Formwork system for pouring concrete wall and construction method

Abstract

The invention discloses a formwork system, particularly discloses a formwork system for pouring a concrete wall and a construction method, and belongs to the technical field of house building construction process equipment design and manufacturing. According to the formwork system for pouring the concrete wall and the construction method, the rough surface or slurry throwing effect can be formed on the surface of the wall in the construction process. The formwork system comprises a formwork support and further comprises a composite formwork provided with a rough surface construction structure, the rough surface construction structure is arranged on the wall face of the side, facing concrete, of the composite formwork, and the composite formwork is detachably and fixedly supported on the outer side of bound concrete reinforcing steel bars through the formwork support. And a plastering rough surface meeting the requirement is constructed on the surface of the poured concrete wall body through the rough surface construction structure in the concrete pouring process.

Description

Technical Field

[0001] This invention relates to a formwork system, and more particularly to a formwork system for pouring concrete walls, belonging to the field of building construction equipment design and manufacturing technology. This invention also relates to a construction method for building concrete walls using the aforementioned formwork system for pouring concrete walls. Background Technology

[0002] In existing concrete wall construction, the wall surface is usually smooth. When the plaster layer is directly attached to the smooth wall, quality problems such as insufficient adhesion, hollowness, cracking, and peeling are prone to occur. To improve adhesion, it is usually necessary to perform a plastering or roughening treatment on the concrete wall surface.

[0003] However, this type of post-processing has the following drawbacks: 1. Cumbersome process: After the concrete wall surface is formed, an additional process of slurry application or roughening is required, increasing the construction steps; 2. High labor costs: It requires a large amount of manual labor and is highly dependent on the technical skills of the construction workers; 3. Long construction period: The grouting process can only be carried out after the wall has initially set, which extends the overall construction period; 4. Unstable quality: The slurry layer is prone to cracking or peeling, affecting the long-term durability of the plaster layer.

[0004] Therefore, there is an urgent need for an improved formwork for concrete walls that can directly create an uneven surface during the wall pouring process, avoiding subsequent slurry application or roughening, thereby improving construction efficiency and reducing construction costs. Summary of the Invention

[0005] The technical problem to be solved by the present invention is to provide a formwork system for pouring concrete walls that can form a rough surface or slurry effect on the wall surface during construction, and a construction method for constructing concrete walls using the formwork system for pouring concrete walls.

[0006] The technical solution adopted to solve the above-mentioned technical problems is: a formwork system for pouring concrete walls, including a formwork support, and the formwork system further includes a composite formwork with a rough surface structure. The rough surface structure is set on the wall surface of the composite formwork facing the concrete. The composite formwork is detachably fixed to the outside of the tied concrete reinforcement through the formwork support. The surface of the poured concrete wall is constructed with a rough plaster surface that meets the requirements through the rough surface structure during the concrete pouring process.

[0007] Furthermore, the formwork support includes a supporting steel pipe frame and tie bolts. The composite formwork is detachably fixed to the outside of the tied concrete reinforcement with the help of the tie bolts and the supporting steel pipe frame.

[0008] The preferred embodiment of the above scheme is that the composite formwork includes at least two sets of composite sub-formwork groups. Each set of composite sub-formwork groups has a rough surface structure on the wall facing the concrete side. Each set of composite sub-formwork groups is detachably supported on both sides of the tied concrete reinforcement by formwork brackets.

[0009] Furthermore, each composite sub-formwork group consists of at least one steel or plastic formwork with a rough surface structure, and each steel or plastic formwork is detachably supported on both sides of the tied concrete reinforcement by a formwork bracket.

[0010] The preferred embodiment of the above scheme is that the rough surface structure consists of multiple conical recesses evenly distributed on the wall surface of the steel or plastic formwork facing the concrete. Each conical recess is arranged in a grid pattern, a rhombus shape, or a staggered arrangement on the wall surface of the steel or plastic formwork. The bottom surface of each conical recess is a platform shape or a pointed shape, and the top surface is a polygon or a circle.

