Fabricated building formwork wall construction modular support frame and construction method thereof

Abstract

The present application relates to the technical field of building construction, in particular to a kind of prefabricated building formwork wall construction modular support frame and its construction method, to solve the problems such as low efficiency, poor adaptability, stress concentration and insufficient durability of traditional support system when supporting prefabricated building formwork wall construction at present.The support frame construction method includes formwork wall three-dimensional positioning, modular support frame assembly, multi-dimensional adjustment correction and rigid-flexible combination fixation and other steps, through three-dimensional adjustable support system, realize X / Y / Z axis adjustment amount ≥±50mm, male corner lock shear strength ≥15kN, female corner lock uplift resistance ≥10kN, realize double lateral displacement locking, make the construction efficiency of the support frame construction method more than 50% higher than traditional process, material turnover rate is greatly improved, wall perpendicularity qualified rate reaches 100%, with significant technical advantages and economic benefits, provide efficient, safe and durable solution for prefabricated building formwork wall construction.

Description

Technical Field

[0001] This invention relates to the field of building construction technology, specifically to a modular support frame for prefabricated building formwork wall construction and its construction method. Background Technology

[0002] With the acceleration of industrialization in construction, prefabricated wall systems have been widely used in residential and public buildings due to their advantages such as light weight, fast construction speed, and good environmental performance. However, traditional support systems still have the following technical bottlenecks that urgently need to be overcome: the use of scaffolding + timber combination requires repeated disassembly and assembly, and the timber is prone to moisture and deformation, resulting in low construction efficiency and unstable wall quality; rigid connections lack buffer structures and cannot adapt to the slight displacement of the wall under thermal expansion and contraction and seismic action, which can easily lead to component cracking; single-point fixing methods are prone to local stress concentration, and metal components lack systematic anti-corrosion treatment, resulting in a short service life of only 3-5 years in humid and high-salt spray environments. Existing adjustable supports are mostly single-dimensional adjustment, which is difficult to meet the complex construction needs of irregular curved walls, and the adjustment accuracy is low, which cannot guarantee the flatness of the wall; although existing technologies have attempted to optimize the adjustable mechanism, they have not formed a complete solution of "assembly-adjustment-fixing-anti-corrosion", and cannot balance construction efficiency, structural safety and long-term durability. Therefore, there is an urgent need for a new support method that integrates modularity, high-precision adjustment, strong resistance to lateral displacement, and full-cycle corrosion protection. Summary of the Invention

[0003] This invention provides a modular support frame for prefabricated building formwork wall construction and its construction method to solve the problems mentioned above.

[0004] To achieve the above objectives, the present invention adopts the following technical solution: A modular support frame for prefabricated building formwork wall construction includes a vertical bar, a horizontal bar movably connected to the vertical bar via a trapezoidal tooth tenon joint, a double threaded screw adjustment device on the top side of the horizontal bar, a double screw turnbuckle tie rod movably and horizontally provided on the bottom side of the horizontal bar, an intermediate adjustment sleeve sleeved on the double screw turnbuckle tie rod, and an adjustable base at the bottom of the vertical bar.

[0005] Furthermore, the double-threaded screw adjusting device is provided with a first adjusting nut, and the double-threaded turnbuckle pull rod is provided with a second adjusting nut, and the second adjusting nut is also connected with an anti-detachment pin.

[0006] Furthermore, a self-locking wedge lock is provided at the external corner of the crossbar, and a U-shaped buckle is provided at the internal corner of the crossbar.

[0007] A construction method for a modular support frame for prefabricated building formwork walls includes the following steps: Step 1, 3D positioning of the formwork wall: Based on the coordination of BIM layout data and building information model, a high-precision total station is used to locate the spatial coordinates of the formwork wall, with the positioning error controlled within ±2mm, and the positioning data is collected and uploaded to the construction management platform simultaneously; Step 2, Modular support frame assembly: a. Prefabricated unit assembly: Galvanized square tubing is selected as the vertical and horizontal bars, which are connected by a modified trapezoidal tooth tenon joint. b. Adjustable mechanism installation: A double-threaded screw adjustment device is installed at the top of the vertical bar, with an adjustment range of 0-120mm. A double-threaded turnbuckle tie rod is installed in the middle of the horizontal bar, with an adjustment accuracy of 0-0.8mm. The surface of the tie rod is covered with a polytetrafluoroethylene wear-resistant layer.

