Construction method of large-size special-shaped interlayer GRC curtain wall

Abstract

The invention relates to the technical field of building construction, in particular to a large-size special-shaped interlayer GRC curtain wall construction method. The method comprises the following steps: S1, model establishment and unit decomposition; s2, prefabricating and numbering components; s3, transforming the operation frame body; s4, surveying, setting out and mounting embedded parts; s5, mounting a keel system; s6, a GRC panel is installed; and S7, slab joint treatment and veneer construction are conducted. Digital overall planning is achieved through a BIM model, a data basis is provided for prefabrication and installation of components, measurement and positioning are conducted based on model data, accumulated errors are reduced, an operation frame matched with the outer contour of a curtain wall is formed by conducting targeted transformation on an original structure scaffold, a necessary operation space can be created for hoisting and in-place of the special-shaped components, and the construction efficiency is improved. And the mounting sequence from top to bottom is adapted.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of building construction, in particular to a large-size special-shaped interlayer GRC curtain wall construction method. BACKGROUND

[0002] With the increasing demand for architectural aesthetics, the design of the exterior of modern public buildings and commercial buildings is becoming increasingly complex, and large-size, special-shaped modeling elements are widely used. GRC (glass fiber reinforced cement) material, due to its excellent plasticity and decoration, has become a common choice for realizing such complex facade modeling. Among them, the interlayer GRC curtain wall in the horizontal direction plays an important role in architectural design due to its strong rhythm and level.

[0003] However, the construction practice of such large-size special-shaped interlayer GRC curtain wall faces many challenges. First, the modeling often exceeds the conventional facade, with significant overhangs and undulations, which poses special requirements for the erection of the construction operation platform. Traditional hangers or fixed scaffolding may not be able to provide sufficient and safe working space, or may interfere with the special-shaped components. Second, the large size and irregular shape of the components make it difficult to measure and lay out on site, position the keel, and accurately install the prefabricated components, which can easily lead to installation misalignment due to cumulative errors, affecting the final visual effect and structural safety. In addition, this construction process usually involves multiple professional cross operations. How to reasonably arrange the construction sequence of the keel system, the thermal insulation layer, the fireproof structure, and the decorative panel, and ensure smooth connection between the links, is the key to ensuring the quality and progress of the project. The existing construction methods often have room for improvement in efficiency, accuracy, and collaboration when dealing with the above systemic challenges.

[0004] Therefore, the industry needs to seek a targeted and clear construction method to systematically solve a series of problems from measurement, support, installation to collaborative work. SUMMARY

[0005] The present application aims to solve the above problems and provides a large-size special-shaped interlayer GRC curtain wall construction method that improves construction efficiency.

[0006] The present application solves the problem by adopting the following technical solution: A large-size special-shaped interlayer GRC curtain wall construction method, characterized by comprising the following steps: S1: Model establishment and unit decomposition: establish a BIM model of the curtain wall according to the building modeling, deepen the layout of the curtain wall, and decompose the GRC curtain wall in the horizontal interlayer into multiple assembly units; S2: Component prefabrication and numbering: based on the BIM model and the layout results, prefabricate GRC panels and support keels in the factory, and uniquely number all prefabricated components; S3: Modification of the operating frame: Modify the original scaffolding structure of the building to form an operating frame that adapts to the outer contour of the irregular curtain wall; S4: Surveying and Setting Out and Installation of Embedded Parts: Based on the positioning data exported from the BIM model, surveying and setting out are carried out on site, and post-installed embedded parts are installed; S5: Keel System Installation: Install the prefabricated support keel onto the post-embedded parts in the order of their numbers to form a keel system that supports the GRC panel; S6: GRC panel installation: According to the direction of the shape lines, in order from top to bottom, the numbered GRC panels are hoisted onto the operating frame in sequence, and rough installation, fine adjustment and welding are performed; S7: Joint Treatment and Finishing Construction: The joints between the installed GRC panels are sealed with caulking, and finally the finishing layer is applied.

