Special-shaped floor support-free formwork system and construction method thereof

Abstract

The invention discloses a special-shaped floor support-free formwork system and a construction method thereof.The formwork system comprises a floor structure, the floor structure comprises a center part, special-shaped parts and connecting components, the multiple connecting components are radially arranged at intervals around the axis of the center part and fixedly connected with the center part, and at least one special-shaped part is arranged between every two adjacent connecting components; the two side edges of each special-shaped part are fixedly connected with the corresponding connecting components correspondingly, and the shape of each special-shaped part is independently determined based on the shape of the floor slab curved surface corresponding to the position where the special-shaped part is located. And the bearing structure is fixedly connected with the floor structure, and the bearing structure and the floor structure form a self-bearing system. The construction method comprises the following steps: prefabrication: prefabricating and forming the special-shaped part and the connecting component in a factory based on three-dimensional model data of a target floor; a structure connecting step: connecting the connecting member with the central part and the bearing structure in a positioning manner; and a template welding step: hoisting each special-shaped part to a preset mounting position, and fixing the side edge of each special-shaped part with the corresponding connecting component.

Description

Technical Field

[0001] This invention relates to the field of building technology, and in particular to a supportless formwork system for irregularly shaped floors and its construction method. Background Technology

[0002] In modern large-scale public buildings, transportation hubs, and landscape structures, to achieve unique architectural aesthetics, irregularly shaped curved concrete floor slabs with free forms and complex shapes are often designed, such as the eaves of large stadiums and the curved shells of viewing platforms. These structures often exhibit multi-curvature, non-standard "bowl" or leaf-shaped forms.

[0003] Traditional formwork techniques for floor slab construction, such as loosely assembled wooden formwork, standardized steel formwork, or common steel truss floor decks and profiled steel sheets, have significant limitations when dealing with irregular curved surfaces. First, traditional formwork systems struggle to accurately fit and cut complex spatial curved surfaces, resulting in substantial on-site adjustments, difficulty in guaranteeing forming quality, and frequent deviations from the architectural design intent. Second, to support the pouring of curved floor slabs, a large-scale, full-span scaffolding support system is typically required. This approach not only consumes a lot of materials, has a long construction period, and high costs, but also poses a risk of collision damage and contamination if there are already installed precision curtain walls, decorations, or equipment within the building's interior space. Furthermore, traditional formwork has numerous joints and poor sealing, making it highly susceptible to cement slurry leakage during concrete pouring and vibration, severely contaminating the completed areas below, leading to high repair costs and construction delays.

[0004] In addition, the conventional construction sequence of "main structure first, then outer enclosure" can greatly increase the installation difficulty and reduce accuracy and efficiency when encountering complex and irregular outer enclosure systems (such as curved curtain walls) due to the limited internal working space after the main structure is completed. Summary of the Invention

[0005] This invention aims to solve at least one of the technical problems existing in the prior art. To this end, this invention proposes a support-free formwork system for irregular floor slabs and its construction method. Through modular factory prefabrication, on-site welding integration, and integrated design with the main load-bearing structure, a self-supporting formwork system that does not require scaffolding support is constructed, thereby supporting the reverse construction process of "installing the building curtain wall first and then pouring the concrete floor slab", realizing collaborative optimization from design to construction.

[0006] In a first aspect, the irregular floor support-free formwork system according to embodiments of the present invention includes: The floor structure includes a central part, irregularly shaped parts, and connecting members. One end of each connecting member is fixedly connected to the central part. Multiple connecting members are arranged radially at intervals around the axis of the central part. At least one irregularly shaped part is provided between two adjacent connecting members. The two sides of each irregularly shaped part extending in the radial direction are fixedly connected to the corresponding connecting members. The shape of each irregularly shaped part is independently determined based on the shape of the floor slab surface corresponding to its location, so that the floor template surface formed by all the irregularly shaped parts matches the designed floor. The load-bearing structure is fixedly connected to the floor structure, and the load-bearing structure and the floor structure form a self-supporting system that does not require the erection of independent supporting scaffolding.

[0007] According to an embodiment of the present invention, the irregular floor support-free formwork system has an edge sealing beam fixedly connected to the edge of the irregular part, and the two ends of the edge sealing beam extend to the intersection of the two connecting members respectively, and the ends of the edge sealing beam are fixedly connected to the connecting members. And / or, The connecting member has a fixing surface that matches the side profile of the adjacent irregular part, and the irregular part is fixedly connected to the connecting member along the fixing surface.

[0008] According to an embodiment of the present invention, the irregular floor support-free formwork system is characterized by full-weld connections and penetration welds between the irregular part and the connecting member, between the irregular part and the central part, between the irregular part and the edge sealing beam, and between the edge sealing beam and the connecting member. And / or, The connecting component is an angle steel.

