Prefabricated assembly type roof and construction method

Abstract

The invention provides a prefabricated assembly type roof construction method which comprises the following steps that S1, a designed building model is divided and decomposed into independent component units through reasonable plate blocks, and the component units are carbon fiber composite building components; s2, all component units are prefabricated in a factory; s3, the position of each component unit on the construction site is determined in a building positioning mode, and a roof main body layer is assembled; s4, performing post-treatment on the main body layer assembled in the step S3; and S5, performing waterproof treatment on the main body layer after the post-treatment in the step S4. According to the characteristics of special-shaped curved surfaces, lightness and thinness of architectural modeling, the factory prefabricated unit component on-site spliced roof is creatively researched. The carbon fiber foam board is used as a main structural component, multiple special-shaped hyperbolic shapes can be achieved through reasonable partitioning and splitting, and prefabrication and assembly of non-standard products are achieved. According to the carbon fiber composite building component, the proportion can be adjusted according to structural calculation to meet the modeling requirements of different spans, and structural stress is achieved.

Description

Technical Field

[0001] The present invention relates to the technical field of construction of a hyperbolic building body, such as a shell roof. Background Art

[0002] In the construction industry, many projects demand free-flowing, flexible curves while also requiring lightweight, minimalist structures. Traditional shell structures often utilize metal components for structural support, with insulation, waterproofing, and finishes added to the structural layer. External insulation layers, including support nodes, often require significant thickness, limiting the design possibilities. Existing roofing panel systems often utilize molds for specialized shapes, but these molds can only be used in one-to-many or one-to-one configurations, resulting in high costs and material waste.

[0003] In recent decades, the molding and manufacturing technology of resin-based composites has developed into an independent, cutting-edge modern engineering discipline. With the accumulation of experience, resin-based composites have gradually expanded beyond aerospace into other industries. Currently, the main markets for composite materials include: aerospace, such as aircraft cabins, fuel silos, and rocket fairings; transportation and marine applications, such as small boat cabins, masts, decks, automobile hulls, tails, battery compartments, and high-speed rail fronts; wind turbine blades; and sports and civilian applications, such as drones, bicycles, fishing rods, and decorative components. Carbon fiber resin composites, when used in main structures in the building industry, such as roofs, can meet the requirements for lightweight, compact, and thin structures.

[0004] However, in the current construction industry, the application of carbon fiber materials in primary structural components is mainly focused on the reinforcement of concrete and steel components, such as wet-bonding reinforcement of beam bottoms, wet-bonding reinforcement of slab bottoms, and carbon fiber winding reinforcement of structural columns. Currently, there is no evidence that carbon fiber products are used as primary structural components. Furthermore, traditional carbon fiber composite component connection methods, such as mechanical connection with external metal heads or laminated gluing, are not suitable for construction scenarios. Summary of the Invention

[0005] The purpose of the present invention is to address the problems existing in the above-mentioned prior art and to provide a prefabricated assembled roof and a construction method, which can be applied to various personalized roof shapes and can be prefabricated in a factory and spliced ​​on site.

[0006] To achieve the above object, the technical solution adopted by the present invention is as follows:

[0007] A prefabricated roof construction method comprises the following steps:

[0008] S1, decomposing the designed architectural form into independent component units through rational plate division, wherein the component units are carbon fiber composite building components;

[0009] S2, prefabricate all component units in the factory;

[0010] S3, determine the position of each component unit on the construction site through building positioning method, and assemble the main roof layer;

[0011] S4, post-processing the main body layer assembled in S3;

[0012] S5: Waterproof the main body layer after S4 treatment.

[0013] In order to cope with the special-shaped curved surfaces and light and thin features of the building shape, the building shape is decomposed into different component units through rational plate division. For example, the entire roof body is divided into morphological layers spliced ​​by carbon fiber composite components. Then, the structure of the component units is adjusted according to the structural calculation requirements to achieve the shape requirements of different spans. After that, they are prefabricated at the manufacturer and transported to the site for splicing after confirmation.

[0014] Furthermore, the method for preparing the carbon fiber composite building component is as follows, comprising:

[0015] S201, dividing the high-density PU foam after curing and molding into polygonal foam blocks in the factory;

[0016] S202, milling a groove at each corner of each polygonal foam block;

[0017] S203, placing the embedded plate of the connector into the groove of the polygonal foam block;

[0018] S204, performing multiple carbon fiber wrapping on the foam block with the connector placed thereon;

[0019] S205, forming and curing the preform obtained in step S104 using a wet forming technology.

[0020] Furthermore, the polygonal foam block is a hexagonal hyperbolic foam block, and the side length and thickness can be calculated and adjusted according to the stress requirements of the entire building; preferably, the thickness is less than 1 / 10 of the overall span of the carbon fiber composite building component.

