Fabricated building outer wall facing forming process and forming device

Abstract

The invention relates to an assembly type building outer wall facing forming process which comprises the step that the compactness, the crack resistance and the waterproof capacity of a base material are enhanced through the synergistic effect of ordinary Portland cement, quartz sand, composite reinforced fibers and other components. A stable substrate is provided for the decorative layer; components such as water-based organic silicon resin and nano titanium dioxide in the surface protective agent form a weather-proof protective film, so that the service life of the decorative layer is prolonged. And by combining the process optimization of shortening the construction period through UV rapid curing, integrating procedures through integrated forming equipment and the like, the long-term quality and attractiveness of the outer wall facing are guaranteed, and the effects of remarkably improving the construction efficiency and reducing the comprehensive cost are achieved by reducing the rework and maintenance requirements.

Description

Technical Field

[0001] This application belongs to the field of prefabricated building construction technology, specifically a prefabricated building exterior wall cladding molding process and molding device. Background Technology

[0002] Prefabricated construction, as an important development direction of building industrialization, has developed rapidly in recent years under the impetus of policies. Currently, the exterior walls of prefabricated buildings are mostly finished by spraying, with real stone paint and coatings as the main decorative materials. These exterior paints are prone to peeling and fading due to long-term exposure to wind and sun, limiting their durability. Furthermore, the variety of decorative materials is limited, making it difficult to meet the aesthetic needs of different projects. Prefabricated construction is a modern building construction method that primarily uses prefabricated components in factories, supplemented by on-site assembly. Its core concept is to mass-produce various parts of the building (such as walls, floors, beams, columns, stairs, etc.) in factories according to standardized designs, and then transport them to the construction site for assembly and connection, thereby achieving industrialization, modularization, and efficiency in building construction. This model has significant advantages such as short construction cycles, low labor intensity, low environmental pollution, and strong quality control, making it an important path to promote the transformation and upgrading of the construction industry and achieve green and low-carbon development. Prefabricated buildings are mainly divided into various types, including concrete structures, steel structures, and wood structures, and are widely used in various types of buildings such as residences, schools, hospitals, and office buildings. In recent years, with strong support from national policies and the continuous development of technologies such as BIM and intelligent manufacturing, prefabricated buildings have been rapidly promoted in China and have become a key direction for the high-quality development of the construction industry.

[0003] However, the current traditional methods of exterior wall decoration suffer from a lack of balance between aesthetic appeal and construction efficiency, and the waterproofing performance of joints is unstable, which needs further improvement. Summary of the Invention

[0004] To avoid leakage and cracking caused by poor joint sealing in traditional processes, this application provides a prefabricated building exterior wall cladding molding process and molding device.

[0005] This application provides a technical solution for a prefabricated building exterior wall cladding molding process, the process comprising the following steps: S1: Substrate Pretreatment. After weighing the materials for preparing high-performance concrete, the substrate is prepared. By adjusting the proportions of aggregates, auxiliary materials, and additives, it is ensured that the large-size slabs are formed without cracking, providing a stable base for subsequent decorative surface materials.

[0006] S2: Industrialized molding of substrate. The pre-treated substrate is molded using integrated intelligent equipment that combines cutting, spraying, and rolling. The equipment provides high kinetic energy through controlled compressed air, compacting the concrete layer and enhancing the mechanical bond between continuous interlayer layers, thereby improving the uniformity of the substrate and providing a smooth and dense base for decorative surface materials.

[0007] S3: Adjustment of decorative surface material parameters. Based on the target color (12 types) and texture (3 types) requirements, control the type, ratio, and molding thickness of the decorative surface material raw materials. Simultaneously adjust the parameters in conjunction with the surface roughness, water absorption rate, and other characteristics of the S2 molding substrate to ensure the adhesion between the surface material and the substrate and the uniformity of the decorative effect.

[0008] S4: Decorative layer spray molding. Using an improved intelligent nozzle device, the prepared decorative surface material is sprayed onto the substrate surface under high pressure. The spraying pressure and angle are dynamically adjusted according to the surface material viscosity determined in S3 and the surface density of the substrate in S2 to ensure that the decorative layer has a uniform thickness and is tightly bonded to the substrate.

[0009] S5: Roller Coating Optimizes Texture. A custom roller is used to roll the sprayed decorative layer. The surface texture and rolling pressure of the roller are adjusted according to the target texture determined in S3. Without damaging the initial adhesion of the sprayed layer, the bonding force between the decorative layer and the substrate is enhanced by rolling, thereby improving the three-dimensional texture.