[0011] Furthermore, the steel template is directly cut from 5-8mm steel plates, and each conical recess is formed by stamping or welding. The polygonal or circular top surface has an arc transition with the connected wall surface.

[0012] The preferred embodiment of the above scheme is that the plastic template is a PP / PE plastic template formed by high-pressure injection molding using an injection molding machine, and each conical recess is formed in one step during the injection molding process, with an arc transition between the polygonal or circular top surface and the connected wall surface.

[0013] Furthermore, the bottom of each conical pit is a circle or square with a diameter of 5-15mm and a height of 3-10mm; the distance between two adjacent pits is 10-30mm.

[0014] The construction method for constructing concrete walls using the aforementioned formwork system for pouring concrete walls involves first setting up steel or plastic formwork outside the concrete reinforcement using formwork supports, then pouring concrete inside the steel or plastic formwork, removing the steel or plastic formwork and formwork supports after curing, and finally performing plastering to obtain concrete wall panels that meet quality requirements.

[0015] Furthermore, when pouring concrete, vibrators or attached vibrators are used to ensure that the concrete is fully filled around each conical depression.

[0016] The beneficial effects of this invention are as follows: The technical solution provided in this application is based on existing template supports. A composite template with a roughened surface structure is added to form the template system of this application. The roughened surface structure is set on the wall surface of the composite template facing the concrete. The composite template is then detachably supported by the template support on the outside of the tied concrete reinforcement. Finally, the surface of the poured concrete wall is constructed with the roughened surface structure during the concrete pouring process to create a plastered rough surface that meets the requirements. Because the technical solution of this application sets a roughened surface structure on one side of the composite template facing the concrete, the roughened surface or slurry structure required for plastering can be formed on the wall surface during concrete pouring. Therefore, before subsequent plastering, it is no longer necessary to roughen or slurry the wall to form a rough surface that ensures the plaster layer can adhere firmly. This solves the technical problem in the prior art that slurry or roughening treatment is required after the wall is formed and before plastering, which not only improves construction efficiency but also effectively reduces construction costs. Attached Figure Description

[0017] Figure 1 This is a schematic diagram of the planar structure of a composite formwork involved in the formwork system and construction method for pouring concrete walls according to the present invention; Figure 2 for Figure 1 Cross-sectional view of the composite template; Figure 3 This is a schematic diagram of another composite formwork involved in the formwork system and construction method for pouring concrete walls according to the present invention. Figure 4 for Figure 3 A cross-sectional view of the composite template.

[0018] The markings in the diagram are: 1. Steel or plastic template; 2. Conical recess. Detailed Implementation

[0019] like Figure 1 , Figure 2 , Figure 3 as well as Figure 4This invention illustrates a formwork system for pouring concrete walls, capable of creating a rough surface or slurry effect on the wall surface during construction, and a construction method for building concrete walls using the aforementioned formwork system. The formwork system includes a formwork support and a composite formwork with a rough surface structure. The rough surface structure is located on the concrete-facing side of the composite formwork, which is detachably supported by the formwork support to the outside of the tied concrete reinforcement. The surface of the poured concrete wall is textured with a rough surface during the concrete pouring process through the rough surface structure. This application's technical solution is based on existing formwork supports, but incorporates a composite formwork with a rough surface structure to form the formwork system. The rough surface structure is located on the concrete-facing side of the composite formwork, which is then detachably supported by the formwork support to the outside of the tied concrete reinforcement. Finally, the surface of the poured concrete wall is textured with a rough surface during the concrete pouring process through the rough surface structure. Because the technical solution of this application has a roughened surface structure on one side of the composite formwork facing the concrete, a roughened or slurry-sprayed structure can be formed on the wall surface during concrete wall pouring. This eliminates the need for roughening or slurry spraying to ensure firm adhesion of the plaster layer before subsequent plastering, solving the technical problem in existing technologies where slurry spraying or roughening is required after wall formation and before plastering. This not only improves construction efficiency but also effectively reduces construction costs. Based on existing technology, the formwork support of this application includes a supporting steel pipe frame and tie bolts. The composite formwork is detachably fixed to the outside of the tied concrete reinforcement using the tie bolts and the supporting steel pipe frame.