[0007] The present invention, which adopts the above technical solution, has the following prominent features compared with the prior art: Digital coordination through BIM models provides a data foundation for component prefabrication and installation. Measurement and positioning based on model data reduces cumulative errors. Targeted modifications to the original scaffolding create operating frames adapted to the curtain wall's outline, providing necessary working space for the hoisting and positioning of irregularly shaped components and accommodating a top-down installation sequence. Prefabricating GRC panels and supporting keels in the factory according to their assigned numbers, and then assembling them on-site according to the defined design lines, facilitates the orderly hoisting and alignment of components. This may positively impact the efficiency of multi-disciplinary collaborative work and ensure the final realization of complex facade designs.

[0008] As a preferred embodiment, a further technical solution of the present invention is: Furthermore, in step S1, after establishing the BIM model, a collision check is performed between the curtain wall and other building components. This helps to identify and resolve potential spatial conflicts between the curtain wall and other building components before construction, which plays a positive role in preventing on-site rework and ensuring smooth construction.

[0009] Furthermore, in step S2, the supporting keel includes a horizontal main keel and a vertical secondary keel. The main keel is a triangular spatial truss structure, and the secondary keel is a horizontal member. The main keel and the secondary keel are fixedly connected. This design is generally considered to provide better structural stability and is beneficial for bearing the load generated by irregularly shaped curtain walls.

[0010] Furthermore, in step S3, the specific method of modifying the operating frame is as follows: an additional row of uprights is added to the outside of the original scaffolding, so that the innermost upright of the operating frame and the curtain wall mounting surface are reserved to meet the GRC panel installation operation. By modifying the operating frame by adding uprights to the outside of the original scaffolding, a suitable operating distance can be formed between the frame and the curtain wall mounting surface, which facilitates the installation process of GRC panels.

[0011] Furthermore, in step S4, the post-installed embedded part is fixed to the building structure by chemical anchors, and the installation position of the post-installed embedded part is located by a total station, which helps to improve the positional accuracy and connection reliability of the embedded part installation.

[0012] Furthermore, in step S5, when installing the main keel, its verticality is controlled by suspending vertical steel wires and adjusted in three dimensions. After adjustment, it is welded and fixed to the rear embedded parts, which helps to improve the positioning accuracy of the keel installation and creates conditions for the precise installation of the subsequent panels.

[0013] Furthermore, in step S6, the installation and fixing of the GRC panel specifically includes: S61. Rough installation: Hoist the GRC panel to the installation position, so that it is initially positioned on the keel system, and use temporary support devices for bottom support; S62. Fine adjustment: Use the adjustment device to finely adjust the height and level of the GRC panel after rough installation, so that the joint width between it and the adjacent panel meets the set requirements. S63. Welding and fixing: Weld the pre-embedded brackets on the back of the GRC panel to the keel system and then remove the temporary support device. The use of temporary support and adjustment device together helps to effectively control the installation position of the panel and the width of the joint.

[0014] Furthermore, after step S5 and before step S6, the external wall insulation layer is constructed between the keel system and the building wall, which is conducive to achieving integrated construction of the insulation layer and the curtain wall system.

[0015] Furthermore, in step S6, setting a horizontal fire-resistant barrier within the keel system at the location between building structural floors before installing the GRC panel is a common measure to enhance the fire resistance of the curtain wall system.

[0016] Furthermore, in step S7, the joint treatment includes filling with sealant, laying reinforcing mesh, and applying crack-resistant mortar, which will have a beneficial effect on ensuring the sealing durability and surface crack resistance of the joint. Attached Figure Description

[0017] Figure 1 This is a schematic diagram of the process of an embodiment of the present invention; Figure 2This is a schematic diagram of the front cross-sectional structure of an embodiment of the present invention; Figure 3 This is a schematic diagram of the irregular exterior facade of an embodiment of the present invention; The components are marked as follows: GRC panel 1, main keel 2, secondary keel 3, rear embedded part 4, fireproof isolation strip 5. Detailed Implementation

[0018] The present invention will be further described below with reference to embodiments, which are intended only to provide a better understanding of the invention. Therefore, the examples given do not limit the scope of protection of the present invention.

