Integrated light building filling external wall panel

Abstract

The invention discloses an integrated light building filling external wall panel (WQ-JKGN panel) capable of replacing an existing filling block wall. The integrated light building filling external wall panel comprises a fireproof thermal insulation material layer, a reinforcing mesh and a silicic acid fiber calcium board layer which are sequentially arranged from the middle to the two sides. Wherein the reinforcing mesh is fixedly connected to the two sides of the fireproof thermal insulation material layer through reinforcing steel bar inclined connecting rods, and lightweight aggregate concrete is poured on the inner side and the outer side of the reinforcing mesh; silicic acid fiber calcium boards are arranged on the inner side and the outer side of the outermost layer of the silicic acid fiber calcium board layer finger board, and a sound insulation felt is arranged between the silicic acid fiber calcium board on the outer side and the lightweight aggregate concrete. According to the integrated light building filling external wall panel, the requirements of national building design specifications for various rigid indexes such as energy conservation, compression resistance, fire resistance and sound insulation of building external walls in current residences and public buildings are met at a time, and design adjustment can be carried out according to different requirements of different national and regional building specifications; the building assembly rate is improved, the construction time is saved, and the building quality is improved.

Description

Technical Field

[0001] This invention relates to the field of exterior wall panels for building engineering, specifically to an integrated lightweight building infill exterior wall panel. Background Technology

[0002] The exterior walls of a building serve as a barrier separating indoor and outdoor spaces, forming a crucial component and representing an important aspect of wall material innovation and building energy conservation. Currently, building exterior walls are typically constructed on-site using masonry blocks, followed by on-site application of cement mortar both inside and out, then on-site insulation using scaffolding, and finally, another layer of mortar. This process requires rigorous testing, including insulation nail pull-out tests. This method is time-consuming, costly, lacks quality assurance, and carries significant risks associated with working at heights. Recent incidents have included instances of insulation layer detachment and fires, posing potential hazards for future use.

[0003] Currently, a better alternative for building exterior wall panels is one with autoclaved aerated concrete (AAC) on both sides and polyurethane foam insulation in the middle, with AAC forming a closed perimeter around the panel; otherwise, the entire panel cannot be made into a unified whole. This structure leads to uneven heat transfer coefficients at the joints and in the middle of the wall, resulting in difficult-to-manage thermal bridging problems. Furthermore, the material's sound insulation performance may not meet specifications, its heavy weight makes construction difficult, and the wall's lateral wind pressure resistance is relatively weak due to the weak flexural strength of AAC and the poor fire resistance of polyurethane foam, making it difficult to achieve Class A insulation.

[0004] The country is currently promoting prefabricated buildings and advocating for better housing. However, in the field of exterior walls for frame structures (including concrete frames and heavy steel frames), existing integrated exterior wall panels cannot simultaneously meet the requirements of national building codes regarding compressive strength, energy efficiency, sound insulation, fire resistance, and the absence of thermal bridges (weak links and defects in energy conservation). They also cannot completely achieve the goals of factory processing, on-site assembly, saving labor and time, and improving the performance and quality of exterior walls. Furthermore, they cannot meet the requirements of on-site construction processes, wall grooving and pipe embedding, and quality inspection and supervision of concealed works. Summary of the Invention

[0005] To overcome the shortcomings of existing building exterior wall construction and design schemes, and to improve building assembly rate and building quality, this invention provides an integrated lightweight building exterior wall panel that can be manufactured in a factory. It makes full use of the inherent advantages of the physical properties of various building materials and addresses various rigid requirements of national building design codes for residential and public building exterior walls, such as energy saving (building heat transfer coefficient), compressive strength (wind speed), fire resistance (fire resistance limit time of building exterior walls), and sound insulation (the sound insulation decibel value that building exterior walls should achieve).

[0006] The technical solution adopted by this invention to solve its technical problem is: The integrated lightweight building infill wall panel (WQ-JKGN panel, WQ: lightweight exterior wall, J: energy saving, K: compressive strength, G: sound insulation, N: fire resistance) includes a fireproof and thermal insulation material layer, a steel mesh and a calcium silicate fiber board layer arranged sequentially from the middle to both sides. The steel mesh is fixedly connected to both sides of the fireproof and heat-insulating material layer by steel diagonal connecting rods, and lightweight aggregate concrete is poured on both the inner and outer sides of the steel mesh. The silica fiber calcium board layer has silica fiber calcium boards on both sides and lightweight aggregate concrete poured in the middle.

[0007] The invention is further configured such that the material of the fireproof and heat-insulating material layer can be one of rock wool, glass wool, polystyrene board or extruded board, depending on the requirements of the building fire protection code.

[0008] The present invention is further configured such that the lightweight aggregate concrete is polystyrene foam concrete.