[0020] Accordingly, considering the actual conditions at the pouring site, the composite formwork of this application includes at least two sets of composite sub-formwork groups. Each set of composite sub-formwork groups has a rough-surface structure on the wall facing the concrete. Each set of composite sub-formwork groups is detachably supported on both sides of the tied concrete reinforcement via formwork supports. Preferably, each set of composite sub-formwork groups consists of at least one steel or plastic formwork 1 with a rough-surface structure. Each steel or plastic formwork 1 is detachably supported on both sides of the tied concrete reinforcement via formwork supports. More specifically, the rough-surface structure consists of multiple conical recesses 2 evenly distributed on the wall facing the concrete of the steel or plastic formwork 1. These conical recesses 2 are arranged in a grid pattern, a rhombus shape, or a staggered arrangement on the wall of the steel or plastic formwork 1. The bottom surface of each conical recess 2 is platform-shaped or pointed, and the top surface is polygonal or circular. When steel templates are used, each template is directly cut from a 5-8mm thick steel plate. Each conical recess is formed by stamping or individual welding, with a curved transition between the polygonal or circular top surface and the connecting wall surface. When plastic templates are used, each template is a PP / PE plastic template formed by high-pressure injection molding. Each conical recess is formed in one step during the injection molding process, with a curved transition between the polygonal or circular top surface and the connecting wall surface. Correspondingly, the bottom surface of each conical recess 2 is a 5-15mm circle or square, with a height of 3-10mm; the distance between two adjacent recesses is 10-30mm.

[0021] Therefore, the construction method for constructing concrete walls using the formwork system described in this application involves first setting up steel or plastic formwork outside the concrete reinforcement using formwork supports; then pouring concrete inside the steel or plastic formwork; after curing, removing the steel or plastic formwork and formwork supports; and finally, plastering to obtain concrete wall panels that meet quality requirements. Vibration is performed using vibrators or attached vibrators to ensure that the concrete is fully filled around each conical depression.

[0022] The technical solution provided in this application also has the following advantages: 1. Simplified procedures and shorter construction period Traditional construction requires grouting or roughening the concrete wall after it has hardened, while this invention can directly form a convex structure in a single pouring process, reducing at least one step. Comparative testing shows that the overall construction cycle can be shortened by approximately 15% to 25%.

[0023] 2. Enhanced adhesion and improved plaster layer durability. The raised structure on the wall surface can form a mechanical bond with the plaster mortar. Compared with a smooth wall surface, the bonding strength between the plaster layer and the base layer is increased by about 30% to 50%, which significantly reduces the phenomena of plaster layer hollowing, cracking and peeling.

[0024] 3. Save costs and reduce reliance on manual labor. By eliminating the mortar application process, labor and mortar material inputs are saved. Taking a typical residential project as an example, labor costs can be reduced by approximately 8% to 12% per 10,000 square meters of wall, and mortar material consumption can be reduced by about 10%.

[0025] 4. Improved construction safety and environmental friendliness This reduces the need for high-altitude grouting, lowering safety risks; it also reduces mortar waste and dust pollution during construction, making it more environmentally friendly. Furthermore, both steel and plastic formwork are 100% recyclable and can be reprocessed into new formwork or other products after being scrapped. There is no timber loss from felling, and construction waste from discarded wooden formwork is avoided; no sawdust, nails, or other waste are produced during construction, resulting in a cleaner site.

[0026] In summary, this invention not only optimizes the construction process of concrete walls, but also has significant advantages in terms of construction period, quality, cost and safety, making it suitable for widespread application in large-scale construction projects.