[0019] A construction method for large-size irregularly shaped interlayer GRC curtain walls, characterized by the following steps: S1: Model Building and Unit Decomposition: Based on the building's shape, a BIM model of the curtain wall is built, the curtain wall layout is refined, and the GRC curtain wall between horizontal floors is decomposed into multiple assembly units; personnel are organized to review the on-site main structure and the dimensions of the external window openings, and a preliminary building facade model is built in conjunction with the building elevation drawings and renderings. The collision between the irregular GRC exterior walls and the external windows and secondary structures between floors is checked. Based on the exterior wall BIM model and on-site re-measurement, the GRC curtain wall between horizontal floors is segmented layer by layer, generating GRC exterior wall facade layout drawings and unit panel details, and accurately obtaining the dimensions of each assembly unit and the location of embedded parts.

[0020] S2: Component Prefabrication and Numbering: Based on the BIM model and layout results, GRC panels 1 and supporting keels are prefabricated in the factory, and all prefabricated components are uniquely numbered; GRC exterior wall panels are uniformly manufactured by professional manufacturers according to the layout drawing requirements and relevant standards and specifications. The curing age of the finished GRC exterior wall panels before leaving the factory is not less than 7 days, and the installation number and installation sequence must be marked on the panels; After the finished GRC exterior wall panels arrive on site, a dedicated temporary storage area is set up. The area is surrounded by protective barriers and paving materials to prevent the panels from being bumped and chipped. The storage area must be kept clean and well-drained. The exterior wall panels are stored according to the numbering rules.

[0021] S3: Scaffold Modification: The original scaffolding structure will be modified to conform to the contours of the irregularly shaped curtain wall. The existing ground-mounted and cantilevered scaffolds have an internal upright spacing of 0.35m from the wall. Due to the large-scale GRC inter-floor molding lines on the building facade, which protrude 900mm horizontally from the wall, the original internal uprights will be used to accommodate these molding lines. An additional row of ground-mounted uprights will be added to the outside of the existing scaffold, creating a three-row upright scaffold. The added outer row of uprights rests on the basement ceiling. Double uprights are required to enhance stability. The height of the double uprights should not be less than 2 / 3 of the erection height. The newly added outer row of uprights should be connected to the original frame as a whole through large and small horizontal bars. The scissor bracing and safety net should be moved outward. The longitudinal and horizontal spacing of the newly added uprights should be consistent with the original frame. The lateral spacing between the curtain wall installation working layer formed by the outer row of uprights of the original frame and the curtain wall should not be less than 850mm. During installation, the innermost row of uprights should be removed to 200mm from the bottom of the curtain wall panel. The working layer of the outer two rows of uprights should be consistent with the installation height of the inter-layer GRC curtain wall.

[0022] S4: Measurement and Layout & Embedded Part Installation: Based on the positioning data exported from the BIM model, measurement and layout are carried out on site, and post-embedded parts 4 are installed; On-site Point Re-measurement: Before on-site positioning and layout, the main structure, masonry secondary structure, and window openings of the exterior wall installation area are re-measured, and the deviations of structural components and opening dimensions are statistically analyzed. At the same time, the main structure plane control network is re-measured; Control Line Positioning and Layout: A plane control network is established using a total station, and the building plane axis is laid out. Using the axis as the control line, control points are marked on the curtain wall installation structure intersecting the axis, and a horizontal line is drawn between each control point; Embedded Plate Positioning: After all the positioning control lines are drawn according to the control points, the dimensions are checked using the method of measuring the total length and measuring the equally divided length distance, and the positions of the added equally divided points are marked. Temporary control points are set up, and the horizontal spacing of the embedded plates given in the exterior wall construction drawings is used to measure the positioning points of the embedded plates in sections with a measuring tape. At the same time, the elevation of the embedded plates is corrected based on the dimensional deviations of structural components and exterior window openings. For the irregular GRC exterior wall embedded parts between floors, post-installed embedded parts 4 are used for construction. Chemical anchors can be used for post-installed anchors, and square hot-dip galvanized embedded parts are used for the embedded plates. During construction, attention should be paid to ensuring that the geometry of the cavity after expanding the bottom hole matches the geometry of the key plate opened by the anchor to form an interlocking mechanism and realize the post-anchoring key connection. According to the measurement points, the installation position of the embedded parts is marked on the structural surface, including the horizontal height and the center position of the post-installed embedded part 4. After initial fixing, the anchor should be carefully checked and confirmed before it can be installed. During reinforcement, the influence of the anchor on the steel reinforcement in the concrete should be avoided.

