Fabricated frame-perlite mortar plate-reinforced foaming ceramic plate wallboard and manufacturing method thereof

Abstract

The invention discloses a fabricated frame-perlite mortar plate-reinforced foamed ceramic plate wallboard and a manufacturing method thereof, which are mainly used as a peripheral wall panel of a light steel frame structure. The composite wallboard is formed by assembling an inner leaf plate combined by an inner leaf frame light steel frame and a calcium silicate plate, an outer leaf plate combined by an outer leaf frame light steel frame and a reinforced foaming ceramic plate, and a sandwich perlite mortar plate. The inner and outer leaf frame light steel frame is formed by welding square steel pipes. The reinforced foamed ceramic plate is formed by compositing a foamed ceramic plate with a decorative surface layer and a high-ductility mortar plate with a shear key, and the high-ductility mortar plate is composed of a built-in steel wire mesh with the thickness not smaller than 20 mm, steel plate strips welded to the periphery of the steel wire mesh and a swallow tail meshing type frame on the periphery of the steel wire mesh. The fabricated frame light steel frame-perlite mortar plate-reinforced foamed ceramic plate combined wallboard has the integrated functions of structure, heat preservation, decoration and enclosure, has the technical characteristics of light weight, good anti-seismic and fire-resistant performance and convenience and rapidness in assembly and construction, and has two anti-seismic defense lines.

Description

Technical Field

[0001] This invention relates to a prefabricated frame light steel grid-perlite mortar board-reinforced foamed ceramic board combined wall panel and its construction method, belonging to the field of prefabricated building technology. Background Technology

[0002] Developing efficient, earthquake-resistant, and energy-saving prefabricated structural systems is a crucial measure to promote the modernization and industrialization of the construction industry. Researching and developing high-performance prefabricated low-rise, multi-story earthquake-resistant, and energy-saving residential buildings is an urgent need for promoting the industrialization of low-density urban and county-level residential construction. Most coastal areas and islands in my country have relatively low bearing capacity and high ecological protection requirements; therefore, most buildings constructed are low-rise or multi-story. The climate and environmental conditions in coastal areas are relatively complex, and adverse factors such as salt spray corrosion affect the mechanical properties and service life of building structures. Foamed ceramic materials, using silica-based tailings as the main raw material, undergo high-temperature melting, crystallization, and foaming processes to form a porous structure with an integrated insulation layer and decorative surface layer. These materials are weather-resistant, corrosion-resistant, fire-resistant, and have a marble-like surface texture, making them ideal for use in building exterior wall components, especially in coastal areas where they exhibit excellent corrosion resistance against salt spray corrosion.

[0003] Current technical bottlenecks: (1) In the common light steel frame-concrete sandwich polystyrene composite wall panel structure in engineering, the concrete is relatively heavy, and the thermal insulation performance of the concrete, especially its resistance to salt spray erosion, is far inferior to that of foamed ceramic panels. (2) When foamed ceramic panels are used as enclosure decorative wall panels in engineering, they fail to play their seismic role because they are not reinforced by high ductility mortar. Summary of the Invention

[0004] This invention proposes a prefabricated frame-light steel grid-perlite mortar board-reinforced foamed ceramic board composite wall panel, mainly used as the outer wall panel for low-rise and multi-story light steel frame structures. It is assembled from an inner leaf frame light steel grid combined with calcium silicate board (inner leaf panel), an outer leaf frame light steel grid combined with reinforced foamed ceramic board (outer leaf panel), and a sandwich perlite mortar board. The inner and outer leaf frame light steel grids are welded from square steel tubes. The reinforced foamed ceramic board is composed of a foamed ceramic board with a decorative surface layer and a high-ductility mortar board with shear keys. The high-ductility mortar board consists of an inner wire mesh with a thickness of not less than 20mm, steel strips welded around the wire mesh, and a dovetail-interlocking frame around the perimeter. The prefabricated frame light steel grid - perlite mortar board - reinforced foamed ceramic board combination wall panel has integrated functions of structure, heat preservation, decoration and enclosure. It is lightweight, has good earthquake resistance, fire resistance and corrosion resistance, and is convenient to assemble and construct. It has two earthquake protection lines: the reinforced foamed ceramic board is the first earthquake protection line, and the frame light steel grid frame is the second earthquake protection line.

[0005] This invention relates to a prefabricated frame-light steel grid-perlite mortar board-reinforced foamed ceramic board composite wall panel and its construction method, comprising a light steel grid, reinforced foamed ceramic board, calcium silicate board, and perlite mortar board; the light steel grid is divided into an inner leaf frame light steel grid and an outer leaf frame light steel grid; the inner leaf frame light steel grid and the calcium silicate board are connected by self-tapping screws to form a composite inner leaf panel. The outer leaf frame light steel grid and the reinforced foamed ceramic board are connected by self-tapping screws to form a composite outer leaf panel. The composite inner leaf panel and the composite outer leaf panel are connected by perlite mortar board.

