Building ice shell structure and rapid construction method of ice shell structure

Abstract

The invention discloses a building ice shell structure and a rapid construction method of the ice shell structure, relates to an ice shell structure and a construction method, and relates to the field of ice structure construction. In order to solve the problems that a traditional masonry type ice structure is single in shape, and an air rib type method is long in construction period, unstable in structure and low in early-stage strength, an outer ice layer is of a shell structure, an air inflation membrane set is installed on an ice shell bottom base layer, and the ice shell bottom base layer and the air inflation membrane set are wrapped with the outer ice layer. The method comprises the steps that firstly, prefabricated ice blocks are manufactured; step 2, fixedly fixing an air inflation membrane group consisting of a plurality of air inflation membranes on the ice shell bottom base layer; 3, liquid is sprayed to the ice shell bottom base layer and the outer portion of the air inflation membrane set, and an outer ice coating is formed; 4, the external ice coating is subjected to modification treatment to form an external ice layer, and meanwhile the internal space is subjected to decoration treatment; fifthly, auxiliary water spraying is conducted on the outer ice layer regularly to form a uniform and smooth sealing covering layer.

Description

Technical Field

[0001] This invention relates to ice shell structures and construction methods, specifically to an architectural ice shell structure and a rapid construction method for ice shell structures. This invention relates to the field of ice structure construction. Background Technology

[0002] Ice shell architecture is a new type of building that uses ice and snow as its core construction material, integrates modern digital design technology, and employs a shell as its main structural form. It not only possesses stable indoor functionality but also boasts high aesthetic value due to the natural properties and unique shapes of ice and snow materials. In terms of structural design, ice shell architecture generally adopts a shell structure form. This structure, through its rationally designed curved surface shape, evenly transmits external forces to the supports, achieving a large spatial span and excellent load-bearing capacity with relatively little material usage. It is an ideal structural solution for the architectural application of ice and snow materials.

[0003] Currently, the construction of ice shells for ice and snow buildings mainly relies on two core techniques: masonry and air-ribbed construction. However, both of these mainstream construction methods have significant technical drawbacks, severely restricting the development and application of ice shell architecture.

[0004] On the one hand, existing construction methods result in ice and snow structures with relatively weak overall load-bearing capacity. Masonry methods rely on manual labor or simple machinery to stack ice and snow components piece by piece, leading to low bonding strength between components and poor overall load-bearing capacity. While air-rib construction uses an inflatable membrane for shaping, the bonding between the sprayed ice layer and the inflatable membrane, as well as the homogeneity of the sprayed ice layer itself, are difficult to precisely control. This results in both methods producing ice shell structures with insufficient stiffness and limited load-bearing capacity, directly restricting the scale and complexity of ice and snow landscape architecture and failing to meet the construction needs of large-span, large-volume ice and snow structures. On the other hand, existing construction technologies suffer from low efficiency, high construction costs, and lengthy construction periods. The masonry method relies heavily on manual labor, has complicated construction procedures, low work efficiency, and high labor and time costs. The air rib construction method presents typical linear operation characteristics, requiring the sequential completion of processes such as air membrane installation and fixing, ice spraying, ice freezing and solidification, air membrane removal, and interior decoration construction. There is a lot of mandatory waiting time between each process—especially in the ice spraying and ice freezing stages, the strength of the ice shell structure depends entirely on the air membrane for support. To avoid the risk of collapse, subsequent work such as interior decoration cannot be carried out in parallel, resulting in a total construction period of 12 days or even longer for a single ice shell building.

[0005] The aforementioned shortcomings in construction techniques not only reduce the economic efficiency and safety of ice shell structures but also hinder their large-scale application in various ice and snow cultural tourism and festival activities. Therefore, developing an ice shell structure and corresponding construction methods that can effectively improve construction efficiency and enhance overall structural performance has become an urgent technical problem to be solved in this field. Summary of the Invention

[0006] This invention aims to solve the problems of monotonous shapes, long construction period, structural instability, and low initial strength of traditional masonry ice structures, and to provide a rapid construction method for building ice shell structures.