[0023] S5: Keel System Installation: Install the prefabricated supporting keels onto the post-embedded parts 4 according to their numbering sequence to form a keel system supporting the GRC panel 1; the irregularly shaped interlayer GRC exterior wall steel frame is mainly composed of "triangular" main keels 2 and secondary keels 3. The main keel 2 is welded from several hot-dip galvanized square steel pipes, and the main frame is installed vertically; the secondary keel 3 is composed of several continuous hot-dip galvanized angle steels, and the secondary keel 3 is installed horizontally, connecting adjacent main keels 2; mark the centerline of the main keel 2 on the embedded plate, and simultaneously... Suspend vertical steel wires to control the verticality of the main keel 2. Install according to the numbering sequence. During installation, fix the upper end first, adjust it, and then fix the lower end. Adjust the main keel 2 in three dimensions according to the positioning steel wires. After adjustment, weld the main frame to the rear embedded plate. According to the construction drawings, mark the vertical spacing of the secondary keels 3 on the main keel 2 as the installation benchmark for the secondary keels 3. Weld the secondary keels 3 to the main keel 2. The installation sequence of the secondary keels 3 is from bottom to top. After the irregular steel frame is welded, apply anti-rust paint to the weld points.

[0024] S6: GRC Panel 1 Installation: According to the direction of the design lines, GRC panels 1, numbered one by one, are hoisted onto the operating frame in a top-to-bottom order, and then rough-fitted, fine-tuned, and welded for fixing. The installation of irregular GRC curtain wall panels between layers follows the principle of "top to bottom" and is installed layer by layer. The operating frame is disassembled layer by layer. The installation of each irregular GRC curtain wall panel is divided into several construction sections. Each construction section is installed from one side of the design line to the other side, according to the direction of the design lines. Before installation, check whether the appearance quality and size of the panel meet the requirements. Only after it is qualified can the installation be carried out. Before the installation, use a laser to project a horizontal installation line on the working surface and hang the line to ensure the accuracy of the exterior wall panel installation. Angle steel is welded between GRC panel 1 and main keel 2 for fixing. Reinforcing ribs are set at intervals on the inner side of GRC panel 1. Drip groove is provided at the bottom of GRC panel 1.

[0025] S7: Joint Treatment and Finishing Construction: The joints between the installed GRC panels 1 are sealed with caulking, and the finishing layer is then applied. The joints between GRC panels 1 are filled tightly with special sealant, fiberglass mesh is pasted on the surface, and crack-resistant mortar is applied for leveling. Waterproof coating is then applied to the surface. The decorative coating of GRC panels 1 is carried out according to the design requirements. After the base layer is treated, fiberglass mesh is applied in batches, crack-resistant putty is scraped, and then the top layer of stone paint is sprayed in layers. After the stone paint dries, the surface is protected in time to protect the exterior wall surface from pollution and damage.

[0026] Furthermore, in step S1, after establishing the BIM model, a collision check is performed between the curtain wall and other building components. This helps to identify and resolve potential spatial conflicts between the curtain wall and other building components before construction, which plays a positive role in preventing on-site rework and ensuring smooth construction.

[0027] Further, in step S2, the supporting keel includes a horizontal main keel 2 and a longitudinal secondary keel 3. The main keel 2 is a triangular spatial truss structure, and the secondary keel 3 is a horizontal member. The main keel 2 and the secondary keel 3 are fixedly connected. This design is generally considered to provide better structural stability and is conducive to bearing the load generated by irregular curtain walls. The "triangular" keel is welded and fixed to the embedded plate, mainly bearing the load of the external wall. The longitudinal horizontal keel is welded and fixed to the "triangular" keel.

[0028] Furthermore, in step S3, the specific method of modifying the operating frame is as follows: an additional row of uprights is added to the outside of the original scaffolding, so that the innermost upright of the operating frame and the curtain wall installation surface are reserved to meet the installation operation of GRC panel 1. By modifying the operating frame by adding uprights to the outside of the original scaffolding, a suitable operating distance can be formed between the frame and the curtain wall installation surface, which facilitates the installation process of GRC panel 1. The operating frame is disassembled layer by layer according to the overall decoration construction progress of the exterior wall until the exterior wall decoration construction is completed.