[0009] According to an embodiment of the present invention, the support-free formwork system for irregular floor slabs includes a load-bearing structure comprising a connecting column, a connecting plate, an inner partition, and a cantilever member. Two connecting plates are spaced apart along the axial extension direction of the connecting column and are fixedly connected to the connecting column. The inner partition and the cantilever member are both disposed between the two connecting plates and are fixedly connected to the connecting column. At least one side of the cantilever member is fixedly connected to the adjacent inner partition.

[0010] According to an embodiment of the present invention, in the irregular floor support-free formwork system, the connecting member is configured as the cantilever member.

[0011] According to an embodiment of the present invention, in the irregular floor support-free formwork system, the inner partition is disposed on the circumference of the connecting column, the inner partition is disposed opposite to the side wall of the connecting column, and the thickness and strength of the inner partition are configured to match the side wall of the connecting column. And / or, Multiple inner partitions are provided, each inner partition is positioned opposite one side wall of the connecting column, and the cantilever member is provided between two adjacent inner partitions.

[0012] According to an embodiment of the irregular floor support-free formwork system of the present invention, the connecting plate located at the top is configured as the central part; or, A connecting beam connects two adjacent cantilever members. The connecting beam, together with the connecting plate above or the central and side cantilever members, forms a second closed area. Multiple second closed areas are arranged circumferentially around the connecting plate. A central plate is provided within the second closed area. The central part is composed of multiple central plates and the connecting plate above.

[0013] The non-supporting formwork system for irregularly shaped floors according to embodiments of the present invention has at least the following beneficial effects: The floor structure provided in this application achieves high-precision fitting of complex curved surfaces through a "radial skeleton + customized irregularly shaped panels" model; the load-bearing structure provides permanent support for the formwork system. The two are fixedly connected to form an organic whole, jointly constituting a self-supporting system, thereby effectively avoiding the use of temporary scaffolding. This integrated design is the basis for realizing the "curtain wall first, floor slab later" process and achieving protection of the finished product below.

[0014] Secondly, according to an embodiment of the present invention, a construction method for a non-supporting formwork system for irregularly shaped floors, used to form the aforementioned non-supporting formwork system for irregularly shaped floors, includes the following steps: Prefabrication steps: Based on the 3D model data of the target floor, multiple irregular-shaped parts and multiple connecting components are prefabricated in the factory; Structural connection steps: Position and connect the connecting components to the central part and the load-bearing structure; Template welding steps: hoist each of the irregular parts to the designed position between two adjacent connecting members, and fix the side of the irregular part to the corresponding connecting member on site by welding to form a sealed irregular curved floor template.

[0015] According to the construction method of the irregular floor support-free formwork system of the present invention, the leak repair step is as follows: after forming the sealed irregular formwork curved surface, the existing local gaps are repaired and sealed by welding. Pouring steps: Reinforcing steel is tied and concrete is poured on the curved surface of the sealed irregular template.

[0016] The construction method of the irregular floor support-free formwork system according to an embodiment of the present invention further includes: Edge sealing step: After the template welding step, an edge sealing beam is welded and fixed to the edge of the irregular part; wherein, the edge sealing beam, the two adjacent connecting members and the central part together form a first closed space, the shape of the first closed space matches the outer contour of the irregular part, and the first closed space is used to accommodate and position the irregular part; And / or, In the structural connection step, when a connecting beam is set between adjacent cantilever members, the connecting beam, the two adjacent cantilever members and the connecting plate located above together form a second closed space. The shape of the second closed space matches the outer contour of the central plate it accommodates. The second closed space is used to accommodate and position the central plate.

[0017] A construction method for a support-free formwork system for irregularly shaped floors according to an embodiment of the present invention has at least the following beneficial effects: The construction method provided in this application establishes a core process of "digital prefabrication in the factory and on-site assembly and welding." Factory prefabrication driven by a three-dimensional model helps ensure the accuracy of components such as irregularly shaped parts. The on-site steps are clear: first, a stable load-bearing frame is established; then, customized panels are installed; and finally, integration and sealing are achieved through welding. This method completes a large amount of processing work in the factory, which helps improve construction quality and efficiency.

[0018] Additional aspects and advantages of the invention will be set forth in part in the description which follows, and in part will be obvious from the description, or may be learned by practice of the invention. Attached Figure Description

[0019] The above and / or additional aspects and advantages of the present invention will become apparent and readily understood from the description of the embodiments taken in conjunction with the following drawings, in which: Figure 1 This is a schematic diagram of the structure of the irregular floor support-free formwork system according to an embodiment of the present invention; Figure 2 This is a partial structural perspective view of the irregular floor support-free formwork system according to an embodiment of the present invention; Figure 3 This is a schematic diagram of the load-bearing structure according to an embodiment of the present invention; Figure 4 This is a flowchart illustrating the construction method according to an embodiment of the present invention.

