A cast-in-situ concrete wall formwork positioning inner support and a construction method thereof

Abstract

The application discloses a cast-in-situ concrete wall formwork positioning inner support and a construction method thereof, which comprises a support block, wherein the support block is a cubic solid block made of waste concrete, and the thickness of the support block is the same as the thickness of a wall to be poured; a pre-embedded reinforcing bar, wherein the pre-embedded reinforcing bar is a waste reinforcing bar head, is pre-embedded in the support block, and extends out of the support block at both ends; and a connecting reinforcing bar, wherein the connecting reinforcing bar is welded with the extending ends of two pre-embedded reinforcing bars to realize overall positioning of the inner support; two support blocks of a plurality of positioning supports are attached to two wall formworks, and the connecting reinforcing bar is located between the two wall formworks, so that the application realizes waste material recycling, avoids purchasing, realizes accurate positioning, realizes rapid formwork erection, and significantly improves construction efficiency and wall forming quality.

Description

Technical Field

[0001] This invention relates to the field of cast-in-place concrete wall technology, and more specifically, to a formwork positioning internal support for cast-in-place concrete walls and its construction method. Background Technology

[0002] In projects such as metallurgical construction, municipal integrated pipe corridors, water tanks, and underground silos, cast-in-place concrete walls are the main structural form. Wall construction typically includes four major processes: surveying and setting out, rebar tying, formwork positioning and reinforcement, and concrete pouring. Among these, formwork positioning and reinforcement directly determine the wall thickness, verticality, flatness, and overall appearance quality.

[0003] Traditional formwork supports often use cement internal bracing, cement strips, special plastic internal bracing, or welded steel bar segments, which have the following problems:

[0004] Specialized internal support components need to be purchased in bulk, resulting in higher costs.

[0005] Ordinary cement internal supports have low strength, are easily broken, and can easily cause formwork displacement and thickness loss.

[0006] Rebar bracing requires on-site cutting of new material, which wastes steel and increases costs.

[0007] Installation requires repeated adjustments to verticality, resulting in high labor costs, low efficiency, and difficulty in meeting urgent work demands.

[0008] Existing related patents, such as CN202210716909.1, disclose an internal support and external tie rod for a formwork used in shear wall casting. It adopts a combination structure of support pipe, glue cup, and screw rod. Although it can achieve positioning and fastening, it still requires special components to be processed and manufactured, and cannot utilize on-site waste materials, resulting in insufficient economy and convenience. Summary of the Invention

[0009] To address the problems existing in the prior art, the purpose of this invention is to provide a positioning internal support for cast-in-place concrete wall formwork and its construction method, which enables waste material reuse, eliminates the need for procurement, ensures precise positioning, and enables rapid formwork erection, thereby significantly improving construction efficiency and wall forming quality.

[0010] The present invention adopts the following technical solution:

[0011] An internal bracing system for positioning cast-in-place concrete wall formwork, comprising:

[0012] The support block is a solid cube made of waste concrete, and the thickness of the support block is the same as the thickness of the wall to be poured.

[0013] The embedded bar is a waste steel bar end, which is embedded inside the support block and extends outward from the outside of the support block at both ends.

[0014] Connecting ribs are welded to the extended ends of two pre-embedded ribs to achieve overall positioning of the internal support;

[0015] Two support blocks with multiple positioning supports are attached to two wall formworks, and the connecting bars are located between the two wall formworks.

[0016] Furthermore, the dimensions of the support block are 50*50*50mm.

[0017] Furthermore, the length of the embedded bar is 100mm, and the diameter of the embedded bar is greater than or equal to 16mm.

[0018] Furthermore, the support block is cast from the remaining concrete from the pump truck at the construction site, and the casting mold is made by cutting and making discarded templates on site.

[0019] Furthermore, the embedded reinforcement is bent in the middle at a 90° angle, with straight sections at both ends each 30mm in length.

[0020] This invention also provides a construction method for positioning internal supports in cast-in-place concrete wall formwork, comprising the following steps:

[0021] S1. Waste material preparation: Collect waste steel bar ends, waste formwork, and leftover materials from concrete pump trucks at the construction site;

[0022] S2. Mold making: Use discarded templates to cut and assemble a cube mold with a wall thickness of 50mm×50mm×50mm;

[0023] S3. Precast support block: The bent and shaped embedded bars are placed into the mold, the remaining concrete from the pump truck is poured, and the mold is removed after 7 days of curing to obtain the support block with the embedded bars.

[0024] S4. Positioning and installation: Weld the connecting bar to the two pre-embedded bars, and then weld and fix the overall internal support to the wall steel reinforcement skeleton.

[0025] S5. Formwork erection: The formwork on both sides of the wall is tightly attached to the outer surface of the support block and reinforced by back bracing and tie rods.

[0026] Furthermore, the internal supports are arranged at 600mm×600mm intervals.

[0027] Beneficial effects

[0028] All components of this invention are made from construction waste sourced from construction sites: prefabricated molds are assembled from discarded templates, embedded and connecting bars are made from scrap steel bars from steel bar processing areas, and support blocks are prefabricated from leftover material after concrete pumping. The entire process eliminates the need for purchasing specialized internal support materials, cutting new steel bars, or customizing molds, achieving on-site disposal and recycling of construction waste from the source. This reduces the cost of transporting and disposing of solid waste, fully complies with the Ministry of Housing and Urban-Rural Development's requirements for green construction and carbon emission reduction, and is particularly suitable for cost reduction needs in large-scale projects such as large-scale metallurgical industrial projects and municipal integrated pipe corridors.