[0009] The present invention is further configured such that the steel mesh is arranged in parallel and the distance between it and the outer surface of the fireproof and heat-insulating material layer is 15-20mm.

[0010] The invention is further configured to include a sound-insulating felt layer, which is disposed between the outer polystyrene concrete and the calcium silicate fiberboard layer.

[0011] The invention is further configured such that lightweight aggregate concrete with a thickness of 35mm is poured on the side of the fireproof and heat-insulating material layer closest to the interior, and the distance between the poured surface and the steel mesh is 35mm, thereby meeting the on-site trenching requirements for water and electricity pipes.

[0012] A construction method for building exterior walls, with product specifications set at 1200mm width and height from the ground to the bottom of the beam, and a height generally between 2400mm and 2700mm. The floor height of typical residential buildings is between 3 meters and 3.3 meters, while public buildings are higher. The height of the wall panel can be customized according to the design drawings. The aforementioned lightweight building infill exterior wall panels are fixed and aligned along the floor and the metal parts at the bottom of the beam, so that the insulation layer in the middle of the two panels is seamlessly connected, avoiding the building thermal bridge problem caused by uneven insulation layer (condensation damage to the interior wall surface caused by uneven distribution of energy-saving materials in the building exterior wall). The vertical ends of the inner and outer calcium silicate boards are reduced by 150mm on each side. A 300mm wide wire mesh is added to the area of ​​the smaller calcium silicate board on the inner and outer sides of the wall panel, and then the surface is leveled with finished cement waterproof bonding mortar.

[0013] When installing the panels on the floor and under the beams, extend them outwards by 80mm-100mm to be flush with the external insulation of the beams and columns later, and fix them with metal angle steel.

[0014] This invention utilizes the inherent physical properties of various building materials: rock wool for thermal insulation and energy saving, steel mesh truss for compressive strength, sound insulation felt for sound insulation, calcium silicate board for fire resistance, and lightweight aggregate concrete for fixing and construction adaptability. It is easy to form and groove. After construction, the indoor and outdoor walls are smooth and can be painted with interior and exterior wall paint, which is very convenient. The high strength of the calcium silicate board can increase the nail holding power of the wall indoors, and it can also be used to tile the exterior.

[0015] The adaptability solutions of this invention to different regional and national standards are as follows: the thickness and quality of the intermediate fireproof and thermal insulation material layer can be adjusted to increase or decrease the heat transfer coefficient; the diameter and spacing of the steel mesh and steel diagonal inserts can be adjusted to improve the stress performance of the steel truss and meet the requirements of different wind pressures; the thickness of the sound insulation felt can be increased or decreased to change the sound insulation volume and meet the sound insulation requirements of the building exterior walls; and the thickness of the silicate fiber calcium board can be increased or decreased to improve the fire resistance limit and meet the fire resistance limit requirements of the building walls.

[0016] Compared with the prior art, the beneficial effects of the present invention are: (1) The integrated lightweight building wall panel of the present invention simultaneously solves the various building code requirements for energy saving, pressure resistance, fire resistance and sound insulation of the exterior walls of residential and public buildings. It can replace the existing process of on-site block building, plastering and then insulation. Furthermore, it can be appropriately adjusted according to different standards and climates in different countries and regions to meet the market demands of different countries and regions.

[0017] (2) The lightweight building exterior wall panel of the present invention can effectively solve the problem of vertical joints during construction. The insulation material between the two panels is tightly connected to avoid thermal bridging. The steel wire mesh and cement mortar are added inside and outside the vertical joint to completely solve the problem of temperature cracking of vertical joints in the later stage of existing products.

[0018] (3) Improve the assembly rate in existing prefabricated building designs, respond to the national policy requirements for promoting prefabricated buildings, and increase the insulation layer to create more energy-efficient houses that exceed the standard requirements. Make them the building exterior wall products required by the passive houses promoted by developed countries at this stage, and respond to the national call for living in good houses.

[0019] (4) The overall mass of the wall is low and the weight is lighter than that of the masonry blocks. In the design of building structure, the load requirements of beams, columns and foundations can be reduced, the design size and reinforcement of beams, columns and foundations can be reduced, the cost of building structure can be saved, and the structure is more reasonable. At the same time, the seismic performance of the building is optimized and improved, because the lighter the building, the better the seismic resistance.

[0020] (5) This product can be factory-produced, with better quality and more guaranteed quality, lower price and more economical savings. The product specification is that one board can go from the floor to the bottom of the beam, making on-site construction more efficient. Attached Figure Description

[0021] Figure 1 This is a vertical cross-sectional structural diagram of the lightweight building wall panel of the present invention; h is the height, which is equal to the building design floor height minus the beam height, and is generally between 2400mm and 2700mm.