[0006] Furthermore, the light steel frame is composed of light steel frame units arranged and combined. Each light steel frame unit is welded together from light steel frame beams and light steel frame columns, and adjacent light steel frame units share light steel frame beams and light steel frame columns.

[0007] Furthermore, the reinforced foamed ceramic board is composed of a foamed ceramic board with a decorative surface layer and a reinforced high-ductility mortar board; the foamed ceramic board with a decorative surface layer and the reinforced high-ductility mortar board are connected by shear keys and dovetail interlocking with dovetail interlocking frames.

[0008] Furthermore, the light steel frame is made of square steel tubes, and self-tapping screws pass through the square steel tubes of the outer leaf frame light steel frame. The frame light steel frame-reinforced foamed ceramic board with decorative surface layer and the reinforced high-ductility mortar board form a frame light steel frame-reinforced foamed ceramic board connection node. This connection node is a self-tapping screw connection structure between the light steel frame and the reinforced foamed ceramic board, which is a steel-high-ductility mortar combined connection structure.

[0009] Furthermore, the combined outer leaf plate, the combined inner leaf plate, and the perlite mortar board are connected as a whole by expanding foam.

[0010] Furthermore, the thickness of the reinforced connection type high ductility mortar plate is not less than 20mm, including an internal wire mesh, steel strips welded around the wire mesh, and a dovetail interlocking frame around the steel strips.

[0011] Furthermore, there is an assembly seam of not less than 20mm between each reinforced foamed ceramic panel. The inner area of ​​the assembly seam is filled with foam adhesive, and the outer area of ​​the assembly seam is sealed with structural adhesive.

[0012] Furthermore, the shear key is an interface reinforcement structure between the reinforced connection type high ductility mortar plate and the foamed ceramic plate with decorative surface layer; the foamed ceramic plate with decorative surface layer has pre-reserved dot-matrix distributed cylindrical grooves, and the high ductility mortar cylinders poured into the cylindrical grooves form shear keys.

[0013] Furthermore, the dovetail-interlocking frame is a frame reinforcement structure between the reinforced connection type high ductility mortar board and the foamed ceramic board with decorative surface layer, and also serves as a connection structure with the light steel frame; the cross-sectional shape of the dovetail-interlocking frame is a right-angled trapezoidal groove.

[0014] Prefabricated frame-type light steel frame - perlite mortar board - reinforced foamed ceramic board combined wall panel and its construction method are as follows: Step 1: Weld the light steel frame beams and light steel frame columns to form a light steel frame, which is divided into inner leaf frame light steel frame and outer leaf frame light steel frame; Step 2: Prepare the wire mesh with bent ends and weld steel strips around the wire mesh; Step 3: Using calcium silicate board, perlite mortar board, and foamed ceramic board with decorative surface layer, cylindrical grooves and trapezoidal dovetail grooves are machined on the inner side and frame of the foamed ceramic board with decorative surface layer, respectively. Step 4: Place the decorative foamed ceramic panel with its inner side facing up and the decorative side facing down on the mold table. Apply interface adhesive to the inner side of the decorative foamed ceramic panel. Lay and weld the bent wire mesh at the ends of the steel strips. The mold table is equipped with a dovetail interlocking frame structure corresponding to the dovetail groove. Pour high-ductility mortar and cure it to form a reinforced high-ductility mortar panel. The reinforced high-ductility mortar panel and the decorative foamed ceramic panel are assembled and connected through the dovetail groove to form a reinforced foamed ceramic panel. Step 5: Use self-tapping screws to connect the reinforced foamed ceramic board to the light steel frame of the outer leaf frame to form the combined outer leaf board; use self-tapping screws to connect the calcium silicate board to the light steel frame of the inner leaf frame to form the combined inner leaf board. Step 6: Transport the combined outer leaf plate, combined inner leaf plate, and perlite mortar slab to the construction site; Step 7: Apply dotted foam adhesive to the surface of the light steel frame beams, light steel frame columns and reinforced foamed ceramic panels of the combined outer leaf plate, and fill the cavity of the combined outer leaf plate with the outer surface of the perlite mortar board. Step 8: Apply dotted expanding foam to the inner surface of the perlite mortar board and fill the cavity of the combined inner blade board with the inner surface of the perlite mortar board. Step 9: First fill the assembly joint between adjacent reinforced foamed ceramic panel units with expanding foam, then use structural adhesive to grout the joints, thus completing the construction of the prefabricated frame-perlite mortar board-reinforced foamed ceramic panel wall panel.