[0010] S6: UV rapid curing. The UV curing equipment is started immediately after the roller coating is completed. The UV wavelength, light intensity and curing time are adjusted according to the photoinitiator content in the S3 topcoat and the wetness of the decorative layer after the S5 roller coating, so as to promote the rapid curing of the topcoat to form a stable structure. Compared with traditional natural drying, the time is greatly shortened and the construction efficiency is improved.

[0011] S7: Surface protection treatment. Select a surface protectant with an improved formulation and apply it evenly to the surface of the cured decorative layer. The penetration ability and film-forming characteristics of the protectant must match the porosity of the decorative layer after S6 curing. Through coverage and penetration, a protective layer is formed, improving the weather resistance, fading resistance and peeling resistance of the decorative layer.

[0012] S8: Joint Sealing Treatment. For the joints of prefabricated exterior walls, a sealant compatible with the decorative layer material is selected for filling and sealing. The thermal expansion coefficient and surface tension of the sealant must match the material properties of the S1 substrate and the surface properties of the S7 protective layer to ensure that the joints are tightly sealed and consistent with the color and texture of the decorative layer, thus solving the problem of unstable waterproofing of traditional joints.

[0013] In a preferred embodiment, in step S1, the substrate comprises: 55-65 parts by weight of ordinary silicate cement, 28-38 parts by weight of quartz sand, 3-5 parts by weight of composite reinforcing fiber (alkali-resistant glass fiber and polypropylene fiber in a 2:1 ratio), 2-4 parts by weight of nano-silica, 0.8-1.2 parts by weight of polycarboxylate superplasticizer, 1-2 parts by weight of organosilicon waterproofing agent, and 2-3 parts by weight of calcium sulfoaluminate expansion agent.

[0014] This formula enhances crack resistance through the synergistic effect of composite fibers (glass fiber provides rigid support, and polypropylene fiber improves toughness), fills the pores with nano-silica to improve density, expanders compensate for molding shrinkage, and waterproofing agents reduce water absorption, thus balancing weather resistance and strength. Compared with traditional formulas, it is more suitable for the industrial molding needs of large-size panels.

[0015] During the pretreatment stage, the raw material storage environment must be strictly controlled. Cement should be stored in a dry warehouse to prevent moisture absorption and clumping. Fiber materials must be sealed to prevent moisture absorption from affecting the reinforcing effect. During mixing, the workshop temperature must be maintained between 15-25℃ to avoid high temperatures accelerating cement hydration or low temperatures delaying the reaction. After mixing, the slurry must complete the molding process within 30 minutes to prevent initial setting from affecting the quality of subsequent pouring. The pretreated substrate must be immediately covered with a curing film to prevent excessive evaporation of surface moisture, which could lead to shrinkage cracks. It should also be protected from contact with oil and chemicals to prevent contamination of the substrate surface.

[0016] In a preferred embodiment, in step S2, the mold must be thoroughly cleaned before molding to remove residual slurry and apply a water-based release agent to ensure smooth demolding of the substrate after molding without surface damage. Before starting the equipment, a calibration test must be performed, focusing on checking whether the nozzles of the spraying system are clogged and whether the parallelism of the rolling rollers meets the standards, to avoid uneven substrate thickness or surface irregularities due to equipment deviations. During the molding process, a dedicated person must conduct regular inspections to observe whether the slurry spraying is continuous and whether the rolling covers the entire area. If any missed spraying or shallow indentations are found, the equipment parameters must be adjusted immediately and additional spraying and pressing performed.

[0017] In a preferred embodiment, step S3 requires preparation in an independent, enclosed mixing room with ambient humidity controlled below 60% to prevent the resin from absorbing moisture from the air and affecting its bonding performance. During preparation, the base material and silica powder should first be pre-mixed at low speed (100-200 rpm), then the pigment should be added and dispersed at high speed (500-800 rpm) for 30 minutes to ensure uniform color and no sedimentation. The prepared surface material must be used within 2 hours. Materials exceeding this time limit must have their viscosity and adhesion retested; only materials meeting the requirements can continue to be used to prevent the decorative layer from peeling off due to material failure.

[0018] In a preferred embodiment, in step S4, before spraying, the surface of the substrate must be cleaned with a high-pressure air gun to ensure a tight bond between the sprayed layer and the substrate. During spraying, the workshop air velocity must be controlled to ≤2m / s to prevent the slurry from being blown away by the airflow, resulting in uneven thickness. Spraying should follow the order of "edges first, then center," first spraying along the perimeter of the substrate to form the boundary, then filling the central area to prevent missed areas at the edges. After spraying each substrate, the surface of the decorative layer should be immediately brushed with a soft brush to eliminate any localized protrusions generated during spraying, ensuring overall flatness.

