Passive building double-layer super-thick outer thermal insulation layer and thermal insulation construction joint filling construction method

Abstract

The invention relates to the technical field of building construction external thermal insulation, and discloses a passive building double-layer super-thick external thermal insulation layer and a thermal insulation construction joint filling construction method. A PC bracket is arranged on each layer at the plate seam of the first-layer heat insulation plate; preparing mortar; the construction of the fireproof isolation belt and the graphite polystyrene board comprises the following steps: mounting anchor bolts; constructing a plastering layer; key nodes are constructed; and external wall insulation expansion joint construction. According to the composite thermal insulation system, the influence on the overall thermal insulation performance is small, and the risk that external wall thermal insulation is ignited due to external wall thermal insulation fire or owner fire is avoided to the maximum extent in physical segmentation.

Description

Technical Field

[0001] This invention relates to the field of external thermal insulation technology in building construction, specifically to a passive building double-layer ultra-thick external thermal insulation layer and a method for filling thermal insulation construction joints. Background Technology

[0002] Double-layer external insulation is a prerequisite for passive buildings to achieve the five constants (constant temperature, constant humidity, constant oxygen, constant cleanliness, and constant quietness), isolating heat exchange and preventing excess heat from entering the room in summer, while also preventing heat loss in winter. Current technologies for passive house external wall insulation still face the following prominent challenges: (i) Traditional building construction uses 80~100m single-layer insulation boards, which have poor insulation effect and cannot meet the energy-saving requirements of ultra-low energy consumption buildings. At the same time, due to the specifications of rock wool board materials, the allowable deviation of the flatness of the thin plastering construction of its insulation layer is less than 3mm, which requires high process. Under long-term exposure to wind and sun in the natural environment, the external insulation is very easy to peel off and fall off, which poses a serious safety hazard.

[0003] (II) The construction of double-layer insulation board structures requires high levels of expertise and skilled workers. In traditional construction, improper joint treatment and loose bonding of staggered joints can easily lead to uneven exterior walls, creating continuous cavities and airflow channels, resulting in convective heat loss and even circulation effects, causing large-area insulation failure. In addition, traditional expansion joints are often filled with hollow, Z-shaped stainless steel channels, whose central cavities are prone to rainwater seepage, affecting insulation performance and accelerating system aging.

[0004] (III) Although graphite polystyrene boards possess excellent thermal insulation properties and a certain degree of flame retardancy, achieving a B1 fire rating, they still fall short of the Class A non-combustible material standard. In the absence of effective fire-resistant isolation measures, a fire could spread rapidly along the insulation layer, causing serious safety accidents. Current fire-resistant isolation strips are inadequate, making it difficult to effectively balance thermal insulation and fire prevention.

[0005] (iv) In the existing system, heat flow short circuits occur at metal anchors, structural gaps, and other locations, causing the actual heat transfer coefficient to exceed the standard and affecting the overall insulation effect. In addition, improper treatment of joints, expansion joints, and other nodes can create airflow channels, further aggravating energy loss and reducing system durability.

[0006] Therefore, there is a need for a construction method that has low safety risks, high construction efficiency, saves construction costs, and meets the high standards required for passive ultra-low energy buildings. Summary of the Invention

[0007] To address the problems of unstable external insulation construction, uncontrollable quality, and the need to achieve the external wall insulation function of passive houses based on fire safety management, this invention provides a method for constructing a double-layer ultra-thick external insulation layer for passive buildings and filling insulation construction joints.

[0008] This invention provides a passive building double-layer ultra-thick external insulation layer and a method for filling insulation construction joints, comprising the following steps: S1. Substrate treatment and graphite polystyrene board processing Clean the wall surface, including removing concrete residue, release agent, rebar ends and formwork. Verify the main dimensions and adjust the layout. Cut graphite polystyrene boards. Use insulation boards with a short side dimension of not less than 200mm at the corners of the wall. Hang baselines and mark control lines to control the verticality and flatness of the insulation board.

