Biomass heat preservation steel keel sandwich composite external wall panel and manufacturing method thereof

Abstract

The invention discloses a biomass heat-preservation steel keel sandwich composite external wall panel and a manufacturing method thereof, and belongs to the technical field of low-carbon fabricated buildings in the building industry, and the biomass heat-preservation steel keel sandwich composite external wall panel comprises a concrete outer acanthus, a steel keel framework, a biomass heat-preservation layer and an indoor panel. The aerogel felt is wrapped on a flange of the steel keel framework, the concrete outer acanthus is fixed on the steel keel framework through the FRP bolts, the concrete outer acanthus and the steel keel framework serve as templates of the biomass heat preservation layer, and the biomass heat preservation layer with negative carbon emission is obtained by tamping stirred biomass heat preservation materials in a layered mode. The indoor panel is fixedly connected to the steel keel framework through FRP bolts. The biomass heat preservation layer is integrally formed, no through gap exists in the heat preservation layer, the heat preservation performance of the wallboard is improved, manufacturing is convenient, high automation is achieved, meanwhile, carbon emission of the wallboard is reduced through the biomass heat preservation layer with negative carbon emission, and the wallboard is suitable for low-carbon and zero-carbon fabricated buildings and has the market popularization value.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of low-carbon fabricated building in the construction industry, more particularly to a biomass heat-insulated steel keel sandwich composite external wall panel and a manufacturing method thereof. BACKGROUND

[0002] The fabricated steel keel external wall panel is 30% lighter than the traditional steel structure, the components of the wall panel are pre-fabricated in the factory, and the on-site construction can be shortened by more than 40%, and the wall panel area can reach 25m 2 due to the high strength of the steel structure in the wall panel. It has the advantages of light weight, high strength, large area, etc. However, due to the fact that the thermal conductivity of steel is about 500 times higher than that of the insulation layer, a clear cold-heat bridge is formed in the wall panel, and heat is directly transmitted to the external environment through the steel keel, increasing the heat loss through the wall panel and reducing the heat insulation performance of the wall panel. At present, in order to reduce the thermal bridge effect of the steel keel, FRP is used to wrap the light steel keel to break the thermal bridge, but since the thermal conductivity of FRP is 0.17~0.4W / (m·K), which is obviously higher than the thermal conductivity of the insulation board 0.032~0.044W / (m·K), when the steel keel is fully wrapped with FRP, the thermal bridge effect is not significantly reduced and the construction difficulty is increased.

[0003] At present, the insulation layer of the fabricated steel keel external wall panel adopts XPS extruded polystyrene board, EPS molded polystyrene board, PU foam polyurethane board or rock wool board. These insulation materials have excellent insulation performance, but the carbon emission of the material is large (1980kgCO2 / t~5220kg CO2 / t), and as the thickness of the insulation layer increases, multiple insulation boards need to be stacked, resulting in gaps in the insulation layer and reducing the insulation performance of the wall panel. At present, there are also large-size and super-thick insulation boards on the market, with a thickness of up to 100mm, but for super-low and near-zero energy consumption buildings in severe cold and cold regions, this thickness is far from meeting the wall panel insulation requirements, and as the size and thickness of the insulation board increase, the price of the material also increases exponentially, resulting in an increase in the cost of the wall panel.

[0004] Therefore, how to provide a low-carbon fabricated sandwich composite external wall panel with large size, light weight and good insulation performance is a problem that needs to be solved by those skilled in the art. SUMMARY

[0005] To solve the above technical problems, the present application provides a biomass heat-insulated steel keel sandwich composite external wall panel and a manufacturing method thereof.

[0006] In order to achieve the above purpose, the present application adopts the following technical solutions: A biomass heat-insulated steel keel sandwich composite external wall panel, comprising: The concrete outer leaf plate and the indoor panel are connected with the steel furring frame by FRP bolts respectively, and the biomass thermal insulation layer is filled in the middle layer between the concrete outer leaf plate and the indoor panel.

[0007] The steel furring frame is wrapped with aerogel blanket. The concrete outer leaf plate is embedded with FRP sleeve, and is connected with the steel furring frame by FRP bolts. The indoor panel is provided with holes corresponding to the steel furring frame, and is connected with the steel furring frame by grouting material and FRP bolts.

