Construction method of complex arc-shaped single aluminum plate curtain wall

Abstract

The invention discloses a construction method of a complex arc-shaped single aluminum plate curtain wall, belongs to the technical field of curtain wall construction, and realizes high-precision, stress-free, efficient and safe construction of the complex arc-shaped single aluminum plate curtain wall. A complex curved surface in a building model is decomposed into a plurality of single aluminum plate units, a unified construction standard is determined, stress relief annealing and a three-dimensional adjustable connecting system are adopted, so that aluminum plates are installed in a free state, and later deformation and cracking caused by forced assembly are avoided; performing through processing, pre-splicing and mounting by using the same digital reference, and combining solid web profiling detection to ensure that the curved surface is smooth and the height difference of adjacent plates is less than or equal to 0.3 mm; 80% or above of high-altitude bulk operation is transferred to ground factorization completion, the high-altitude operation time of modular hoisting of a single module is shorter than or equal to 30 minutes, and the safety risk is remarkably reduced; a factory preset water stop adhesive tape and on-site precise glue injection double-channel waterproof system is adopted, and no leakage exists in a water spraying test; the three-dimensional adjustable system can absorb errors of a main body structure and machining, and high attachment of the aluminum plate is achieved.

Description

Technical Field

[0001] This invention relates to the field of curtain wall construction technology, specifically to a construction method for complex curved single aluminum panel curtain walls. Background Technology

[0002] The construction of complex curved single-aluminum panel curtain walls typically uses theoretical design dimensions as the sole installation benchmark, employing methods such as forced stretching, welding, or on-site assembly. However, due to unavoidable construction errors in the main structure, this forced installation method easily leads to significant assembly stress within the aluminum panel, frequently resulting in quality problems such as deformation, cracking, loosening, and leakage during long-term service. Furthermore, for complex curved panels such as hyperboloids or three-dimensional twisted surfaces, traditional manual hammering, simple mold pressing, or free stretching forming processes are insufficient to precisely control the curved shape, often resulting in defects such as springback, wrinkles, and twisting after forming. Moreover, the lack of effective stress relief methods further exacerbates the risk of deformation during later use.

[0003] Furthermore, existing connection systems are mostly fixed or have very little adjustment margin, failing to effectively absorb errors in the main structure and aluminum panel processing. This leads to difficulties in on-site installation, making it hard to achieve a high fit between the back of the aluminum panel and the supporting keel, resulting in a loose fit. Moreover, traditional construction often involves high-altitude assembly and welding, which is technically challenging and poses significant safety hazards. On-site manual waterproofing is also significantly affected by operator skill and weather conditions, easily leading to problems such as incomplete sealant application, air bubbles, and uneven thickness, resulting in frequent curtain wall leaks. Therefore, there is an urgent need for a construction method for complex curved single-aluminum panel curtain walls that can achieve high precision, stress-free operation, adjustability, safety, efficiency, and reliable waterproofing. Summary of the Invention

[0004] The present invention aims to solve at least one of the technical problems existing in the prior art.

[0005] Therefore, one objective of this invention is to propose a construction method for complex curved single aluminum panel curtain walls, which can achieve high-precision, stress-free, efficient and safe construction of complex curved single aluminum panel curtain walls.

[0006] To achieve the above objectives, the present invention provides the following technical solution: a construction method for complex curved single-aluminum panel curtain walls, comprising the following steps: S1. Parametric detailed design: Decompose the complex curved surfaces in the building model into several single aluminum plate units and determine a unified construction benchmark; S2. Stress relief molding: The single aluminum plate unit is sequentially subjected to molding and stress relief annealing to eliminate its internal stress; S3. Install an adjustable connection system: Install a three-dimensional adjustable connection system on the back of each single aluminum plate unit, the three-dimensional adjustable connection system being capable of providing multi-degree-of-freedom adjustment; S4. Factory pre-assembly: On the factory pre-assembly platform, based on the unified construction benchmark, multiple single aluminum plate units equipped with the three-dimensional adjustable connection system are pre-assembled, and their relative positions are locked after passing the test. S5. Ground modular assembly: Assemble multiple pre-assembled and qualified single aluminum plate units into a hoisting module on the ground and install the first waterproof structure; S6. Install the main body adapter: Based on the unified construction standard, install the adapter for connecting the three-dimensional adjustable connection system on the main structure; S7. High-altitude hoisting and positioning: Hoist the hoisting module to the designed position, connect it to the adapter through the three-dimensional adjustable connection system, and adjust the three-dimensional adjustable connection system to eliminate installation errors and achieve stress-free fixing; S8. Install a second waterproof seal: Construct a second waterproof seal at the joint between adjacent hoisting modules; S9. Overall Inspection: Conduct precision inspection and water spray test on the installed curtain wall.

