Fabricated construction method for ultra-large cornice curtain wall

Abstract

The invention belongs to the technical field of building curtain wall construction, and particularly relates to an ultra-large type cornice curtain wall assembly type construction method, through prefabricating keel modules and aluminum plate units, on-site assembly type construction is conducted, on-site welding and cutting operation is reduced, and the construction period is shortened by more than 30%. A specific construction sequence is utilized, the hydraulic lifting platform is erected at the semi-laid upper cornice, and compared with traditional cornice curtain wall construction, erection of high-altitude scaffolds is reduced, and the safety risk is reduced. And during on-site modular installation, an overturning device is combined to realize accurate positioning of the aluminum plate unit, and the deviation is controlled within 3mm. A sound insulation layer-steel plate-waterproof roll sandwich synchronous layout structure layer is adopted, the waterproof layer and the sound insulation layer are constructed immediately after keels are installed, and follow-up damage is avoided.

Description

TECHNICAL FIELD

[0001] The present application belongs to the technical field of building curtain wall construction, and particularly relates to a super-large eave curtain wall assembly construction method, which is particularly suitable for the construction of large-span eave curtain walls. BACKGROUND

[0002] At present, super-large eave curtain wall structures are often used in large public buildings (such as stadiums, airport terminals, etc.). The traditional construction method has the following disadvantages. The on-site welding operation is large in amount, the construction period is long, and there are many safety hazards for high-altitude operation; when installing a large eave curtain wall unit, it is difficult to position due to the large cantilever length, and deviation is easy to occur; and during the installation process, complex scaffolding often needs to be erected, which is high in cost and low in efficiency, and the quality of secondary construction such as waterproof layer and sound insulation layer is difficult to guarantee, and leakage problems are easy to occur. Therefore, there is an urgent need for a super-large eave curtain wall assembly construction method that is efficient, safe, and quality controllable. SUMMARY

[0003] The technical problem to be solved by the present application is to provide a super-large eave curtain wall assembly construction method to solve the problems of long construction period, high risk of high-altitude operation, difficult installation at staggered floor positions, and difficult guarantee of waterproof and sound insulation construction quality in the traditional construction method.

[0004] In order to achieve the above-mentioned purpose, the technical solution adopted by the present application is as follows: A super-large eave curtain wall assembly construction method, comprising the following steps: S1, hoisting equipment is erected on site, and the upper eave main ridge is hoisted to the installation position and welded and fixed after positioning and installation; S2, after the upper eave main ridge is installed in place, the upper eave profiled steel plate is laid from low to high along the eave slope; S3, a hydraulic lifting platform is erected on the staggered floor eave, the lower eave end cross ridge is installed first, and then the lower eave root cross ridge is installed; the lower eave main ridge is installed by insertion, and is welded and reinforced; S4, the lower eave aluminum plate unit is turned over, the aluminum plate unit is hoisted to the installation position, and the joint is filled with sealant after installation and fixation; S5, the insulation board is laid on the upper eave, the galvanized steel plate above the sound insulation layer is point welded with the ridge, and the joint is waterproofed; S6, the aluminum alloy secondary ridge is installed according to the grid size, and is connected with the main ridge through bolts, with a spacing error of less than or equal to 2 mm; S7, the upper eave aluminum plate is scattered on site and fixed to the secondary ridge through a special hanging piece, the plate warping degree is adjusted, and the joint is ensured to be horizontal and vertical.

[0005] Furthermore, before assembly, parametric modeling is used, and relevant software is used to complete the segmentation and panel drawing of the eaves surface, generating three-dimensional coordinates to guide on-site layout; the steel structure is 3D scanned, and after reverse modeling, the length of the connectors is adjusted to eliminate structural errors; then the main keel of the upper eaves, profiled steel plate, and aluminum plate modular components of the lower eaves are prefabricated in the factory.

[0006] Specifically, in step S1, a hydraulic lifting platform is set up on site for the construction of the lower eaves, a gantry crane with a span of ≥25m is installed for the flipping of aluminum plate units, and a 25T-300T truck crane and a 30° angle jib are configured.

[0007] Specifically, in step S1, the main keel is lifted from the yard to the installation position by a truck crane, and then transported over a short distance by a manual forklift. The main keel of the eaves is then lifted by a truck crane and a 30° jib. The elevation is calibrated with the help of a laser positioning instrument, and the support is positioned by a total station. After the keel is in place, it is welded and fixed. The quality of the weld must meet the specifications, and the weld height must be in accordance with the design requirements. After welding, anti-corrosion treatment is carried out.