[0007] To address the aforementioned problems, this application provides the following technical solution:

[0008] An architectural ice shell structure, comprising a base layer at the bottom of the ice shell, an inflatable membrane assembly, and an outer ice layer;

[0009] The outer ice layer is a shell structure, and the inflatable membrane assembly is installed on the base layer at the bottom of the ice shell. The outer ice layer wraps around the base layer at the bottom of the ice shell and the inflatable membrane assembly.

[0010] Furthermore, it includes a base layer at the bottom of the ice shell consisting of multiple pre-made ice blocks, an inflatable membrane assembly consisting of multiple inflatable membranes, the base layer at the bottom of the ice shell consisting of multiple pre-made ice blocks, and the top of the shell consisting of multiple inflatable membranes.

[0011] Furthermore, the prefabricated ice block includes a three-dimensional fiber mesh and an ice matrix. The three-dimensional fiber mesh is installed in the ice matrix and has a single-layer mesh structure or a double-layer mesh structure.

[0012] Furthermore, the double-layer mesh structure includes an intermediate connecting fiber bundle and two fiber mesh layers;

[0013] Two fiber web layers are arranged opposite each other and connected by an intermediate connecting fiber bundle to form a double-layer mesh structure.

[0014] A rapid construction method for building ice shell structures, the method being implemented according to the following steps:

[0015] Step 1: Prepare the materials and make pre-made ice cubes;

[0016] Step 2: Assemble the pre-made ice blocks into the base layer of the ice shell, and fix the inflatable membrane group composed of multiple inflatable membranes onto the base layer of the ice shell, and support the inflatable membrane group with the inflatable template;

[0017] Step 3: Spray liquid onto the base layer at the bottom of the ice shell and the outside of the inflatable membrane assembly in an environment with an ambient temperature below -15°C to form an external ice coating layer;

[0018] Step 4: When the external ice coating reaches the required thickness, remove the inflatable template, modify the external ice coating to form the external ice layer, and at the same time decorate the interior space.

[0019] Step 5: Periodically spray water on the external ice layer to form a uniform and smooth sealing layer.

[0020] Furthermore, in step one, when making pre-made ice blocks, a release layer is laid inside the pre-made mold, and ice blocks are laid under the three-dimensional fiber mesh. Then, ice solution is poured into the pre-made mold for low-temperature freezing. After freezing, the ice blocks are demolded and the surface of the ice blocks is smoothed with tools to make them pre-made ice blocks.

[0021] Furthermore, the ice solution used in the production of pre-made ice is pure water or an aqueous solution with 2% paper pulp fiber added.

[0022] Furthermore, the three-dimensional fiber mesh is a mesh made of basalt fiber material.

[0023] Furthermore, in step two, multiple inflatable membranes are fixed by cable netting, and in step four, the cable netting is removed at the same time as the inflatable template is dismantled.

[0024] Furthermore, in step three, when spraying liquid onto the base layer at the bottom of the ice shell and the outside of the inflatable membrane group, a small amount of cold water is first sprayed onto the base layer at the bottom of the ice shell and the inflatable membrane group to initially freeze the joints of the base layer at the bottom of the ice shell and the inflatable membrane group, forming a shell base layer with preliminary self-supporting ability, and then liquid is sprayed to form the outer ice coating layer.

[0025] The technical advantages of this application compared to existing technologies are as follows:

[0026] 1. This solution effectively solves the problems of loose component bonding and poor homogeneity of air-ribbed sprayed ice layers in traditional masonry methods by optimizing the structural design and molding process of the ice shell. The structure in this application adopts integrated molding or modular collaborative design, eliminating weak points between components and fully utilizing the load-bearing potential of the ice and snow materials. Furthermore, by precisely controlling the surface morphology of the structure and the distribution of ice layer thickness, it ensures that external forces can be uniformly transmitted along the shell surface, significantly improving the overall stiffness and load-bearing capacity of the structure. Therefore, the limitations on the span and volume of ice shell architecture are effectively overcome, enabling the construction of larger-scale and more complex ice and snow landscapes, meeting the practical and aesthetic needs of large-span ice and snow architecture.