[0007] Preferably, the compression molding in step S2 is a 3-5 step progressive compression molding using a multi-point shaping mold; the process parameters for the stress-relieving annealing treatment are: heating to 180-220℃ and holding for 2-3 hours, followed by slow cooling to room temperature.

[0008] Preferably, the three-dimensional adjustable connection system includes an adjustable base, an adjusting screw, and a locking nut connected in sequence. The three-dimensional adjustable connection system can achieve linear adjustment of ±50mm in each of the X, Y, and Z directions and angular deflection of ±15°.

[0009] Preferably, the pre-assembly platform in step S4 is a 1:1 high-precision planar platform with a flatness tolerance of ≤0.3mm / m, and the pre-assembly platform is precisely marked with baselines and contour lines consistent with the parametric model.

[0010] Preferably, in step S4, a solid-body template is used to check the surface accuracy of the pre-assembled single aluminum plate unit to ensure that the height difference between adjacent single aluminum plate units is ≤0.2mm and the overall arc surface deviation is ≤1mm / 2m.

[0011] Preferably, the first waterproofing structure is a waterproof tape pre-attached to the seam on the back of the single aluminum plate unit; the second waterproof sealing structure is a sealant filled in the seam between the plates.

[0012] Preferably, in step S5, the size of the hoisting module is controlled within 3m×6m, and the overall rigidity of the hoisting module is tested after assembly.

[0013] Preferably, in step S7, the high-altitude installation time of the hoisting module is controlled within 30 minutes.

[0014] Preferably, the accuracy detection in step S9 includes using a total station or a 3D laser scanner to perform 100% detection of the overall curvature smoothness of the curtain wall, the height difference between adjacent panels, and the gap width. The detection standards are: overall curvature smoothness deviation ≤1mm / 2m, height difference between adjacent panels ≤0.5mm / m, and gap width deviation ≤0.5mm.

[0015] Preferably, the water spray test parameters in step S9 are: water pressure ≥ 0.3 MPa, continuous water spray time ≥ 30 minutes / area, and no leakage is the qualified standard.

[0016] Compared with the prior art, the beneficial effects of the present invention are: This invention achieves high-precision, stress-free, efficient, and safe construction of complex curved single-aluminum panel curtain walls. Compared with existing technologies, it offers several advantages: First, it eliminates assembly stress: by employing stress-relief annealing and a three-dimensional adjustable connection system, the aluminum panels are installed in a free state, avoiding later deformation and cracking caused by forced assembly. Second, it significantly improves precision: using the same digital benchmark throughout processing, pre-assembly, and installation, combined with solid web template testing, ensures smooth curved surfaces and a height difference between adjacent panels ≤0.3mm. Third, it is highly efficient and safe: transferring over 80% of high-altitude assembly work to the ground factory for completion, with modular hoisting single-module high-altitude operation time ≤30 minutes, significantly reducing safety risks. Fourth, it provides reliable waterproofing: employing a double-layer waterproofing system of factory-pre-installed water-stop tape and on-site precision injection, with no leakage in water spray tests. Fifth, it boasts strong adaptability: the three-dimensional adjustable system can absorb errors in the main structure and processing, achieving a high degree of fit between the aluminum panels. Attached Figure Description

[0017] Figure 1 This is a schematic diagram of the construction method for the complex arc-shaped single aluminum panel curtain wall of the present invention. Figure 2 This is a flowchart illustrating the stress relief molding and pre-assembly process in the construction method of complex curved single aluminum panel curtain walls according to the present invention. Detailed Implementation