[0008] Step 3, Multidimensional Adjustment and Correction: a. Verticality adjustment: A laser plumb line is used in conjunction with a double-threaded screw adjustment device to adjust the verticality of the formwork wall in stages, first coarse adjustment and then fine adjustment. After adjustment, the verticality error of the wall within a 2m height range is ≤2.5mm. A digital display inclinometer is used for secondary verification at the same time.

[0009] b. Flatness correction: The flatness of the formwork wall is finely adjusted by using double screw turnbuckles. During the adjustment process, an electronic level is used for real-time monitoring. A monitoring point is set at every 500mm interval. The flatness error is controlled within 2mm. The monitoring data automatically generates a flatness curve report and is saved to the construction archive.

[0010] Step 4: Fixed with a combination of rigidity and flexibility: a. Node locking: The external corner uses a self-locking wedge lock with an anti-loosening washer inside. The internal corner is equipped with a double-bolt U-shaped buckle. After tightening, the torque wrench is used for verification.

[0011] b. Structural connection: anti-seismic clamps are used, with an adjustable clamp opening range of 30-80mm. The support frame is connected to the formwork wall. Anti-slip rubber pads are pasted on the inside of the clamps. A reinforcing connector is installed every 800mm. The connector is fully welded to the pre-embedded steel plate of the formwork wall.

[0012] Step 5: Full-cycle anti-corrosion treatment: After the modular support frame is assembled, polyurea waterproof and anti-corrosion coating is sprayed onto the bolt connection nodes and mortise and tenon nodes. After construction, the support system is inspected for corrosion protection every 6 months, and any damage to the coating is repaired in time.

[0013] The present invention has the following beneficial effects: This invention provides a modular support frame and its construction method for prefabricated building formwork walls, including three-dimensional positioning of the formwork wall, assembly of the modular support frame, multi-dimensional adjustment and correction, and rigid-flexible fixing. Through a three-dimensional adjustable support system, the X / Y / Z axis adjustment range is ≥±50mm, the shear strength of the external corner lock is ≥15kN, and the pull-out force of the internal corner lock is ≥10kN, achieving double anti-lateral displacement locking. This support frame construction method improves construction efficiency by more than 50% compared to traditional processes, greatly increases material turnover rate, and achieves a 100% wall verticality qualification rate. It has significant technical advantages and economic benefits, providing an efficient, safe, and durable solution for prefabricated building formwork wall construction. It solves the problems of low efficiency, poor adaptability, stress concentration, and insufficient durability of traditional support systems in prefabricated building formwork wall construction.

[0014] The three-dimensional positioning of the molded wall in this invention combines BIM technology with high-precision measuring equipment to achieve digital positioning and precise error control, laying the foundation for subsequent construction. The modular support frame assembly uses high-strength galvanized pipes and improved mortise and tenon joints to enhance the connection strength and stability of components, while optimizing the adjustable mechanism design to expand the adjustment range and improve adjustment accuracy. Multi-dimensional adjustment and correction, through graded adjustment and dual-device monitoring, ensures that the verticality and flatness errors of the wall are reduced to a lower level, guaranteeing the quality of the molding. The rigid-flexible combination fixing upgrade node locking structure enhances shear and pull-out resistance, while adding anti-seismic clamps and anti-slip components to improve the overall wind and earthquake resistance of the system. The full-cycle anti-corrosion treatment addresses the problem of easy corrosion of metal components by adopting a dual anti-corrosion solution of "zinc-aluminum alloy coating + polyurea coating" to extend the service life of the support system.

[0015] The support frame of this invention consists of vertical bars, horizontal bars, an adjustable mechanism, and fasteners. The structural design can be flexibly adjusted according to the wall type, whether it is a standard wall or an irregular curved wall. The stability of the support frame is ensured through the synergistic action of external corner locks, internal corner locks, and anti-seismic clamps. At the same time, the addition of full-cycle anti-corrosion treatment significantly solves the pain point of insufficient durability of traditional support systems. Attached Figure Description

[0016] Figure 1 This is a schematic diagram of the overall structure of the support frame of the present invention.