[0027] 2. Addressing the drawbacks of existing linear construction operations and long waiting times, this solution innovatively adopts parallel construction logic and efficient forming technology, reconstructing the process flow of ice shell construction. The sequential process of "ice spraying and freezing - demolding - interior decoration" in traditional air-rib construction is transformed into partially parallel processes. Interior decoration preparation work can be safely carried out as soon as the ice layer reaches initial strength, without waiting for the ice layer to fully solidify, significantly reducing mandatory waiting time between processes. It abandons the labor-intensive operation of masonry methods, employing more mechanized and automated construction equipment and processes, improving construction efficiency per unit time. With this solution, the total construction period for a single ice shell building can be shortened to less than 9 days, greatly improving the timeliness of ice and snow construction, especially suitable for time-sensitive scenarios such as ice and snow festivals and short-term cultural tourism projects. The shortened construction cycle directly reduces equipment usage and on-site management costs, while enabling ice shell buildings to be put into use earlier, improving the project's economic benefits. Furthermore, the improved structural performance reduces the need for later maintenance and reinforcement, further reducing the total life cycle cost.

[0028] 3. This solution enhances construction safety through dual safeguards: During the forming process, the optimized ice shell structure no longer relies entirely on the inflatable membrane for support. By setting up temporary auxiliary supports or adopting a more self-stabilizing forming method, the structure has a certain degree of independent load-bearing capacity during the construction phase, effectively avoiding the risk of collapse when interior decoration work is carried out in parallel, and providing reliable protection for the safety of construction personnel and equipment. Attached Figure Description

[0029] Figure 1 This is the main structural view of this application;

[0030] Figure 2 This is a schematic diagram of pre-made ice blocks;

[0031] Figure 3 This application shows a diagram of a double-layered fibrous mesh structure within the prefabricated ice block.

[0032] Figure 4 This is a schematic diagram of the ice shell structure for construction in this application;

[0033] Figure 5 A schematic diagram illustrating the construction principle of an ice shell structure using existing technology. Detailed Implementation

[0034] Combination Figure 1 This embodiment describes an ice shell structure, which includes a base layer 1 at the bottom of the ice shell, an inflatable membrane assembly 2, and an outer ice layer 3.

[0035] The outer ice layer 3 is a shell structure, and the inflatable membrane group 2 is installed on the base layer 1 at the bottom of the ice shell. The outer ice layer 3 is wrapped around the base layer 1 at the bottom of the ice shell and the inflatable membrane group 2.

[0036] In this embodiment, an inflatable membrane assembly 2 is installed on the base layer 1 at the bottom of the ice shell, and the outer ice layer 3 is wrapped around the base layer 1 and the inflatable membrane assembly 2. During construction, there is no need to wait for the ice layer to completely solidify, which significantly reduces the mandatory waiting time between processes and improves construction efficiency.

[0037] Combination Figure 1 As shown, it includes a base layer 1 at the bottom of the ice shell comprising multiple pre-made ice blocks, an inflatable membrane assembly 2 comprising multiple inflatable membranes, the base layer 1 at the bottom of the ice shell comprising multiple pre-made ice blocks, and the top of the shell comprising multiple inflatable membranes.

[0038] Combination Figures 1-3 As shown, the prefabricated ice block includes a three-dimensional fiber mesh and an ice matrix. The three-dimensional fiber mesh is installed in the ice matrix and can be a single-layer mesh structure or a double-layer mesh structure.