[0020] Explanation of reference numerals in the attached figures: Floor structure 1; Load-bearing structure 2; Central section 100; Irregular section 200; Connecting component 300; Edge sealing beam 400; 500 connecting post; Connecting plate 600; Inner partition 700; Connecting beam 800; Tension member 900. Detailed Implementation

[0021] Embodiments of the present invention are described in detail below. Examples of these embodiments are shown in the accompanying drawings, wherein the same or similar reference numerals denote the same or similar elements or elements having the same or similar functions throughout. The embodiments described below with reference to the accompanying drawings are exemplary and are only used to explain the present invention, and should not be construed as limiting the present invention.

[0022] In the description of this invention, it should be understood that the orientation descriptions, such as up, down, front, back, left, right, etc., are based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limiting this invention.

[0023] In the description of the invention, "several" means one or more, "multiple" means two or more, "greater than," "less than," and "exceeding" are understood to exclude the number itself, while "above," "below," and "within" are understood to include the number itself. If the terms "first" and "second" are used, they are only for distinguishing technical features and should not be construed as indicating or implying relative importance, or implicitly indicating the number of indicated technical features, or implicitly indicating the order of the indicated technical features.

[0024] In the description of this invention, unless otherwise explicitly defined, terms such as "set up," "install," and "connect" should be interpreted broadly, and those skilled in the art can reasonably determine the specific meaning of the above terms in this invention in conjunction with the specific content of the technical solution.

[0025] Reference Figures 1 to 3 This invention provides a supportless formwork system for irregularly shaped floors, comprising a floor structure 1 and a load-bearing structure 2. The floor structure 1 has a central portion 100, multiple irregularly shaped portions 200, and multiple connecting members 300. One end of each connecting member 300 is fixedly connected to the central portion 100, and the multiple connecting members 300 are arranged radially at intervals around the axis of the central portion 100. An irregularly shaped portion 200 is positioned between two adjacent connecting members 300, and its two sides extending radially are fixedly connected to the corresponding connecting member 300. The shape of each irregularly shaped portion 200 is independently determined based on the curved surface shape of the floor slab corresponding to its location, thereby ensuring that the floor formwork surface formed by the irregularly shaped portions 200 matches the designed floor slab. The load-bearing structure 2 is fixedly connected to the floor structure 1, and together they form a self-supporting system that eliminates the need for independent support scaffolding.

[0026] Specifically, the system consists of two parts: the floor structure 1, which is responsible for forming the formwork, and the load-bearing structure 2, which is responsible for supporting it. Radially arranged connecting members 300 form the main framework of the formwork system, providing a regular installation positioning reference for the irregularly shaped parts 200. Each irregularly shaped part 200 serves as a filling panel, and its shape is individually designed and manufactured according to the curvature of the floor's three-dimensional model at its corresponding position. The load-bearing structure 2, as the permanent main load-bearing component, is rigidly connected to the floor structure 1 through the connecting members 300, so that the entire formwork system no longer relies on the temporary scaffolding below for support during the concrete pouring stage. It can be understood that the load-bearing structure 2 is constructed first; then the connecting members 300 of the floor structure 1 are connected and fixed to the corresponding parts of the load-bearing structure 2; finally, the prefabricated irregularly shaped parts 200 are installed between adjacent connecting members 300 and their sides are welded and fixed, thus assembling to form a complete irregularly shaped formwork surface. The working principle of this system is that the concrete load is transferred to the connecting member 300 through the formwork panel, and then directly introduced into the permanent load-bearing structure 2 through the connecting member 300. The force flow path is clear, creating a construction platform integrated with the permanent structure. It combines the traditional temporary formwork system with the permanent load-bearing structure 2 in the design stage, so that the load during the pouring stage is borne by the permanent structure, thereby eliminating the need for full-scale scaffolding. This creates the necessary conditions for safely installing finished products such as curtain walls in the space below before the floor slab is constructed, and optimizes the construction process.

[0027] According to some embodiments of this application, such as Figures 1 to 2 As shown, the edge of the irregular part 200 is also fixedly connected to a sealing beam 400. The two ends of the sealing beam 400 extend to the intersection of the two connecting members 300 connected to the irregular part 200, and the ends of the sealing beam 400 are fixedly connected to the connecting members 300.