[0008] Specifically, in step S2, when the corrugated steel sheet for the overhanging eaves is laid, the spacing between self-tapping screws is ≤300mm and the overlap width is ≥100mm.

[0009] Specifically, in step S3, a hydraulic lifting platform is erected on the eaves of the staggered floor, with a platform bearing capacity of ≥2kN / ㎡ and guardrails are set up around it; first, the horizontal keel at the end of the lower eaves is installed, and then the horizontal keel at the root of the lower eaves is installed. The keel is hoisted by a cableway hoist and the direction is controlled by the traction rope to ensure positioning accuracy. The main keel is inserted from the root of the eaves to the end and welded with the horizontal keel to form a frame. Then, segmented skip welding is used for reinforcement to reduce deformation.

[0010] Specifically, in step S4, the lower eaves aluminum panel unit is flipped using a jig and gantry crane. The flipping process involves horizontal lifting, tilting at a 30° angle, flipping at a 60° angle, and positioning at a 90° angle. The flipping angle is controlled at 90° to ensure that the panel does not deform. The unit panel is transported to the installation position using a rail crane and electric hoist, employing a four-point lifting method. After the unit panel is in place, it is first initially secured with high-strength bolts, and then reinforced by welding. The bolt tightening torque must meet the design requirements, and the joints are filled with sealant.

[0011] Specifically, in step S5, a 130mm thick composite-faced foam glass insulation board is laid on the eaves, fixed with a special adhesive, and there are no gaps at the joints. A 1.5mm galvanized steel plate is laid on top of the sound insulation layer and spot-welded to the keel, with the edges overlapping the structural beams by ≥50mm. In the unorganized drainage areas on the upper surface, TPO single-layer roll material is used, and in the organized drainage areas on the upper surface, polyurea is sprayed and the overlap seams are mechanically welded, with an overlap width of ≥80mm. The waterproof integrity of all joints is checked, especially the gutters and corners, and sealant is used to fill them to ensure no leakage.

[0012] Specifically, in step S7, the range of plate warping is adjusted from 80 to 0.

[0013] Furthermore, during the construction process, the actual structure was compared with the model multiple times using 3D scanning. The maximum overhang distance of the eaves was controlled to be 25m and the tilt angle to be 15°. The height difference of the aluminum plate joints was ≤1mm and the joint width error was ≤0.5mm. The joints were inspected section by section using feeler gauges and straightedges. The TPO membrane and polyurea waterproof layer were subjected to a water spray test for 30 minutes to check for any leakage.

[0014] Compared with the prior art, the present invention has the following beneficial effects: (1) The present invention uses prefabricated keel modules and aluminum plate units for on-site assembly construction, which reduces on-site welding and cutting operations and shortens the construction period by more than 30%.

[0015] (2) The present invention utilizes a specific construction sequence to erect a hydraulic lifting platform at the half-paved eaves, which reduces the need for high-altitude scaffolding and lowers safety risks compared with traditional eaves curtain wall construction.

[0016] (3) The present invention achieves precise positioning of aluminum plate units by combining a flipping device during on-site modular installation, with the deviation controlled within 3mm.

[0017] (4) The present invention adopts a "sound insulation layer-steel plate-waterproof membrane" sandwich structure layer for simultaneous installation. The waterproof layer and sound insulation layer are constructed immediately after the keel is installed to avoid subsequent damage.

[0018] (5) The present invention uses multiple three-dimensional scans to locate the irregular parts according to the parameters, which greatly improves the installation accuracy.

[0019] (6) The “keel-profiled steel sheet-sandwich layer-secondary keel” laying pattern of the present invention can greatly reduce the risk of water leakage at the corners and joints caused by the separate construction of the waterproof layer and the keel structure in stages during the construction of the eaves.

[0020] (7) The construction method of the present invention greatly reduces construction waste, and the reduction of some welding steps in the process greatly reduces carbon emissions. Attached Figure Description

[0021] The present invention will be further described in detail below with reference to the accompanying drawings and specific embodiments, and the advantages of the present invention in the above and / or other aspects will become clearer.

[0022] Figure 1 This is a diagram illustrating the transport of the keel.

[0023] Figure 2 This is a schematic diagram of the keel hoisting process.

[0024] Figure 3 This is a diagram showing the installation of the keel.

[0025] Figure 4 This is a diagram showing the completed installation of the keel.

[0026] Figure 5 This is a schematic diagram of the profiled sheet installation.

[0027] Figure 6 This is a schematic diagram of the platform setup.

[0028] Figure 7 This is a schematic diagram of the installation of the end cross keel.