[0019] In a preferred embodiment, in step S5, before roller coating, a corresponding roller (e.g., a dark-textured roller for imitation stone texture, a light-textured roller for imitation wood grain) should be selected according to the target texture, and the roller surface should be checked for any residual slurry to avoid contaminating the newly coated area. During roller coating, the roller should be kept at a 45° angle to the substrate surface and moved at a uniform speed. The reciprocating roller coating direction should be perpendicular to the spraying direction to ensure a more natural cross-over of the texture. After roller coating is completed, the texture details should be checked immediately with a magnifying glass. If local textures are found to be blurred, they should be touched up with the same type of roller before the surface material is cured to avoid irreparable damage after subsequent curing.

[0020] In a preferred embodiment, in step S6, the curing equipment needs to be preheated for 10 minutes before starting, and the operation should only begin after the mercury lamp power has stabilized, to avoid insufficient light intensity in the initial stage affecting the curing effect. A light-shielding curtain should be installed in the curing area to prevent external ultraviolet radiation from interfering with the equipment monitoring system; the substrate should be kept stationary during the curing process to avoid movement that could lead to insufficient local light exposure. After curing, wait 3-5 minutes for the decorative layer to cool naturally to room temperature before proceeding to the next step to prevent surface cracking due to sudden cooling.

[0021] In a preferred embodiment, in step S7, the surface protective agent comprises: 45-55 parts by weight of waterborne silicone resin, 8-12 parts by weight of nano titanium dioxide (rutile type), 3-5 parts by weight of γ-aminopropyltriethoxysilane (silane coupling agent), 15-20 parts by weight of fluorocarbon resin modified emulsion, 15-25 parts by weight of deionized water, and 0.5-1.5 parts by weight of wetting and dispersing agent.

[0022] This formulation utilizes water-based silicone resin to form a dense, elastic film layer, providing basic weather resistance. Nano-titanium dioxide (rutile type) efficiently absorbs ultraviolet light and reflects some visible light, inhibiting fading of the decorative layer. Silane coupling agents penetrate into the pores of the decorative layer, reacting with the hydroxyl groups of the substrate to form chemical bonds, enhancing the adhesion between the protective agent and the decorative layer and preventing peeling. Fluorocarbon resin-modified emulsion improves the film's resistance to chemical erosion and damp heat aging. Combined with deionized water and wetting and dispersing agents, it optimizes application penetration. Compared to traditional single-component protective agents, this formulation offers a synergistic and innovative improvement in anti-fading, anti-peeling, and long-term durability.

[0023] Before applying the protective agent, ensure the decorative layer surface is completely dry (not sticky to the touch). If the surface is damp or wet, dry it with a hot air blower at a low temperature before application. For small, delicate areas, roller application is suitable; roll evenly in the same direction to avoid back-and-forth movement that could cause agent buildup. Airless spraying is suitable for large areas; keep the nozzle 30-50cm away from the decorative layer to ensure uniform film formation. Do not allow the coating to come into contact with rain or be washed within 24 hours of application to prevent the protective agent from being washed away before it has fully formed.

[0024] In a preferred embodiment, in step S8, the sealant packaging must be checked for integrity before use. If skinning or delamination is found, the sealant must be discarded and replaced with new material. During application, closed-cell foam rods must be tightly filled into the bottom of the joint, with a filling depth of 1 / 2 to 2 / 3 of the joint width, ensuring that the sealant forms a "backing" constraint to prevent tearing under stress. After the sealant is filled, a special joint pressing tool must be used to compact it along the joint direction to ensure a smooth transition between the sealant surface and the decorative layer surface, while removing internal air bubbles. The joint area should not be stepped on or bumped within 2 hours after application. After the sealant has surface-dried (approximately 4-6 hours), a water spray test must be conducted to confirm no leakage before acceptance.

[0025] In summary, this application includes at least one of the following beneficial technical effects: 1. Starting from the substrate preparation stage, strict pretreatment control and precise operation of industrial molding equipment ensure the high density and dimensional stability of the substrate, laying a physical foundation for the precise alignment of subsequent joints. In the joint treatment stage, a silicone sealant compatible with the decorative layer is used, and a standardized construction process effectively avoids leakage and cracking problems caused by poor joint sealing in traditional processes. Simultaneously, the composite formula of the surface protective agent enhances the weather resistance and corrosion resistance of the decorative layer, further reducing problems such as joint edge peeling or color difference caused by environmental aging, ultimately achieving a lasting and beautiful overall exterior wall decoration effect.