[0039] In this embodiment, the three-dimensional fiber mesh of the precast ice block shares the stress with the ice matrix. Tensile stress is transferred to the three-dimensional fiber mesh through adhesive force. The three-dimensional fiber mesh is made of carbon fiber or basalt fiber material, chosen for its high tensile strength, good adhesion to ice, durability, and high economic efficiency. The three-dimensional fiber mesh possesses excellent tensile properties, effectively bearing and transferring tensile stress. Therefore, its bending performance is also extremely excellent. Simultaneously, it strengthens the precast ice block, improving its brittleness and providing better ductility and crack resistance, significantly enhancing its bending load-bearing capacity and ductility. Therefore, the bending strength of precast ice blocks with three-dimensional fiber mesh is more than 1.5 times that of pure ice. Adding basalt fiber mesh to composite ice containing pulp fiber results in a bending strength of 2 to 3 times or more.

[0040] Combination Figures 1-3 As shown, the double-layer mesh structure includes a central connecting fiber bundle and two fiber mesh layers;

[0041] Two fiber web layers are arranged opposite each other and connected by an intermediate connecting fiber bundle to form a double-layer mesh structure.

[0042] Three-dimensional fiber mesh is a type of fiber material that combines green and low-carbon properties with excellent durability and superior mechanical properties. In freeze-thaw cycles and acid / alkali environments, the mechanical properties of three-dimensional fiber mesh exhibit minimal degradation, a significant advantage that enhances the durability of reinforced pre-made ice.

[0043] Combination Figures 1-4 This embodiment describes a rapid construction method for an ice shell structure, which is implemented according to the following steps:

[0044] Step 1: Prepare materials and make pre-made ice blocks; Pre-made ice blocks are made in the factory or on site to improve work efficiency. The bending strength of the pre-made ice blocks in an environment of -15°C is not less than 2.5MPa, which is sufficient to withstand the subsequent construction load.

[0045] Step 2: Assemble the pre-made ice blocks to form the base layer 1 at the bottom of the ice shell. The pre-made ice blocks are assembled from the bottom and laid layer by layer. The joints between the pre-made ice blocks are sealed and bonded with snow and water, or sealed and bonded with a mixture of fine ice chips and water near the freezing point at a volume ratio of 2:1. The bonding slurry can be initially frozen within about 30 minutes, providing sufficient initial bonding strength to fix the inflatable membrane group 2, which consists of multiple inflatable membranes, to the base layer 1 at the bottom of the ice shell. The inflatable membrane group 2 is supported by an inflatable template.

[0046] Step 3: Spray liquid onto the base layer 1 and the outside of the inflatable membrane group 2 at an ambient temperature below -15°C to form an external ice coating layer.

[0047] Step 4: When the external ice covering layer reaches the required thickness, remove the inflatable template and modify the external ice covering layer to form external ice layer 3. At the same time, decorate the internal space. When decorating the internal space, work is carried out inside a solid ice structure, rather than working under a separate air membrane. Work safety is guaranteed. It has a high-strength structure and strong resistance to accidental loads.

[0048] Step 5: Regularly spray water on the outer ice layer 3 to form a uniform and smooth sealing layer. After construction is completed, maintain it every 5 days. In cold weather, replenish water in time to ensure the landscape is intact. This completes the construction of the large-span composite ice shell structure.

[0049] The construction method described in this embodiment reduces labor and management costs due to the shorter construction period, and also reduces material costs due to the reuse of formwork. The construction period is reduced by approximately 40-50% in this embodiment, which is of great significance for short-term construction projects in icy and snowy conditions.

[0050] Combination Figure 2 As shown, in step one, when making pre-formed ice blocks, a release layer is laid inside the pre-formed mold, and ice blocks are placed under the three-dimensional fiber mesh. Then, an ice solution is poured into the pre-formed mold for low-temperature freezing. After freezing, the ice blocks are demolded and the surface is smoothed with tools to form pre-formed ice blocks. The ice solution poured into the pre-formed mold is pure ice water or ice water mixed with a small amount of fiber or nanomaterials. The pre-formed ice blocks have sufficient strength and rigidity, allowing for hoisting, transportation, and storage. The three-dimensional fiber mesh provides continuous two-dimensional reinforcement, uniform stress distribution, and effectively suppresses the brittleness of the ice, giving the shell structure better integrity and toughness.