[0015] Compared with the prior art, the present invention relates to a prefabricated frame light steel grid-perlite mortar board-reinforced foamed ceramic board composite wall panel and its construction method, which has the following advantages: (1) In the prefabricated frame light steel grid-perlite mortar board-reinforced foamed ceramic board composite wall panel of the present invention, the reinforced foamed ceramic board serves as the first line of earthquake resistance, and the light steel grid frame serves as the second line of earthquake resistance. The perlite mortar board-reinforced foamed ceramic board fireproof and heat insulation unit significantly improves the fire resistance performance of the structure. The prefabricated frame light steel grid-perlite mortar board-reinforced foamed ceramic board composite wall panel has integrated functions of earthquake resistance, heat insulation, decoration, and enclosure, and has the technical characteristics of light weight, good earthquake and fire resistance performance, and convenient assembly and construction.

[0016] (2) Shear keys are set between the foamed ceramic board and the high-ductility mortar, which improves the shear resistance and synergistic deformation capacity of the interface between the foamed ceramic and the high-ductility mortar, and avoids the peeling of the mortar layer and cracking of the foamed ceramic due to the difference in shrinkage performance between the two. The combined frame formed by the high-ductility mortar with dovetail interlocking frame, the wire mesh and the steel strip enhances the interlocking bonding capacity between the foamed ceramic board and the high-ductility mortar surface layer, and provides strong edge restraint for the foamed ceramic board, which significantly improves the deformation capacity and load-bearing capacity of the foamed ceramic board. The dovetail interlocking frame with built-in steel strip is connected to the light steel frame with self-tapping screws, which is reliable in terms of force, significantly improves the assembly construction speed and reduces the construction cost.

[0017] (3) The light steel frame is welded in the factory. The reinforced foamed ceramic panel unit, which matches the size of the light steel frame, is small and easy to hoist. The foamed ceramic panel with decorative surface layer of this invention is combined with reinforced high-ductility mortar board and then combined with light steel frame. It can be used as an exterior wall with a marble-like surface texture that integrates earthquake resistance, enclosure, heat preservation and decoration. It overcomes the disadvantages of dry-hanging marble exterior walls, such as heavy weight, easy hollowing, poor thermal performance, high cost, easy falling off, and serious consumption of natural resources. The assembly gaps of adjacent reinforced foamed ceramic panels are sealed with viscoelastic foam and structural adhesive. This not only makes it waterproof, but also allows for small deformation expansion or contraction under temperature action. It also avoids direct compression and displacement between the assembled reinforced foamed ceramic panels under horizontal earthquake action. This improves the overall earthquake resistance of the assembled frame light steel frame-perlite mortar board-reinforced foamed ceramic panel composite wall panel and significantly improves the ability of the composite wall panel to resist large earthquakes. Attached Figure Description

[0018] Figure 1 Prefabricated frame light steel frame - perlite mortar board - reinforced foamed ceramic board combination wall panel.

[0019] Figure 2 Light steel frame - reinforced foamed ceramic panel combination outer leaf panel.

[0020] Figure 3 Light steel frame - calcium silicate board inner leaf combination panel.

[0021] Figure 4Reinforced foamed ceramic panels.

[0022] Figure 5 Frame light steel grid - reinforced foamed ceramic panel connection node. (a) is the edge node, (b) is the middle node. Detailed Implementation

[0023] The present invention will now be described in detail with reference to the accompanying drawings and embodiments.

[0024] Prefabricated frame light steel grid - perlite mortar board - reinforced foamed ceramic board combined wall panel and construction method: The aforementioned light steel frame is divided into inner leaf light steel frame and outer leaf light steel frame, and is composed of light steel frame units. Each light steel frame unit is welded from square steel tube frame columns and beams, and adjacent light steel frame units share frame columns and beams.

[0025] The reinforced foamed ceramic panel is composed of a foamed ceramic panel with a decorative surface layer and a reinforced, high-ductility mortar panel. The reinforced, high-ductility mortar panel consists of an internal wire mesh panel with a thickness of not less than 20mm, steel strips welded around the wire mesh, and a perimeter frame with dovetail joints. An assembly joint of not less than 20mm is provided between the reinforced foamed ceramic panels in each reinforced foamed ceramic panel composite wall panel unit. The internal area of ​​the assembly joint is filled with expanding foam, and the external area of ​​the assembly joint is sealed with structural adhesive.

[0026] The shear-resistant key is an interface reinforcement structure between the reinforced connection type high-ductility mortar plate and the foamed ceramic plate, which is a high-ductility mortar cylinder filled into a pre-reserved cylindrical groove in the dot-matrix distributed foamed ceramic plate.