[0026] 2. UV rapid curing technology shortens the curing time of the decorative layer, significantly reducing the waiting period for each process. Secondly, the application of integrated molding equipment consolidates multi-stage operations into a continuous process, reducing the time spent on manual site transfers and equipment debugging. Furthermore, strict control of the raw material storage environment and standardization of the mixing process during the substrate pretreatment stage reduce material waste. The highly efficient film-forming properties of the surface protectant reduce the frequency of subsequent maintenance. These measures improve efficiency from material preparation to on-site construction, and significantly reduce overall costs by reducing rework, minimizing waste, and extending maintenance cycles.

[0027] 3. In the substrate formulation, the synergistic effect of ordinary silicate cement, quartz sand, and composite reinforcing fibers enhances density, crack resistance, and waterproofing, providing a stable base for the decorative layer. The surface protectant, containing water-based silicone resin and nano-titanium dioxide, forms a weather-resistant protective film, extending the lifespan of the decorative layer. Combined with optimized processes such as UV rapid curing to shorten construction time and integrated molding equipment to streamline procedures, this not only ensures the long-term quality and aesthetics of the exterior wall finish but also significantly improves construction efficiency and reduces overall costs by minimizing rework and maintenance needs. Attached Figure Description

[0028] Figure 1 This is a schematic diagram illustrating the process principle of this application. Detailed Implementation

[0029] To make the objectives, technical solutions, and advantages of this application clearer, the following detailed description is provided in conjunction with the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative and not intended to limit the scope of this application.

[0030] Reference Figure 1 , A prefabricated building exterior wall cladding forming process, the process method includes the following steps: S1: Substrate Pretreatment. After weighing the materials for preparing high-performance concrete, the substrate is prepared. By adjusting the proportions of aggregates, auxiliary materials, and additives, it is ensured that the large-size slabs are formed without cracking, providing a stable base for subsequent decorative surface materials.

[0031] S2: Industrialized molding of substrate. The pre-treated substrate is molded using integrated intelligent equipment that combines cutting, spraying, and rolling. The equipment provides high kinetic energy through controlled compressed air, compacting the concrete layer and enhancing the mechanical bond between continuous interlayer layers, thereby improving the uniformity of the substrate and providing a smooth and dense base for decorative surface materials.

[0032] S3: Adjustment of decorative surface material parameters. Based on the target color (12 types) and texture (3 types) requirements, control the type, ratio, and molding thickness of the decorative surface material raw materials. Simultaneously adjust the parameters in conjunction with the surface roughness, water absorption rate, and other characteristics of the S2 molding substrate to ensure the adhesion between the surface material and the substrate and the uniformity of the decorative effect.

[0033] S4: Decorative layer spray molding. Using an improved intelligent nozzle device, the prepared decorative surface material is sprayed onto the substrate surface under high pressure. The spraying pressure and angle are dynamically adjusted according to the surface material viscosity determined in S3 and the surface density of the substrate in S2 to ensure that the decorative layer has a uniform thickness and is tightly bonded to the substrate.

[0034] S5: Roller Coating Optimizes Texture. A custom roller is used to roll the sprayed decorative layer. The surface texture and rolling pressure of the roller are adjusted according to the target texture determined in S3. Without damaging the initial adhesion of the sprayed layer, the bonding force between the decorative layer and the substrate is enhanced by rolling, thereby improving the three-dimensional texture.

[0035] S6: UV rapid curing. The UV curing equipment is started immediately after the roller coating is completed. The UV wavelength, light intensity and curing time are adjusted according to the photoinitiator content in the S3 topcoat and the wetness of the decorative layer after the S5 roller coating, so as to promote the rapid curing of the topcoat to form a stable structure. Compared with traditional natural drying, the time is greatly shortened and the construction efficiency is improved.

[0036] S7: Surface protection treatment. Select a surface protectant with an improved formulation and apply it evenly to the surface of the cured decorative layer. The penetration ability and film-forming characteristics of the protectant must match the porosity of the decorative layer after S6 curing. Through coverage and penetration, a protective layer is formed, improving the weather resistance, fading resistance and peeling resistance of the decorative layer.

[0037] S8: Joint Sealing Treatment. For the joints of prefabricated exterior walls, a sealant compatible with the decorative layer material is selected for filling and sealing. The thermal expansion coefficient and surface tension of the sealant must match the material properties of the S1 substrate and the surface properties of the S7 protective layer to ensure that the joints are tightly sealed and consistent with the color and texture of the decorative layer, thus solving the problem of unstable waterproofing of traditional joints.