[0027] The technical solution of this application will be further described below through specific embodiments: The purpose of this invention is to provide a concrete wall template with a concave surface structure, which can directly form a convex wall surface during the concrete pouring process, thereby significantly enhancing the mechanical bonding force between the plaster layer and the base layer, eliminating the need for the slurry application process, shortening the construction cycle, reducing construction costs, and improving the adhesion effect and construction quality of the plaster layer.

[0028] The technical solution is as follows: 1. Template structure 1.1 Template Body The formwork is made of steel or plastic. Common building formwork steels such as Q235 or Q345 can be used, which have good strength and durability. The surface of the formwork is treated with rust prevention to extend its service life. The plastic can be made of polypropylene (PP) or polyethylene (PE).

[0029] 1.2 Concave Structure The inner wall of the template is evenly arranged with several conical concave points; the conical concave points are evenly arranged in a grid pattern along the longitudinal and transverse directions, or they can be arranged in a rhomboid or staggered pattern according to design requirements to obtain the best surface roughness; the geometric parameters of each concave point are: the bottom diameter ranges from 5-15mm (or square), the height ranges from 3-10mm, and the top is rounded to facilitate template removal and avoid forming sharp burrs on the concrete surface; the spacing between the concave points is preferably 10-30mm to ensure the continuity of the concave-convex structure without affecting the compactness of the concrete pouring.

[0030] 1.3 Dimple Machining Method Steel formwork can be directly stamped onto steel plates using CNC stamping technology, or standard conical parts can be fixed to the surface of the steel formwork by electric welding; the arrangement and size parameters of the concave points can be modularly customized according to construction requirements to adapt to different engineering needs.

[0031] Plastic templates can be produced using injection molding. Molten PP / PE plastic is injected into a metal mold cavity with pre-set concave patterns through an injection molding machine under high pressure. After cooling and solidification, the template is demolded to directly form a plastic template with concave patterns.

[0032] 2. Construction Method 2.1 Template Installation The template with tapered concave points is installed on the outside of the reinforced concrete structure; it is fixed by a template support system (such as steel pipe support, tie bolts, etc.) to ensure the overall stability of the template during installation, with the convex point facing the direction of concrete pouring.

[0033] 2.2 Concrete Pouring The concrete is poured into the formwork using conventional methods and compacted using a vibrator or attached vibrator to ensure that the concrete is fully filled around the depressions. Since the depressions are small, they have a limited impact on the flowability of the concrete, so no additional construction steps are required.

[0034] 2.3 Formwork Removal Once the concrete reaches the specified strength, the formwork is removed; the resulting concrete wall surface has a uniformly distributed convex structure, with the raised and recessed parts transitioning continuously to form a small embellished geometric effect.

[0035] 2.4 Plastering Construction Plastering is performed directly on the wall surface, with the plaster mortar filling and embedding in the raised structure; the plaster layer and the wall base form a mechanical interlock, improving the overall adhesion strength and preventing hollowing and peeling.

[0036] 3. Optional Implementation Methods The shape of the concave points can be optimized according to different construction requirements, such as conical, truncated conical, hemispherical, etc.; the template can adopt a detachable concave point insert structure, which is convenient for changing the size or arrangement of the concave points; for large-area walls, spliced ​​steel templates or customized plastic templates can be used, and the size of each template unit is standardized, which is convenient for transportation and on-site installation.

[0037] Example 1 In a residential building project, the designed wall thickness was 200mm. The concrete wall formwork with a surface textured structure, as described in this invention, was used for construction. The formwork body is made of Q345 steel plate, 6mm thick, with a hot-dip galvanized surface for corrosion protection. The inner wall of the formwork is evenly distributed with conical protrusions, each with a base diameter of 10mm and a height of 5mm. The center-to-center distance between adjacent protrusions is 20mm, forming a uniform grid pattern. There are approximately 2500 protrusions per square meter of formwork. During construction, the formwork is used in conjunction with a reinforcing steel frame. After being fixed with tie bolts and a support system, concrete is poured and compacted using an immersion vibrator to ensure the concrete is fully filled between the protrusions. After the concrete hardens to the design strength, the formwork is removed, resulting in a wall surface with a uniform textured structure.