[0018] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0019] Please see Figures 1-2 The embodiments of the present invention provide a construction method for complex curved single aluminum panel curtain walls, including the following steps: S1. Parametric detailed design: Decompose the complex curved surfaces in the building model into several single aluminum plate units and determine a unified construction benchmark; S2. Stress relief molding: The single aluminum plate unit is sequentially molded and stress-relief annealed to eliminate its internal stress; S3. Install an adjustable connection system: Install a three-dimensional adjustable connection system on the back of each single aluminum plate unit. The three-dimensional adjustable connection system can provide multi-degree-of-freedom adjustment. S4. Factory pre-assembly: On the factory pre-assembly platform, multiple single aluminum plate units equipped with a three-dimensional adjustable connection system are pre-assembled according to a unified construction standard, and their relative positions are locked after passing the test. S5. Ground modular assembly: Assemble multiple pre-assembled and qualified single aluminum panel units on the ground into a hoisting module and install the first waterproof structure; S6. Install the main body adapter: Based on the unified construction standards, install the adapter for connecting the three-dimensional adjustable connection system on the main structure; S7. High-altitude hoisting and positioning: Hoist the hoisting module to the design position, connect it with the adapter through the three-dimensional adjustable connection system, and adjust the three-dimensional adjustable connection system to eliminate installation errors and achieve stress-free fixing; S8. Install a second waterproof seal: Construct a second waterproof seal at the joint between adjacent hoisting modules; S9. Overall Inspection: Conduct precision inspection and water spray test on the installed curtain wall.

[0020] In step S2, the compression molding is a 3-5 step progressive compression molding using a multi-point shaping mold; the process parameters for stress-relief annealing are: heating to 180-220℃ and holding for 2-3 hours, followed by slow cooling to room temperature.

[0021] The three-dimensional adjustable connection system includes an adjustable base, an adjusting screw, and a locking nut connected in sequence. The three-dimensional adjustable connection system can achieve linear adjustment of ±50mm in each of the X, Y, and Z directions and angular deflection of ±15°.

[0022] In step S4, the pre-assembly platform is a 1:1 high-precision planar platform with a flatness tolerance of ≤0.3mm / m, and the pre-assembly platform is precisely marked with baselines and contour lines consistent with the parametric model.

[0023] In step S4, a solid web template is used to check the surface accuracy of the pre-assembled single aluminum plate unit to ensure that the height difference between adjacent single aluminum plate units is ≤0.2mm and the overall arc surface deviation is ≤1mm / 2m.

[0024] The first layer of waterproofing is a waterproof tape pre-attached to the joint on the back of the single aluminum panel unit; the second layer of waterproof sealing is a sealant filled in the joint between the panels.

[0025] In step S5, the size of the hoisting module is controlled within 3m×6m, and the overall rigidity of the hoisting module is tested after assembly.

[0026] In step S7, the high-altitude installation time of the hoisting module is controlled within 30 minutes.

[0027] The accuracy test in step S9 includes using a total station or a 3D laser scanner to perform 100% testing on the overall curvature smoothness of the curtain wall, the height difference between adjacent panels, and the gap width. The testing standards are: overall curvature smoothness deviation ≤1mm / 2m, height difference between adjacent panels ≤0.5mm / m, and gap width deviation ≤0.5mm.

[0028] The water spray test parameters in step S9 are: water pressure ≥ 0.3 MPa, continuous water spray time ≥ 30 minutes / area, and no leakage is the qualified standard.

[0029] First, a BIM-based parametric detailed design was carried out: a precise model of the building's exterior skin was created using Rhino software, and the complex hyperboloid and three-dimensional twisted surfaces were decomposed into approximately 1200 single aluminum plate units of varying sizes. Each unit was numbered, and its boundary dimensions, radius of curvature, and thickness were optimized. In this embodiment, a 2.5mm thick 3003-H24 aluminum plate was selected. At the same time, the detailed design of the three-dimensional adjustable connection system and the main structure transition parts was completed, and the construction benchmark points of the entire curtain wall were uniformly determined.

[0030] Secondly, a stress-relieving forming process is performed: the detailed design drawing of each aluminum plate is imported into the control system of the multi-point forming equipment, automatically generating 1:1 mold surface data, and adjusting the height of the pressure head to form a continuous mold surface that perfectly fits the theoretical curved surface; the aluminum plate is placed on a special fixed mold frame, and a 5-step progressive pressing process is adopted, with the pressing amount gradually decreasing each time, and the strain of the plate is monitored throughout the process; then the pressed curved plate is sent into an annealing furnace and held at 200℃±10℃ for 2.5 hours, and slowly cooled to room temperature with the furnace to completely release the internal stress generated by cold working; after annealing, CNC equipment is used to perform precision machining such as edge trimming, corner opening, and drilling on the aluminum plate, with the accuracy controlled within ±0.2mm.