[0038] In step S1, the substrate includes: 55-65 parts by weight of ordinary silicate cement, 28-38 parts by weight of quartz sand, 3-5 parts by weight of composite reinforcing fiber (alkali-resistant glass fiber and polypropylene fiber are compounded in a 2:1 ratio), 2-4 parts by weight of nano silica, 0.8-1.2 parts by weight of polycarboxylate superplasticizer, 1-2 parts by weight of organosilicon waterproofing agent, and 2-3 parts by weight of calcium sulfoaluminate expansion agent.

[0039] This formula enhances crack resistance through the synergistic effect of composite fibers (glass fiber provides rigid support, and polypropylene fiber improves toughness), fills the pores with nano-silica to improve density, expanders compensate for molding shrinkage, and waterproofing agents reduce water absorption, thus balancing weather resistance and strength. Compared with traditional formulas, it is more suitable for the industrial molding needs of large-size panels.

[0040] By using the above formula to select different types of substrates (such as fiber-reinforced aerated cement-based materials, high-performance concrete, etc.), and adjusting the amount and proportion of aggregates, auxiliary materials, and additives, the fire resistance, weather resistance, water resistance, strength, and other properties of the material are improved to prepare the board. This ensures that the overall molding of large-size boards does not crack. The specific performance parameters of large-size boards are shown in the table below: Table 2 Main Material Properties of Fiber Reinforced Cement Board During the pretreatment stage, strict control of the raw material storage environment is required. Cement should be stored in a dry warehouse to prevent moisture absorption and clumping; fiber materials must be stored in sealed containers to prevent moisture absorption from affecting the reinforcing effect. During mixing, the workshop temperature must be maintained between 15-25℃ to avoid high temperatures accelerating cement hydration or low temperatures delaying the reaction. After mixing, the slurry must complete the molding process within 30 minutes to prevent initial setting from affecting the quality of subsequent pouring. The pretreated substrate must be immediately covered with a curing film to prevent excessive surface moisture evaporation leading to shrinkage cracks, and to avoid contact with oil and chemicals that could contaminate the substrate surface. In step S2, the mold must be thoroughly cleaned before molding to remove residual slurry and apply a water-based release agent to ensure smooth demolding of the substrate without surface damage after molding. Before starting the equipment, a calibration test must be performed, focusing on checking whether the nozzles of the spraying system are clogged and whether the parallelism of the rolling rollers meets the standards, to avoid uneven substrate thickness or surface irregularities due to equipment deviations. During the molding process, a dedicated person must conduct regular inspections to observe whether the slurry spraying is continuous and whether the rolling covers the entire area. If any missed spraying or shallow indentations are found, the equipment parameters must be adjusted immediately and additional spraying and pressing performed.

[0041] In step S3, the preparation must be carried out in a separate, enclosed mixing room, with the ambient humidity controlled below 60% to prevent the resin from absorbing moisture from the air and affecting its bonding performance. During preparation, the base material and silica powder must first be pre-mixed at low speed (100-200 rpm), then the pigment is added and dispersed at high speed (500-800 rpm) for 30 minutes to ensure uniform color and no sedimentation. The prepared surface material must be used within 2 hours. Materials exceeding this time limit must have their viscosity and adhesion retested; only materials meeting the requirements can continue to be used to avoid the decorative layer peeling off due to material failure.

[0042] In step S4, before spraying, the surface of the substrate must be cleaned with a high-pressure air gun to remove any loose dust, ensuring a tight bond between the sprayed layer and the substrate. During spraying, the workshop airflow must be controlled to ≤2m / s to prevent the slurry from being blown away by the airflow, resulting in uneven thickness. Spraying should follow the order of "edges first, then center," first spraying along the perimeter of the substrate to form the boundary, then filling the central area to prevent missed areas at the edges. After spraying each substrate, immediately use a soft brush to lightly sweep the surface of the decorative layer to eliminate any localized protrusions created during spraying, ensuring overall flatness.

[0043] In step S5, before roller coating, select the appropriate roller according to the target texture (e.g., a dark-textured roller for stone grain and a light-textured roller for wood grain), and check the roller surface for any residual slurry to avoid contaminating the newly coated area. During roller coating, maintain a 45° angle with the substrate surface and advance at a uniform speed. The reciprocating roller direction should be perpendicular to the spray direction to ensure a more natural cross-over of the texture. After roller coating, immediately inspect the texture details with a magnifying glass. If any areas are found to be blurry, apply additional pressure with the same type of roller before the surface material cures to prevent irreparable damage after curing.