[0028] Specifically, the edge-sealing beam 400 is a linear component installed along the outer periphery of the irregular section 200. One end is welded to a connecting component 300, and then extends along the arc-shaped edge of the irregular section 200, finally welding the other end to another adjacent connecting component 300. The edge-sealing beam 400 plays multiple roles in the system. First, it stiffens and constrains the free edges of the thin steel plate of the irregular section 200, improving the local stiffness of the edge region. Second, it connects the edges of all the independent irregular sections 200, forming a continuous annular closed frame around the perimeter of the template system, enhancing the overall stability and deformation resistance of the entire system's edges. Understandably, after the irregular part 200 is welded and fixed to the connecting members 300 on both sides, the prefabricated edge sealing beam 400 is fitted into the edge of the irregular part 200 and its two ends are welded firmly to the corresponding connecting members 300. The edge sealing beam 400 not only strengthens the edge of the template itself, but also provides an ideal installation base for the building envelope system (such as metal decorative panels and glass curtain wall trim), so that the structural function and architectural aesthetics can be combined, and the overall completion of the project can be improved.

[0029] Furthermore, in some optional embodiments, the connecting member (300) can be configured to have a fixing surface adapted to the side profile of the adjacent irregular part. Specifically, the shape of the fixing surface is designed or processed according to the edge curvature of the specific irregular part (200) to be connected, so that during installation, the irregular part (200) can achieve a large-area contact with the connecting member (300) along the fixing surface and be fixedly connected by welding or other means. This "surface-fitting" connection method significantly increases the connection area and improves the connection stiffness and strength compared to simple line contact or point contact, ensuring that the load is transferred more effectively and evenly from the irregular part (200) to the connecting member (300) and the load-bearing structure (2), thereby improving the stability and reliability of the entire supportless formwork system.

[0030] In some embodiments, all connections between the irregular portion 200 and the connecting member 300, between the irregular portion 200 and the central portion 100, between the irregular portion 200 and the sealing beam 400, and between the sealing beam 400 and the connecting member 300, employ a full-penetration welding process. Full-penetration welding refers to a welding method in which a bevel is created at the joint during welding, allowing the arc heat to completely melt and penetrate the base metal. Specifically, during construction, continuous and full welding is performed on the contact edges of all the aforementioned connection locations, ensuring the weld penetration reaches the required depth and achieving complete fusion of the connection interface. This process aims to make the mechanical properties of the weld approach or even reach the level of the base metal. It is understood that after the components are precisely positioned and temporarily fixed by spot welding, skilled welders use full-penetration welding to weld all permanent connection welds, and necessary non-destructive testing is performed to ensure quality. The choice of full-penetration welding aims to achieve "equal-strength connection" and high sealing performance in the joint area. High-strength connections ensure the safety and reliability of the self-supporting system under construction loads; while high sealing performance eliminates the risk of cement grout leakage at the joints of the formwork to the greatest extent. This is the core technical guarantee for protecting the finished curtain wall and other finished products on the lower layer.

[0031] Furthermore, the connecting member 300 is made of angle steel. The angle steel participates in the construction with its two mutually perpendicular legs. Typically, one leg (horizontal leg) is used to support and weld the sides and center 100 of the irregular part 200; the other leg (vertical leg) is used to connect and fix to the load-bearing structure 2 below (such as a cantilever beam). As an intermediate member, the angle steel plays the role of a force transmission hub for transmitting the load of the formwork above and connecting to the main structure below. Advantageously, this application uses angle steel, a standardized and economical profile, which reduces material costs and processing difficulty. Its simple geometry makes positioning, installation, and welding very intuitive and convenient, which helps to improve on-site construction efficiency and control costs.

[0032] According to some embodiments of this application, such as Figures 2 to 3 As shown, the load-bearing structure 2 specifically includes a connecting column 500, a connecting plate 600, an inner partition 700, and a cantilever member. Two connecting plates 600 are arranged at a certain distance along the axial direction of the connecting column 500 and are firmly connected to the connecting column 500. The inner partition 700 and the cantilever member are both disposed between the two connecting plates 600 and are both fixedly connected to the connecting column 500. At least one side of the cantilever member is fixedly connected to the adjacent inner partition 700.

[0033] Specifically, such as Figures 1 to 3As shown, the load-bearing structure 2 provided in this application is a hub-shaped node system. Specifically, two connecting plates 600 are fixed to the connecting column 500 and arranged at intervals along its axial direction to form a mezzanine space. An inner partition 700 is disposed within this mezzanine space and fixedly connected to the connecting column 500, located circumferentially on the connecting column 500, with the inner partition 700 directly opposite the sidewall of the connecting column 500. Furthermore, a cantilever member is also disposed between the two connecting plates 600 and fixedly connected to them, and at least one side of the cantilever member is fixedly connected to an adjacent inner partition 700.