[0027] The aforementioned dovetail-interlocking frame is a reinforcing structure for the frame, where the dovetail joints of the foamed ceramic panel and the high-ductility mortar panel interlock, and it also serves as a connection structure to the light steel frame. The dovetail-interlocking frame consists of a right-angled trapezoidal groove around the perimeter of the foamed ceramic panel, an internal steel wire mesh filled into the right-angled trapezoidal groove, and high-ductility mortar with steel strips, making it a steel-high-ductility mortar composite frame.

[0028] The aforementioned combined inner leaf plate is a composite plate formed by connecting the inner leaf frame light steel grid and the calcium silicate board with self-tapping screws.

[0029] The aforementioned combined outer leaf plate is a composite plate formed by connecting the outer leaf frame light steel grid and the reinforced foamed ceramic plate with self-tapping screws.

[0030] The aforementioned frame-light steel grating-reinforced foamed ceramic panel connection node is a self-tapping screw connection structure between the frame-light steel grating and the reinforced foamed ceramic panel. The connection node is formed as follows: the self-tapping screw passes through the square steel tube of the light steel grating and through the dovetail interlocking high-ductility mortar layer of the reinforced foamed ceramic panel, connecting with the self-tapping screws of the steel strips welded around the wire mesh. It is a steel-high-ductility mortar composite connection structure.

[0031] The perlite mortar board-reinforced foamed ceramic board fireproof and heat-insulating unit consists of perlite mortar boards filled within the cavity of a light steel frame and reinforced foamed ceramic boards attached to the outside. The perlite mortar board is a fireproof material made primarily of cement mortar and expanded perlite particles, with an internal double-layer metal mesh, cured and dried. It possesses non-combustible properties and good thermal insulation capabilities. The fireproof and heat-insulating unit formed by the combination of perlite mortar boards and reinforced foamed ceramic boards significantly improves the fire resistance of the light steel composite structure.

[0032] A prefabricated frame light steel grid-perlite mortar board-reinforced foamed ceramic board composite wall panel was proposed. Figure 1 ), Framed light steel grid - reinforced foamed ceramic board combined outer leaf panel ( Figure 2 ), Framed light steel grid - calcium silicate board inner leaf composite panel ( Figure 3 ), reinforced foamed ceramic board ( Figure 4 ), Frame light steel grid - reinforced foamed ceramic board connection node ( Figure 5 ): Inner leaf frame light steel frame (1), outer leaf frame light steel frame (2), light steel frame beam (3), light steel frame column (4), foamed ceramic board with decorative surface layer (5), reinforced connection type high ductility mortar board (6), wire mesh (7), steel strip (8), reinforced foamed ceramic board (9), shear key (10), frame with dovetail interlocking (11), calcium silicate board (12), perlite mortar board (13), self-tapping screw (14), foaming adhesive (15), structural adhesive (16).

[0033] The inner leaf frame light steel frame (1) and the outer leaf frame light steel frame (2) are formed by welding light steel frame beams (3) and light steel frame columns (4); Reinforced foamed ceramic board (9): It is composed of a foamed ceramic board with decorative surface layer (5), a reinforced and connected high ductility mortar board (6), a wire mesh (7), and a steel strip (8). The reinforced foamed ceramic board (9) has a dot matrix distribution of anti-shear keys (10), and the edge of the reinforced foamed ceramic board (9) is provided with a dovetail interlocking frame (11).

[0034] The reinforced foamed ceramic board (9) is connected to the outer leaf frame light steel frame (2) by self-tapping screws (14); the calcium silicate board (12) is connected to the inner leaf frame light steel frame (1) by self-tapping screws (14).

[0035] Perlite mortar board (13) is filled in the cavity between reinforced foamed ceramic board (9) and calcium silicate board (12); Foam (15) and structural adhesive (16) are used to fill the assembly seams of adjacent reinforced foamed ceramic plate (9) units.

[0036] The inner leaf frame light steel lattice (1) and outer leaf frame light steel lattice (2) are formed by welding light steel lattice beams (3) and light steel lattice columns (4). The light steel lattice beams (3) and light steel lattice columns (4) are square steel tubes with a cross-sectional dimension of 80mm×40mm×4mm. The steel strength grade of the light steel lattice members should preferably be Q335 grade steel.

[0037] The aforementioned foamed ceramic board (5) with decorative surface layer is a weather-resistant, corrosion-resistant, fire-resistant, heat-insulating board with a surface texture similar to marble, formed by using silicon-based tailings as the main raw material and undergoing high-temperature melting, crystallization, and foaming processes to create a porous structure insulation layer and decorative surface layer. The foamed ceramic board consists of porous foamed ceramic and a high-density ceramic surface layer with a total thickness of 100mm. The 5mm thick surface layer is made of high-density ceramic with a marble-like texture. The high-density ceramic has a compressive strength higher than 30MPa, and the porous foamed ceramic has a compressive strength of 3.5~7.5MPa. The inner surface of the foamed ceramic board (5) with decorative surface layer has machined dot-matrix distributed cylindrical grooves with a diameter and depth of 40mm. The frame is machined into a right-angled trapezoidal dovetail groove with a depth of 40mm and an angle of 45°.