[0044] In step S6, the curing equipment needs to be preheated for 10 minutes before starting, and operation should only begin after the mercury lamp power has stabilized to avoid insufficient light intensity in the initial stage affecting the curing effect. A light-shielding curtain should be set up in the curing area to prevent external ultraviolet rays from interfering with the equipment monitoring system. During the curing process, the substrate must be kept stationary to avoid movement that could lead to insufficient localized light exposure. After curing, wait 3-5 minutes for the decorative layer to cool naturally to room temperature before proceeding to the next step to prevent surface cracking due to sudden cooling.

[0045] In step S7, the surface protective agent includes: 45-55 parts by weight of waterborne silicone resin, 8-12 parts by weight of nano titanium dioxide (rutile type), 3-5 parts by weight of γ-aminopropyltriethoxysilane (silane coupling agent), 15-20 parts by weight of fluorocarbon resin modified emulsion, 15-25 parts by weight of deionized water, and 0.5-1.5 parts by weight of wetting and dispersing agent.

[0046] This formulation utilizes water-based silicone resin to form a dense, elastic film layer, providing basic weather resistance. Nano-titanium dioxide (rutile type) efficiently absorbs ultraviolet light and reflects some visible light, inhibiting fading of the decorative layer. Silane coupling agents penetrate into the pores of the decorative layer, reacting with the hydroxyl groups of the substrate to form chemical bonds, enhancing the adhesion between the protective agent and the decorative layer and preventing peeling. Fluorocarbon resin-modified emulsion improves the film's resistance to chemical erosion and damp heat aging. Combined with deionized water and wetting and dispersing agents, it optimizes application penetration. Compared to traditional single-component protective agents, this formulation offers a synergistic and innovative improvement in anti-fading, anti-peeling, and long-term durability.

[0047] Before applying the protective agent, ensure the decorative layer surface is completely dry (not sticky to the touch). If the surface is damp or wet, dry it with a hot air blower at a low temperature before application. Roller application is suitable for small, delicate areas; roll evenly in the same direction to avoid back-and-forth movement that could cause agent buildup. Airless spraying is suitable for large areas; keep the nozzle 30-50cm away from the decorative layer to ensure uniform film formation. Do not allow the coating to come into contact with rain or be washed away within 24 hours after application to prevent the protective agent from being washed away before it has fully formed. In step S8, check the packaging of the sealant before use. If skinning or delamination is found, discard the sealant and replace it with new material. During application, tightly fill the bottom of the joint with closed-cell foam rods to a depth of 1 / 2-2 / 3 of the joint width, ensuring the sealant forms a "backing" constraint to prevent tearing under stress. After filling the sealant, use a special joint pressing tool to compact it along the joint direction, ensuring a smooth transition between the sealant surface and the decorative layer surface, while also removing internal air bubbles. Do not step on or bump into the joint area within 2 hours after construction is completed. After the sealant has dried to the touch (about 4 to 6 hours), a water spray test must be conducted. Only after confirming that there is no leakage can the application be accepted.

[0048] A prefabricated building exterior wall cladding forming device, wherein the device uses the above-mentioned prefabricated building exterior wall cladding forming process to perform forming operation on the prefabricated building exterior wall cladding.

[0049] From the above, we can conclude that: Starting from the substrate preparation stage, strict pretreatment control and precise operation of industrial molding equipment ensure the high density and dimensional stability of the substrate, laying a physical foundation for the precise alignment of subsequent joints. In the joint treatment stage, a silicone sealant compatible with the decorative layer is used, and a standardized construction process effectively avoids leakage and cracking problems caused by poor joint sealing in traditional processes. Simultaneously, the composite formula of the surface protective agent enhances the weather resistance and corrosion resistance of the decorative layer, further reducing problems such as joint edge peeling or color difference caused by environmental aging, ultimately achieving a lasting and aesthetically pleasing overall exterior wall decoration effect.

[0050] UV rapid curing technology shortens the curing time of the decorative layer, significantly reducing the waiting period for each process. Secondly, the application of integrated "cutting, spraying, and rolling" molding equipment consolidates multiple operations into a continuous process, reducing the time spent on manual site transfers and equipment debugging. Furthermore, strict control of the raw material storage environment and standardization of the mixing process during the substrate pretreatment stage reduces material waste. The highly efficient film-forming properties of the surface protectant reduce the frequency of subsequent maintenance. These measures improve efficiency from material preparation to on-site construction, while significantly reducing overall costs by minimizing rework, reducing waste, and extending maintenance cycles.