[0017] Figure 2 This is a schematic diagram illustrating the adjustment of the adjustable lead screw turnbuckle of the present invention.

[0018] Figure 3 This is a schematic diagram of the locking structure of the corner lock of the present invention.

[0019] Figure 4 This is a schematic diagram of the U-shaped buckle locking mechanism at the inner corner of the node according to the present invention.

[0020] Figure 5This is a schematic diagram of the adjustable base structure of the present invention.

[0021] Figure 6 This is a schematic diagram of the assembly of the arc-shaped wall support frame of the present invention.

[0022] The attached figures are labeled as follows: 1. Vertical bar; 2. Horizontal bar; 3. Trapezoidal tooth tenon joint; 4. Double threaded screw adjustment device; 5. Double screw turnbuckle pull rod; 6. Adjustable base; 7. Intermediate adjusting sleeve; 8. First adjusting nut; 9. Second adjusting nut; 10. Anti-detachment pin; 11. Curved wall; 12. Self-locking wedge lock; 13. U-shaped buckle; 14. External corner; 15. Internal corner. Detailed Implementation

[0023] The present invention will be further described below with reference to the accompanying drawings and specific embodiments.

[0024] A modular support frame for prefabricated building formwork wall construction includes a vertical bar 1, which is movably connected to a horizontal bar 2 via a trapezoidal tooth tenon joint 3. The top side of the horizontal bar 2 is equipped with a double-threaded screw adjustment device 4, and the bottom side of the horizontal bar 2 is movably and horizontally equipped with a double-threaded turnbuckle pull rod 5. An intermediate adjusting sleeve 7 is fitted onto the double-threaded turnbuckle pull rod 5. An adjustable base 6 is also provided at the bottom of the vertical bar 1. The double-threaded screw adjustment device 4 is equipped with a first adjusting nut 8, and the double-threaded turnbuckle pull rod 5 is equipped with a second adjusting nut 9, which is also connected to an anti-detachment pin 10. A self-locking wedge-shaped lock 12 is provided at the external corner 14 of the horizontal bar 2, and a U-shaped buckle 13 is provided at the internal corner 15 of the horizontal bar 2.

[0025] The adjustable base 6 includes a base plate, an adjusting nut, an anti-slip pad, and an anti-vibration spring. The base plate is made of Q345 steel plate with specifications of 250×250×12mm, and the surface is sandblasted to Sa2.5 grade for rust removal. The adjusting nut is M30 with trapezoidal thread and a pitch of 6mm. The anti-slip pad is made of neoprene rubber with a thickness of 5mm and a friction coefficient ≥0.6. The anti-vibration spring has a diameter of 12mm and a free length of 50mm, and is sleeved on the outside of the adjusting screw. The load-bearing capacity of a single adjustable base is not less than 60kN. The base is fixed to the structural floor slab with expansion bolts of specification M16×100. After fixing, a pull-out test is performed with a test force ≥30kN and a holding time of 10min without loosening. The double-threaded lead screw adjustment device 4 includes a lead screw body, an adjusting nut, a mounting base, and a dust cover. The threads at both ends of the lead screw body are opposite in direction, with a pitch of 5mm. It is rotatably connected to the mounting base via a deep groove ball bearing (model 6304). A rubber dust cover with an IP65 protection rating is installed on the outside of the bearing. A rotating handle with a length of 120mm and a knurled surface is added to the outside of the adjusting nut for easy manual operation. A limit block made of 45# steel with a thickness of 10mm is installed at the top of the lead screw to prevent over-adjustment from causing the component to detach. The double-threaded turnbuckle tie rod 5 includes a middle adjusting sleeve 7, two reverse-threaded lead screws at both ends, and an anti-detachment pin 10. The inner wall of the middle adjusting sleeve 7 is provided with anti-slip texture. The two lead screws at both ends are welded to the crossbar 2 and the mold wall connector, respectively, with a weld grade of Class II. An anti-detachment pin 10 with a diameter of 8mm and an insertion depth of ≥20mm is installed at the end of the lead screw to prevent the lead screw from detaching from the sleeve during adjustment. The tie rod has a maximum tensile load of ≥80kN and an elongation at break of ≤5%.