[0031] Next, the three-dimensional adjustable connection system is installed: the system includes an adjustable base fixed to the back of the aluminum plate by rivets, a long screw (Z-axis adjustment rod) passing through the base, and a locking nut. The other end of the long screw is connected to a hot-dip galvanized steel adapter fixed to the main structure through a cross connector, which can realize the adjustment of 50mm in the X and Y directions, ±50mm in the Z direction, and ±15° angle deflection. The system components are pre-installed on the back of the aluminum plate in the factory, but not completely locked, leaving room for movement.

[0032] Next, high-precision pre-assembly is carried out in the factory: a 1:1 high-precision pre-assembly platform with an area of ​​100 square meters is built in the factory. The flatness of the platform is checked to be 0.2mm / m by a laser tracker. The axis grid lines and the outline lines of each aluminum plate are accurately drawn on the platform, consistent with the BIM model. According to the number, the processed aluminum plate units and their pre-installed adjustable bases are placed in the corresponding positions on the platform. A special alignment module is used to check the surface accuracy of each aluminum plate and adjust the gaps between adjacent plates and the smoothness of the arc surface to ensure that the height difference between adjacent plates is ≤0.2mm and the overall arc surface deviation is ≤1mm / 2m. After the pre-assembly is qualified, the relative positions of adjacent aluminum plates are fixed using special positioning clamps. Pairing marks, installation directions and positioning scales are marked on the back of the aluminum plates and on the connectors. Then the clamps are removed and the plates are packaged for shipment.

[0033] Following this, modular ground assembly was carried out: an assembly platform with the same precision as the factory was built on site, and the pre-assembled and qualified aluminum plate units were recombined according to the factory markings, and the connection system was installed; a layer of butyl waterproof tape was pre-applied to the joints on the back of the aluminum plates to form the first layer of waterproofing; 4-6 adjacent aluminum plates were combined into a hoisting module of approximately 3m × 6m, and its overall rigidity was tested. Simultaneously, the main structure transition components were installed: using a total station and based on a unified construction benchmark, the installation points of each transition component were precisely laid out on the main steel structure with an accuracy of ≤±1mm; hot-dip galvanized steel through-type transition components were installed and firmly connected to the main structure using chemical anchors or welding; the three-dimensional coordinates of each transition component were re-measured, and marked after passing inspection.

[0034] Then, high-altitude modular precision hoisting is carried out: a truck crane is used to smoothly lift the hoisting modules assembled on the ground to the installation floor; after the modules are close to the installation position, workers use mobile scaffolding to quickly connect the pre-adjustable screws on the modules with the adapters on the main body; after initial fixation, a total station and a solid web template are used to check the installation position and surface accuracy of the modules. The modules are finely adjusted in the X / Y / Z directions and angles by rotating the screws on the three-dimensional adjustable system until they fully meet the design requirements. Finally, all locking nuts are tightened to achieve stress-free fixation. The high-altitude installation time of a single module is controlled within 25 minutes.

[0035] The second layer of sealing and waterproofing is then applied: foam rods are embedded in the joints between adjacent hoisting modules, and then high-weather-resistant silicone sealant is injected using a specialized curved glue gun, ensuring full coverage and no air bubbles. A curved scraper is then used to smooth the joint into a smooth arc surface, allowing for a natural transition with the curved aluminum panel surface. The straightness deviation of the joint is ≤0.3mm. This constitutes the second layer of waterproof sealing system, which, together with the first layer of butyl tape, forms a double waterproof layer. Finally, overall accuracy testing and a water spray test are conducted: after all installations are completed, a 3D laser scanner is used to scan the entire curtain wall, generating a point cloud model which is compared with the BIM theoretical model. The results show that the overall arc surface smoothness deviation is ≤1mm / 2m, and the height difference between adjacent panels is ≤0.3mm. Subsequently, a water spray test is conducted according to specifications, with continuous water spraying at 0.4MPa for 30 minutes per area. No leaks were found, and the test was deemed successful. The above are merely preferred embodiments of the present invention and are not intended to limit the present invention. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