[0009] S2, Mounting bracket In passive houses, thermal bridging should be avoided in principle when setting up external insulation frames. However, according to Article 6.7.7, Item 2 of the "Code for Fire Protection Design of Buildings," "A horizontal fire-resistant barrier should be installed on each floor of the insulation system. The fire-resistant barrier should be made of materials with a fire rating of Class A, and its height should not be less than 300mm." Therefore, the PC bracket is installed at the joint of the insulation board on the first floor, with the insulation layer resting on the fire-resistant barrier.

[0010] PC brackets are installed at the joints of the first layer of insulation boards. The PC brackets are 500mm wide, 50mm high, and 170mm thick. The horizontal spacing between the PC brackets is 600mm. They are made of non-metallic polymer material to achieve the purpose of breaking thermal bridges.

[0011] S3, Mortar Preparation Prepare mortar, which includes bonding mortar and finishing mortar. The bonding mortar is prepared at a weight ratio of mortar to water of 1:(0.19~0.21), preferably 1:0.2. The finishing mortar is prepared at a weight ratio of mortar to water of 1:(0.20~0.22), preferably 1:0.2. After stirring evenly, let it stand for 5~10 minutes and use it within 2 hours.

[0012] S4. Attach the insulation board. The process involves attaching insulation boards, including the installation of fireproof barriers and graphite polystyrene boards, which together form a composite system.

[0013] Firebreak construction: At each junction of layers, Class A rock wool boards are fully bonded as fireproof isolation strips using a double-layer staggered bonding method. The width of the first layer is 450mm, and the width of the second layer is 300mm. The insulation board surface of the second layer of rock wool strip is 3mm lower than the adjacent graphite polystyrene board surface to prevent the rock wool strip from becoming misaligned after the two layers of mesh cloth are installed, which would affect the appearance and flatness.

[0014] Graphite polystyrene board construction: A 100mm thick graphite polystyrene board is pasted on the main surface, using a double-layer staggered bonding method. The first layer uses a dot-frame bonding method, and the second layer uses a strip bonding method. After compaction, a full bond is formed. For insulation board joints larger than 2mm, polyurethane foam is used to fill the joints and then the surface is sanded.

[0015] S5. Install anchor bolts After the insulation board is pasted in step S4, the anchor bolts are installed. The anchor bolts are recessed thermal break anchor bolts, and the effective depth of the anchor bolts into the wall is 50mm. When the base wall is a shear wall, the number of anchor bolts shall not be less than 6 per square meter; when the base wall is a masonry wall, the number of anchor bolts shall not be less than 11 per square meter; after installation, a special insulation cover shall be added.

[0016] S6. Finishing layer construction Apply a base coat of plastering mortar to the surface of the insulation board. The thickness of the base coat of plastering mortar should be 2-3mm. After stretching the mesh cloth taut, lay it on the base coat of plastering mortar and press the mesh cloth into it from the center outwards. Flatten and compact it. Wrinkles in the mesh cloth are strictly prohibited. Dry hanging of the mesh cloth is strictly prohibited. The overlap length of the mesh cloth should not be less than 100mm. For large-area construction of the surface plastering mortar, the verticality and flatness deviation after the surface plastering layer is completed should not exceed 4mm.

[0017] S7, Key Node Construction This includes attaching door and window connecting lines, pressing in fiberglass mesh, installing corner guards, and setting diagonal reinforcing mesh in door and window openings.

[0018] Specifically, the steps include: attaching the T-shaped door and window connecting strip to the window frame and ensuring that the final finished surface of the exterior wall paint is flush with the rolled edge of the window sill; and applying a 400mm×200mm fiberglass mesh to each of the four corners of the door and window openings at a 45° angle using plastering mortar.

