Integrated prefabricated shear wall with double-layer composite thermal insulation structure and construction method

Abstract

The invention discloses an integrated prefabricated shear wall of a double-layer composite heat preservation structure. The integrated prefabricated shear wall comprises an outer plate and an inner plate. The inner sheet plate is composed of a transverse reinforcing bar, a vertical hole channel anchoring steel bar, a plastic pipe, a connecting buckle assembly and a miniature pressure sensor. The outer page plate is composed of a heat preservation plate, a concave-convex block and a combination layer, and the superimposed shear wall is composed of a concrete inner page plate and a heat preservation outer page plate. The outer page plate can be made of light thermal insulation materials such as an extruded sheet and an FS thermal insulation plate, concave-convex blocks in specific shapes are arranged at intervals, when the inner page plate is poured, concrete is naturally filled into the concave-convex blocks of the outer page plate to form mortise and tenon connection, and the mechanical meshing and cooperative working performance between the inner layer and the outer layer is remarkably enhanced while thermal insulation bridge cutoff is achieved. The inner sheet plate is composed of the steel reinforcement framework, the ribbed high-density polyethylene plastic pipe, the concrete and the partial embedded part, the adopted ribbed high-density polyethylene plastic pipe is low in manufacturing cost, and the production cost and the transportation and installation cost of the prefabricated wall can be directly reduced.

Description

Technical Field

[0001] This invention relates to the field of prefabricated building structure technology, specifically to an integrated prefabricated shear wall with double-layer composite thermal insulation structure and its construction method. Background Technology

[0002] As my country's construction industry develops towards industrialization and intelligentization, prefabricated concrete structures are widely used in residential and public buildings. However, the following problems still exist in existing technologies: High self-weight and transportation costs of traditional solid precast shear walls: The large size and weight of traditional solid precast shear walls make transportation and hoisting difficult; Complex on-site assembly and low efficiency: There is a lot of wet work on-site, and the connection method relies on grouting sleeves or welding, resulting in a long construction cycle; Secondary construction is required for thermal insulation and fireproofing: The separation of thermal insulation materials from the structure increases the construction process and affects the overall progress; Difficulty in quality control: Large errors in manual operation and difficulty in real-time monitoring of grout fullness pose safety hazards; Low reuse rate: Most of the connectors in existing precast shear walls are not detachable, which is not conducive to later modification or recycling.

[0003] Therefore, there is an urgent need for a new type of lightweight, modular, and intelligent prefabricated composite shear wall system to improve construction efficiency, reduce overall costs, and meet the development needs of green building. Summary of the Invention

[0004] The technical objective of this invention is to address the above-mentioned shortcomings by providing an integrated precast shear wall with a double-layer composite thermal insulation structure and a construction method therefor, thereby resolving the aforementioned problems.

[0005] The technical solution of this invention is implemented as follows: According to one aspect of the present invention, an integrated precast shear wall with a double-layer composite thermal insulation structure is provided.

[0006] It includes: an outer sheet and an inner sheet; the inner sheet consists of horizontal reinforcement, vertical channel anchoring steel bars, plastic pipes, connecting buckle components, and miniature pressure sensors; the outer sheet consists of insulation board, bumps, and bonding layer.

[0007] Preferably, the plastic pipe is a ribbed high-density polyethylene plastic pipe, which consists of several corrugated strips and vertical channels.

[0008] Preferably, the connecting buckle assembly is composed of an L-shaped steel plate, which includes an upper steel plate and a lower steel plate. A first elongated hole is provided at the center of the lower steel plate, and a second elongated hole is provided at the center of the upper steel plate.

[0009] Preferably, the inner side of the insulation board is provided with several protrusions and depressions that are in contact with the inner sheet, and the outer side of the insulation board is provided with several elongated grooves that are filled with cement mortar to form a concrete bonding layer.

[0010] Preferably, the transverse cross-sectional length of the elongated groove is the same as that of the insulation board, the width of the elongated groove is 1-2cm, the depth of the elongated groove is 1-2cm, and the spacing between adjacent elongated grooves is 300-500mm.