[0008] A method for manufacturing a biomass thermal insulation steel furring sandwich composite external wall plate, comprising: Firstly, a concrete outer leaf plate is laid on the bottom of a mold. Secondly, a steel furring frame is installed on the concrete outer leaf plate: the FRP sleeve of the concrete outer leaf plate is aligned with the hole of the steel furring flange, and the concrete outer leaf plate and the steel furring frame are connected by FRP bolts. Thirdly, the concrete outer leaf plate and the steel furring frame are used as a template, and the biomass thermal insulation mixture is poured into the template in the thickness of 50-100 mm each time, and is tamped by an automatic tamping machine, and is tamped in multiple times until the required thickness of the thermal insulation layer is reached.

[0009] Fourthly, the indoor panel is connected with the steel furring frame by FRP bolts. Preferably, the aerogel blanket wrapping layer can be customized by 3D printing technology or injection molding technology to ensure the adhesion with the steel furring frame.

[0010] Preferably, the multiple times of tamping are based on the control of the density of the biomass thermal insulation layer to ensure that each tamping reaches the designed thickness.

[0011] Preferably, the biomass thermal insulation mixture is composed of the following raw materials in percentage by weight: crop straw 11-22%, gypsum 34-45%, fly ash 7-11%, lime 1-2%, water 32-36%, and methyl sodium silicate 0.6-0.7%.

[0012] Preferably, the crop straw is the mature crop stem of wheat, rice, highland barley, corn, rape, sugarcane residue or coconut shell.

[0013] Preferably, the crop straw is subjected to cutting, cold water soaking and drying treatment to obtain treated straw.

[0014] Preferably, the biomass thermal insulation mixture stirring step comprises: (1) gypsum, fly ash and lime are weighed according to the proportion, stirred until uniform to obtain a mixture A; (2) tap water and methyl sodium silicate are weighed according to the proportion, stirred until uniform to obtain a mixed solution B; (3) the mixed solution B is added to the mixture A, stirred until uniform, to obtain a mixed solution C; (4) the treated straw is added to the mixed solution C, stirred until the mixed solution is uniformly adhered to the straw, to obtain a biomass heat preservation mixture.

[0015] Preferably, the concrete outer leaf plate is embedded with an FRP sleeve, and the length of the FRP bolt connecting the steel joist and the concrete outer leaf plate is greater than the length of the FRP sleeve.

[0016] Preferably, the indoor panel and the steel joist framework are connected through grouting material and FRP bolts Preferably, the concrete outer leaf plate is fair-faced concrete, ultra-high performance concrete or fiber reinforced concrete, and the indoor panel is fair-faced concrete, fiber reinforced concrete or gypsum board.

[0017] Through the above technical scheme, the application provides a biomass heat preservation steel joist sandwich composite external wall panel and a manufacturing method thereof. The steel joist flange wraps aerogel blanket and FRP bolts to reduce the thermal bridge effect of the steel joist framework and the bolt connection node. Meanwhile, the biomass heat preservation layer is integrally formed without through gaps, which improves the heat preservation performance of the wall panel. The biomass heat preservation layer uses a large amount of crop straw, which reduces the carbon emission of the wall panel and is suitable for low-carbon and zero-carbon fabricated buildings, and has market promotion value. BRIEF DESCRIPTION OF DRAWINGS

[0018] Figure 1 A biomass heat preservation steel joist sandwich composite external wall panel provided by the application is shown in the figure; Figure 2 A steel joist framework and flange part hole opening diagram of the biomass heat preservation steel joist sandwich composite external wall panel provided by the application is shown in the figure; Figure 3 A three-dimensional structure diagram of the concrete outer leaf plate side of the biomass heat preservation steel joist sandwich composite external wall panel provided by the application is shown in the figure; Figure 4 A template diagram formed by the concrete outer leaf plate and the steel joist framework provided by the application is shown in the figure; Figure 5 A cross-sectional diagram of the biomass heat preservation steel joist sandwich composite external wall panel provided by the application is shown in the figure.