[0019] S8. Construction of Exterior Wall Insulation Expansion Joints Includes the following steps: S81, Fixed-point layout. S82. Installation of brackets and heat insulation pads: Brackets are installed in three layers or at intervals not exceeding 10m. The brackets are made of 1.0mm galvanized steel, 30cm wide, 5cm high, and 15cm thick. Heat insulation pads are installed at the bottom of the brackets. S83. Rock wool strips are adhered using the full-adhesion method. The rock wool strips are 20cm wide and 20cm thick, and their height is the height of the parapet wall. S84. Installation of panels and heat insulation blocks. S85, polyurethane foam filler for board seams. S86. Set a pre-compression expansion sealing strip and make the surface of the board 3mm higher than the insulation surface.

[0020] Compared with the prior art, the present invention has the following beneficial effects: This invention provides a passive building double-layer ultra-thick external insulation layer and a construction method for filling insulation construction joints. Compared with traditional polystyrene boards, graphite polystyrene boards have a slower ignition time, a lower heat release rate, and significantly better combustion performance and fire hazard. However, by setting rock wool expansion joints and Class A fire-resistant materials in each layer of fireproof isolation strips, the thermal conductivity of the rock wool board is close to that of the graphite polystyrene board, which has a smaller impact on the overall insulation performance. The resulting composite insulation system, through physical separation, minimizes the risk of external wall insulation fires or fires caused by the owner igniting the external wall insulation.

[0021] However, in practice, it is important to ensure the integrity of the external wall insulation system and guarantee its insulation performance. Water protection measures should be implemented to prevent water ingress and subsequent insulation failure.

[0022] During the construction of external wall insulation, sample templates should be used to guide on-site construction. Detailed optimizations should be made based on the actual construction needs and quality requirements of the project. For example, at the fireproof isolation strip of the expansion joint, the galvanized steel plate with a U-shape should be treated with rock wool board, while polyurethane foam expansion filling and sealing should be used for sealing and expansion sealing tape filling. The arrangement of PC brackets for each layer of graphite polystyrene board should be different, and 1.2-thick aluminum alloy plates should be arranged every three layers of rock wool strips at intervals not exceeding 10 meters. The two should be superimposed to strengthen the elastic sealing and prevent rainwater from seeping into the graphite polystyrene board from here, forming cavities and channels, causing insulation failure. Attached Figure Description

[0023] Figure 1 A schematic diagram of the process of this invention.

[0024] Figure 2 A schematic diagram of point-to-frame bonding in step S4 of the present invention.

[0025] Figure 3 A schematic diagram of the strip bonding method in step S4 of the present invention.

[0026] Figure 4 The diagram shows the two-layer laying arrangement of the insulation board in step S4 of this invention.

[0027] Figure 5 The diagram showing the arrangement of insulation boards for door and window openings in step S4 of this invention.

[0028] Figure 6 A schematic diagram of the staggered laying of a single layer of insulation board in step S4 of the present invention.

[0029] Figure 7 A schematic diagram of the double-layer staggered laying of the temperature plate in step S4 of the present invention.

[0030] Figure 8 A schematic diagram of the arrangement of fireproof isolation strip anchor bolts in step S5 of the present invention.

[0031] Figure 9 A schematic diagram of the arrangement of graphite polystyrene board anchor bolts in step S5 of the present invention.

[0032] Figure 10 A schematic diagram of the construction of the door and window openings with mesh in step S72 of the present invention.

[0033] Figure 11 A schematic diagram of the construction of the reinforcing mesh for door and window openings in step S72 of the present invention.

[0034] Figure 12 A schematic diagram of the construction of the internal and external corner plastering layer in step S72 of the present invention.

[0035] In the diagram: 1-Adhesive mortar, 2-Insulation board, 3-Door and window openings, 4-Base wall, 5-Diagonal reinforcing mesh, 6-Folding mesh, 7-Small corner reinforcing mesh. Detailed Implementation

[0036] Specific embodiments of the present invention will now be described with reference to the accompanying drawings.