[0011] Preferably, a steel mesh is formed by binding the horizontal reinforcement and the vertical duct anchoring steel bars, and a plastic tube is installed inside the steel mesh, with a miniature pressure sensor attached to the bottom of the plastic tube.

[0012] According to another aspect of the present invention, a construction method for an integrated precast shear wall with a double-layer composite thermal insulation structure is provided.

[0013] Includes the following steps: Several long grooves are evenly distributed on the outer side of the insulation board; The polymer cement mortar is filled into the long groove, which promotes the formation of a concrete bonding layer on the outside of the long groove; Several protrusions and recesses are evenly distributed on the inner side of the insulation board; A steel mesh is formed by binding the horizontal reinforcement and the vertical duct anchoring steel bars, and a plastic pipe is installed inside the steel mesh to form a concrete inner slab. A miniature pressure sensor was attached to the bottom of the plastic tube; The assembled inner concrete sheet is hoisted above the outer sheet, and concrete is poured to fill the concave and convex blocks set on the inner side of the insulation board. After the concrete inner slab has been cured to a certain strength, the formwork is removed to form a shear wall, which is then transported to the construction site. The anchoring steel bars of the vertical ducts protruding from the top of the lower shear wall are spliced ​​by external mechanical anchoring or welding to increase the length of the anchoring steel bars of the vertical ducts. Align the plastic tube inside the upper shear wall with the vertical duct protruding from the lower shear wall and anchor the reinforcing steel bars, then slowly lower it; Adjust the front-back and left-right directions of the shear wall through the first and second elongated holes to maintain the verticality and flatness of the shear wall, and then tighten it with the fixing anchor bolts; Concrete is poured into plastic pipes and compacted by external vibrators to create a rigid connection between the upper and lower shear walls. By connecting a miniature pressure sensor to an external testing instrument, and collecting grouting pressure, temperature and displacement data in real time through an IoT platform, the obtained data is analyzed to determine the grouting fullness and density, thus completing the construction of the shear wall.

[0014] Compared with the prior art, the advantages and positive effects of the present invention are as follows: 1. Modular Lightweight Double-Layer Mortise and Tenon Joint Composite Wall Structure: The composite shear wall consists of an inner concrete slab and an outer insulated slab. The outer slab can be made of lightweight insulation materials such as extruded polystyrene (XPS) board or FS insulation board, with specially shaped protrusions and recesses at intervals. During the pouring of the inner slab, the concrete naturally fills into the protrusions and recesses of the outer slab, forming a mortise and tenon joint. This significantly enhances the mechanical interlocking and collaborative performance between the inner and outer layers while providing thermal insulation. The inner slab consists of a steel reinforcement frame, ribbed high-density polyethylene (HDPE) plastic pipes, concrete, and some embedded parts. The use of ribbed HDPE plastic pipes results in low manufacturing costs, directly reducing the production, transportation, and installation costs of the precast wall.

[0015] 2. Snap-on 3D Adjustable Quick Connection System: A dedicated L-shaped snap-on assembly is developed and pre-embedded in the edge of the wall panel. This L-shaped assembly features a first elongated hole at the bottom for front-to-back or depth adjustment, and a second elongated hole at the top for left-to-right or horizontal adjustment, ensuring accurate leveling of the precast exterior wall. The L-shaped snap-on assembly is pre-embedded in the edge of the double-layer wall panel. During installation, the upper and lower snaps engage elastically for quick locking. This system completely eliminates traditional welding or grouting sleeve connections, offering excellent shear resistance, seismic resistance, and support for 3D adjustment. Simultaneously, the upper and lower wall panels are connected through reinforcing steel bars within ribbed high-density polyethylene plastic pipes, replacing the traditional sandwich-type precast wall reinforcement grouting sleeve connection method. This effectively reduces the wall's self-weight, lowers the installation accuracy requirements of the precast wall, and improves the installation efficiency of precast wall panel components.