[0036] All parts not described in this invention are the same as or can be implemented using existing technology. Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions, and variations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A construction method for complex curved single-aluminum panel curtain walls, characterized in that: Includes the following steps: S1. Parametric detailed design: Decompose the complex curved surfaces in the building model into several single aluminum plate units and determine a unified construction benchmark; S2. Stress relief molding: The single aluminum plate unit is sequentially subjected to molding and stress relief annealing to eliminate its internal stress; S3. Install an adjustable connection system: Install a three-dimensional adjustable connection system on the back of each single aluminum plate unit, the three-dimensional adjustable connection system being capable of providing multi-degree-of-freedom adjustment; S4. Factory pre-assembly: On the factory pre-assembly platform, based on the unified construction benchmark, multiple single aluminum plate units equipped with the three-dimensional adjustable connection system are pre-assembled, and their relative positions are locked after passing the test. S5. Ground modular assembly: Assemble multiple pre-assembled and qualified single aluminum plate units into a hoisting module on the ground and install the first waterproof structure; S6. Install the main body adapter: Based on the unified construction standard, install the adapter for connecting the three-dimensional adjustable connection system on the main structure; S7. High-altitude hoisting and positioning: Hoist the hoisting module to the designed position, connect it to the adapter through the three-dimensional adjustable connection system, and adjust the three-dimensional adjustable connection system to eliminate installation errors and achieve stress-free fixing; S8. Install a second waterproof seal: Construct a second waterproof seal at the joint between adjacent hoisting modules; S9. Overall Inspection: Conduct precision inspection and water spray test on the installed curtain wall.

2. The construction method for complex arc-shaped single aluminum panel curtain walls according to claim 1, characterized in that, The compression molding in step S2 is a 3-5 step progressive compression molding using a multi-point shaping mold; the process parameters for the stress-relieving annealing treatment are: heating to 180-220℃ and holding for 2-3 hours, followed by slow cooling to room temperature.

3. The construction method for complex arc-shaped single aluminum panel curtain walls according to claim 1, characterized in that, The three-dimensional adjustable connection system includes an adjustable base, an adjusting screw, and a locking nut connected in sequence. The three-dimensional adjustable connection system can achieve linear adjustment of ±50mm in each of the X, Y, and Z directions and angular deflection of ±15°.

4. The construction method for complex arc-shaped single aluminum panel curtain walls according to claim 1, characterized in that, The pre-assembly platform in step S4 is a 1:1 high-precision planar platform with a flatness tolerance of ≤0.3mm / m, and the pre-assembly platform is precisely marked with baselines and contour lines consistent with the parametric model.

5. The construction method for complex arc-shaped single aluminum panel curtain walls according to claim 1, characterized in that, In step S4, a solid web template is used to check the surface accuracy of the pre-assembled single aluminum plate unit to ensure that the height difference between adjacent single aluminum plate units is ≤0.2mm and the overall arc surface deviation is ≤1mm / 2m.

6. The construction method for complex arc-shaped single aluminum panel curtain walls according to claim 1, characterized in that, The first waterproofing layer is a waterproof tape pre-attached to the seam on the back of the single aluminum plate unit; the second waterproof sealing layer is a sealant filled in the seam between the plates.

7. The construction method for complex arc-shaped single aluminum panel curtain walls according to claim 1, characterized in that, In step S5, the size of the hoisting module is controlled within 3m×6m, and the overall rigidity of the hoisting module is tested after assembly.

8. The construction method for complex arc-shaped single aluminum panel curtain walls according to claim 1, characterized in that, In step S7, the high-altitude installation time of the hoisting module is controlled within 30 minutes.

9. The construction method for complex arc-shaped single aluminum panel curtain walls according to claim 1, characterized in that, The accuracy detection in step S9 includes using a total station or a 3D laser scanner to perform 100% detection of the overall curvature smoothness of the curtain wall, the height difference between adjacent panels, and the gap width. The detection standards are: overall curvature smoothness deviation ≤1mm / 2m, height difference between adjacent panels ≤0.5mm / m, and gap width deviation ≤0.5mm.

10. The construction method for complex arc-shaped single aluminum panel curtain walls according to claim 1, characterized in that, The water spray test parameters in step S9 are: water pressure ≥ 0.3 MPa, continuous water spray time ≥ 30 minutes / area, and no leakage is the qualified standard.

Images