[0038] The reinforced high-ductility mortar panel (6) is a fiber-reinforced composite material with cement, quartz sand, etc. as the matrix. The reinforced high-ductility mortar panel (6) is 20mm thick. The high-ductility mortar and the foamed ceramic panel (5) with decorative surface layer are bonded together and then poured together. During the pouring process, the high-ductility mortar cylindrical shear key (10) filled with the cylindrical groove of the foamed ceramic panel and the dovetail interlocking frame (11) with high-ductility mortar poured into the right-angled trapezoidal dovetail groove of the foamed ceramic panel frame are formed. The high-ductility mortar has the mechanical characteristics of good deformation and high strength. Combined with the interface adhesive, shear key (10) and dovetail interlocking frame (11), which are all interface reinforcement measures, the deformation capacity of the foamed ceramic panel (5) with decorative surface layer is significantly improved, and its brittleness is reduced.

[0039] The wire mesh (7) is a galvanized orthogonal wire mesh arranged in the middle of the thickness of the reinforced high-ductility mortar board (6). The wire mesh diameter is 1.5mm~2mm and the spacing is 50mm. The wire mesh (7) is bent 135° towards the foamed ceramic board at the position of the dovetail interlocking frame (11) for anchoring. The length of the wire mesh anchored in the dovetail interlocking frame (11) is not less than 50mm. The wire mesh (7) can enhance the deformation capacity of the reinforced high-ductility mortar board (6) and its anti-shrinkage capacity under alternating cold / heat and dry / wet conditions, while also enhancing the stress performance of the reinforced foamed ceramic board (9).

[0040] The steel strip (8) is a long strip of thin steel plate welded around the wire mesh (7). The steel strip (8) is welded to the side of the wire mesh (7) near the foamed ceramic board and is located in the high ductility mortar with dovetail interlocking frame (11). The steel strip (8) is 40 mm wide and 3 mm thick.

[0041] The reinforced foamed ceramic panel (9) is composed of a foamed ceramic panel with a decorative surface layer and a reinforced high-ductility mortar panel. The reinforced high-ductility mortar panel consists of an internal wire mesh panel with a thickness of not less than 20mm, steel strips welded around the wire mesh, and a frame with dovetail interlocking around the perimeter. Shear keys are set between the foamed ceramic panel and the high-ductility mortar, which improves the shear resistance and coordinated deformation capacity of the interface between the foamed ceramic and the high-ductility mortar. The constraint frame formed by the high-ductility mortar with dovetail interlocking frame, the wire mesh, and the steel strips enhances the interlocking and bonding capacity between the foamed ceramic panel and the high-ductility mortar surface layer, and forms a strong edge constraint on the foamed ceramic panel, which significantly improves the deformation capacity and load-bearing capacity of the foamed ceramic panel. The reinforced foamed ceramic panel (9) has the technical advantages of integrating structure, enclosure, decoration, and insulation.

[0042] The shear key (10) is an interface reinforcement structure between the reinforced high-ductility mortar plate and the foamed ceramic plate. The foamed ceramic plate has a dot matrix of cylindrical grooves with a diameter and depth of 40 mm and a spacing of 300 mm. After the high-ductility mortar is poured into the inner side of the foamed ceramic plate (5) with decorative surface layer, the high-ductility mortar is poured into the cylindrical groove and solidifies to form the shear key.

[0043] The dovetail-interlocking frame (11) is a reinforced and connected structure for the foamed ceramic board. The edge of the foamed ceramic board (5) with decorative surface layer is machined with a groove. The groove has a right-angled trapezoidal cross-section, a depth of 40mm, and an angle of 45°. Steel strips (8) are welded onto the wire mesh (7) in the area of ​​the dovetail-interlocking frame (11), and the wire mesh (7) is bent 135° into the groove. After pouring high-ductility mortar, a trapezoidal cross-section steel-high-ductility mortar composite frame strip is formed. The dovetail-interlocking frame (11) enhances the interlocking bonding ability between the high-ductility concrete surface layer and the foamed ceramic board, providing stronger edge constraints for the foamed ceramic board and significantly improving its load-bearing performance. The dovetail-interlocking frame (11) provides a reliable structure for the self-tapping screw assembly connection between the outer leaf frame light steel frame (2) and the reinforced foamed ceramic board (9).

[0044] The calcium silicate board (12) is a silicon-calcium board formed by molding and steam curing with fly ash, cement, and reinforcing fiber materials. The present invention uses a 20mm thick standard fire-resistant calcium silicate board. The calcium silicate board (12) has a strength of not less than 30MPa. It is fastened to the inner leaf frame light steel frame (1) with self-tapping screws (14).