[0026] Furthermore, for the construction of the irregular curved wall 11, the vertical bar 1 adopts a segmented hinged design, with each segment ≤1200mm in length. The hinged parts use stainless steel pins, φ16×50mm in size, with chrome-plated surfaces for connection. Cotter pins are installed at both ends of the pins to prevent loosening. The horizontal bar 2 is equipped with a three-way adjustable turnbuckle, which can achieve ±18° angle adjustment with an adjustment torque ≤40N・m. The node lock is replaced with a spherical contact connector, increasing the spherical contact area to ≥200mm². The connector has a built-in self-lubricating copper sleeve made of ZCuSn10Pb5 to reduce frictional resistance during multi-angle adjustment. The spherical contact connector includes a connector seat with a spherical groove, made of 45# steel with a surface hardening hardness of HRC50-55, a ball head connector made of 304 stainless steel, and an elastic sealing ring made of fluororubber with a temperature range of - The temperature range is 20℃-200℃. The spherical fit clearance between the ball joint connector and the connecting seat is controlled at 0.1-0.2mm. The elastic sealing ring is embedded in the groove of the connecting seat to achieve waterproof and dustproof sealing. The maximum allowable deflection angle of the connector is ±20°, and the rated load is ≥50kN. A graded monitoring system is implemented during concrete pouring. The support system is checked every 20 minutes for the first hour and every 30 minutes thereafter. The inspection content includes "displacement monitoring at component connections" using displacement sensors with an accuracy of ±0.05mm and "bolt torque verification" using a digital torque wrench. After pouring, continuous monitoring is carried out for 24 hours, with data recorded every 2 hours. The monitoring data is uploaded to the cloud platform in real time. If any abnormality occurs, such as displacement exceeding 1mm or torque change exceeding 10%, an early warning is automatically triggered, and construction personnel must arrive on site within 15 minutes to handle the situation.

[0027] The construction method for modular support frames in prefabricated building formwork walls includes the following steps: Step 1, 3D positioning of the formwork wall: Based on the coordination of BIM layout data and building information model, a high-precision total station is used to locate the spatial coordinates of the formwork wall. The positioning error is controlled within ±2mm, and the positioning data is collected and uploaded to the construction management platform simultaneously.

[0028] Step 2, Modular support frame assembly: a. Prefabricated unit assembly: Galvanized square tubing is selected as vertical bars 1 and horizontal bars 2. Vertical bars 1 and horizontal bars 2 are connected by modified trapezoidal tooth tenon joints 3. b. Adjustable mechanism installation: A double-threaded screw adjustment device 4 is installed at the top of vertical bar 1, with an adjustment range of 0-120mm. A double-threaded turnbuckle tie rod 5 is installed in the middle of horizontal bar 2, with an adjustment accuracy of 0-0.8mm. The surface of the tie rod is covered with a polytetrafluoroethylene wear-resistant layer.

[0029] Step 3, Multidimensional Adjustment and Correction: a. Verticality adjustment: A laser plumb line is used in conjunction with a double threaded screw adjustment device 4 to adjust the verticality of the formwork wall in stages, first coarse adjustment and then fine adjustment. After adjustment, the verticality error of the wall within a 2m height range is ≤2.5mm. A digital display inclinometer is used for secondary verification at the same time.

[0030] b. Flatness correction: The flatness of the formwork wall is finely adjusted by using double screw turnbuckles 5. During the adjustment process, an electronic level is used for real-time monitoring. A monitoring point is set at every 500mm interval. The flatness error is controlled within 2mm. The monitoring data automatically generates a flatness curve report and is saved to the construction archive.

[0031] Step 4: Fixed with a combination of rigidity and flexibility: a. Node locking: The external corner 14 is equipped with a self-locking wedge lock 12, and an anti-loosening washer is added inside the self-locking wedge lock 12. The internal corner 15 is equipped with a double bolt U-shaped buckle 13. After tightening, the torque wrench is used for verification.

[0032] b. Structural connection: anti-seismic clamps are used, with an adjustable clamp opening range of 30-80mm. The support frame is connected to the formwork wall. Anti-slip rubber pads are pasted on the inside of the clamps. A reinforcing connector is installed every 800mm. The connector is fully welded to the pre-embedded steel plate of the formwork wall.