[0029] Figure 8 This is a schematic diagram of the installation of the horizontal keel at the base.

[0030] Figure 9 This is a schematic diagram of the installation of the eaves keel.

[0031] Figure 10 This is a schematic diagram of keel welding reinforcement.

[0032] Figure 11 This is a schematic diagram of the transportation, placement, and hoisting of aluminum plate units.

[0033] Figure 12 This is a schematic diagram of the aluminum plate unit hoisting.

[0034] Figure 13 This is a schematic diagram showing the completed hoisting of the aluminum plate unit.

[0035] Figure 14 This is a schematic diagram of the installation of the sound insulation, steel plate, and waterproof layer for the overhanging eaves.

[0036] Figure 15 This is a schematic diagram of the installation of the secondary keel of the eaves.

[0037] Figure 16 This is a schematic diagram of the installation of the overhanging aluminum eaves panel.

[0038] Figure 17 This is a schematic diagram of the finishing edge of the aluminum panel on the eaves. Detailed Implementation

[0039] The present invention can be better understood from the following embodiments.

[0040] like Figures 1-17 As shown, the prefabricated construction method for ultra-large cantilever curtain walls of the present invention includes the following steps: S1. Set up hoisting equipment on site and hoist the main keel of the upper eaves to the installation position. After positioning and installation, weld and fix it. S2. After the main keel of the eaves is installed, lay the profiled steel plate of the eaves from low to high along the slope of the eaves. S3. Construct a hydraulic lifting platform on the eaves of the staggered floor. First, install the horizontal keel at the end of the lower eaves, and then install the horizontal keel at the base of the lower eaves. The main keel of the lower eaves is installed in a crisscross pattern and reinforced by welding. S4. Flip over the lower eaves aluminum panel unit, hoist the aluminum panel unit to the installation position, and fill the joint with sealant after installation and fixing; S5. Lay insulation boards on the upper eaves, galvanized steel plates above the sound insulation layer, spot weld them to the keel, and waterproof the joints. S6. Install the aluminum alloy secondary keel according to the grid size, and connect it to the main keel with bolts. The spacing error is ≤2mm. S7. On-site bulk installation of eaves aluminum panels, fixed to the secondary keel with special hangers, adjustment of panel warping to ensure horizontal and vertical joints.

[0041] In some embodiments, before assembly, parametric modeling is used, and relevant software is used to complete the segmentation and panel drawing of the eaves surface, and generate three-dimensional coordinates to guide the on-site layout; the steel structure is 3D scanned, and after reverse modeling, the length of the connectors is adjusted to eliminate structural errors; then the main keel of the upper eaves, profiled steel plate, and aluminum plate modular components of the lower eaves are prefabricated in the factory.

[0042] In this embodiment, in step S1, a hydraulic lifting platform is set up on site for the construction of the lower eaves, a gantry crane with a span of ≥25m is installed for the flipping of aluminum plate units, and a 25T-300T truck crane and a 30° angle auxiliary boom are configured.

[0043] In this embodiment, in step S1, as follows: Figure 1 , Figure 2 As shown, the main keel was transported from the yard to the installation position using a truck crane, then transferred short distances using a manual forklift. The main keel of the eaves was then installed using a truck crane and a 30° jib, with a laser positioning device assisting in elevation calibration and a total station used to mark and position the supports. Figure 3 , 4 As shown, the keel is welded and fixed after it is in place. The quality of the weld must meet the specifications, the weld height must be in accordance with the design requirements, and anti-corrosion treatment must be carried out after welding.

[0044] Specifically, in step S2, such as Figure 5 As shown, when the corrugated steel sheet for the overhanging eaves is installed, the spacing between self-tapping screws is ≤300mm and the overlap width is ≥100mm.

[0045] Specifically, in step S3, such as Figure 6 As shown, a hydraulic lifting platform is erected on the eaves of the staggered-level building. The platform's load-bearing capacity is ≥2kN / ㎡, and protective railings are installed around its perimeter. Figure 7 , 8 As shown, first install the horizontal joists at the end of the lower eaves, then install the horizontal joists at the base of the lower eaves. Use a cableway hoist for hoisting, and control the direction with a traction rope to ensure positioning accuracy. Figure 9 ,10 As shown, the main keel is inserted and installed from the base of the eaves to the end, and welded with the horizontal keel to form a frame. Then, segmented skip welding is used for reinforcement to reduce deformation.

