Mold sealing device for cast-in-place belt at bottom of prefabricated hollow laminated shear wall and construction method

Abstract

The invention discloses a mold sealing device for a cast-in-place belt at the bottom of a prefabricated hollow superimposed shear wall and a construction method, the mold sealing device comprises a base, a vertical plate, a hinge assembly and an insertion piece, the base and the vertical plate are rotatably connected through the hinge assembly, a clamping groove is formed in the vertical plate, and the insertion piece can be inserted into and penetrate out of the clamping groove. During construction, the device is arranged on the two sides of the prefabricated wall plate, the vertical plate is turned over to be perpendicular to the base, then the insertion piece is inserted into the clamping groove, the wall plate slowly falls down till the bottom of the wall plate falls on the insertion piece, and temporary fixing is conducted; after the steel bars are bound, concrete pouring is conducted; and after the concrete strength of the cast-in-place section reaches certain strength, the mold sealing device is dismounted. The mold sealing device is easy to machine, reliable in quality and convenient to install, and the construction period is shortened; the device is detachable and can be recycled; when the device is used for constructing the cast-in-place belt at the bottom of the prefabricated hollow superposed shear wall, the construction quality can be guaranteed, the construction efficiency can be greatly improved, and the assembly type construction cost is saved.

Description

TECHNICAL FIELD

[0001] The application belongs to the technical field of building construction, and particularly relates to a form closing device for a bottom cast-in-place zone of a prefabricated hollow composite shear wall and a construction method. BACKGROUND

[0002] As the main lateral force resisting member of building structure, the construction quality of the bottom joint (cast-in-place zone) of a shear wall directly affects the seismic performance and durability of the overall structure. In fabricated buildings, the connection between the prefabricated shear wall and the cast-in-place foundation is particularly critical, and the development of the bottom formwork device directly determines the construction efficiency, concrete forming quality and structural safety.

[0003] At present, the following methods are mainly used for the bottom formwork of a shear wall:

[0004] 1) Opposite bolt fixing method, which drills holes in the prefabricated wall and inserts opposite bolts to fix the formwork.

[0005] 2) Pre-buried sleeve connection method, which pre-buries sleeves in the prefabricated wall and uses a screw to fix the formwork during installation.

[0006] 3) Clamping formwork method, which uses adjustable steel clamps to hold the prefabricated wall without the need for bolt fixing.

[0007] However, the opposite bolt fixing method and the pre-buried sleeve connection method have the following disadvantages:

[0008] 1) Complex process: the construction process of the existing technology is: measurement and positioning → adjustment of bolts / placement of cushion blocks → wall plate installation → repeated correction → setting of formwork → sealing treatment.

[0009] 2) Material waste and cost increase: 80% of the site construction uses the method of placing rubber cushion blocks between the EMC prefabricated shear wall and the cast-in-place floor slab, which cannot realize material turnover and wastes materials, thereby increasing the engineering cost.

[0010] 3) Precision cannot be guaranteed, and node strength is weakened: the method of placing rubber cushion blocks is permanently left in the post-cast zone, forming a hidden danger, leading to an increase in cumulative error, weakening the strength at the node position, and reducing the connection reliability. At the same time, the integrity of the prefabricated wall is damaged, and the seismic performance is reduced.

[0011] 4) Precision is difficult to guarantee; the strength of the adjusting bolt is not enough, and it is easy to bend: now the process needs to reserve a threaded sleeve at the bottom of the EMC prefabricated wall, and the corresponding size of the bolt is screwed in before the prefabricated wall is lifted, and the depth of the bolt screwed into the sleeve is adjusted by using a wrench to realize the height adjustment of the prefabricated wall. However, the positioning accuracy of the sleeve is high (±2mm), otherwise it is difficult to align; it is only suitable for a specific formwork system, and the universality is poor, and the adjusting bolt needs to be adjusted before and after the EMC wall is installed, and the strength is difficult to meet the requirements, and the wall needs 7cm space, which is easy to bend and cause the wall to be insufficient. Precision deviation.

[0012] 5) Expanding mold, leaking slurry: after the concrete construction is completed, the joint is not tightly sealed, and the node is prone to leaking slurry and misalignment.

[0013] 6) The bolt hole needs to be sealed after the formwork is removed, increasing the construction steps.

[0014] And the fixture type formwork method has strict requirements on the thickness of the wall (usually only suitable for walls above 200mm); the sealing performance is poor, and there is still a risk of slurry leakage. SUMMARY

[0015] The purpose of the present application is to provide a form sealing device and construction method for the bottom of a prefabricated hollow composite shear wall, which can guarantee the construction quality, facilitate disassembly, be recycled, greatly improve the construction efficiency, and save the cost of assembly type construction.