[0016] 3. IoT-based Intelligent Grouting Quality Monitoring System: Miniature pressure sensors are pre-embedded in the grouting ducts of precast composite shear walls. The system collects grouting pressure, temperature, and displacement data in real time via an IoT platform, and analyzes the grouting fullness and density using AI algorithms. This system offers the following advantages: it enables dynamic and visual monitoring of the grouting process, eliminating subjective errors from manual observation; it predicts potential voids or defects through data analysis, improving the quality of node connections; and the data can be stored and used for later maintenance, forming a quality archive for the entire building lifecycle. Attached Figure Description

[0017] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0018] Figure 1 This is a schematic diagram of the overall structure according to an embodiment of the present invention; Figure 2 This is a schematic diagram of the outer page plate structure according to an embodiment of the present invention; Figure 3 This is a schematic diagram of the connection structure between the inner page plate and the insulation plate according to an embodiment of the present invention; Figure 4 This is a schematic diagram of a plastic tube structure according to an embodiment of the present invention; Figure 5 This is a schematic diagram of the connection structure between the miniature pressure sensor and the plastic tube according to an embodiment of the present invention; Figure 6 This is a schematic diagram of the connecting snap-fit ​​assembly structure according to an embodiment of the present invention.

[0019] In the picture: 1. Outer leaf plate; 2. Inner leaf plate; 3. Horizontal reinforcement; 4. Vertical channel anchoring reinforcement; 5. Plastic pipe; 6. Connecting buckle assembly; 7. Miniature pressure sensor; 8. Corrugated pipe with concave and convex strips; 9. Vertical channel; 10. First elongated hole; 11. Second elongated hole; 12. Insulation board; 13. Concave and convex blocks; 14. Bonding layer; 15. Long strip groove. Detailed Implementation

[0020] To better understand the above-mentioned objectives, features, and advantages of the present invention, the present invention will be further described below in conjunction with the accompanying drawings and embodiments. It should be noted that, unless otherwise specified, the embodiments and features described in these embodiments can be combined with each other.

[0021] The present invention will be further described below with reference to the accompanying drawings and specific embodiments. Example 1

[0022] like Figure 1-6 As shown in the document: This invention provides a double-layer composite thermal insulation integrated precast shear wall, including an outer panel 1 and an inner panel 2. The inner panel 2 uses a steel frame combined with ribbed high-density polyethylene plastic pipes to reduce the weight of the core structure. The outer panel 1 uses lightweight insulation materials such as extruded polystyrene board or FS board and integrates fireproof function, eliminating the need for a thick concrete protective layer. The inner and outer panels are connected by mortise and tenon joints 13, achieving overall lightweighting of the wall while ensuring structural integrity, effectively reducing transportation and hoisting costs and difficulties. The inner panel 2 is composed of horizontal reinforcement 3, vertical channel anchoring steel bars 4, plastic pipes 5, connecting buckle components 6, and miniature pressure sensors 7. The outer panel 1 is composed of insulation board 12, mortise and tenon joints 13, and bonding layer 14. Among them, the plastic pipe 5 is a ribbed high-density polyethylene plastic pipe, which is composed of several corrugated pipes 8 with concave and convex strips and vertical channels 9. The connecting buckle assembly 6 is composed of L-shaped steel plates, including an upper steel plate and a lower steel plate. The lower steel plate has a first elongated hole 10 at the center position, and the upper steel plate has a second elongated hole 11 at the center position. Through the special L-shaped connecting buckle assembly 6 pre-embedded in the edge of the wall panel, the upper and lower walls can be quickly locked by utilizing its elastic interlocking characteristics. The elongated hole structure designed on the buckle allows for stepless adjustment of the wall installation in the front-to-back or depth and left-to-right or horizontal directions, which significantly simplifies the on-site connection operation, reduces the stringent requirements for installation accuracy, and improves assembly efficiency and connection reliability. The inner side of the insulation board 12 is evenly provided with several concave and convex blocks 13, which are set with a smaller upper opening and a smaller lower opening. The large trapezoidal structure has a depth that can be half the depth of the insulation board 12. When the inner concrete sheet 2 is poured, the concrete can naturally fill the concave and convex blocks 13, making the mating surfaces of the inner sheet 2 and the outer sheet 1 form a tenon-and-mortise connection. The concave and convex blocks 13 are in contact with the inner sheet 2. Several long strip grooves 15 are evenly provided on the outer side of the insulation board 12. The long strip grooves 15 are filled with cement mortar to form a concrete bonding layer 14. The transverse cross-sectional length of the long strip grooves 15 is the same as that of the insulation board 12. The width of the long strip grooves 15 is 1-2cm, the depth of the long strip grooves 15 is 1-2cm, and the spacing between adjacent long strip grooves 15 is 300-500mm. The transverse reinforcement 3 and the vertical channel anchoring reinforcement 4 are tied to form a steel mesh. The plastic tube 5 is installed inside the steel mesh, and the bottom of the plastic tube 5 is attached with a miniature pressure sensor 7.