[0019] Explanation of reference signs: 1-steel skeleton; 2-flange opening; 3-aerogel blanket; 4-concrete outer leaf; 5-biomass insulation layer; 6-FRP sleeve; 7-FRP bolt; 8-interior panel; 101-vertical steel girt; 102-horizontal steel girt. DETAILED DESCRIPTION

[0020] The embodiments of the present application will be described below in conjunction with the accompanying drawings, and the described embodiments are only some of the embodiments of the present application, not all. Based on the embodiments in the present application, all other embodiments obtained by those skilled in the art without creative labor are within the scope of protection of the present application.

[0021] Embodiment 1 Referring to the accompanying drawings Figure 1 to the accompanying drawings Figure 2 The embodiments of the present application disclose a biomass insulation steel girt sandwich composite outer wallboard and a manufacturing method thereof, comprising: The steel skeleton 1 comprises a plurality of vertical steel girts 101 and a plurality of horizontal steel girts 102, the vertical steel girts 101 are arranged in the vertical direction, the horizontal steel girts 102 are arranged in the horizontal direction, and the vertical steel girts 101 and the horizontal steel girts 102 are perpendicular to each other and fixedly connected; wherein the vertical steel girt 101 has the same cross-sectional height as the design thickness of the biomass insulation layer 6, and the horizontal steel girt 103 located on the upper and lower sides of the steel skeleton 1 has the same cross-sectional height as the design thickness of the biomass insulation layer 6; The concrete outer leaf 4 is embedded with the FRP sleeve 6. The interior panel 8 is provided with holes corresponding to the steel skeleton.

[0022] The flanges of the steel skeleton 1 on both sides are provided with openings 2, and the flanges of the steel skeleton 1 are wrapped with aerogel blankets 4.

[0023] The aerogel blanket 3 wrapping layer can be customized by 3D printing technology or injection molding technology.

[0024] The concrete outer leaf 4 and the steel skeleton 1 are connected through the embedded FRP sleeve 6 and the FRP bolt 7.

[0025] The biomass insulation mixture is composed of the following raw materials in weight percentage: crop straw 11%~22%, gypsum 34%~45%, fly ash 7%~11%, lime 1%~2%, water 32%~36%, and methyl sodium silicate 0.6~0.7%.

[0026] Crop straw is cut into small pieces with a length of less than 30 mm, then soaked in cold water for 24 hours, and the water is changed 2-5 times until the PH value of the effluent is within 10% of that of tap water. The crop straw is then dried in an oven.

[0027] The dry density of the biomass insulation layer 6 is 300 kg / m 3 700 kg / m 3 The thermal conductivity is 0.05-0.1 W / (m·K).

[0028] The biomass insulation layer 6 is unloaded and compacted by automatic layered compaction equipment to ensure the consistency of the insulation layer thickness.

[0029] The mold table is provided with sensors to monitor the compaction density in real time, ensuring the uniformity of the insulation layer.

[0030] The indoor panel 8 is connected to the steel keel framework 1 by grouting material and FRP bolts 7.

[0031] The manufacturing method of the biomass insulation steel keel sandwich composite external wall panel provided in the embodiment is as follows: Step one: refer to the attached Figure 2 The steel keel framework 1 is composed of a plurality of vertical steel keels 101 and a plurality of horizontal steel keels 102. The vertical steel keel 101 and the upper and lower horizontal steel keel 103 are channel steel with a height of 200 mm, a width of 73 mm, and a thickness of 7 mm. The horizontal steel keel 102 is channel steel with a height of 160 mm, a width of 63 mm, and a thickness of 5.5 mm.

[0032] Step two: refer to the attached Figure 2 The steel keel framework 1 is wrapped with aerogel felt material 3 at the flange position.

[0033] Step three: refer to the attached Figure 3 and the attached Figure 4 The concrete outer leaf panel 4 is installed and connected to the steel keel framework 1: the concrete outer leaf panel 4 is laid at the bottom of the mold, and the concrete outer leaf panel 4 is pre-buried with FRP sleeves 6 corresponding to the steel keel framework 1. The concrete outer leaf panel 4 can be made of fair-faced concrete, ultra-high performance concrete, or fiber-reinforced concrete, with a thickness of 30 mm. Align the FRP sleeves 6 and the reserved holes 2 on the steel keel framework 1, and use FRP bolts 7 to connect the concrete outer leaf panel 4 and the steel keel framework 1.