[0034] Understandably, the connecting column 500 is the primary vertical force-transferring component; the upper and lower connecting plates 600 are welded to the column body, forming a flat, box-shaped node domain; the inner diaphragm 700 is vertically positioned within the node domain and directly welded to the column wall; the cantilever member extends horizontally outward from the node domain. The core function of the inner diaphragm 700 is to connect to the side of the cantilever member, transferring part of the load (especially shear force) borne by the root of the cantilever beam more directly to the side wall of the connecting column 500, thus constructing a direct force transmission path of "cantilever member → connecting plate 600 → inner diaphragm 700 → side wall of node connecting column 500". The two connecting plates 600 and the inner diaphragm 700 together form a rigid node domain, making the load transfer from the cantilever member efficient and clear, significantly simplifying the node stress model, and improving the overall stiffness and safety of the node. The load from the floor formwork is transferred to the cantilever member through the connecting member 300. As a bending member, the bending moment and shear force at the root of the cantilever member are transferred and diffused throughout the entire node domain through the connection of its flange, web with the connecting plate 600 and the connecting column 500, and the side connection of its web with the inner diaphragm 700, and finally safely transferred to the connecting column 500. This provides a node structure form with clear force transmission and high load-bearing capacity for this application. At the same time, the hub-shaped node transforms the complex multi-member converging force into a clear "plate force transmission" mode, which has high structural efficiency, and its radial shape is in line with the support requirements of irregular floor slabs.

[0035] In some embodiments, the connecting member 300 in the floor structure 1 is directly served by the cantilever member in the load-bearing structure 2. That is, the irregular part 200 of the formwork system is directly fixed to the upper flange or specific part of the structural member such as the H-beam or box beam that serves as the cantilever member by welding. The cantilever member simultaneously performs the dual functions of supporting the main structure and the formwork, realizing a high degree of integration of the structural system, eliminating redundant members, simplifying construction nodes, reducing steel consumption and welding workload, and making the force transmission path from the formwork to the main structure the shortest and most direct, resulting in higher overall economy and structural efficiency.

[0036] According to some embodiments of this application, an inner diaphragm 700 is disposed circumferentially around the connecting column 500 and directly opposite a side wall of the connecting column 500. The thickness and strength grade of the inner diaphragm 700 are configured to match the side wall of the connecting column 500 it faces. Specifically, in this application, this generally means the same thickness and material; that is, the thickness and strength of the inner diaphragm 700 are configured to match the side wall of the node connecting column 500, for example, using steel with the same thickness and strength grade as the column side wall. This equal-strength and equal-thickness matching design ensures that the inner diaphragm 700, as a direct extension of the column side wall, will not become a weak link due to abrupt changes in cross-section or strength when transferring loads. This helps to achieve an "equal-strength connection" between the node domain and the main load-bearing column, greatly improving the integrity of the node and its reliability under ultimate loads.

[0037] Understandably, multiple inner diaphragms 700 can be provided, each inner diaphragm 700 being positioned directly opposite one sidewall of the connecting column 500, with a cantilever member between two adjacent inner diaphragms 700. This standardized and modular layout of "one column surface, one diaphragm, two cantilever members" allows each inner diaphragm 700 to be dedicated to transferring the load from the cantilever members on both sides to the corresponding sidewall of the connecting column 500, forming multiple parallel and independent force transmission units. The force transmission responsibilities are extremely clear, which helps to eliminate mutual interference between loads in different directions, ensuring balanced force distribution at the node and a high degree of modularity, providing a structural foundation for automated design, digital manufacturing, and factory prefabrication. In this embodiment, the inner diaphragm 700 is considered as an extension of the sidewall of the connecting column 500 within the node domain. It is precisely positioned so that its plate surface is flush with or corresponds to one of the outer surfaces of the column. Furthermore, the selection of plate material of the same specifications as the column wall is to ensure the continuity of cross-section and stiffness when force flows through it. When the load of the cantilever member is transferred through the inner diaphragm 700, the inner diaphragm 700 acts like a reinforcing rib of the column wall, smoothly guiding the load into the column body and avoiding local stress concentration caused by abrupt changes in cross section. Through meticulous "alignment" and "equal strength" design, the force flow transmission in the core area of ​​the node is optimized, and the bearing capacity and durability of the node under complex stress conditions are improved. This is a key detail to ensure the safety of the node under large loads.

[0038] Preferably, the connecting column 500 has a rectangular cross-section. For the rectangular connecting column 500, an inner diaphragm 700 is installed at the center of each of its four sides, and a cantilever member radiates outward between every two adjacent inner diaphragms 700. This forms four force transmission units of "cantilever-inner diaphragm 700" surrounding the column. Through precise "alignment," "equal strength matching," and standardized modular layout, the force flow transmission, stress distribution, and manufacturability of the node core area are optimized, significantly improving the node's load-bearing capacity, durability, and economy under complex stress conditions.