[0037] This invention provides a passive building double-layer ultra-thick external insulation layer and a method for filling insulation construction joints, applicable to the construction of ultra-low energy passive houses in the cold B zone of Shaanxi Province. Figures 1-12 This includes the following steps: S1. Substrate treatment and graphite polystyrene board processing S11. Clean the wall surface base, specifically, clean away concrete residue, release agent, rebar ends, and formwork from the wall surface; S12. Based on the construction drawings and layout drawings and combined with the actual dimensions on site, the main body dimensions are checked and the layout is adjusted. Graphite polystyrene boards are cut with electric heating wires, and insulation boards with a short side dimension of not less than 200mm are used at the corners of the walls. S13. Based on the building facade design and external insulation technical requirements, establish baselines. Specifically, mark the horizontal and vertical control lines for exterior doors and windows, as well as expansion joint lines, decorative lines, and decorative seams on the wall surface. Establish vertical baselines at the corners (inside and outside) of the building's exterior walls. Establish horizontal lines at appropriate locations on each floor, specifically by marking a horizontal line with an ink line 500mm from the drainage level. Use control lines to determine the bracket position and control the verticality and flatness of the insulation board adhesion.

[0038] S2, Mounting bracket PC brackets are installed at the joints of the first layer of insulation boards. The PC brackets are 500mm wide, 50mm high, and 170mm thick. The horizontal spacing between the PC brackets is 600mm. They are made of non-metallic polymer material to achieve the purpose of breaking thermal bridges.

[0039] S3, Mortar Preparation Prepare the mortar, which includes bonding mortar and finishing mortar. Specifically, add a certain amount of clean water to a clean container, and then pour in the bonding mortar or finishing mortar. Both the bonding mortar and finishing mortar are commercially available products. Refer to the product instructions for the specific amount of water to add. Stir evenly with an electric mixer, let stand for 5 to 10 minutes, and use within 2 hours.

[0040] S4. Attach the insulation board. like Figure 4 The insulation boards are pasted horizontally and continuously, with vertical staggered overlaps between upper and lower rows. The staggered overlap length is 1 / 2 board length and not less than 200mm. Vertical continuous seams to the wall are strictly prohibited. This includes the construction of fire-resistant insulation strips and graphite polystyrene boards. The thermal conductivity of rock wool boards is ≤0.042W(m2.k), and that of graphite polystyrene boards is ≤0.033W(m2.k). Since their thermal conductivity is similar, their impact on overall insulation performance is minimal. Firebreak construction: At each junction of layers, a 100 mm thick Class A rock wool board is fully bonded as a fireproof isolation strip. Double-layer staggered bonding is used, with the first layer being 450 mm wide and the second layer being 300 mm wide. The insulation board surface of the second layer of rock wool strip is 3 mm lower than the adjacent graphite polystyrene board surface to prevent the rock wool strip from becoming misaligned after the two layers of mesh cloth are installed, which would affect the appearance and flatness. Graphite polystyrene board construction: like Figure 2 , 3 Adhesive mortar is used to adhere 100mm thick graphite polystyrene boards to the main surface, employing a double-layer staggered bonding method. The first layer uses a dot-frame bonding method, and the second layer uses a strip bonding method. After compaction, full adhesion is achieved. A 2-meter straightedge is used to flatten the boards, ensuring flatness and strong adhesion. The boards must be tightly pressed together, with no large gaps. For joints larger than 2mm caused by irregular surfaces or improper cutting, polyurethane foam should be used for filling and followed by sanding. High thermal conductivity materials such as cement mortar should not be used for filling. For irregularly shaped areas, insulation boards can be cut on-site, with 300mm shorter sides used at the corners of the entire wall surface.

[0041] Special attention, such as Figure 5 When pasting the external corners of the window frame and the external corners of the exterior wall, a baseline needs to be marked first as a basis for controlling the verticality of the external corners. The insulation board 2 at the four corners of the door and window opening 3 should be laid by cutting a whole piece of insulation board into an "L" shape. No splicing is allowed. The distance between the joint and the four corners of the door and window opening 3 should not be less than 200mm.

[0042] like Figure 6 , 7 At the corner of the wall, the bonding should be done vertically and intersectingly, straight and perpendicular. The dimensions need to be arranged properly before cutting the insulation board 2.