[0016] To achieve the above purpose, the first aspect of the present application provides a form sealing device for the bottom of a prefabricated hollow composite shear wall, comprising a base, a vertical plate, a hinge assembly and a plug, the base and the vertical plate are rotatably connected through the hinge assembly, the vertical plate is provided with a clamping groove penetrating the thickness direction thereof, the length direction of the clamping groove extends along the horizontal direction, and the plug can be inserted into and passed through the clamping groove.

[0017] Further, the hinge assembly is a stainless steel hinge.

[0018] Further, the base and the vertical plate are connected by a plurality of hinge assemblies, and the vertical plate is provided with a plurality of clamping grooves distributed along the horizontal direction.

[0019] Further, the shape of the clamping groove is rectangular, the cross-sectional shape of the plug is also rectangular, and the size of the clamping groove matches the size of the plug.

[0020] Further, the base, the vertical plate and the plug are all made of steel material.

[0021] Further, the base size is 1000*140*30mm, the material is Q235B 30mm thick steel plate; the vertical plate size is 1000*120*10mm, the material is Q235B 10mm thick steel plate; the clamping groove section size is 50*6mm; the insert size is 50*50*6mm, the material is Q235B 6mm thick steel plate; the size of the stainless steel hinge is 102*100*2.8mm.

[0022] To achieve the above object, the second aspect of the present application provides a construction method of a prefabricated hollow composite shear wall bottom cast-in-place zone, which is applied to the mold closing device, and the construction method comprises the following steps:

[0023] (1) Measurement and line laying

[0024] According to the main structure control network, the axis is measured and laid to the construction floor as the wall positioning reference; the edge line, door hole position and inclined support pre-burying point position line of the wall are popped out on the floor to ensure the installation accuracy;

[0025] (2) Steel bar preparation

[0026] The vertical steel bar with a straight threaded sleeve is inserted into the vertical hole reserved in the prefabricated wall plate, and is fixed with the lower layer extended steel bar through mechanical connection to check the connection quality; the lap length and position of the horizontal steel bar reserved at the edge of the prefabricated wall plate and the steel bar of the cast-in-place section are checked to see whether they meet the design requirements;

[0027] (3) Floor cleaning

[0028] The garbage, floating soil, wood chips and concrete slag on the floor are cleaned before the hoisting of the EMC prefabricated shear wall, so that the mold closing device is placed flat to ensure the installation accuracy;

[0029] (4) Placement of mold closing device

[0030] The mold closing device is arranged on both sides of the popped wall line, the vertical plate is folded to be 90° with the base, then the insert is inserted into the clamping groove and is deeply inserted into the vertical plate by 20-30mm;

[0031] (5) Installation of EMC prefabricated wall plate

[0032] The special lifting tool is symmetrically hooked to ensure the stable hoisting of the wall plate and avoid collision; the wall plate is slowly lowered to the popped line position, and the bottom of the wall plate is placed on the insert, at this time, the bottom of the wall plate is away from the concrete floor by a distance, the vertical plate is tightly attached to the wall, 2-3 adjustable inclined braces are installed for each wall plate to adjust the perpendicularity of the wall plate and fix the bottom bolt; after the perpendicularity correction is qualified, the lifting hook is removed and temporary fixing is performed;

[0033] (6) Concrete pouring

[0034] After the reinforcement is bound, the concrete is poured, and the concrete is poured in layers and vibrated and compacted during pouring;

[0035] (7) Demolding

[0036] After the cast-in-place section concrete reaches a certain strength, the mold sealing device is removed, and the device is directly removed during demolding. By adjusting the angle of the vertical plate and the base, the mold sealing device can be removed, and the steel insert is left in the concrete, without the need for plugging operation.

[0037] Compared with the prior art, the present application has the following advantages:

[0038] The mold sealing device provided by the present application is simple to process, has a wide range of processing materials and low cost, is reliable in quality, convenient to install, saves construction period, is highly detachable and assembled, and can be recycled. The use of the device in the construction of the bottom cast-in-place band of the prefabricated hollow composite shear wall can not only ensure the construction quality, but also greatly improve the construction efficiency and save the cost of assembly type construction, and has good economic efficiency. BRIEF DESCRIPTION OF DRAWINGS

[0039] Figure 1 is a perspective view of a mold sealing device (before inserting the insert) provided by an embodiment of the present application;

[0040] Figure 2 is a front view of a mold sealing device (before inserting the insert) provided by an embodiment of the present application;

[0041] Figure 3 is a side view of a mold sealing device (before inserting the insert) provided by an embodiment of the present application;

[0042] Figure 4 is a side view of a mold sealing device provided by an embodiment of the present application;

[0043] Figure 5 is a mold sealing diagram of the joint between the wallboard bottom and the floor provided by an embodiment of the present application.