[0023] Furthermore, the outer panel 1 is made of integrated Class A fireproof and thermal insulation material. During the pouring of the inner panel 2, the concrete fills the concave and convex blocks of the outer panel 1 to form a non-thermal bridge tenon-and-mortise joint, blocking the heat conduction path of the connector. At the same time, an IoT grouting monitoring system is used to collect real-time grouting pressure and temperature data inside the ribbed high-density polyethylene plastic pipe 5, and the grouting fullness is dynamically evaluated through AI algorithms to ensure the visual verification of structural performance. Example 2

[0024] A construction method for an integrated precast shear wall with double-layer composite insulation structure includes the following steps: S101: Several elongated grooves 15 are evenly provided on the outer side of the insulation board 12; S103: Fill the elongated groove 15 with polymer cement mortar to promote the formation of a concrete bonding layer 14 on the outside of the elongated groove 15; S105: Several protrusions and recesses 13 are evenly provided on the inner side of the insulation board 12; S107: Tie the transverse reinforcement 3 and the vertical duct anchoring reinforcement 4 to form a steel mesh, and install the plastic pipe 5 inside the steel mesh to form a concrete inner slab 2; S109: Attach the miniature pressure sensor 7 to the bottom of the plastic tube 5; S1011: Hoist the assembled inner concrete sheet 2 above the outer sheet 1, pour concrete, and make the concrete fill the concave and convex blocks 13 set on the inner side of the insulation board 12. S1013: After the concrete inner slab 2 has been cured to a certain strength, the formwork is removed to form a shear wall, and then the shear wall is transported to the construction site; S1015: The vertical duct anchoring steel bars 4 protruding from the top of the lower shear wall are spliced ​​by external mechanical anchoring or welding to increase the length of the vertical duct anchoring steel bars 4. S1017: Align the plastic tube 5 inside the upper shear wall with the anchoring steel bar 4 protruding from the vertical duct of the lower shear wall, and then slowly lower it; S1019: Adjust the front-to-back and left-to-right directions of the shear wall through the first elongated hole 10 and the second elongated hole 11 to maintain the verticality and flatness of the shear wall, and then tighten it with the fixed anchor bolts; S1021: Concrete is poured into the plastic pipe 5 and compacted by an external vibrator to rigidly connect the upper and lower shear walls. S1023: Connect the miniature pressure sensor 7 to an external testing instrument, and collect grouting pressure, temperature and displacement data in real time through the Internet of Things platform. Analyze the obtained data to determine the grouting fullness and density, and complete the construction of the shear wall.

[0025] Through the specific embodiments described above, those skilled in the art can easily implement the present invention. However, it should be understood that the present invention is not limited to the specific embodiments described above. Based on the disclosed embodiments, those skilled in the art can arbitrarily combine different technical features to achieve different technical solutions.