[0043] S5. Install anchor bolts After step S4, 24 hours after the insulation board 2 is pasted, install the anchor bolts. In this embodiment, the anchor bolts are φ8×175mm special thermal break bridge anchor bolts. Drill holes with an electric drill. The drilling depth is 10mm greater than the anchor bolt length. Insert the expansion plug sleeve and screw in the anchor nail. After installation, cover with a special heat insulation cap. like Figure 8 , 9 The number of anchor bolts on the graphite polystyrene board shall be no less than 6 per square meter, and the number of anchor bolts on the fireproof isolation strip shall be no less than 8 per square meter.

[0044] S6. Finishing layer construction Apply a base coat of plastering mortar to the surface of the insulation board. The thickness of the base coat of plastering mortar is 2-3mm. After stretching the mesh cloth, lay it on the base coat of plastering mortar and press the mesh cloth into it from the center to the perimeter. The overlap length of the mesh cloth should not be less than 100mm. After the plastering layer is completed, the verticality and flatness deviation should not be greater than 4mm.

[0045] S7, Key Node Construction Includes the following steps: S71, Paste door and window connection wires Apply the T-shaped door and window connecting strip to the window frame, ensuring the final finished surface of the exterior wall paint is flush with the rolled edge of the window sill. It is important to note that the installation position of the door and window connecting strip should be determined in advance with the door and window supplier based on the window sill dimensions. This ensures that the final finished surface of the exterior wall paint is flush with the rolled edge of the window sill, preventing the window opening from forming an "inward" or "outward" shape, which would create misalignment and affect the appearance.

[0046] S72, Press in fiberglass mesh, install corner protectors, and install diagonal reinforcing mesh in door and window openings; Press in fiberglass mesh to ensure a straight surface, and install corner protectors at the external corners of the insulation panels on both sides of the window. Specifically, for example... Figure 10Apply the exposed end of the fiberglass mesh to the surface of the insulation board with plastering mortar to form the 6th layer of mesh. Note that the plastering mortar should be as thin as possible to fix the fiberglass mesh in place and make it flat and wrinkle-free.

[0047] like Figure 11 On the exterior wall surface at the four corners of the door and window openings, a 400mm×200mm fiberglass mesh is laid at a 45° angle using plastering mortar as a diagonal reinforcing mesh 5, and a reinforcing mesh is laid at the small inside corner as a small inside corner reinforcing mesh 7.

[0048] Things to note, such as Figure 12 At inside and outside corners, the fiberglass mesh should be overlapped for reinforcement.

[0049] S8. Construction of Exterior Wall Insulation Expansion Joints Includes the following steps: S81, Fixed-point layout. S82. Installation of brackets and heat insulation pads: Brackets are installed in three layers or at intervals not exceeding 10m. The brackets are made of 1.0mm galvanized steel, 30cm wide, 5cm high, and 15cm thick. Heat insulation pads are installed at the bottom of the brackets. S83. Rock wool strips are adhered using the full-adhesion method. The rock wool strips are 20cm wide and 20cm thick, and their height is the height of the parapet wall. S84. Installation of panels and heat insulation blocks. S85, polyurethane foam filler for board seams. S86. Set a pre-compression expansion sealing strip, that is, set a pre-compression expansion sealing strip at the junction of the board and the second layer of insulation, and make the surface of the board 3mm higher than the surface of the insulation. After the mesh, putty and coating are applied, make it flat with the aluminum plate surface.

[0050] The traditional single-layer insulation with an external insulation thickness of 80-100mm is used as a comparative example.

[0051] Compared to the comparative example, the embodiment has a slower ignition time, a lower heat release rate, and significantly better combustion performance and fire hazard. The embodiment has a smaller impact on the overall thermal insulation performance and avoids the risk of external wall insulation fire or fire caused by the owner igniting the external wall insulation.

[0052] The scope of protection claimed by this invention is not limited to the specific embodiments described above. Moreover, for those skilled in the art, this invention can have various modifications and alterations. Any modifications, improvements, and equivalent substitutions made within the concept and principles of this invention should be included within the scope of protection of this invention.