[0045] The perlite mortar board (13) is a new type of building insulation and fireproof material. It is a fireproof board with Class A fire resistance, made from cement, sand, vitrified microspheres, expanded perlite, slag powder, fly ash and other industrial wastes, mixed in a certain proportion and cured. The perlite mortar board (13) has a thermal conductivity of less than 0.085 W / mK and is filled in the cavity between the reinforced foamed ceramic board (9) and the calcium silicate board (12). The perlite mortar board (13) is bonded to the light steel frame beam (3) and the light steel frame column (4) with foam adhesive around its perimeter, and its inner and outer surfaces are bonded to the reinforced foamed ceramic board (9) and the calcium silicate board (12) with foam adhesive respectively.

[0046] The self-tapping screw (14) is a 6.3mm diameter self-tapping screw. It is used for fastening the inner leaf frame light steel frame (1) and calcium silicate board (12) and the outer leaf frame light steel frame (2) and reinforced foamed ceramic board (9).

[0047] The foaming adhesive (15) is a moisture-curing polyurethane elastic sealing foaming material. It fills the 80mm depth of the assembly seam of adjacent reinforced foamed ceramic plate (9) units, which can block the cold bridge of the assembly seam of adjacent reinforced foamed ceramic plate (9) units and improve the thermal insulation performance of the structure. The structural adhesive (16) is a high-performance silicone structural adhesive that fills the surface of the assembly joint of adjacent reinforced foamed ceramic board (9) units to a depth of 20mm. After the assembly joint is sealed with viscoelastic structural adhesive (16), it can be waterproof, allow small deformation expansion or contraction under temperature action, and avoid direct compression and displacement between the assembled reinforced foamed ceramic boards under horizontal earthquake action, thereby improving the overall seismic toughness of the assembled frame light steel grid-perlite mortar board-reinforced foamed ceramic board composite wall panel.

[0048] This invention relates to a prefabricated frame light steel grid-perlite mortar board-reinforced foamed ceramic board combined wall panel and its construction method, the specific construction method of which is as follows: Step 1: Using square steel pipes, thin steel plates, and wire mesh, fabricate light steel frame beams and columns, process steel strips, and cut the wire mesh. The factory welds the light steel frame beams and columns to form inner and outer leaf-shaped light steel frames; steel strips are welded around the perimeter of the wire mesh, and the edges of the wire mesh are bent 135° towards the side where it is welded. Step 2: Prepare perlite mortar boards and use calcium silicate boards and foamed ceramic boards with decorative surface layers. Cut the two types of boards to the design size, machine cylindrical grooves on the inner side of the foamed ceramic boards with decorative surface layers, and machine right-angled trapezoidal frame dovetail grooves on the inner periphery of the foamed ceramic boards with decorative surface layers.

[0049] Step 3: Place the decorative foamed ceramic board with the decorative surface facing down and the porous textured surface facing up. Apply interface adhesive to the porous textured surface of the foamed ceramic board. Place the steel wire mesh with welded steel strips and bent edges on the decorative foamed ceramic board. Place spacers between the steel wire mesh and the foamed ceramic board, and support templates around the decorative foamed ceramic board.

[0050] Step 4: Prepare high-ductility mortar and pour it into the inner side of the foamed ceramic board with decorative surface layer. The wire mesh with welded steel strips is located in the middle of the high-ductility mortar surface layer. After the high-ductility mortar is poured, it is cured to form a reinforced foamed ceramic board.

[0051] Step 5: Use self-tapping screws to connect the reinforced foamed ceramic board outer leaf to the light steel frame of the outer leaf frame to form a combined outer leaf panel; use self-tapping screws to connect the calcium silicate board inner leaf to the light steel frame of the inner leaf frame to form a combined inner leaf panel.

[0052] Step 6: Transport the combined outer leaf plate, combined inner leaf plate, and perlite mortar board to the construction site. Push the light steel frame of the combined outer leaf plate into the light steel frame from the outside and connect the outer leaf light steel frame and the light steel frame with self-tapping screws.

[0053] Step 7: Apply dotted foaming adhesive to the high-ductility concrete surface of the outer leaf light steel frame beams and columns and the reinforced foamed ceramic board, and then fill the cavity of the outer leaf light steel frame with perlite mortar board.

[0054] Step 8: Apply dotted expanding foam to the inner surface of the perlite mortar board, then push the light steel frame of the inner leaf panel into the light steel frame from the inside, and connect the inner leaf light steel frame and the light steel frame with self-tapping screws.