[0034] Step four: make biomass insulation mixture: (1) Weigh the following raw materials in proportion: crop straw 21.3%, gypsum 38.3%, fly ash 3.8%, lime 1%, water 35%, and methyl sodium silicate 0.6%; (2) Add gypsum, fly ash, and lime to the bucket and stir for 1 minute to obtain mixture A; (3) Weigh tap water and sodium methyl silicate by proportion, stir to get mixture B; (4) Add mixture B into mixture A, stir for 2 minutes to get mixture C; (5) Add treated straw into mixture C, stir for 2 minutes to get biomass insulation mixture 10.

[0035] Step five: refer to the attached Figure 4 , weigh biomass insulation layer 5 with density of 400 kg / m 3 , take concrete outer leaf plate 4 and steel skeleton 1 as formwork, pour into the formwork according to 50 mm thickness of each time, use automatic tamping machine to tamp, real-time monitor tamping density through sensor on the formwork to reach 400 kg / m 3 , continue to add material and tamp until the thickness of biomass insulation layer reaches 200 mm.

[0036] Step six: refer to the attached Figure 2 , install indoor panel 8: indoor panel 8 can be adopted by using water concrete, fiber reinforced concrete or gypsum board, thickness of 15 mm, install FRP bolt 7 on steel skeleton 1, align the reserved hole of FRP bolt 7 with indoor panel 8, and pour grouting material.

[0037] Example 2 The remaining steps of this example are the same as those of example 1, the difference is that vertical steel skeleton 101 and upper and lower two horizontal steel skeletons 103 adopt channel steel with height of 220 mm, width of 77 mm and thickness of 7 mm; the thickness of biomass insulation layer 5 is 220 mm; the weight percentage of biomass insulation mixture is: crop straw 18.6%, gypsum 37.2%, fly ash 8.3%, lime 1%, water 34.3%, and sodium methyl silicate 0.6%; real-time monitor tamping density of biomass insulation layer 5 through sensor on the formwork to reach 500 kg / m 3 .

[0038] Example 3 The remaining steps of this example are the same as those of example 1, the difference is that vertical steel skeleton 101 and upper and lower two horizontal steel skeletons 103 adopt channel steel with height of 250 mm, width of 78 mm and thickness of 7 mm; the thickness of biomass insulation layer 5 is 250 mm; the weight percentage of biomass insulation mixture is: crop straw 15.4%, gypsum 41.1%, fly ash 9.2%, lime 1%, water 32.7%, and sodium methyl silicate 0.6%; real-time monitor tamping density of biomass insulation layer 5 through sensor on the formwork to reach 600 kg / m 3 .

[0039] Example 4 The remaining steps of this embodiment are the same as those of Example 1, except that the vertical steel keel 101 and the upper and lower two transverse steel keels 103 are channel steel with a height of 280 mm, a width of 82 mm, and a thickness of 7.5 mm; the thickness of the biomass thermal insulation layer 5 is 280 mm; the weight percentage of the biomass thermal insulation mixture is: crop straw 13.3%, gypsum 42.6%, fly ash 9.6%, lime 1.1%, water 32.8%, and methyl sodium silicate 0.6%; and the tamping density of the biomass thermal insulation layer 5 is 700 kg / m 3 .

[0040] Example 5 The remaining steps of this embodiment are the same as those of Example 1, except that the vertical steel keel 101 and the upper and lower two transverse steel keels 103 are channel steel with a height of 280 mm, a width of 82 mm, and a thickness of 7.5 mm; the thickness of the biomass thermal insulation layer 5 is 280 mm; the weight percentage of the biomass thermal insulation mixture is: crop straw 11.3%, gypsum 45.2%, fly ash 10.2%, lime 1.1%, water 31.6%, and methyl sodium silicate 0.6%; and the tamping density of the biomass thermal insulation layer 5 is 800 kg / m 3 .

[0041] Comparative Example 1: A preparation method of a biomass-enhanced cement-based thermal insulation wall material and the wall material (application publication number: CN 120903895 A), which uses cement, modified wood fiber, nano-SiO2 particles, and calcium stearate to obtain a low-carbon thermal insulation material.

[0042] Comparative Example 2: A biomass low-carbon concrete material and a preparation method thereof (application publication number: CN 118373660 A), which uses animal bone glue, sandstone, magnesium oxide, magnesium chloride hexahydrate, and water to prepare a low-carbon thermal insulation material.