Claims

1. A construction method for a passive building with a double-layer ultra-thick external insulation layer and for filling insulation construction joints, characterized in that: The method comprises the following steps: S1, base treatment and graphite polystyrene board processing Clean the wall base, check and adjust the main size, cut the graphite polystyrene board, and use the short side size of the thermal insulation board not less than 200mm at the wall corner; Hang the reference line and the elastic control line to control the verticality and flatness of the thermal insulation board sticking; S2, install bracket PC bracket is arranged at the thermal insulation board joint of the first layer; S3, mortar configuration The mortar comprises bonding mortar and finishing mortar; S4, stick thermal insulation board (2) Stick thermal insulation board (2), including the construction of fireproof isolation belt and graphite polystyrene board: Fireproof isolation belt construction: Rock wool board is pasted as fireproof isolation belt at the joint of each layer by full sticking method, double-layer staggered sticking is carried out, the thermal insulation board surface of the second layer rock wool belt is 3mm lower than the adjacent graphite polystyrene board surface; Graphite polystyrene board construction: Large-area graphite polystyrene board is pasted, double-layer staggered sticking is carried out, the first layer adopts point frame sticking method, the second layer adopts strip sticking method, and full sticking is formed after compaction, the thermal insulation board joint larger than 2mm is filled with polyurethane foaming agent and polished; S5, install anchor bolt After the step S4 of sticking thermal insulation board (2) is completed, the anchor bolt is installed, and the effective depth of the anchor bolt into the wall is 50mm; After installation, special thermal insulation cover is added; S6, finishing layer construction The surface of the thermal insulation board (2) is coated with bottom finishing mortar, the thickness of the bottom finishing mortar is 2-3mm, the mesh cloth is tightly stretched and pasted on the bottom finishing mortar, the mesh cloth is pressed into the bottom finishing mortar from the middle to the four sides, the lap length of the mesh cloth is not less than 100mm, the surface layer finishing mortar is applied in large area, and the verticality and flatness deviation after the finishing layer construction is completed should be not more than 4mm; S7, key node construction Including sticking door and window connecting line, pressing glass fiber mesh, installing corner line, and setting inclined reinforcing mesh at door and window hole; S8, outer wall thermal insulation expansion joint construction.

2. The construction method according to claim 1, characterized in that: In step S2, the PC bracket is 500mm wide, 50mm high and 170mm thick, and the horizontal interval between the PC brackets is 600mm.

3. The construction method according to claim 1, characterized in that: In step S3, the bonding mortar is configured according to the weight ratio of mortar: water 1: (0.19-0.21); the finishing mortar is configured according to the weight ratio of mortar: water 1: (0.20-0.22), and is stirred uniformly, then is placed for 5-10min, and is used up within 2 hours.

4. The construction method according to claim 1, characterized in that: In step S4, the first layer width is 450mm and the second layer width is 300mm when double-layer staggered sticking is carried out.

5. The construction method according to claim 1, characterized in that: In step S5, when the base wall (4) is a shear wall, the number of anchor bolts is not less than 6 per square meter; when the base wall (4) is a masonry wall, the number of anchor bolts is not less than 11 per square meter.

6. The construction method according to claim 1, characterized in that: In step S8, the outer wall thermal insulation expansion joint construction comprises the following steps: S81, fixed point setting out, S82, install bracket and heat insulation block construction, the bracket is set according to three layers or interval not more than 10m, the bracket is 1.0mm galvanized steel bracket, the width is 30cm, the height is 5cm, and the thickness is 15cm, the bracket bottom is provided with heat insulation block, S83, rock wool strip is pasted by full sticking method, the width of the rock wool strip is 20cm, the thickness is 20cm, and the height of the rock wool strip is the height of the parapet, S84, install the board and the thermal insulation block, S85, polyurethane foaming filling board joint, S86, set the pre-pressing expansion sealing tape, and make the board living surface 3mm higher than the thermal insulation surface.

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