[0021] Furthermore, the depth of the groove milled in S202 is the same as the thickness of the embedded plate of the connector, preferably a fan-shaped groove; a limiting pit is further milled on the side wall of the groove, and the outer edge of the embedded plate of the connector is fixed in the limiting pit. Alternatively, the connector is fixed to the groove by glue.

[0022] Furthermore, the connector described in S203 includes an embedded plate and two angled edges, the height of the two edges being lower than the top surface of the PU foam block, and the two edges having oblong holes. The connection between the two edges can be further welded. When the foam block is hexagonal, the angle between the two edges of the connector is 120°. The connector is preferably a one-piece bent sheet metal part, with the two edges bent at 90°. The connector further includes matching bolts that penetrate the oblong holes during construction to connect and secure adjacent carbon fiber composite building components.

[0023] Furthermore, S204 is wrapped with 3K (0-90) carbon fiber woven cloth and 12K (0-90) carbon fiber woven cloth multiple times in sequence and fixed with spray glue at the edges.

[0024] Furthermore, the wet forming technology described in S205 refers to: placing the preform obtained in S104 on a diversion mold, setting vacuum films that exceed the edge size on the upper and lower sides, using double-sided tape to seal the edges on all sides, setting drainage tubes at each corner inside to allow the resin to be evenly introduced and discharged, installing a diversion pump to check the sealing, and loading 0.08-0.09Mpa pressure for diversion; then observe and judge the resin infiltration state, and close the diversion valve after completion; finally, let it stand for more than 24 hours, and demold after curing.

[0025] S3 completes the roof assembly by bolting all adjacent carbon fiber composite building components together. During on-site construction, bolt washers of varying thicknesses can be used for further calibration, with bolts tightened after accurate positioning.

[0026] Furthermore, S3 can install a light-transmitting plate 4, circular glass, etc. on the top of the roof.

[0027] The post-processing described in S4 includes filling the gaps between the joints of the assembled roof with a resin-based adhesive material. Furthermore, a layer of carbon fiber cloth is laid on the roof after the gaps are filled and fixed with resin glue.

[0028] Furthermore, the waterproofing described in S5 refers to applying a hydrophobic topcoat on the roof that has been reinforced with caulking or laying a carbon fiber cloth layer.

[0029] Furthermore, the prefabricated and assembled roof construction method also includes installing an indoor ceiling system on the connecting parts. A conventional light steel keel ceiling can be used, and indoor lighting, air conditioning, fire protection and other pipelines can be integrated and installed on the ceiling.

[0030] The prefabricated roof construction mentioned above can have its lower supports fixed directly to the building's beam, column, and wall system. If the building does not have beams, columns, or walls, spaced steel columns can also be installed to support it, eliminating the complex beams, columns, or walls required for traditional roofing.

[0031] Beneficial effects of the present invention:

[0032] The prefabricated and assembled roof construction method provided by this invention addresses the unique curved surfaces and lightness of architectural shapes, pioneering the development of a roof system using factory-prefabricated unit components that are assembled on-site. Carbon fiber foam boards are used as the primary structural component, making them considerably lighter and thinner than other structural materials, such as steel or concrete. Through rational block division and splitting, a wide range of unusual and hyperbolic shapes can be achieved, enabling the prefabrication and assembly of non-standard products and embodying the practical application of BIM forward design. Furthermore, the preparation of carbon fiber composite building components can adjust the proportions and thicknesses according to structural calculation requirements to achieve the desired shapes and structural stresses for different spans.

[0033] The specific embodiments of the present invention are described below with reference to the accompanying drawings: BRIEF DESCRIPTION OF THE DRAWINGS

[0034] Figure 1 A schematic diagram of the deconstruction of the roof morphological layer provided in an embodiment of the prefabricated assembled roof construction method of the present invention.

[0035] Figure 2 This is a schematic structural diagram of a carbon fiber composite building component provided by an embodiment of the present invention.

[0036] Figure 3 Schematic diagram of the connection piece of the carbon fiber composite building component provided by an embodiment of the present invention being separated from the groove of the PU foam base layer.

[0037] Figure 4 A partial cross-sectional view of a carbon fiber composite building component provided by an embodiment of the present invention.

[0038] Figure 5 A schematic cross-sectional view of a carbon fiber composite building component provided by an embodiment of the present invention.

[0039] Figure 6 A schematic diagram of the splicing of carbon fiber composite building components provided by an embodiment of the present invention.

[0040] Figure 7 Schematic diagram of the splicing and forming of carbon fiber composite building components provided by an embodiment of the present invention.

[0041] Figure 8 This is a schematic diagram of an example of a roof obtained by using the prefabricated assembled roof construction method of the present invention.