[0043] The carbon emissions of the biomass materials obtained in Examples 1-5 and Comparative Examples 1-2 are calculated, and the results are shown in Table 1.

[0044] Table 1

[0045] The biomass thermal insulation steel keel sandwich composite external wall panel provided in this embodiment reduces the thermal bridge effect through the steel keel framework and bolts by wrapping the aerogel blanket and FRP bolts with the steel keel flanges. At the same time, the biomass thermal insulation layer is obtained by on-site pouring and ramming, and there are no through gaps in the thermal insulation layer, which improves the thermal insulation performance of the wall panel. A large amount of crop straw is used in the biomass thermal insulation layer, which reduces the carbon emissions of the wall panel and is suitable for low-carbon and zero-carbon prefabricated buildings, and has market promotion value.

Claims

1. A biomass-insulated steel keel sandwich composite exterior wall panel, characterized in that: The wall panel is composed of an outer concrete leaf panel (4), a steel keel frame (1), a biomass insulation layer (5), and an inner panel (8) arranged sequentially from the outside to the inside. The outer concrete leaf panel (4) is connected to the steel keel frame (1) by FRP bolts (7). The web height of the steel keel frame (1) is the same as the thickness of the biomass insulation layer (5). The inner panel (8) is connected to the steel keel frame (1) by FRP bolts (7). The biomass insulation layer (5) is filled in the interlayer between the outer concrete leaf panel (1) and the inner panel (8). The steel keel frame (1) has flange openings (2) on both sides and is wrapped with aerogel felt (3). FRP sleeves (6) are pre-embedded on the outer concrete leaf panel (4). The biomass insulation layer (5), the concrete outer leaf plate (4), and the indoor panel (8) are reserved with holes corresponding to the steel keel frame (1). The indoor panel (8) is connected to the steel keel frame (1) by grouting material and FRP bolts (7).

2. The method for manufacturing a biomass-insulated steel keel sandwich composite exterior wall panel as described in claim 1, characterized in that, include: The first step is to lay concrete outer leaf plates at the bottom of the mold (4). The second step is to install the steel keel frame (1) on the concrete outer leaf plate (4): align the FRP sleeve (6) of the concrete outer leaf plate (4) with the flange opening (2), and connect the concrete outer leaf plate (4) and the steel keel frame (1) using FRP bolts (7). The third step is to use the concrete outer leaf plate (4) and the steel keel frame (1) as templates, and pour the biomass insulation mixture into the template in layers of 50mm~100mm thickness each time until the required insulation layer thickness is achieved. The fourth step is to connect the interior panel (8) to the steel keel frame (1) using FRP bolts (7).

3. The manufacturing method according to claim 2, characterized in that, The biomass insulation mixture is composed of the following raw materials by weight percentage: 11%~22% crop straw, 34%~45% gypsum, 7%~11% fly ash, 1%~2% lime, 32%~36% water, and 0.6%~0.7% sodium methylsilicate.

4. The manufacturing method according to claim 3, characterized in that, Crop straw is made from the mature stalks of wheat, rice, barley, corn, rapeseed, sugarcane bagasse, or coconut shells.

5. The manufacturing method according to claim 3, characterized in that, The crop straw is processed by cutting it into sections, soaking it in cold water, and drying it to obtain the processed straw.

6. The manufacturing method according to claim 5, characterized in that, The biomass thermal insulation mixture is prepared using the following method: (1) Weigh out gypsum, fly ash and lime in proportion, and stir them evenly to obtain mixture A; (2) Weigh out tap water and sodium methylsilicate in proportion, and stir evenly to obtain mixture B; (3) Add mixture B to mixture A and stir until homogeneous to obtain mixture C; (4) Add the treated straw to the mixture C and stir until the mixture adheres evenly to the straw to obtain the biomass heat preservation mixture.

7. The manufacturing method according to claim 2, characterized in that, The concrete outer leaf plate (4) is connected to the steel keel frame (1) by FRP bolts (7), the length of which is greater than the length of the FRP sleeve (6).

8. The manufacturing method according to claim 2, characterized in that, The outer concrete leaf slab (4) is made of fair-faced concrete, ultra-high performance concrete or fiber reinforced concrete, and the inner panel (8) is made of fair-faced concrete, fiber reinforced concrete or gypsum board.

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