[0038] During the plastering process, the cement mortar can fully embed itself into the uneven structure, eliminating the need for additional plastering treatment. Testing showed that the average bonding strength between the plaster layer and the substrate increased by approximately 40%, with no large-scale hollowing or detachment observed. Compared to the traditional smooth formwork + plastering process, one construction step is reduced, shortening the construction period by approximately 20%; simultaneously, mortar usage is reduced by approximately 10%, labor costs are lowered by approximately 12%, and dust pollution at the construction site is significantly reduced, resulting in a substantial improvement in construction safety and environmental performance.

Claims

1. A formwork system for casting concrete walls, comprising a formwork support, characterized in that: The template system also includes a composite template with a rough surface structure. The rough surface structure is set on the wall of the composite template facing the concrete. The composite template is detachably fixed to the outside of the tied concrete reinforcement by the template bracket. The surface of the poured concrete wall is constructed with a rough plaster surface that meets the requirements during the concrete pouring process through the rough surface structure.

2. The formwork system for casting concrete walls according to claim 1, characterized in that: The formwork support includes a supporting steel pipe frame and tie bolts. The composite formwork is detachably fixed to the outside of the tied concrete reinforcement with the help of the tie bolts and the supporting steel pipe frame.

3. The formwork system for casting concrete walls according to claim 1 or 2, characterized in that: The composite formwork includes at least two sets of composite sub-formwork sets. Each set of composite sub-formwork sets has a rough surface structure on the wall facing the concrete. Each set of composite sub-formwork sets is detachably supported on both sides of the tied concrete reinforcement by formwork brackets.

4. The formwork system for casting concrete walls according to claim 3, characterized in that: Each composite sub-formwork group consists of at least one steel or plastic formwork (1) with a rough surface structure. Each steel or plastic formwork (1) is detachably supported on both sides of the tied concrete reinforcement by a formwork bracket.

5. The formwork system for casting concrete walls according to claim 4, characterized in that: The rough surface structure consists of multiple conical pits (2) evenly distributed on the wall surface of the steel or plastic template facing the concrete. Each conical pit (2) is arranged in a grid, a rhombus, or a staggered arrangement on the wall surface of the steel or plastic template (1). The bottom surface of each conical pit (2) is platform-shaped or pointed, and the top surface is polygonal or circular.

6. The formwork system for casting concrete walls according to claim 5, characterized in that: The steel formwork is directly cut from 5-8mm steel plates. Each conical recess is formed by stamping or welding. The polygonal or circular top surface has an arc transition with the connected wall surface.

7. The formwork system for casting concrete walls according to claim 5, characterized in that: The plastic template is a PP / PE plastic template formed by high-pressure injection molding using an injection molding machine. Each conical recess is formed in one step during the injection molding process, and the polygonal or circular top surface has an arc transition with the connected wall surface.

8. The formwork system for casting concrete walls according to claim 7, characterized in that: The bottom of each conical pit (2) is a circle or square with a diameter of 5-15 mm and a height of 3-10 mm; the distance between two adjacent pits is 10-30 mm.

9. A construction method for constructing concrete walls using the formwork system for pouring concrete walls according to claim 8, characterized in that: The construction method involves first setting up steel or plastic formwork outside the concrete reinforcement using formwork supports, then pouring concrete inside the steel or plastic formwork, and finally removing the steel or plastic formwork and formwork supports after curing. Plastering is then carried out to obtain concrete wall panels that meet the quality requirements.

10. The construction method according to claim 9, characterized in that: When pouring concrete, use a vibrator or attached vibrator to ensure that the concrete is fully filled around each conical depression.

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