[0044] BRIEF DESCRIPTION OF DRAWINGS

[0045] Base 1, vertical plate 2, clamping groove 21, hinge assembly 3, insert 4. DETAILED DESCRIPTION

[0046] In order to make the invention purpose, features and advantages of the present application more obvious and easy to understand, the technical solutions in the embodiments of the present application will be described clearly and completely below in conjunction with the drawings in the embodiments of the present application. Obviously, the following described embodiments are only a part of the embodiments of the present application, but not all the embodiments. Based on the embodiments in the present application, all other embodiments obtained by those skilled in the art without creative labor are within the scope of protection of the present application.

[0047] In the description of the present application, it should be noted that the terms "center", "upper", "lower", "left", "right", "front", "back", "vertical", "horizontal", "inner", "outer" and the like indicate the orientation or positional relationship shown in the drawings, which are only for the convenience of describing the present application and simplifying the description, and do not indicate or imply that the devices or elements referred to must have a particular orientation, be constructed and operated in a particular orientation, and therefore cannot be understood as a limitation on the present application; the terms "first", "second", "third" are only for the purpose of description, and cannot be understood as indicating or implying relative importance; in addition, unless otherwise explicitly specified and limited, the terms "mounting", "connecting", "connecting" should be understood in a broad sense, for example, it can be fixedly connected, or it can be detachably connected, or integrally connected; it can be directly connected, or indirectly connected through an intermediate medium, or the communication inside two components. For those skilled in the art, the specific meaning of the above terms in the present application can be understood according to the specific circumstances.

[0048] The technical background of the EMC prefabricated hollow composite shear wall bottom formwork device is derived from the rapid development of prefabricated buildings. The traditional method cannot meet the construction demand of high quality and high efficiency. The existing technology has problems such as structural damage, slurry leakage and low efficiency, and innovative solutions are urgently needed. The future development direction is a non-destructive fixing and high sealing formwork system to improve the construction quality and economic benefits of prefabricated buildings.

[0049] There is an urgent need in the industry for a new formwork device that meets the following requirements:

[0050] 1) without damaging the prefabricated wall (avoiding drilling or slotting);

[0051] 2) high sealing (slurry leakage rate <3%);

[0052] 3) fast installation (single-layer construction time <2 hours);

[0053] 4) height adjustable (adapt to different cast-in-place belt requirements of 7cm etc.);

[0054] 5) high turnover rate;

[0055] 6) cost saving;

[0056] 7) improve construction quality and visual effect.

[0057] Therefore, the present embodiment provides a prefabricated hollow composite shear wall bottom cast-in-place belt formwork device and construction method, which can ensure construction quality, facilitate disassembly, be recycled, greatly improve construction efficiency and save prefabricated construction cost.

[0058] The technical solutions of the present application are further illustrated below in combination with the drawings and through specific embodiments.

[0059] Please refer to Figures 1 to 4 , a prefabricated hollow composite shear wall bottom cast-in-place strip sealing mold device is provided, which comprises a base 1, a vertical plate 2, a hinge assembly 3 and an insert piece 4. The base 1 and the vertical plate 2 are rotatably connected through the hinge assembly 3. The vertical plate 2 is provided with a clamping groove 21 extending through its thickness direction. The length direction of the clamping groove 21 extends horizontally, and the insert piece 4 can be inserted and passed through the clamping groove 21.

[0060] In this embodiment, the base 1 and the vertical plate 2 are connected by three hinge assemblies 3. The vertical plate 2 is provided with two clamping grooves 21 distributed along the horizontal direction.

[0061] The shape of the clamping groove 21 is rectangular, and the cross-sectional shape of the insert piece 4 is also rectangular. The size of the clamping groove 21 matches the size of the insert piece 4.