[0046] Specifically, in step S4, such as Figures 11-13 As shown, the aluminum panel units of the lower eaves are flipped using a jig and gantry crane. The flipping process involves horizontal lifting, tilting at a 30° angle, flipping at a 60° angle, and positioning at a 90° angle. The flipping angle is controlled at 90° to ensure that the panels do not deform. The unit panels are transported to the installation position using a rail crane and electric hoist, employing a four-point lifting method. After the unit panels are in place, they are first initially secured with high-strength bolts, and then reinforced by welding. The bolt tightening torque must meet the design requirements, and the joints are filled with sealant.

[0047] Specifically, in step S5, such as Figure 14 As shown, a 130mm thick composite-faced foam glass insulation board is laid on the eaves, fixed with a special adhesive, with no gaps at the joints. A 1.5mm galvanized steel plate is laid on top of the sound insulation layer and spot-welded to the keel, with an overlap of ≥50mm between the edges and the structural beams. In areas without organized drainage on the upper surface, a single layer of TPO roll material is used, while in areas with organized drainage on the upper surface, polyurea is sprayed and the overlap seams are mechanically welded, with an overlap width of ≥80mm. The waterproof integrity of all joints is checked, especially at gutters and corners, and filled with sealant to ensure no leakage.

[0048] Specifically, in step S7, the range of plate warping is adjusted from 80 to 0.

[0049] Furthermore, during the construction process, the actual structure was compared with the model multiple times using 3D scanning. The maximum overhang distance of the eaves was controlled to be 25m and the tilt angle to be 15°. The height difference of the aluminum plate joints was ≤1mm and the joint width error was ≤0.5mm. The joints were inspected section by section using feeler gauges and straightedges. The TPO membrane and polyurea waterproof layer were subjected to a water spray test for 30 minutes to check for any leakage.

[0050] This invention adopts a combined construction mode of "bulk welding of the upper eaves + assembly and hoisting of the lower eaves in sections". The lower eaves adopts the process of "lifting platform + positioning of the end root horizontal keel + overall hoisting of unit panels". The overall construction is modular and segmented. The main keel of the upper eaves adopts a four-step method of "transfer → hoisting → positioning → welding". The main keel of the lower eaves is installed without scaffolding through a detachable lifting platform. After the installation of the main keel and profiled steel sheet of the upper eaves is completed, a hydraulic lifting platform is erected at the upper eaves. The lower eaves keel of the staggered eaves is erected using the lifting platform. The root and end keels of the lower eaves are installed first using electric hoists. After initial fixing with high-strength bolts, the main keel is hoisted in and finally welded for reinforcement. The lower eaves aluminum panel units are flipped using a flipping process of horizontal lifting → 30° tilting angle → 60° rotation → 90° positioning. Then, four sets of electric hoists are used to hoist the aluminum panel units. After the aluminum panels for the underglaze eaves are installed, as follows: Figures 14-17 As shown, the process of simultaneously laying the "sound insulation layer-steel plate-waterproof membrane" is used. The membrane is laid on the upper eaves. After the three layers are laid, the secondary keel is laid. After the secondary keel is laid, the aluminum plate units are laid. Finally, EPDM sealing strips are used to seal the aluminum plate edges.

[0051] This invention provides a conceptual approach and method for the prefabricated construction of ultra-large overhanging curtain walls. Many methods and approaches exist for implementing this technical solution; the above description is merely a preferred embodiment of the invention. It should be noted that those skilled in the art can make various improvements and modifications without departing from the principles of this invention, and these improvements and modifications should also be considered within the scope of protection of this invention. All components not explicitly stated in this embodiment can be implemented using existing technologies.

Claims

1. A prefabricated construction method for an ultra-large cantilevered curtain wall, characterized in that, Includes the following steps: S1. Set up hoisting equipment on site and hoist the main keel of the upper eaves to the installation position. After positioning and installation, weld and fix it. S2. After the main keel of the eaves is installed, lay the profiled steel plate of the eaves from low to high along the slope of the eaves. S3. Construct a hydraulic lifting platform on the eaves of the staggered floor. First, install the horizontal keel at the end of the lower eaves, and then install the horizontal keel at the base of the lower eaves. The main keel of the lower eaves is installed in a crisscross pattern and reinforced by welding. S4. Flip over the lower eaves aluminum panel unit, hoist the aluminum panel unit to the installation position, and fill the joint with sealant after installation and fixing; S5. Lay insulation boards on the upper eaves, galvanized steel plates above the sound insulation layer, spot weld them to the keel, and waterproof the joints. S6. Install the aluminum alloy secondary keel according to the grid size and connect it to the main keel with bolts. The spacing error is ≤2mm. S7. On-site bulk installation of eaves aluminum panels, fixed to the secondary keel with special hangers, adjustment of panel warping, and ensuring that the joints are horizontal and vertical.