[0029] Furthermore, in step S4, the post-installed embedded part 4 is fixed to the building structure by chemical anchors, and the installation position of the post-installed embedded part 4 is located by a total station, which helps to improve the positional accuracy and connection reliability of the embedded part installation.

[0030] Furthermore, in step S5, when installing the main keel 2, its verticality is controlled by suspending vertical steel wires and adjusted in three dimensions. After adjustment, it is welded and fixed to the rear embedded part 4, which helps to improve the positioning accuracy of the keel installation and creates conditions for the precise installation of the subsequent panel.

[0031] Furthermore, in step S6, the installation and fixing of the GRC panel 1 specifically includes: S61. Rough Installation: Hoist GRC panel 1 to the installation position, so that it is initially positioned on the keel system, and use temporary support devices for bottom support. According to the construction drawings, determine the installation position of each panel according to the panel number and construction sequence. Use a tower crane to hoist the panels one by one onto the operating frame, and then use manual labor to assist the tower crane in placing the panels in the installation position. During installation, first align the top edge of the upper horizontal plate of GRC panel 1 with the top horizontal control line, and slowly place GRC panel 1 on the keel frame. After the bottom of GRC panel 1 is fixed with jack support, the slings can be released. Use jacks to adjust the installation height of the panel until the upper and lower horizontal plates of GRC panel 1 are aligned with the horizontal control line. S62. Fine adjustment: Use the adjustment device to finely adjust the height and level of the rough-installed GRC panel 1 so that the joint width with the adjacent panel meets the set requirements. The panel position adjustment mainly corrects the installation level of the panel. During correction, place a spirit level on the rough-installed GRC panel 1 to observe the level. If there is a large deviation, use the bottom jack to adjust until the panel level meets the installation requirements. The joint width between each panel should be controlled at 10mm, and the error should not exceed ±2mm. S63. Welding and fixing: Weld the pre-embedded brackets on the back of GRC panel 1 to the keel system and then remove the temporary support device. After the GRC panel 1 is finely adjusted, weld the pre-embedded brackets on the inside of the panel to the keel frame to ensure the weld length and component stability. The use of temporary support and adjustment device helps to effectively control the panel installation position and joint width.

[0032] Furthermore, after step S5 and before step S6, the external wall insulation layer is constructed between the keel system and the building wall. The external wall insulation material is 50mm thick insulating rock wool. After the base surface is cleaned, the insulation material is fixed with bonding mortar. After standing for 12 hours, it is anchored with anchors. The surface of the insulation material is coated with plastering mortar, which is conducive to the integrated construction of the insulation layer and the curtain wall system.

[0033] Furthermore, in step S6, before installing the GRC panel 1, a horizontal fire-resistant isolation zone 5 is set within the keel system at the location between the building structure floors. A horizontal fire-resistant zone is set in the irregular GRC exterior wall between floors. The material is non-combustible rock wool or mineral wool for isolation, with a thickness of not less than 200mm (density not less than 120kg / m³). The horizontal fire-resistant isolation zone 5 between floors is supported by a 1.5mm thick galvanized steel plate to ensure that it forms a fully enclosed isolation zone with the floor slab or wall to prevent smoke from spreading. This is a common measure to enhance the fire resistance of the curtain wall system.

[0034] Furthermore, in step S7, the joint treatment includes filling with sealant, laying reinforcing mesh, and applying crack-resistant mortar, which will have a beneficial effect on ensuring the sealing durability and surface crack resistance of the joint.

[0035] Digital coordination through BIM models provides a data foundation for component prefabrication and installation. Measurement and positioning based on model data reduces cumulative errors. Targeted modifications to the original scaffolding create an operational frame adapted to the curtain wall's outline, providing necessary working space for the hoisting and positioning of irregularly shaped components and accommodating a top-down installation sequence. Prefabricating GRC panels 1 and supporting keels in the factory according to their assigned numbers, and then assembling the keels and GRC panels 1 on-site according to the defined design lines, facilitates the orderly hoisting and alignment of components. This may positively impact the efficiency of multi-disciplinary collaborative work and ensure the final realization of complex facade designs.