[0033] Step 5: Full-cycle anti-corrosion treatment: After the modular support frame is assembled, polyurea waterproof and anti-corrosion coating is sprayed onto the bolt connection nodes and mortise and tenon nodes. After construction, the support system is inspected for corrosion protection every 6 months, and any damage to the coating is repaired in time.

[0034] Example 1 Construction of standard layer formwork walls in coastal areas with high salt spray: Pre-treatment of structural floor slabs: Apply epoxy sealing primer (thickness ≥80μm), and pre-embed anchor bolts (specification M20×150, material 316 stainless steel) in a quincunx pattern at 1000mm intervals, with an exposed bolt length of 50mm. After installation, conduct a pull-out test (test force ≥35kN).

[0035] Support unit assembly: Vertical bars 1 are spaced 500mm apart, horizontal bars 2 are set according to a floor height of 2000mm, and each horizontal bar 2 is reinforced with double splicing (two 60×40×3mm galvanized square tubes are connected in parallel). After the trapezoidal tooth tenon joint 3 bolts are tightened, polyurea anti-corrosion coating is applied.

[0036] Lifting and positioning: A hydraulic lift truck with a level (rated load ≥ 5t) is used for overall lifting. Before lifting, a three-dimensional control line is projected using a laser positioning system, and the positioning deviation is controlled within ±1mm.

[0037] Multi-dimensional adjustment: First, adjust the verticality using the first adjusting nut 8 (the height error is ≤2.5mm per 2m, verified by a digital inclinometer), then correct the flatness using the second adjusting nut 9 (the monitoring point spacing is 400mm, and the error is ≤1.5mm). After adjustment, lock the adjustable mechanism.

[0038] Rigid-flexible fixing: Self-locking wedge lock 12 (applied with anti-rust grease) is installed at the external corner 14, and double bolt U-shaped buckle 13 (bolt torque 48 N·m) is installed at the internal corner 15. Anti-vibration clamps (800 mm spacing) are used to connect the support frame and the mold wall, and the rubber pad on the inside of the clamps ensures a tight fit.

[0039] Corrosion protection finishing touches: All joints, bolts and exposed metal parts are sprayed with polyurea waterproof and anti-corrosion coating (dry film thickness 1.5mm), and anti-corrosion labels (indicating the anti-corrosion validity period) are affixed to the surface of the components.

[0040] Concrete pouring monitoring: During concrete pouring, check at a frequency of "20 minutes / time (first 1 hour) + 30 minutes / time (after 1 hour)", focusing on monitoring displacement, torque and bolt tightness. Record data every 2 hours within 24 hours after pouring.

[0041] Example 2 Construction of irregular curved wall with radius R=2500mm: Component customization: Vertical bar 1 adopts a segmented hinged design, with each segment being 1000mm long. The hinged parts are connected by φ16×50mm stainless steel pins, and the pins are fitted with self-lubricating copper sleeves; Horizontal bar 2 is equipped with a three-way adjustable turnbuckle, with an adjustment angle range of ±18°.

[0042] Curved surface adaptation: Before installing the spherical contact connector, clean the spherical groove and ball head, apply special grease to ensure smooth multi-angle adjustment, and the gap between the connector and the mold wall should be ≤0.2mm.

[0043] Precision control: A 3D laser scanner (accuracy ±0.1mm) is used to monitor the contour of the curved wall in real time. A monitoring point is set every 500mm. The angle of the crossbar is finely adjusted by a three-way adjustable turnbuckle to ensure that the curvature deviation of the wall is ≤1mm / m.

[0044] Strengthening fixation: Diagonal supports (80×40×3.5mm galvanized square tubes) are added to both ends of the curved wall 11. The diagonal supports are fully welded to the vertical bar 1 and the floor slab (weld height 8mm), and the weld surface is treated with anti-corrosion.