2. The prefabricated construction method for ultra-large overhanging eaves curtain walls according to claim 1, characterized in that, Before assembly, parametric modeling is used, and relevant software is used to complete the segmentation and panel drawing of the eaves surface, and generate three-dimensional coordinates to guide the on-site layout; the steel structure is 3D scanned, and after reverse modeling, the length of the connectors is adjusted to eliminate structural errors; then the main keel of the upper eaves, profiled steel plate, and aluminum plate modular components of the lower eaves are prefabricated in the factory.

3. The prefabricated construction method for ultra-large overhanging eaves curtain walls according to claim 1, characterized in that, In step S1, a hydraulic lifting platform is set up on site for the construction of the lower eaves, and a gantry crane with a span of ≥25m is installed for the flipping of aluminum plate units. A 25T-300T truck crane and a 30° angle jib are configured.

4. The prefabricated construction method for ultra-large overhanging eaves curtain walls according to claim 1, characterized in that, In step S1, the main keel is lifted from the yard to the installation position by a truck crane, and then transported over a short distance by a manual forklift. The main keel of the eaves is then lifted by a truck crane and a 30° jib. The elevation is calibrated with the help of a laser positioning instrument, and the support is positioned by a total station. After the keel is in place, it is welded and fixed. The quality of the weld must meet the specifications, and the weld height must be in accordance with the design requirements. Corrosion protection treatment is carried out after welding.

5. The prefabricated construction method for ultra-large overhanging eaves curtain walls according to claim 1, characterized in that, In step S2, when the corrugated steel sheet for the overhanging eaves is laid, the spacing between self-tapping screws is ≤300mm and the overlap width is ≥100mm.

6. The prefabricated construction method for ultra-large overhanging eaves curtain walls according to claim 1, characterized in that, In step S3, a hydraulic lifting platform is erected on the eaves of the staggered floor. The platform has a load-bearing capacity of ≥2kN / ㎡ and is surrounded by guardrails. First, the horizontal keel at the end of the lower eaves is installed, and then the horizontal keel at the root of the lower eaves is installed. The keel is hoisted by a cableway hoist and the direction is controlled by the traction rope to ensure positioning accuracy. The main keel is inserted from the root of the eaves to the end and welded with the horizontal keel to form a frame. Then, segmented skip welding is used for reinforcement to reduce deformation.

7. The prefabricated construction method for ultra-large overhanging eaves curtain walls according to claim 1, characterized in that, In step S4, the lower eaves aluminum panel unit is flipped using a jig and gantry crane. The flipping process involves horizontal lifting, tilting at 30°, flipping at 60°, and positioning at 90°. The flipping angle is controlled at 90° to ensure that the panel does not deform. The unit panel is then transported to the installation position using a rail crane and electric hoist, employing a four-point lifting method. After the unit panel is in place, it is first initially secured with high-strength bolts, and then reinforced by welding. The bolt tightening torque must meet the design requirements, and the joints are filled with sealant.

8. The prefabricated construction method for ultra-large overhanging eaves curtain walls according to claim 1, characterized in that, In step S5, a 130mm thick composite-faced foam glass insulation board is laid on the upper eaves, fixed with a special adhesive, and the joints are seamless. A 1.5mm galvanized steel plate is laid on top of the sound insulation layer and spot-welded to the keel, with the edges overlapping the structural beams by ≥50mm. In the unorganized drainage areas on the upper surface, a single layer of TPO roll material is used, and in the organized drainage areas on the upper surface, polyurea is sprayed and the overlap seams are mechanically welded, with an overlap width of ≥80mm. The waterproof integrity of all joints is checked, especially the gutters and corners, and filled with sealant to ensure no leakage.

9. The prefabricated construction method for ultra-large overhanging eaves curtain walls according to claim 1, characterized in that, In step S7, adjust the range of plate warpage gradient from 80 to 0.

10. The prefabricated construction method for ultra-large overhanging eaves curtain walls according to claim 1, characterized in that, During construction, the actual structure was compared with the model multiple times using 3D scanning. The maximum overhang distance of the eaves was controlled to be 25m and the tilt angle to be 15°. The height difference of the aluminum plate joints was ≤1mm and the joint width error was ≤0.5mm. The test was carried out section by section using feeler gauges and straightedges. The TPO membrane and polyurea waterproof layer were subjected to a water spray test for 30 minutes to check for any leakage.

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