[0062] Specifically, the size of the base 1 of the present embodiment is 1000*140*30mm, and the material is Q235B 30mm thick steel plate; the size of the vertical plate 2 is 1000*120*10mm, and the material is Q235B 10mm thick steel plate; the size of the insert piece 4 is 50*50*6mm, and the material is Q235B 6mm thick steel plate. The cross-sectional size of the clamping groove 21 is 50*6mm; the lower edge of the clamping groove 21 is 34mm away from the bottom of the vertical plate 2, which ensures that the EMC prefabricated hollow composite shear wall has a space of 7cm. The size of the hinge assembly is 102*100*2.8mm, and the material is stainless steel hinge.

[0063] The processing steps of the sealing mold device of the present embodiment are as follows:

[0064] Place the vertical plate 2 along the length direction at the end of the base 1, so that the outermost side of the base 1 is flush with the outside of the vertical plate 2, and the other side of the vertical plate 2 is 130mm away from the edge of the base 1; then weld the hinge assembly 3 with the vertical plate 2 and the base 1 to complete the assembly of the sealing mold device.

[0065] Please refer to Figure 5 , the present embodiment also provides a construction method for the prefabricated hollow composite shear wall bottom cast-in-place strip, which is applied to the sealing mold device described above. The construction method comprises the following steps:

[0066] 1. Measurement and line laying

[0067] According to the main structure control network, the axis is measured and introduced to the construction floor as the positioning reference of the wall body; the edge line, door hole position and inclined support pre-burying point position line of the wall body are popped out on the floor to ensure the installation accuracy;

[0068] 2. Steel bar preparation

[0069] Insert vertical steel with straight thread sleeve into the vertical hole reserved in prefabricated wallboard, fix it with the lower layer of protruding steel through mechanical connection and check the connection quality; check whether the lap length and position of horizontal steel reserved in the edge of prefabricated wallboard and cast-in-place section steel meet the design requirements;

[0070] 3. Floor cleaning

[0071] Clean the garbage, floating soil, wood chips, concrete slag and the like on the floor before hoisting the EMC prefabricated shear wall, so that the mold sealing device is placed flat and the installation accuracy is ensured.

[0072] 4. Place the mold sealing device

[0073] Place the mold sealing device on both sides of the wall line, fold the vertical plate 2 to make it 90° with the base 1, then insert the insert piece 4 into the clamping groove 21 and insert it 20-30 mm into the vertical plate 2.

[0074] 5. EMC prefabricated wallboard installation

[0075] Use a special lifting tool to symmetrically hook to ensure that the wallboard is hoisted smoothly and avoid collision; slowly lower the wallboard to the elastic line position, and place the bottom of the wallboard on the insert piece 4, at this time the bottom of the wallboard is 7 cm away from the concrete floor, the vertical plate 2 is tightly attached to the wall, 2-3 adjustable inclined braces (angle ≤60°) are installed for each wallboard, the verticality of the wallboard is adjusted (detected by a laser plumb instrument), and the bottom bolts are fixed; after the verticality is corrected, the hooks are removed and temporary fixing is performed.

[0076] 6. Concrete pouring

[0077] Pour concrete after the steel bar binding is completed, and pour in layers (each layer ≤1m) and vibrate to compact.

[0078] 7. Demoulding

[0079] Remove the mold sealing device after the cast-in-place section concrete reaches a certain strength, remove the device directly when demoulding, remove the mold sealing device by adjusting the angle of the vertical plate 2 and the base 1, and the insert piece 4 is left in the concrete, without the need for plugging operation.

[0080] The mold sealing device of the embodiment has the following advantages:

[0081] (1) Non-destructive fixing

[0082] Base 1 + hinge structure: through the hinge design (4-inch steel bearing hinge) of the welding of the vertical plate 2 and the base 1, the mold plate is opened and closed, without the need for drilling or slotting fixing.

[0083] Insert piece 4 locking: use the insert piece 4 to lock the bottom of the prefabricated wallboard, avoiding damage to the wall by traditional bolts.

[0084] 2) High sealing design

[0085] Precise slot matching: the slot 21 of the vertical plate 2 is tightly matched with the plug 4, the gap is ≤1mm, and the slurry leakage rate is controlled below 3%.

[0086] Welding integration of the vertical plate 2 and the base 1: eliminating the risk of slurry leakage of traditional assembled formwork joints.

[0087] 3) Quick installation and height adjustment

[0088] Modular assembly: the base 1 and the vertical plate 2 are prefabricated in the factory, and only need to be inserted into the plug 4 on site to complete the fixation (single-layer construction time <2 hours).

[0089] 7cm cast-in-place strip adaptation: the lower edge of the slot 21 is 34mm away from the bottom of the vertical plate 2, combined with the thickness of the plug 4 (6mm) and the thickness of the base 1 (30mm), ensuring a clear space of 70mm (34+6+30) for the cast-in-place strip.