[0039] In some embodiments, this application directly uses the connecting plate 600 located above the hub-shaped node as the central part 100 of the floor formwork system. That is, in this application, the central part 100 is not an additional component. The annular connecting plate 600 (upper ring plate) inherent in the hub-shaped node, located above, performs the node's load-bearing function while its plate surface area is directly used as the support surface for the central area of ​​the formwork. When installing the formwork, the ends of the radial connecting members 300 (or cantilever members) are directly welded to the edge of the connecting plate 600 located above, realizing the integration of structural function and formwork function. The construction is simple, saving materials and labor time for separately manufacturing and installing the central part 100 formwork. The construction steps are few, reflecting the design concept of efficient integration.

[0040] Furthermore, such as Figure 2 As shown, a connecting beam 800 connects two adjacent cantilever members. The connecting beam 800, together with the connecting plate 600 above and the cantilever members on both sides, enclose a second enclosed area. Multiple such second enclosed areas are arranged circumferentially around the center. A separately prefabricated center plate is placed within each second enclosed area and welded in place. Ultimately, the central part 100 is formed by combining these center plates with the connecting plate 600 above.

[0041] Understandably, the central area is formed using a "secondary skeleton + infill plate" approach. The connecting beam 800 increases the density and stiffness of the central area's skeleton. The prefabricated central plate, acting as an infill module, precisely matches the boundary of the second enclosed area. After the cantilever members and upper connecting plate 600 are installed, the connecting beam 800 is welded to form grids; then, each central plate is hoisted into its corresponding grid, adjusted, and welded to the surrounding connecting beams 800, cantilever members, and upper connecting plate 600. This achieves flexibility in the central section 100's structure, adapting to various large-span, irregular, or open-ended central area designs. It helps to decompose a potentially complex overall central surface into multiple prefabricated small units, reducing fabrication and installation difficulty and demonstrating the advantages of modular construction.

[0042] Furthermore, such as Figures 1 to 3As shown, in a macroscopic tree structure composed of multiple such hub-shaped nodes, tension connecting members 300 can be introduced to enhance the overall integrity. Specifically, each hub-shaped node can be fixedly connected to at least two tension members 900. Adjacent hub-shaped nodes (i.e., the load-bearing structure 2 of this application) are fixedly connected to each other through their respective connected tension members 900, thereby forming a stable tie network in space. In this system, the hub-shaped nodes act as rigid "force pools," mainly bearing pressure and bending moment; the tension members 900 act as flexible "force chains," mainly bearing tension. The two work together to effectively convert the horizontal force or overturning moment generated by the tree-like cantilevered part into tension within the system for balance. This systematic solution of "rigid nodes + flexible ties" extends the clear force transmission logic from a single node to the entire structural network, thereby significantly improving the stability, safety, and seismic performance of the overall structure while achieving a large-span, lightweight architectural form.

[0043] In another embodiment, reference is made to Figure 4 This application also provides a construction method for forming the aforementioned template system. Specifically, it includes the following steps: Prefabrication Steps: Based on the complete Building Information Model (BIM) data of the target irregular floor plan, components are digitally laid out and produced in the factory. First, the spatial surface data of each irregular section 200 is extracted from the 3D model. CNC cutting and bending equipment is then used to process steel plates into irregular section 200 units of various shapes, ensuring their curvature perfectly matches the design. Simultaneously, according to the radial skeleton layout, the necessary connecting components 300 (such as angle steel), edge sealing beams 400, connecting beams 800, and possibly a center plate are prefabricated in the factory. All components are numbered and labeled, and pre-assembly inspection can be performed in the factory to verify processing accuracy and compatibility.

[0044] The structural connection steps include the following sub-steps: S1: First, hoist the connecting column 500 to the design position, and make precise adjustments to its verticality and position before fixing it.

[0045] S2: Based on the design elevation and orientation, hoist the connecting plate 600 located below to the predetermined position of the connecting column 500 and complete the positioning and fixing.

[0046] S3: After the lower connecting plate 600 is positioned and fixed, the inner partition 700 is installed. The prefabricated inner partition 700 is hoisted into place, aligning it with the predetermined side wall of the connecting column 500, and initially fixed with the lower connecting plate 600 and the connecting column 500 by spot welding. Next, the cantilever components are installed. The root of the cantilever component is inserted into the designed position between the lower connecting plate 600 and the future upper connecting plate 600, adjusting its plane angle and elevation to ensure its side is tightly fitted with the already positioned inner partition 700, and then fixed by spot welding. Next, the upper connecting plate 600 is installed, fixed to the connecting column 500, and fitted with the upper surface of all cantilever components and the upper edge of the inner partition 700. After the position, angle, and gap of all components (connecting column 500, upper and lower connecting plates 600, inner partition 700, and cantilever components) are adjusted to meet the design requirements, the formal welding stage begins.