[0036] The above description is merely a preferred embodiment of the present invention and is not intended to limit the scope of the present invention. All equivalent changes made based on the description and drawings of the present invention are included within the scope of the present invention.

Claims

1. A construction method for large-size irregularly shaped interlayer GRC curtain walls, characterized in that: It includes the following steps: S1: Model building and unit decomposition: Based on the building shape, a BIM model of the curtain wall is built, the curtain wall is further refined and laid out, and the GRC curtain wall between horizontal floors is decomposed into multiple assembly units. S2: Component Prefabrication and Numbering: Based on the BIM model and layout results, GRC panels and supporting keels are prefabricated in the factory, and all prefabricated components are uniquely numbered. S3: Modification of the operating frame: Modify the original scaffolding structure of the building to form an operating frame that adapts to the outer contour of the irregular curtain wall; S4: Surveying and Setting Out and Installation of Embedded Parts: Based on the positioning data exported from the BIM model, surveying and setting out are carried out on site, and post-installed embedded parts are installed; S5: Keel System Installation: Install the prefabricated support keel onto the post-embedded parts in the order of their numbers to form a keel system that supports the GRC panel; S6: GRC panel installation: According to the direction of the shape lines, in order from top to bottom, the numbered GRC panels are hoisted onto the operating frame in sequence, and rough installation, fine adjustment and welding are performed; S7: Joint Treatment and Finishing Construction: The joints between the installed GRC panels are sealed with caulking, and finally the finishing layer is applied.

2. The construction method for large-size irregular-shaped interlayer GRC curtain walls according to claim 1, characterized in that: In step S1, after the BIM model is established, a collision check is performed between the curtain wall and other building components.

3. The construction method for large-size irregularly shaped interlayer GRC curtain walls according to claim 1, characterized in that: In step S2, the supporting keel includes a horizontal main keel and a vertical secondary keel. The main keel is a triangular spatial truss structure, and the secondary keel is a horizontal member. The main keel and the secondary keel are fixedly connected.

4. The construction method for large-size irregularly shaped interlayer GRC curtain walls according to claim 1, characterized in that: In step S3, the specific method of modifying the operating frame is as follows: an additional row of uprights is added to the outside of the original scaffolding, so that the innermost upright of the operating frame and the curtain wall mounting surface are reserved to meet the GRC panel installation operation.

5. The construction method for large-size irregularly shaped interlayer GRC curtain walls according to claim 1, characterized in that: In step S4, the post-installed embedded part is fixed to the building structure by chemical anchors, and the installation position of the post-installed embedded part is determined by a total station.

6. The construction method for large-size irregularly shaped interlayer GRC curtain walls according to claim 1, characterized in that: In step S5, when installing the main keel, its verticality is controlled by suspending vertical steel wires and adjusted in three dimensions. After adjustment, it is welded and fixed to the post-embedded parts.

7. The construction method for large-size irregularly shaped interlayer GRC curtain walls according to claim 1, characterized in that: Step S6, the installation and fixing of the GRC panel specifically includes: S61. Rough installation: Hoist the GRC panel to the installation position, so that it is initially positioned on the keel system, and use temporary support devices for bottom support; S62. Fine adjustment: Use the adjustment device to finely adjust the height and level of the GRC panel after rough installation, so that the joint width between it and the adjacent panel meets the set requirements. S63. Welding and fixing: Weld the pre-embedded brackets on the back of the GRC panel to the keel system and then remove the temporary support device.

8. The construction method for large-size irregularly shaped interlayer GRC curtain walls according to claim 1, characterized in that: After step S5 and before step S6, the external wall insulation layer is constructed between the keel system and the building wall.

9. The construction method for large-size irregularly shaped interlayer GRC curtain walls according to claim 1, characterized in that: In step S6, before installing the GRC panels, a horizontal fire-resistant barrier is installed within the keel system at locations between building structural floors.

10. The construction method for large-size irregularly shaped interlayer GRC curtain walls according to claim 1, characterized in that: In step S7, the joint treatment includes filling with sealant, laying reinforcing mesh, and applying crack-resistant mortar.

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