[0022] Numbering on the map: 1-Fireproof and thermal insulation material layer; 2-Lightweight aggregate concrete; 3-Steel mesh; 4-Sound insulation felt; 5-Calcium silicate fiberboard layer. Detailed Implementation The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0023] like Figure 1 As shown, the present invention provides an integrated lightweight building exterior wall, comprising a fireproof and heat-insulating material layer 1, a steel mesh 3, a sound insulation felt 4, and a calcium silicate fiber board layer 5 arranged sequentially from the middle to both sides.

[0024] As shown in Table 1, in this embodiment, the fireproof and thermal insulation material layer 1 is made of 100mm thick rock wool, with a mass of 100 kg per cubic meter, a fire rating of Class A, and a thermal conductivity of 0.0356 W / m*K. On both sides of the rock wool are two 3mm diameter steel meshes 3, arranged parallel to each other with a spacing of 140mm, and 20mm from the inner and outer surfaces of the rock wool on both sides. Between the two steel meshes 3 are 3mm diameter diagonal connecting rods welded together with a spacing of 100mm, forming a miniature steel truss structure. Lightweight concrete 2 is filled on both sides to stabilize the frame and resist lateral wind loads on the wall.

[0025] Table 1. Material Performance Parameters and Energy Saving Calculation Table

[0026] As shown in the calculation formula in Table 1, the total thermal resistance of the above materials is 3.710, the estimated thermal resistance R of the interior and exterior decoration is 0.15, the total thermal resistance of the exterior wall composite material layer plus interior and exterior decoration is 3.860, and the heat transfer coefficient after the main exterior wall is completed is 0.259 (common requirement K<0.35, higher requirements in cold regions).

[0027] In this embodiment, the lightweight concrete 2 is made of polystyrene foam concrete. This concrete contains polystyrene foam particles and a foaming agent, making it lightweight and providing some thermal insulation. After pouring a 20mm layer between the reinforcing mesh and rock wool in the interior direction, another 35mm layer is poured inwards, for a total inner thickness of 55mm. This is to meet the requirements for the depth of the conduit groove in the inner wall during construction (grooves need to be cut inside the building walls to bury conduits and run electrical wires). The required groove depth for the conduit is 25mm, and the outer plaster thickness is not less than 10mm.

[0028] In this embodiment, the sound insulation felt 4 is 3mm thick, which greatly improves the sound insulation effect of the wall, reaching 70 decibels.

[0029] On the outside of the sound insulation felt 4 is a 10mm layer of calcium silicate fiber board 5. The calcium silicate fiber board 5 has calcium silicate fiber boards on both sides and polystyrene foam concrete in the middle, so that it is waterproof, fireproof, termite-proof, and does not crack or delaminate after 100 freeze-thaw cycles. Its fire resistance limit can be up to 3 hours.

[0030] In other embodiments, the fireproof and thermal insulation material layer 1 can also be replaced with other fireproof and thermal insulation materials such as glass wool, polystyrene board or extruded board, according to building code requirements.

[0031] The specific on-site construction solution for the lightweight building exterior wall panels in this application is as follows: Reduce the thickness of the calcium silicate board at both longitudinal ends of the panel by 150 mm on both the inner and outer sides (simultaneously reducing the thickness of the polystyrene foam concrete by 15 mm). After aligning and fixing the two panels on-site, add a 300 mm wide wire mesh on both the inner and outer sides, and then level with pre-finished cement waterproof bonding mortar. This ensures a seamless connection between the rock wool layers of the two panels, preventing thermal bridging. Simultaneously, the wire mesh and subsequent mortar enhance the connection performance and eliminate vertical cracks caused by panel stress.

[0032] The stress calculation process for the lightweight building infill exterior wall panel structure in this application is as follows: 1. Calculation of standard wind load values: According to Article 8.1.1 of the Code for Design of Building Structures (GB 50009--2012), calculate the standard value of wind load: According to Article 8.3.3 of the Code for Design of Building Structures (GB 50009--2012), for enclosed buildings, the area with the largest wind load shape coefficient of the wall panels is at the corner of the lower side under suction, and the shape coefficient is -1.4.

[0033] The ground roughness is Class C, the height above the ground is 10m, and the gust coefficient of the enclosure structure is 1.70.

[0034] The ground roughness is Class C, the height above the ground is 10m, and the wind pressure height variation coefficient of the enclosure structure is 1.00.

[0035] The basic wind pressure for a 50-year return period is 0.5 kN / m².

[0036] The standard value of wind load is w = -1.4 x 1.7 x 0.5 = 1.19 kN / m².

[0037] 2. Calculation of the bending capacity of the wall panel: The wall panel is simply supported on the structural beams at the top and bottom. The wall panel is 1.2m wide and has a span of 3m.

