars, forming an integrated embedding and encapsulation system.

[0059] Step 8. Curing: 7 days of wet curing (wet curing involves spraying with water and covering with film), 7 days of natural curing, and full-load use after 28 days. The actual curing time should be based on the strength test results of the on-site curing test blocks during the same period. The standard value is the minimum limit.

[0060] The specific embodiments described above further illustrate the objectives, technical solutions and beneficial effects of the present invention in detail. It should be understood that the above are only specific embodiments of the present invention and do not limit the present invention. Any modifications, equivalent substitutions, improvements, etc. made within the spirit and principles of the present invention are included in the scope of protection of the present invention.

Claims

1. A shear wall structure, characterized in that: include: A steel cage system (1) comprises: two groups of first metal meshes (11), the two groups of first metal meshes (11) being spaced apart and parallel to each other in the longitudinal direction; a plurality of groups of second metal meshes (12), spaced apart and distributed between the two groups of first metal meshes (11) from top to bottom, the second metal meshes (12) being connected to the first metal meshes (11); a plurality of tie bars (13), the two ends of the plurality of tie bars (13) being fixed to the two groups of first metal meshes (11) respectively; The inlay comprises a plurality of groups of stone layers, wherein the plurality of groups of stone layers are distributed one-to-one on a plurality of groups of second metal mesh sheets (12), and each group of stone layers comprises a plurality of stone blocks; A 3D printed template (2) is formed on-site by stacking layers one by one, and has a cavity for accommodating the steel cage system (1); The concrete layer is formed by pouring concrete into the cavity, enclosing the steel cage system (1) and the stone blocks.

2. A shear wall structure according to claim 1, characterized in that: The size of the stone blocks is 50 mm to 90 mm.

3. A shear wall structure according to claim 1, characterized in that: The first metal mesh (11) comprises: There are a plurality of longitudinal stress-bearing steel bars (111), and the plurality of longitudinal stress-bearing steel bars (111) are distributed at intervals; There are multiple transverse distribution steel bars (112), and the multiple transverse distribution steel bars (112) are distributed at intervals. The transverse distribution steel bars (112) are fixed to the longitudinal stress-bearing steel bars (111), and the transverse distribution steel bars (112) on the two groups of first metal meshes (11) are connected by the tie bars (13).

4. A shear wall structure according to claim 3, characterized in that: The 3D printing template (2) is provided with an anchor (20), one end of the anchor (20) is located in the cavity and connected to the transverse distribution steel bar (112), and the other end is located in the cavity and is used to connect to an external component.

5. A shear wall structure according to claim 4, characterized in that: The anchor (20) comprises: A steel sleeve (201) is inserted into the 3D printing template (2), with one end of the steel sleeve (201) located in the cavity and the other end located outside the 3D printing template (2); An anchor plate (202) is arranged at one end of the steel bar sleeve (201) located in the cavity. A connection hole is provided on the anchor plate (202), and the connection hole is connected to the end of the transverse distribution steel bar (112).

6. The shear wall structure according to claim 1, characterized in that: The concrete is fiber-reinforced self-compacting concrete.

7. A method for constructing a shear wall, characterized in that: The construction of the shear wall stone embedded structure according to any one of claims 1 to 6 specifically comprises the following steps: Two groups of first metal mesh sheets (11) are placed vertically at intervals, and a second metal mesh sheet (12) and a tie bar (13) are fixed between the two groups of first metal mesh sheets (11) to prepare a steel cage system (1); Hoist the steel cage system (1) to the designated location; Placing blocks of stone on the bottom second metal mesh (12) to form a block stone layer, preparing a 3D printing template (2) on the periphery of the steel cage system (1), stopping printing until the layers are bonded when the height of the 3D printing template (2) approaches the height of the next second metal mesh (12), laying blocks of stone on the next second metal mesh (12) to form a block stone layer, and continuing printing until the height of the 3D printing template (2) approaches the height of the next second metal mesh (12); repeating the steps until the block stone layer is laid and the 3D printing template (2) reaches a preset height; Pour the concrete layer.

8. A method for constructing a shear wall according to claim 7, characterized in that: Construction preparations were also carried out before construction, and the steps of the construction preparations were as follows: Structural modeling of the shear wall stone embedded structure was carried out, and three-dimensional parametric design was performed based on the design dimensions, reinforcement arrangement, and stone size of the shear wall stone embedded structure; The steel cage system (1) is prepared according to the design size and steel bar arrangement; The arrangement of the blocks is based on a layout diagram generated by three-dimensional parameters of the structural modeling, which controls the particle size distribution, layout density and spacing.

9. The method for constructing a shear wall according to claim 7, wherein: The 3D printed template (2) needs to be cured for 3 to 7 days before pouring the concrete layer.

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