[0055] Step 9: First fill the assembly joint between adjacent reinforced foamed ceramic panel units with expanding foam, then use structural adhesive to grout the joints, thus completing the construction of the prefabricated frame light steel grid - perlite mortar board - reinforced foamed ceramic panel composite wall panel. Example

[0056] First, based on the structural layout of the building design, determine the arrangement and specific dimensions of the prefabricated frame light steel grid-perlite mortar board-reinforced foamed ceramic board composite wall panel. Then, perform stress calculations on the wall panel according to the designed wall panel cross-sectional dimensions and material strength. Design and perform stress calculations on the connection node structure. Based on the design scheme of the wall panel and its assembly connection nodes, draw detailed structural drawings and carry out manufacturing, transportation and on-site assembly construction.

[0057] The construction process for prefabricated frame light steel grid - perlite mortar board - reinforced foamed ceramic board combined wall panel is as follows: 1) Welded square steel pipe light steel frame beams and columns form inner and outer leaf frame light steel frames; 2) Use steel wire mesh and steel plates to prepare steel wire mesh with bent ends, and weld steel plate strips around the steel wire mesh; 3) Prepare perlite mortar board by using calcium silicate board and foamed ceramic board with decorative surface layer. Machining cylindrical grooves and trapezoidal dovetail grooves on the inner side and frame of the foamed ceramic board with decorative surface layer respectively. 4) Place the foamed ceramic panel with decorative surface layer facing up and the decorative surface facing down on the mold table. Apply interface adhesive to the inside of the foamed ceramic panel with decorative surface layer layer. Lay and weld the end of the steel strip and bend the wire mesh. Pour high ductility mortar and cure. 5) Self-tapping screws are used to connect the reinforced foamed ceramic board outer leaf to the light steel frame of the outer leaf frame to form a combined outer leaf panel; self-tapping screws are used to connect the calcium silicate board inner leaf to the light steel frame of the inner leaf frame to form a combined inner leaf panel.

[0058] 6) Transport the combined outer leaf plate, combined inner leaf plate, and perlite mortar board to the construction site. Push the light steel frame of the combined outer leaf plate into the light steel frame from the outside and connect the outer leaf light steel frame and the light steel frame with self-tapping screws.

[0059] 7) Apply dotted foaming adhesive to the high-ductility concrete surface of the outer leaf light steel frame beams and columns and the reinforced foamed ceramic board, and fill the cavity of the outer leaf light steel frame with perlite mortar board.

[0060] 8) Apply dotted expanding foam to the inner surface of the perlite mortar board, push the light steel frame of the combined inner leaf board into the light steel frame from the inside, and connect the inner leaf light steel frame and the light steel frame with self-tapping screws.

[0061] 9) First fill the assembly joint between adjacent reinforced foamed ceramic panel units with foaming adhesive, then use structural adhesive to grout the joints to complete the construction of the prefabricated frame light steel grid-perlite mortar board-reinforced foamed ceramic panel composite wall panel.

[0062] The above is a typical embodiment of the present invention, and the implementation of the present invention is not limited thereto.

Claims

1. Prefabricated frame-perlite mortar board-reinforced foamed ceramic wall panel, characterized in that: The system includes a light steel frame, reinforced foamed ceramic board (9), calcium silicate board (12), and perlite mortar board (13). The light steel frame is divided into an inner leaf frame light steel frame (1) and an outer leaf frame light steel frame (2). The inner leaf frame light steel frame (1) and the calcium silicate board (12) are connected by self-tapping screws (14) to form a combined inner leaf board. The outer leaf frame light steel frame (2) and the reinforced foamed ceramic board (9) are connected by self-tapping screws (14) to form a combined outer leaf board. The combined inner leaf board and the combined outer leaf board are connected by perlite mortar board (13). The perlite mortar board (13) is a fireproof material made of cement mortar and expanded perlite particles as the main materials, with a double-layer metal mesh inside, and is cured and dried. The perlite mortar board (13) and the reinforced foamed ceramic board (9) form a fireproof and heat-insulating unit.

2. The prefabricated frame-perlite mortar board-reinforced foamed ceramic panel wall panel according to claim 1, characterized in that: The light steel frame is composed of light steel frame units arranged and combined; the light steel frame unit is welded from light steel frame beams (3) and light steel frame columns (4), and adjacent light steel frame units share light steel frame beams (3) and light steel frame columns (4).

3. The prefabricated frame-perlite mortar board-reinforced foamed ceramic panel wall panel according to claim 1, characterized in that: The reinforced foamed ceramic board (9) is composed of a foamed ceramic board (5) with a decorative surface layer and a reinforced high-ductility mortar board (6); the foamed ceramic board (5) with a decorative surface layer and the reinforced high-ductility mortar board (6) are connected by a shear key (10) and a dovetail interlocking frame (11).