[0038] The design value of the bending moment generated by the maximum wind load at the mid-span of the wall panel is M = 1.5 x 0.125 x 1.19 x 1.2 x 3 x 3 = 2.41 kN*m, and the design value of the cold-drawn steel wire mesh strength is f = 320 N / mm². 2 The area of ​​the wire mesh on one side is 7mm. 2 24 pieces = 168mm 2 The wire mesh spacing is 140mm. Since the wire mesh is fixed on both sides of the fiber cover plate, there is no risk of overall instability.

[0039] The maximum bending moment that the wall panel can withstand is 320x168x140=7.5KN*m. Since 7.5KN*m>2.41KN*m, the maximum bending moment that the wall panel can withstand is greater than the bending moment generated by wind load. Therefore, the bending bearing capacity is safe.

[0040] 3. Calculation of shear bearing capacity of wall panels: The design value of the maximum wind load at both ends of the wall panel is V1 = 1.5 x 0.5 x 1.19 x 1.2 x 3 = 3.2 kN. The maximum shear force borne by the steel wire at the end of the wall panel is V2 = 7 x 320 x 12 = 26.9 kN. Since 26.9 kN > 3.2 kN*m, the maximum shear force that the wall panel can withstand is greater than the shear force generated by the wind load. Therefore, the shear bearing capacity is safe.

[0041] 4. Deflection calculation: Υ=5*q*L^4 / (384EI) =5*0.95*3600^4 / (384*200000*168*140*140*2)=1.57mm.

[0042] 1.57mm < 3000 / 300 = 10mm meets the requirements of the current national standards for wall panel deflection.

[0043] As shown above, the overall heat transfer coefficient of the exterior wall panel in this example is 0.259 W / m²*K, which is less than the standard requirement of 0.35 W / m²*K. The fire resistance limit is 3 hours, which is greater than the standard requirement of 1 hour for the fire resistance limit of building infill walls. The wind pressure resistance can reach 3.48 kPa (theoretical calculation value multiplied by a coefficient of 0.66), which meets the structural code requirement of 0.5 kPa in the coastal areas of Shandong. The sound insulation can reach 70 decibels, which meets the requirement of not less than 55 decibels for exterior walls. The product specifications are 1200 mm wide and 2400 mm-2700 mm high. The total weight of each panel is 230 kg. It can be moved and installed by two people using a small trolley.

[0044] It will be apparent to those skilled in the art that the present invention is not limited to the details of the exemplary embodiments described above, and that the invention can be implemented in other specific forms without departing from its spirit or essential characteristics. Therefore, the embodiments should be considered in all respects as exemplary and non-limiting, and the scope of the invention is defined by the appended claims rather than the foregoing description. Thus, all variations falling within the meaning and scope of equivalents of the claims are intended to be included within the present invention. No reference numerals in the claims should be construed as limiting the scope of the claims.

Claims

1. An integrally integrated lightweight construction infill external wall panel characterised in that: It comprises a fireproof and heat-insulating material layer (1), a steel mesh (3) and a calcium silicate fiber board layer (5) arranged from the middle to both sides in sequence. The steel mesh (3) is fixedly connected to both sides of the fireproof and heat-insulating material layer (1) through steel inclined connecting rods, and both the inner and outer sides of the steel mesh (3) are poured with lightweight aggregate concrete (2). Both sides of the calcium silicate fiber board layer (5) are calcium silicate fiber boards, and the middle is poured with lightweight aggregate concrete (2).

2. A lightweight construction infill external wall panel according to claim 1, characterised in that: The material of the fireproof and heat-insulating material layer (1) is one of rock wool, glass silk wadding, polystyrene board or extruded board.

3. A lightweight construction infill external wall panel according to claim 2, characterised in that: The lightweight concrete (2) is polystyrene foam concrete.

4. A lightweight construction infill external wall panel according to claim 3, characterised in that: The steel mesh (3) is arranged in parallel, and the spacing between the steel mesh (3) and the outer surface of the fireproof and heat-insulating material layer (1) is 15-20 mm.

5. The lightweight architectural filled exterior wall panel of claim 1, wherein: It further comprises soundproof felt (4) arranged between the steel mesh and the calcium silicate fiber board layer.

6. The lightweight architectural filled exterior wall panel of claim 1, wherein: The side of the fireproof and heat-insulating material layer (1) close to the indoor side is further poured with lightweight aggregate concrete (2) with a thickness of 35 mm.

7. A method of constructing an exterior wall of a building, characterized by: The lightweight building filling outer wall board of any one of claims 1-6 is fixedly aligned along the floor and beam bottom metal parts, the middle heat-insulating layer of the two boards is seamlessly connected at the butt joint, the vertical two side ends of the inner and outer calcium silicate fiber board layers are each reduced by 150 mm, a steel mesh with a width of 300 mm is additionally arranged in the reduced area of the calcium silicate board on the vertical inner and outer sides of the wall board, and finished cement waterproof bonding mortar is used for leveling.

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