[0042] Description of reference numerals:

[0043] 1PU foam base, 101 groove, 102 limit pit

[0044] 2 Connectors, 201 embedded base plate, 202 folded edge, oblong hole 202a, 203 bolts

[0045] 3 carbon fiber covering layers, 4 light-transmitting panels, 5 carbon fiber cloth layers DETAILED DESCRIPTION

[0046] The specific embodiments described herein are only used to explain the technical solutions of this patent, and are not intended to limit the disclosed technical solutions. It should also be noted that, for ease of description, the accompanying drawings only show parts related to the disclosed technical solutions, rather than all structures.

[0047] Before discussing the exemplary embodiments in more detail, it should be mentioned that the structures of the device components and / or modules themselves mentioned in the embodiments, if not described in detail, can be understood by those skilled in the art based on existing public technologies or commercially available products.

[0048] refer to Figure 1 First, the designed architectural form is decomposed into independent component units through rational plate division. In this embodiment, the hexagonal plate units are used. The following embodiments are also described using hexagonal carbon fiber composite building component units as an example.

[0049] Prefabricate all carbon fiber composite building components in the factory:

[0050] Prepare the foam substrate:

[0051] In the factory, 80 density PU (polyurethane) foam is fully matured and formed, and the formed foam blocks are processed into hyperbolic foam blocks with a side length of 600mm and a thickness of 30mm through CNC or other milling production lines. Figure 2 , mill out fan-shaped grooves with a radius of 85mm and a depth of 20mm at each corner of the hexagonal foam block, and mill out the arc at an obtuse angle of 141°; on this basis, mill out a 3mm limit pit downward at the top of the fan.

[0052] Prepare the connecting parts:

[0053] The connecting parts are made of Q235 3mm steel plate, which is laser cut in the factory. Figure 3 The connector consists of an internal panel 201 and two angled hems 202. The height of the two hems needs to be lower than the top surface of the PU foam block, and each hem is provided with an oblong hole 202a. The internal panel 201 is machined into a fan-shaped shape with a radius of 63.1mm and a central angle of 120°. The two hems are formed by bending the pre-cut hems 90° using a sheet metal bending process. The two hems are connected by fillet welding. The two hems are 19mm high, 87mm long, and 3mm thick, and the angle between them and the embedded panel is approximately 51°.

[0054] Embed the connector into the foam base:

[0055] The processed metal connector is placed on the processed groove 101 of the foam block 1 , and the outer edge of the built-in plate 101 is placed in the limiting pit 102 .

[0056] refer to Figure 4 and Figure 5 . The foam block with the connector installed is coated with carbon fiber multiple times: the foam block with the connector installed is placed on the platform for carbon fiber coating, and 6 layers of 3K (0-90) carbon fiber woven cloth and 7 layers of 12K (0-90) carbon fiber woven cloth are wrapped in sequence, and finally a universal spray glue is used to preliminarily fix it at the edge. The wet molding technology is further used to shape and solidify the unit plate wrapped with carbon fiber: the RTM process is used to place the unit plate with the connector fixed on the diversion mold, and a vacuum membrane about 200mm beyond the edge is set on the upper and lower parts respectively. The edges are sealed with double-sided tape all around, and drainage pipes are set at each corner inside to evenly introduce and discharge the resin. The diversion pump is installed to check the sealing, and a pressure of 0.08-0.09Mpa is applied for diversion; then the resin infiltration state is observed and judged, and the diversion valve is closed after completion; finally, it is left to stand for more than 24 hours, and demoulding is completed after curing to obtain the unit plate with the connector ( Figure 2 ).

[0057] On-site splicing and forming:

[0058] Before on-site construction, the unit panels with composite connectors are subjected to a load test to check whether their mechanical properties meet the design requirements. After confirmation, they are transported to the construction site for splicing.

[0059] During construction, each unit plate is set in the exact position by positioning methods such as laying out lines and marking points. Figure 6 、 Figure 7 , the adjacent unit plates are fixed by cylindrical head bolts penetrating into the oblong holes of the connectors. If necessary, bolt washers of different thicknesses can be used for calibration and accurate positioning. The type of bolt 203 selected matches the oblong hole on the folding edge 202. When both adopt industry standard sizes, commercially available parts can be used. After the connection is fixed, the gap is filled with resin structural glue. After all the splicing is completed, it is obtained. Figure 1 Shell roof shown.

[0060] After filling the gaps, a layer of carbon fiber cloth 5 is laid on the roof and fixed with resin glue to further strengthen the overall roof strength. Finally, Teflon hydrophobic topcoat is applied to ensure overall waterproofness and protect the metal connectors on the top. If natural lighting is required, Figure 8 A circular glass is set on the top to take in natural light.