4. The prefabricated frame-perlite mortar board-reinforced foamed ceramic panel wall panel according to claim 1, characterized in that: The light steel frame is made of square steel tubes. Self-tapping screws (14) pass through the square steel tubes of the outer leaf frame light steel frame (2), and the decorative surface layer foamed ceramic board (5) and the reinforced connection type high ductility mortar board (6) form a frame light steel frame-reinforced foamed ceramic board connection node. This connection node is a self-tapping screw connection structure between the light steel frame and the reinforced foamed ceramic board, which is a steel-high ductility mortar combined connection structure.

5. The prefabricated frame-perlite mortar board-reinforced foamed ceramic panel wall panel according to claim 1, characterized in that: The outer leaf plate, the inner leaf plate, and the perlite mortar board (13) are connected as a whole by foaming adhesive.

6. The prefabricated frame-perlite mortar board-reinforced foamed ceramic panel wall panel according to claim 3, characterized in that: The thickness of the reinforced connection type high ductility mortar plate (6) is not less than 20mm, including an internal wire mesh (7), steel strips (8) welded around the wire mesh (7), and a dovetail interlocking frame (11) around the steel strips (8).

7. The prefabricated frame-perlite mortar board-reinforced foamed ceramic panel wall panel according to claim 3, characterized in that: There is an assembly seam of not less than 20mm between each reinforced foamed ceramic plate (9). The inner area of ​​the assembly seam is filled with foam (15), and the outer area of ​​the assembly seam is sealed with structural adhesive (16).

8. The prefabricated frame-perlite mortar board-reinforced foamed ceramic panel wall panel according to claim 3, characterized in that: The shear key (10) is an interface reinforcement structure between the reinforced connection type high ductility mortar plate (6) and the foamed ceramic plate (5) with decorative surface layer; the foamed ceramic plate (5) with decorative surface layer has a dot matrix distributed cylindrical groove, and the high ductility mortar cylinder poured into the cylindrical groove forms the shear key (10).

9. The prefabricated frame-perlite mortar board-reinforced foamed ceramic panel wall panel according to claim 3, characterized in that: The dovetail-interlocking frame (11) is a frame reinforcement structure between the reinforced connection type high ductility mortar board (6) and the foamed ceramic board (5) with decorative surface layer, and also serves as a connection structure with the light steel frame; the cross-sectional shape of the dovetail-interlocking frame (11) is a right trapezoidal groove.

10. A method for constructing a prefabricated frame-light steel frame-perlite mortar board-reinforced foamed ceramic board composite wall panel as described in any one of claims 1-9, characterized in that, The procedure includes the following: Step 1: Weld the light steel frame beams (3) and light steel frame columns (4) to form a light steel frame, which is divided into inner leaf frame light steel frame (1) and outer leaf frame light steel frame (2). Step 2: Prepare the wire mesh (7) with bent ends, and weld steel strips (8) around the wire mesh (7); Step 3: Using calcium silicate board (12), perlite mortar board (13), and foamed ceramic board with decorative surface layer (5), respectively machine cylindrical grooves and trapezoidal dovetail grooves on the inner side and frame of the foamed ceramic board with decorative surface layer (5); Step 4: Place the decorative foamed ceramic board (5) with its inner side facing up and its decorative side facing down on the mold table. Apply interface adhesive to the inner side of the decorative foamed ceramic board (5). Lay and weld the end of the steel strip (8) with bent wire mesh (7). The mold table is equipped with a dovetail interlocking frame (11) structure corresponding to the dovetail groove. Pour high-ductility mortar and cure it to form a reinforced connection type high-ductility mortar board (6). The reinforced connection type high-ductility mortar board (6) and the decorative foamed ceramic board (5) are assembled and connected through the dovetail groove to form a reinforced foamed ceramic board (9). Step 5: Use self-tapping screws (14) to connect the reinforced foamed ceramic board (9) to the outer leaf frame light steel frame (2) to form a combined outer leaf board; use self-tapping screws (14) to connect the calcium silicate board (12) to the inner leaf frame light steel frame (1) to form a combined inner leaf board; Step 6: Transport the combined outer leaf plate, combined inner leaf plate, and perlite mortar board (13) to the construction site; Step 7: Apply dotted foam adhesive to the surface of the light steel frame beam (3), light steel frame column (4) and reinforced foamed ceramic board (9) of the combined outer leaf plate, and fill the cavity of the combined outer leaf plate with the outer surface of the perlite mortar board (13). Step 8: Apply dotted foam adhesive to the inner surface of the perlite mortar board (13) and fill the cavity of the combined inner leaf board with the inner surface of the perlite mortar board (13). Step 9: First fill the assembly joint between adjacent reinforced foamed ceramic panel units with foam adhesive (15), then use structural adhesive (16) to grout the joint, and complete the construction of the prefabricated frame-perlite mortar board-reinforced foamed ceramic panel wall panel.

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