[0051] In the substrate formulation, the synergistic effect of ordinary silicate cement, quartz sand, and composite reinforcing fibers enhances density, crack resistance, and waterproofing, providing a stable base for the decorative layer. The surface protectant, composed of water-based silicone resin and nano-titanium dioxide, forms a weather-resistant protective film, extending the lifespan of the decorative layer. Combined with optimized processes such as UV rapid curing to shorten construction time and integrated molding equipment to streamline procedures, this approach ensures the long-term quality and aesthetics of the exterior wall finish while significantly improving construction efficiency and reducing overall costs by minimizing rework and maintenance needs.

[0052] The above are all preferred embodiments of this application, and are not intended to limit the scope of protection of this application. Therefore, all equivalent changes made in accordance with the structure, shape and principle of this application should be covered within the scope of protection of this application.

Claims

1. A prefabricated building exterior wall cladding molding process, characterized in that: The process includes the following steps: S1: Substrate pretreatment; After weighing the materials for preparing high-performance concrete, the substrate is prepared. By adjusting the proportions of aggregates, auxiliary materials and additives, it is ensured that the large-size slabs are formed without cracking, providing a stable base for subsequent decorative surface materials. S2: Industrialized molding of substrate; The pre-treated substrate is molded using integrated intelligent equipment that combines cutting, spraying, and rolling. The equipment provides high kinetic energy through controlled compressed air, compacts the concrete layer, enhances the mechanical bond between continuous layers, improves the uniformity of the substrate, and provides a flat and dense base for decorative surface materials. S3: Adjustment of decorative surface material parameters; Based on the target color and texture requirements, control the type, ratio, and molding thickness of the decorative surface material raw materials, and simultaneously adjust the parameters in conjunction with the surface roughness and water absorption characteristics of the S2 molding substrate to ensure the adhesion between the surface material and the substrate and the uniformity of the decorative effect. S4: Decorative layer spraying; using an improved intelligent nozzle device, the prepared decorative surface material is sprayed onto the substrate surface under high pressure. The spraying pressure and angle are dynamically adjusted according to the surface material viscosity determined in S3 and the surface density of the substrate in S2 to ensure that the decorative layer has a uniform thickness and is tightly bonded to the substrate. S5: Roller coating optimizes texture; A customized roller is used to roll the sprayed decorative layer. The surface texture and rolling pressure of the roller are adjusted according to the target texture determined in S3. Without damaging the initial adhesion of the sprayed layer, the bonding force between the decorative layer and the substrate is enhanced by rolling, thereby improving the three-dimensional texture. S6: UV rapid curing; The UV curing equipment is started immediately after the roller coating is completed. The UV wavelength, light intensity and curing time are adjusted according to the photoinitiator content in the S3 surface material and the wet state of the decorative layer after the S5 roller coating, so as to promote the rapid curing of the surface material to form a stable structure. Compared with traditional natural drying, the time is greatly shortened and the construction efficiency is improved. S7: Surface protection treatment; Select a surface protective agent with an improved ratio and apply it evenly to the surface of the cured decorative layer. The penetration ability and film-forming characteristics of the protective agent must match the porosity of the decorative layer after S6 curing. A protective layer is formed through coverage and penetration to improve the weather resistance, fading resistance and peeling resistance of the decorative layer. S8: Joint sealing treatment; For the joints of prefabricated exterior walls, use a sealant compatible with the decorative layer material to fill and seal them. The thermal expansion coefficient and surface tension of the sealant must match the material properties of the S1 substrate and the surface properties of the S7 protective layer.

2. The prefabricated building exterior wall cladding molding process as described in claim 1, characterized in that: In step S1, the substrate includes: 55-65 parts by weight of ordinary silicate cement, 28-38 parts by weight of quartz sand, 3-5 parts by weight of composite reinforcing fiber, 2-4 parts by weight of nano silica, 0.8-1.2 parts by weight of polycarboxylate superplasticizer, 1-2 parts by weight of organosilicon waterproofing agent, and 2-3 parts by weight of calcium sulfoaluminate expansion agent.