[0061] The hyperbolic roof produced by the present invention allows for direct installation of an indoor ceiling system on the connecting components. For the roof of the aforementioned embodiment, the ceiling keel can be constructed using 32mm single-curved circular tubes arranged along the longitude and latitude of the curved surface. A series of simulations and tests have demonstrated the structural stress calculations, further simplifying construction procedures and saving materials.

[0062] The lower part of the roof is supported by an inner and outer circle thin column system. The outer circle uses 50 steel pipes with a spacing of 1.8 meters. The top is connected to the carbon fiber roof through 40mm angle steel and fastened with M8 bolts with a spacing of 450mm. The inner circle uses 50 steel pipes with a spacing of 1 meter. The top is connected to the carbon fiber roof through 150mm*50mm steel beams and fastened with M8 bolts with a spacing of 450mm.

[0063] Figure 8 The shell roof is an experimental engineering example. During on-site installation, the pre-formed carbon fiber composite panel units, with pre-embedded connectors, were precisely positioned using methods such as marking and marking. Bolts were then used to secure all the carbon fiber composite panel units, completing the shell roof. On-site construction was simple, fast, and accurate, perfectly suiting the project's minimalist architectural requirements.

[0064] The present invention adopts a prefabricated assembly method to realize many special-shaped hyperbolic shapes, which can not only meet the structural forming of various curved building bodies, but also realize the prefabrication and assembly of non-standard products according to parameter design and quickly assemble the roof.

[0065] The above is an illustration of the preferred implementation of the present invention, but the invention is not limited to the embodiments. Those skilled in the art can make various equivalent modifications or substitutions without violating the spirit of the present invention. These equivalent modifications or substitutions are all included in the scope defined by the claims of this application.

Claims

1. A prefabricated roof construction method comprising the following steps: S1, decomposing the designed architectural form into independent component units through rational plate division, wherein the component units are carbon fiber composite building components; S2, prefabricate all component units in the factory; S3, determine the position of each component unit on the construction site through building positioning method, and assemble the main roof layer; S4, post-processing the main body layer assembled in S3; S5: Waterproof the main body layer after S4 treatment.

2. The prefabricated and assembled roof construction method according to claim 1, wherein: The method for preparing the carbon fiber composite building component is as follows: S201, dividing the high-density PU foam after curing and molding into polygonal foam blocks in the factory; S202, milling a groove at each corner of each polygonal foam block; S203, placing the embedded plate of the connector into the groove of the polygonal foam block; S204, performing multiple carbon fiber wrapping on the foam block with the connector placed thereon; S205, forming and curing the preform obtained in step S104 using a wet forming technology.

3. The prefabricated and assembled roof construction method according to claim 2, wherein: The depth of the groove milled in S202 is the same as the thickness of the embedded plate of the connector described in S203, and a limited pit is formed at the side wall of the groove.

4. The prefabricated and assembled roof construction method according to claim 2, wherein: The connecting piece described in S203 includes an embedded plate and two folded edges at an angle, the height of the two folded edges is lower than the top surface of the PU foam block, and oblong holes are provided on the two folded edges.

5. The prefabricated and assembled roof construction method according to claim 2, wherein: S204 is wrapped with 3K (0-90) carbon fiber woven cloth and 12K (0-90) carbon fiber woven cloth multiple times in sequence.

6. The prefabricated and assembled roof construction method according to claim 2, wherein: The wet forming technology described in S205 refers to: placing the preform obtained in S104 on a diversion mold, setting vacuum films that exceed the edge size on the upper and lower sides, using double-sided tape to seal the edges on all sides, setting drainage tubes at each corner inside to allow the resin to be evenly introduced and discharged, installing a diversion pump to check the sealing, and applying a pressure of 0.08-0.09Mpa for diversion; then observing and judging the resin infiltration state, and closing the diversion valve after completion; finally, letting it stand for more than 24 hours, and demoulding after curing.

7. The prefabricated and assembled roof construction method according to claim 1, wherein: S3 completes the assembly of the entire roof by fastening all adjacent carbon fiber composite building components through bolts.

8. The prefabricated and assembled roof construction method according to claim 1, wherein: The post-processing described in S4 includes filling the gaps between the connecting parts of the assembled roof with a resin-based adhesive material.

9. The prefabricated and assembled roof construction method according to claim 8, characterized in that: A layer of carbon fiber cloth is laid on the roof after filling and fixed with resin glue.

10. The prefabricated and assembled roof construction method according to claim 8, wherein: The waterproofing described in S5 refers to applying a hydrophobic topcoat on the roof that has been reinforced with caulking or laying a carbon fiber cloth layer.

11. The prefabricated and assembled roof construction method according to claim 2, wherein: Install the interior ceiling system on the connector.

12. A roof obtained by the prefabricated and assembled roof construction method according to any one of claims 1 to 11.

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