[0090] 4) Low cost and high turnover

[0091] Standardized steel: all Q235B steel plates are used (easy to purchase, low cost), and the hinge assembly 3 is a finished stainless steel part, with low processing cost.

[0092] Reusable: the device is undamaged after disassembly, and the turnover frequency is ≥50 times.

[0093] In summary, the sealing device provided by the embodiment is simple to process, has a wide range of processing materials and low cost; reliable quality, convenient installation, saves construction period; can be disassembled, has high assembly degree, and can be recycled; the device is used for construction of the bottom cast-in-place strip of the prefabricated hollow composite shear wall, which can not only ensure the construction quality, but also greatly improve the construction efficiency, save the cost of fabricated construction, and has good economic efficiency compared with the traditional method.

[0094] The above only describes the preferred embodiments of the present application and is not intended to limit the present application. Any modification, equivalent replacement and improvement made within the spirit and principle of the present application shall be included in the protection scope of the present application.

Claims

1. A mold sealing device for the bottom cast-in-situ zone of a prefabricated hollow composite shear wall, characterized in that: It includes a base, a vertical plate, a hinge assembly and an insert. The base and the vertical plate are rotatably connected through the hinge assembly. The vertical plate is provided with a slot running through its thickness direction. The length direction of the slot extends in the horizontal direction. The insert can be inserted into and out of the slot.

2. The mold sealing device according to claim 1, characterized in that The hinge assembly is a stainless steel hinge.

3. The mold sealing device according to claim 1, characterized in that: The base and the vertical plate are connected via a plurality of hinge assemblies, and the vertical plate is provided with a plurality of slots spaced apart along a horizontal direction.

4. The mold sealing device according to claim 1, characterized in that The shape of the card slot is rectangular, the cross-section of the inserting piece is also rectangular, and the size of the card slot matches the size of the inserting piece.

5. The mold sealing device according to claim 2, characterized in that: The base, the vertical plate and the insert are all made of steel.

6. The mold sealing device according to claim 5, characterized in that: The base measures 1000*140*30mm and is made of Q235B 30mm thick steel plate; the vertical plate measures 1000*120*10mm and is made of Q235B 10mm thick steel plate; the slot cross-sectional dimensions are 50*6mm; the insert measures 50*50*6mm and is made of Q235B 6mm thick steel plate; the stainless steel hinge measures 102*100*2.8mm.

7. A method for constructing the bottom cast-in-situ strip of a prefabricated hollow composite shear wall, applied to the mold sealing device according to any one of claims 1 to 6, characterized in that: The construction method comprises the following steps: (1) Measurement and layout According to the main structure control network, the axis is measured to the construction floor as the wall positioning reference; the wall edge line, door opening position and inclined support embedded point position line are popped up on the floor to ensure installation accuracy; (2) Steel bar preparation Insert vertical steel bars with straight threaded sleeves into the reserved vertical holes in the precast wall panels, secure them to the protruding steel bars in the lower layer through mechanical connection, and inspect the quality of the connection; check whether the overlap length and position of the horizontal steel bars reserved at the edge of the precast wall panels and the steel bars in the cast-in-place section meet the design requirements; (3) Floor cleaning Before hoisting the EMC prefabricated shear wall, clean up the garbage, loose soil, wood chips, concrete slag, etc. on the floor; so that the sealing device can be placed flat and ensure installation accuracy; (4) Place the sealing device Place the sealing device on both sides of the wall line, fold the vertical plate so that it is 90 degrees with the base, and then insert the insert into the slot, 20 to 30 mm deep into the vertical plate; (5) EMC prefabricated wall panel installation Use a special lifting device with symmetrical hooks to ensure smooth lifting of the wall panel to avoid collisions; slowly lower the wall panel to the spring line position, and place the bottom of the wall panel on the insert. At this time, the bottom of the wall panel is a certain distance away from the concrete floor, and the vertical panel is close to the wall. Install 2 to 3 adjustable diagonal braces on each wall panel to adjust the verticality of the wall panel and fix the bottom bolts; after the verticality is corrected and qualified, remove the hook and perform temporary fixation; (6) Concrete pouring After the reinforcement is tied, pour the concrete in layers and vibrate to make it dense. (7) Demolding When the strength of the cast-in-place concrete reaches a certain level, the sealing device is removed. When removing the mold, the device is directly removed. The sealing device can be removed by adjusting the angle between the vertical plate and the base. The steel inserts are left in the concrete and no sealing operation is required.

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