Claims

1. A precast shear wall with an integrated double-layer composite insulation structure, characterized in that, It includes an outer sheet (1) and an inner sheet (2); The inner plate (2) is composed of horizontal reinforcement (3), vertical channel anchoring reinforcement (4), plastic pipe (5), connecting buckle assembly (6), and miniature pressure sensor (7); The outer sheet (1) is composed of insulation board (12), bumps (13), and bonding layer (14).

2. The integrated precast shear wall with double-layer composite thermal insulation structure according to claim 1, characterized in that, The plastic pipe (5) is a ribbed high-density polyethylene plastic pipe, which is composed of several corrugated pipes (8) and vertical channels (9).

3. The integrated precast shear wall with double-layer composite thermal insulation structure according to claim 2, characterized in that, The connecting buckle assembly (6) is composed of an L-shaped steel plate, which includes an upper steel plate and a lower steel plate. A first elongated hole (10) is provided at the center of the lower steel plate, and a second elongated hole (11) is provided at the center of the upper steel plate.

4. The integrated precast shear wall with double-layer composite thermal insulation structure according to claim 3, characterized in that, The inner side of the insulation board (12) is uniformly provided with several protrusions and depressions (13), which are in contact with the inner sheet (2). The outer side of the insulation board (12) is uniformly provided with several long grooves (15), which are filled with cement mortar to form a concrete bonding layer (14).

5. The integrated precast shear wall with double-layer composite thermal insulation structure according to claim 4, characterized in that, The transverse cross-sectional length of the elongated groove (15) is the same as that of the insulation board (12). The width of the elongated groove (15) is 1-2cm, the depth of the elongated groove (15) is 1-2cm, and the distance between adjacent elongated grooves (15) is 300-500mm.

6. The integrated precast shear wall with double-layer composite thermal insulation structure according to claim 5, characterized in that, A steel mesh is formed by binding the horizontal reinforcement (3) and the vertical duct anchoring reinforcement (4). A plastic tube (5) is installed inside the steel mesh, and a miniature pressure sensor (7) is attached to the bottom of the plastic tube (5).

7. A construction method for an integrated precast shear wall with double-layer composite thermal insulation structure, characterized in that, The integrated precast shear wall with double-layer composite thermal insulation structure as described in claim 6 includes the following steps: Several long strip grooves (15) are evenly provided on the outer side of the insulation board (12); The polymer cement mortar is filled into the elongated groove (15), which promotes the formation of a concrete bonding layer (14) on the outside of the elongated groove (15). Several protrusions (13) are evenly provided on the inner side of the insulation board (12); A steel mesh is formed by binding the horizontal reinforcement (3) and the vertical duct anchoring reinforcement (4), and the plastic pipe (5) is installed inside the steel mesh to form a concrete inner slab (2). A miniature pressure sensor (7) is attached to the bottom of the plastic tube (5); The assembled inner concrete sheet (2) is hoisted above the outer sheet (1), and concrete is poured to fill the concave and convex blocks (13) set on the inner side of the insulation board (12). After the concrete inner sheet slab (2) is cured to a certain strength, the formwork is removed to form a shear wall, and then the shear wall is transported to the construction site. The vertical duct anchoring steel bars (4) protruding from the top of the lower shear wall are spliced ​​by external mechanical anchoring or welding to increase the length of the vertical duct anchoring steel bars (4); Align the plastic tube (5) inside the upper shear wall with the anchoring steel bar (4) protruding from the vertical duct of the lower shear wall, and then slowly lower it; Adjust the front-back and left-right directions of the shear wall through the first elongated hole (10) and the second elongated hole (11) to maintain the verticality and flatness of the shear wall, and then tighten it with the fixed anchor bolts; Concrete is poured into the plastic pipe (5) and compacted by an external vibrator to rigidly connect the upper and lower shear walls. Connect the miniature pressure sensor (7) to an external testing instrument and collect grouting pressure, temperature and displacement data in real time through the Internet of Things platform. Analyze the obtained data to determine the grouting fullness and density, and complete the construction of the shear wall.

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