[0051] Combination Figure 1 and Figure 2 As shown, the ice solution used in the production of pre-made ice is pure water or an aqueous solution with 2% paper pulp fiber added.

[0052] Combination Figure 3 As shown, the three-dimensional fiber mesh is a mesh made of basalt fiber material.

[0053] Combination Figure 1 As shown, in step two, multiple inflatable membranes are placed on the base layer 1 at the bottom of the ice shell and inflated. The inflatable membranes are fixed by cable nets to form the designed structure. The inflatable membranes are inflated by a blower to stabilize the internal air pressure at 100-150 Pascals. In step four, the cable nets are removed at the same time as the inflatable templates are removed.

[0054] Combination Figure 1 As shown, in step three, when spraying liquid onto the exterior of the base layer 1 and the inflatable membrane group 2 at the bottom of the ice shell, a small amount of cold water is first sprayed onto the base layer 1 and the inflatable membrane group 2 at the bottom of the ice shell to initially freeze the joint between the base layer 1 and the inflatable membrane group 2, forming a shell base layer with preliminary self-supporting ability. The function of the shell base layer is to seal and level, ensuring that the shell becomes a continuous and smooth whole. Then, liquid is sprayed to form an outer ice coating layer, so that the outer ice coating layer and the base layer 1 and the inflatable membrane group 2 at the bottom of the ice shell are fused together through freezing, working together to form a thicker and stronger composite shell.

[0055] Example:

[0056] 1. Precast Ice Blocks: Rectangular ice blocks with dimensions of 1m × 2m and a thickness of 5cm are cast using molds at the factory or on-site prefabrication yard. During the casting process, a standard fiberglass mesh (4mm mesh size, 0.5mm fiber diameter) is placed in the center of the ice plate, completely encasing it in ice to form a fiber-reinforced ice plate inflatable membrane template. The precast ice blocks are then laid from bottom to top to form the base layer 1 of the ice shell.

[0057] II. On the building foundation, lay inflatable membrane module 2 and inflate it to the design pressure to form a complete circular shell template. III. Suspend and fix it using rope loops pre-embedded in the ice plate and rope loops fixed to the inflatable membrane. IV. After laying, let it stand for 2-4 hours, or spray a small amount of cold water to allow the joints between the ice plate and the inflatable membrane, as well as between the plates, to freeze initially, forming a complete shell base with preliminary self-supporting ability.

[0058] The structure in this embodiment is a large-span ice shell structure, and the thickness-to-diameter ratio of the ice shell structure is controlled at 1 / 150, that is, the ratio of the ice shell thickness to the maximum radius of curvature of the ice shell. Interior finishing work is carried out in the inner shell space, such as installing lights, laying electrical wiring, and decorating the inner walls. At this time, the robust reinforced ice shell is sufficient to withstand the finishing load and ensure worker safety. Simultaneously or after the interior finishing work, auxiliary ice spraying is performed on the outside of the already laid outer ice layer 3. The main purpose of this stage of ice spraying is to completely cover and seal the structure, forming a uniform and smooth final design shape. This allows the structure to be used for a sufficiently long time.

[0059] Example 1: When making pre-made ice blocks in step one, low-voltage flexible LED light strips can be pre-laid in the mold. The light strips and their wires are frozen together in the ice body, and the ends of the wires are led out from the pre-reserved channels on one side of the ice block.

[0060] In step two, when assembling the ice blocks, the wires leading out from the adjacent ice blocks are connected simultaneously.

[0061] In step four, the interior decoration work is greatly simplified because the basic lighting system has been installed along with the structure. The main workload is concentrated on the installation of other functions. After the main building is assembled and powered on, a uniform wall lighting effect can be achieved inside.