[0047] For the welding of hub-shaped nodes, the principle of equal strength connection should be strictly followed. All butt welds, including the circumferential welds between the upper and lower connecting plates 600 and the connecting column 500, the welds between the inner diaphragm 700 and the connecting column 500 and the upper and lower connecting plates 600, the welds between the root of the cantilever member and the upper and lower connecting plates 600 and the connecting column 500, and the welds between the web of the cantilever member and the inner diaphragm 700, shall employ a beveled full penetration welding process, and adopt symmetrical and segmented welding sequences to reduce welding deformation. Critical welds shall undergo visual inspection and non-destructive testing (such as ultrasonic testing) after welding to ensure that the weld quality meets the design requirements, thereby guaranteeing the stiffness and force transmission reliability of the node area.

[0048] After the node welding is completed and passes inspection, if the central part 100 adopts the above connecting plate 600 as the central part 100, then the connecting plate 600 becomes the reference surface for subsequent construction after this step.

[0049] Template Welding Steps: Assemble the template system on a stable load-bearing frame. First, if the central section 100 is a composite type (using connecting beams 800 and a central plate), install and weld the connecting beams 800 to form a lattice structure for the second closed area. Then, place the prefabricated central plates into the corresponding lattice structures and weld them in place, forming a complete central section 100 together with the upper connecting plate 600. Next, begin installing the irregular sections 200. Following the component numbering sequence, hoist each irregular section 200 to its designed position—the space defined by the edge of the central section 100 and two adjacent connecting components 300 (or cantilever components). After the irregular section 200 is in place, immediately weld its two sides along the radial direction to the corresponding connecting components 300 (or the corresponding parts of the cantilever components) on-site. All joints between irregular sections 200 and between irregular sections 200 and the central section 100 are continuously and fully welded to ensure a sealed joint, ultimately forming a continuous, sealed irregular curved surface template.

[0050] Leak Repair Steps: After all formwork welding is completed, a systematic inspection of the entire irregular-shaped formwork surface is conducted. The focus is on checking whether all welds are continuous and full, whether there are defects such as porosity, undercut, or lack of fusion, and whether there are any minor gaps at the component joints caused by manufacturing or installation errors. Any potential leaks are sealed by welding. This step is the final guarantee to ensure the formwork system is "absolutely leak-proof," and is crucial for protecting the finished products such as the curtain wall installed below.

[0051] Pouring Procedure: After confirming the structural safety, reliable connections, and complete sealing of the formwork system, concrete pouring can proceed. Reinforcement binding and embedded part installation are performed on the self-supporting formwork system, followed by concrete pouring. Since the entire load of the formwork and the wet concrete above it is reliably transferred to the permanent load-bearing structure 2 through the connecting members 300, no temporary support scaffolding of any kind is required below the formwork during the entire pouring, vibration, and curing process. This provides an open and undisturbed environment for the space below, perfectly protecting the completed workpiece.

[0052] Depending on the specific design, it may also include an edge sealing step, that is, after the template is welded, an edge sealing beam 400 is welded to the outer edge of the irregular part 200 to form a first closed space, so as to strengthen the edge and provide a base for the building finishing, etc.

[0053] The construction method provided in this application follows an advanced logic of "digital design-driven, lean factory prefabrication, load-bearing frame first, customized module positioning, fully welded integrated sealing, and load-bearing combination of permanent and temporary." Its workflow is interconnected, with each step providing a precise foundation for the next. In particular, the application of "first enclosed space" and "second enclosed space" cleverly simplifies the spatial positioning of complex irregularly shaped components into a "matching" assembly process, significantly reducing the difficulty of on-site measurement and layout and human error, greatly improving installation efficiency and forming accuracy. This forms a complete, refined, and highly efficient advanced construction method for irregularly shaped curved concrete structures. It not only integrates modern construction concepts of digital design, industrial manufacturing, and prefabricated construction, achieving high-quality realization of complex architectural shapes, but also systematically overcomes long-standing problems in traditional construction, such as reliance on scaffolding, grout leakage and contamination, finished product protection, and process conflicts, through two core technologies: "self-supporting formwork system" and "fully welded sealing," providing innovative technical solutions for the construction of similar complex projects.

[0054] In the description of this specification, the references to terms such as "one embodiment," "some embodiments," "illustrative embodiment," "example," "specific example," or "some examples," etc., indicate that a specific feature, structure, material, or characteristic described in connection with that embodiment or example is included in at least one embodiment or example of the invention. In this specification, the illustrative expressions of the above terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in one or more embodiments or examples.

[0055] Although embodiments of the invention have been shown and described, those skilled in the art will understand that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the claims and their equivalents.