3. The prefabricated building exterior wall cladding molding process as described in claim 1, characterized in that: In step S2, the mold must be thoroughly cleaned before molding to remove residual slurry and apply a water-based release agent to ensure that the substrate can be easily demolded without surface damage after molding. Before starting the equipment, a calibration test must be performed, focusing on checking whether the nozzles of the spraying system are clogged and whether the parallelism of the rolling rollers meets the standards, to avoid uneven substrate thickness or uneven surface due to equipment deviation. During the molding process, a dedicated person must be assigned to inspect and observe whether the slurry spraying is continuous and whether the rolling covers the entire area. If any missed spraying or shallow indentation is found, the equipment parameters must be adjusted immediately and additional spraying and pressure applied.

4. The prefabricated building exterior wall cladding molding process as described in claim 1, characterized in that: In step S3, the preparation must be carried out in an independent and enclosed mixing room, with the ambient humidity controlled below 60% to prevent the resin from absorbing moisture from the air and affecting the bonding performance. During preparation, the base material and silica powder must be pre-mixed at low speed first, and then the pigment must be added and dispersed at high speed for 30 minutes to ensure uniform color and no sedimentation. The prepared surface material must be used within 2 hours. Materials that exceed the time limit must be retested for viscosity and adhesion. Only after meeting the requirements can they continue to be used to avoid the decorative layer from falling off due to material failure.

5. The prefabricated building exterior wall cladding molding process as described in claim 1, characterized in that: In step S4, before spraying, the surface dust of the substrate must be cleaned with a high-pressure air gun to ensure that the sprayed layer is tightly bonded to the substrate. During the spraying process, the wind speed in the workshop must be controlled to be ≤2m / s to avoid the slurry being blown away by the airflow, resulting in uneven thickness. When spraying, the order of "edge first, then middle" must be followed. First, spray along the perimeter of the substrate to form the boundary, and then fill the middle area to prevent the edge from being missed. After each substrate is sprayed, the surface of the decorative layer must be lightly swept with a soft brush immediately to eliminate the local protrusions generated during spraying and ensure overall flatness.

6. The prefabricated building exterior wall cladding molding process as described in claim 1, characterized in that: In step S5, before roller coating, the corresponding roller should be selected according to the target texture, and the roller surface should be checked for any slurry residue to avoid contaminating the new roller coating area. During roller coating, the roller should be kept at a 45° angle to the substrate surface and moved at a uniform speed. The back-and-forth roller coating direction should be perpendicular to the spraying direction to ensure that the texture cross-coverage is more natural. After roller coating is completed, the texture details should be checked with a magnifying glass immediately. If local textures are found to be blurred, the same type of roller should be used to press them before the surface material is cured.

7. The prefabricated building exterior wall cladding molding process as described in claim 1, characterized in that: In step S6, the curing equipment needs to be preheated for 10 minutes before starting the machine, and the operation should only begin after the mercury lamp power has stabilized, so as to avoid insufficient light intensity in the initial stage affecting the curing effect; a light-shielding curtain needs to be set up in the curing area to prevent external ultraviolet rays from interfering with the equipment monitoring system; the substrate needs to be kept still during the curing process to avoid movement that would cause insufficient local light exposure time; after curing is completed, wait 3 to 5 minutes for the decorative layer to cool naturally to room temperature before proceeding to the next process.

8. The prefabricated building exterior wall cladding molding process as described in claim 1, characterized in that: In step S7, the surface protective agent includes: 45-55 parts by weight of waterborne silicone resin, 8-12 parts by weight of nano titanium dioxide, 3-5 parts by weight of γ-aminopropyltriethoxysilane, 15-20 parts by weight of fluorocarbon resin modified emulsion, 15-25 parts by weight of deionized water, and 0.5-1.5 parts by weight of wetting and dispersing agent.

9. The prefabricated building exterior wall cladding molding process as described in claim 1, characterized in that: In step S8, before using the sealant, the packaging must be checked for integrity. If the sealant is found to have formed a skin or delaminated, it must be discarded and replaced with new material. During construction, the closed-cell foam rod must be tightly filled into the bottom of the joint, with a filling depth of 1 / 2 to 2 / 3 of the joint width, to ensure that the sealant forms a "backing" constraint and prevents it from cracking under stress. After the sealant is filled, a special joint pressing tool must be used to press it firmly along the joint direction to make the sealant surface smoothly transition to the decorative layer surface, while removing internal air bubbles. Do not step on or bump the joint area within 2 hours after construction is completed. After the sealant is surface dry, a water spray test must be conducted to confirm that there is no leakage before acceptance.

10. A prefabricated building exterior wall cladding forming device, characterized in that: The device uses the prefabricated building exterior wall cladding molding process as described in any one of claims 1 to 9 to perform molding operations on the prefabricated building exterior wall cladding.

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