[0045] Verified through multiple engineering practices, covering coastal residential buildings, inland public buildings, and irregular curved wall projects, this invention, compared to traditional methods, achieves: over 50% improved construction efficiency (reducing the construction cycle of a single 10-story building to 7 days); a 3-fold increase in material turnover (the support system can be reused more than 8 times, compared to only 2-3 times with traditional methods); 100% wall verticality compliance rate; and a flatness error ≤1.5mm, far exceeding industry standards (≤3mm); the support system's service life is extended to over 8 years (compared to 3-5 years for traditional systems), and in high-salt-fog coastal environments, the component corrosion rate is ≤0.5% after 1 year (compared to ≥5% for traditional systems). Through structural optimization and functional upgrades, this invention balances construction efficiency, structural safety, and durability, providing a superior solution for prefabricated building formwork wall construction in various scenarios.

Claims

1. A modular support frame for prefabricated building formwork wall construction, characterized in that: It includes a vertical bar (1), which is movably connected to a horizontal bar (2) through a trapezoidal tooth tenon joint (3). The top side of the horizontal bar (2) is provided with a double threaded screw adjustment device (4), and the bottom side of the horizontal bar (2) is movably and horizontally provided with a double screw turnbuckle pull bar (5). An intermediate adjustment sleeve (7) is fitted on the double screw turnbuckle pull bar (5). The bottom of the vertical bar (1) is also provided with an adjustable base (6).

2. The modular support frame for prefabricated building formwork wall construction according to claim 1, characterized in that: The double-threaded screw adjusting device (4) is provided with a first adjusting nut (8), and the double-threaded turnbuckle pull bar (5) is provided with a second adjusting nut (9). The second adjusting nut (9) is also connected with an anti-detachment pin (10).

3. The modular support frame for prefabricated building formwork wall construction according to claim 1, characterized in that: The crossbar (2) is provided with a self-locking wedge lock (12) at the external corner (14) and a U-shaped buckle (13) at the internal corner (15).

4. A construction method for a modular support frame for prefabricated building formwork walls, characterized in that, Includes the following steps: Step 1, 3D positioning of the formwork wall: Based on the coordination of BIM layout data and building information model, a high-precision total station is used to locate the spatial coordinates of the formwork wall, with the positioning error controlled within ±2mm, and the positioning data is collected and uploaded to the construction management platform simultaneously; Step 2, Modular support frame assembly: a. Prefabricated unit assembly: Galvanized square tubes are selected as vertical bars (1) and horizontal bars (2). The vertical bars (1) and horizontal bars (2) are connected by modified trapezoidal tooth tenon joints (3); b. Adjustable mechanism installation: A double threaded screw adjustment device (4) is set at the top of the vertical bar (1), with an adjustment range of 0-120mm. A double threaded turnbuckle pull bar (5) is set in the middle of the horizontal bar (2), with an adjustment accuracy of 0-0.8mm. The surface of the pull bar is wrapped with a polytetrafluoroethylene wear-resistant layer; Step 3, Multidimensional Adjustment and Correction: a. Verticality adjustment: The verticality of the formwork wall is adjusted in stages using a laser plumb line with a double threaded screw adjustment device (4). First, a coarse adjustment is made, then a fine adjustment is made. After adjustment, the verticality error of the wall within a height range of 2m is ≤2.5mm. A digital display inclinometer is used for secondary verification at the same time. b. Flatness correction: The flatness of the formwork wall is finely adjusted by using double screw turnbuckles (5). During the adjustment process, an electronic level is used for real-time monitoring. A monitoring point is set every 500mm. The flatness error is controlled within 2mm. The monitoring data automatically generates a flatness curve report and is saved to the construction archive. Step 4: Fixed with a combination of rigidity and flexibility: a. Node locking: The external corner (14) is equipped with a self-locking wedge lock (12), and an anti-loosening washer is added inside the self-locking wedge lock (12). The internal corner (15) is equipped with a double bolt U-shaped buckle (13). After tightening, a torque wrench is used for verification. b. Structural connection: anti-seismic clamps are used, with the clamp opening adjustable from 30-80mm. The support frame is connected to the formwork wall. Anti-slip rubber pads are pasted on the inside of the clamps. A reinforcing connector is installed every 800mm. The connector is fully welded to the pre-embedded steel plate of the formwork wall. Step 5: Full-cycle anti-corrosion treatment: After the modular support frame is assembled, polyurea waterproof and anti-corrosion coating is sprayed onto the bolt connection nodes and mortise and tenon nodes. After construction, the support system is inspected for corrosion protection every 6 months, and any damage to the coating is repaired in time.

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