[0062] Example 2: In step two, when making pre-made ice blocks, a "male-female" mortise and tenon structure is formed on its four sides using pre-embedded engineering plastic parts. Specifically, for two adjacent ice blocks, one side has a protruding trapezoidal tenon, and the other side has a matching groove.

[0063] In step three, when assembling the load-bearing base layer, minimal adhesive is required. Workers simply align the tenon of one ice block with the tenon of the adjacent ice block and apply pressure to achieve mechanical interlocking. Only a small amount of ice slurry is used for auxiliary sealing on the top layer and in special areas. This connection method increases assembly speed by approximately 50% and results in a more robust wall structure with extremely high lateral displacement resistance even before ice spraying.

Claims

1. A building ice shell structure, characterized by: It comprises an ice shell bottom base layer (1), an air-filled membrane group (2) and an external ice layer (3); The external ice layer (3) is a shell structure, the air-filled membrane group (2) is installed on the ice shell bottom base layer (1), and the external ice layer (3) is wrapped on the ice shell bottom base layer (1) and the air-filled membrane group (2).

2. The architectural ice shell structure of claim 1, wherein: It comprises an ice shell bottom base layer (1) comprising a plurality of prefabricated ice blocks, an air-filled membrane group (2) comprising a plurality of air-filled membranes, the plurality of prefabricated ice blocks being assembled to form the ice shell bottom base layer (1), and the plurality of air-filled membranes being assembled to form a shell top.

3. The architectural ice shell structure of claim 2, wherein: The prefabricated ice block comprises a three-dimensional fiber grid and an ice base body, the three-dimensional fiber grid being installed in the ice base body, and the three-dimensional fiber grid being a single-layer mesh structure or a double-layer mesh structure.

4. The architectural ice shell structure of claim 2, wherein: The double-layer mesh structure comprises a middle connecting fiber bundle and two fiber mesh layers. The two fiber mesh layers are oppositely arranged and connected by the middle connecting fiber bundle to form the double-layer mesh structure.

5. The method for quickly constructing the ice shell structure according to any one of claims 1 to 4, characterized in that: The method is implemented according to the following steps: Step one: preparing materials and making prefabricated ice blocks; Step two: assembling the prefabricated ice blocks to form the ice shell bottom base layer (1), fixing the air-filled membrane group (2) comprising a plurality of air-filled membranes on the ice shell bottom base layer (1), and supporting the air-filled membrane group (2) by an air-filled template; Step three: spraying liquid on the outside of the ice shell bottom base layer (1) and the air-filled membrane group (2) in an environment with a temperature lower than -15°C to form an external ice coating layer; Step four: removing the air-filled template when the external ice coating layer reaches a certain thickness, and modifying the external ice coating layer to form the external ice layer (3), while decorating the internal space; Step five: regularly spraying water on the external ice layer (3) to form a uniform and smooth sealing coating layer.

6. The method of claim 5, wherein: In step one, a release layer is laid in a prefabricated mold, a three-dimensional fiber grid is laid under the ice block, and then ice solution is poured into the prefabricated mold for low-temperature freezing. After freezing, the ice block is demolded and the surface of the ice block is ground flat to form a prefabricated ice block.

7. The method of claim 6, wherein: The ice solution used in the prefabricated ice block is pure water or a water solution with 2% paper pulp fiber.

8. The method of claim 6, wherein: The three-dimensional fiber grid is a grid made of basalt fiber material.

9. The method of claim 5, wherein: In step two, the plurality of air-filled membranes are fixed by cable net anchoring, and in step four, the cable net is removed at the same time as the air-filled template is removed.

10. The method of claim 5, wherein: In step three, when spraying liquid on the outside of the ice shell bottom base layer (1) and the air-filled membrane group (2), a small amount of cold water is first sprayed on the ice shell bottom base layer (1) and the air-filled membrane group (2) to preliminarily freeze the joints of the ice shell bottom base layer (1) and the air-filled membrane group (2), and form a shell base layer with preliminary self-standing ability, and then the liquid is sprayed to form the external ice coating layer.

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