Claims

1. A support-free formwork system for irregularly shaped floors, characterized in that, include: The floor structure (1) includes a central part (100), irregular parts (200) and connecting members (300). One end of the connecting member (300) is fixedly connected to the central part (100). Multiple connecting members (300) are arranged radially and spaced apart around the axis of the central part (100). At least one irregular part (200) is provided between two adjacent connecting members (300). The two sides of the irregular part (200) extending in the radial direction are fixedly connected to the corresponding connecting member (300). The shape of each irregular part (200) is independently determined based on the floor surface shape corresponding to its position, so that the floor template surface formed by the irregular parts (200) matches the designed floor. The load-bearing structure (2) is fixedly connected to the floor structure (1), and the load-bearing structure (2) and the floor structure (1) form a self-supporting system that does not require the erection of independent supporting scaffolding.

2. The irregular floor support-free formwork system according to claim 1, characterized in that, The edge of the irregular part (200) is fixedly connected to a sealing beam (400), and the two ends of the sealing beam (400) extend to the intersection of the two connecting members (300), and the end of the sealing beam (400) is fixedly connected to the connecting member (300). And / or, The connecting member (300) has a fixing surface that is adapted to the side profile of the adjacent irregular part (200), and the irregular part (200) is fixedly connected to the connecting member (300) along the fixing surface.

3. The irregular floor support-free formwork system according to claim 2, characterized in that, The irregular part (200) and the connecting member (300), the irregular part (200) and the center part (100), the irregular part (200) and the edge sealing beam (400), and the edge sealing beam (400) and the connecting member (300) are all fully welded and are fully penetrated welds; And / or, The connecting member (300) is an angle steel.

4. The irregular floor support-free formwork system according to claim 1, characterized in that, The load-bearing structure (2) includes a connecting column (500), a connecting plate (600), an inner partition (700), and a cantilever member. Two connecting plates (600) are arranged at intervals along the axial extension direction of the connecting column (500) and are fixedly connected to the connecting column (500). The inner partition (700) and the cantilever member are both disposed between the two connecting plates (600) and are fixedly connected to the connecting column (500). At least one side of the cantilever member is fixedly connected to the adjacent inner partition (700).

5. The irregular floor support-free formwork system according to claim 4, characterized in that, The connecting member (300) is configured as the cantilever member.

6. The irregular floor support-free formwork system according to claim 4, characterized in that, The inner partition (700) is disposed in the circumferential direction of the connecting column (500), and the inner partition (700) is disposed opposite to the side wall of the connecting column (500). The thickness and strength of the inner partition (700) are configured to match the side wall of the connecting column (500). And / or, Multiple inner partitions (700) are provided, each inner partition (700) is arranged opposite to one side wall of the connecting column (500), and the cantilever member is provided between two adjacent inner partitions (700).

7. The irregular floor support-free formwork system according to claim 6, characterized in that, The connecting plate (600) located above is configured as the central portion (100); or, A connecting beam (800) connects two adjacent cantilever members. The connecting beam (800), together with the connecting plate (600) above or the central part (100) and the cantilever members on both sides, form a second closed area. Multiple second closed areas are arranged circumferentially around the connecting plate (600). A central plate is provided in the second closed area. The central part (100) is composed of multiple central plates and the connecting plate (600) above.

8. A construction method for a support-free formwork system for irregularly shaped floors, characterized in that, The method for forming the support-free formwork system for irregular floor slabs as described in any one of claims 1 to 7 includes the following steps: Prefabrication steps: Based on the three-dimensional model data of the target floor, multiple irregular parts (200) and multiple connecting components (300) are prefabricated in the factory. Structural connection steps: Position and connect the connecting component (300) to the central part (100) and the load-bearing structure (2); Template welding steps: hoist each of the irregular parts (200) to the designed position between two adjacent connecting members (300), and fix the side of the irregular part (200) to the corresponding connecting member (300) by on-site welding to form a sealed irregular curved floor template.

9. A construction method for a support-free formwork system for irregularly shaped floors according to claim 8, characterized in that, Also includes: Repair steps: After forming the sealed irregular-shaped template surface, the existing local gaps are repaired and sealed by welding; Pouring steps: Reinforcing steel is tied and concrete is poured on the curved surface of the sealed irregular template.

10. A construction method for a support-free formwork system for irregularly shaped floors according to claim 9, characterized in that, Also includes: Edge sealing step: After the template welding step, an edge sealing beam (400) is welded and fixed to the edge of the irregular part (200); wherein, the edge sealing beam (400), two adjacent connecting members (300) and the central part (100) together form a first closed space, the shape of the first closed space matches the outer contour of the irregular part (200), and the first closed space is used to accommodate and position the irregular part (200). And / or, In the structural connection step, when a connecting beam (800) is provided between adjacent cantilever members, the connecting beam (800), the two adjacent cantilever members and the connecting plate (600) located above together form a second closed space. The shape of the second closed space matches the outer contour of the central plate it accommodates. The second closed space is used to accommodate and position the central plate.

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