[0029] Unlike traditional single-block internal supports, which are prone to tilting, loose end-face fit, and positioning benchmark failure, this invention uses a combined positioning structure of "symmetrical support blocks on both sides + rigid connecting ribs in the middle". The outer end faces of the two support blocks form complete surface contact with the wall templates on both sides, resulting in a large contact area and precise positioning benchmarks. Combined with the rigid connection of the connecting ribs, it eliminates problems such as inward tilting and outward expansion of the templates and uneven wall thickness. At the same time, it eliminates the residue of plastic, foreign objects, and other materials incompatible with the main structure, preventing the formation of water seepage channels and solving the leakage risks of underground silos, fire water tanks, and other walls with anti-seepage requirements.

[0030] This invention adopts a modular combination structure, which can flexibly adjust the length of the connecting bars according to the design thickness of different walls, and is suitable for conventional wall thicknesses ranging from 200mm to 500mm. It eliminates the need to remake precast molds and has extremely strong versatility. At the same time, the spacing of the internal bracing can be flexibly adjusted according to the wall height, length, and concrete lateral pressure. It is not only suitable for conventional walls such as shear walls in residential buildings, municipal pipe corridors, pump rooms, and fire water tanks, but also for the construction of thick-walled, large-volume concrete walls such as the foundations of elevated equipment in metallurgical projects and underground material receiving troughs. It is applicable to cast-in-place wall projects in both civil and industrial buildings.

[0031] The prefabrication of support blocks only requires the assembly of simple molds using discarded templates on site, and the pouring of leftover concrete from the pump truck. The bending and welding of steel bars are all conventional processes on the construction site. There is no need for off-site prefabrication plants or special production equipment. The components can be made on-site without being restricted by site or schedule. It can be flexibly matched with the on-site construction rhythm and is especially suitable for industrial projects in remote areas and construction scenarios where off-site prefabrication conditions are insufficient. Attached Figure Description

[0032] Figure 1 This is a schematic diagram of the connection between the embedded reinforcement and the support block according to an embodiment of the present invention;

[0033] Figure 2 This is a schematic diagram of an embodiment of the present invention;

[0034] Figure 3 This is a schematic diagram illustrating the support of an embodiment of the present invention. Detailed Implementation

[0035] To make the objectives, technical solutions, and advantages of this invention clearer, the invention will be further described in detail below with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative and not intended to limit the invention.

[0036] As shown in the figure, this invention discloses a positioning internal brace for cast-in-place concrete wall formwork, comprising:

[0037] Support block 1, wherein the support block 1 is a solid cube precast from waste concrete, and the thickness of the support block is the same as the thickness of the wall to be poured.

[0038] Embedded reinforcement 2, wherein the embedded reinforcement is a scrap steel bar end, embedded inside the support block, with both ends extending outward from the outside of the support block;

[0039] Connecting rib 3, the connecting rib is welded to the extended ends of the two pre-embedded ribs to achieve overall positioning of the internal support;

[0040] Two support blocks 1 with multiple positioning supports are attached to two wall formwork 4, and the connecting ribs 3 are located between the two wall formwork 4.

[0041] In one embodiment of the present invention, the size of the support block 1 is 50*50*50mm.

[0042] The support blocks are made of concrete with the same strength as the wall, which can withstand the lateral pressure during the concrete pouring process, avoiding cracking and deformation. This ensures the accuracy of the wall thickness from the source and solves the pain points of traditional cement internal supports being easy to break and failing to position.

[0043] The standardized anchorage design of the pre-embedded reinforcement makes the reinforcement and the support block form a rigid whole, eliminating the problems of reinforcement detachment and slippage during use, ensuring the effective transmission of support force, and improving the structural reliability by more than 80% compared with the direct-embedded reinforcement internal bracing.

[0044] The rigid welded structure of the connecting bars and the embedded bars ensures that the two support blocks always maintain coaxiality, eliminating the problems of tilting and misalignment of a single inner support and loose end face fit. The two support blocks form a surface contact with the template, with a large contact area and accurate positioning reference, which completely solves the common quality problems of template inclination, outward expansion and uneven wall thickness.

[0045] The core structure is made entirely from construction waste on site, eliminating the need to purchase special internal support components or cut steel bars. The cost of internal support materials per square meter of wall is reduced by more than 90%. At the same time, construction waste is disposed of on-site without the need for external transportation and disposal, which fully meets the engineering requirements of green construction and carbon emission reduction.

[0046] The internal support structure contains no plastic or PVC sleeves or other materials that are incompatible with the main structure. After molding, it will not form water seepage channels in the wall, thus solving the leakage problem in underground silos, fire water tanks and other walls with anti-seepage requirements, and improving the durability of the structure.

[0047] In one embodiment of the present invention, the length of the embedded bar 2 is 100mm and the diameter of the embedded bar 2 is greater than or equal to 16mm.

[0048] In one embodiment of the present invention, the support block 1 is cast from the remaining concrete from the pump truck at the construction site, and the casting mold is made by cutting and making discarded templates on site.

[0049] By using the remaining concrete from the pump truck to pour support blocks, the waste of tail material during the concrete pouring process is completely eliminated, and the transportation and disposal of the remaining concrete is avoided. This reduces the loss of concrete materials and the cost of solid waste disposal, and realizes the on-site recycling of construction waste.

[0050] Molds are made from discarded templates on-site, eliminating the need for custom-made precast molds or additional mold materials. Mold making is cost-free. Furthermore, the cutting and assembling of discarded templates is a standard construction process, allowing workers to quickly learn without additional training. This method is suitable for all site conditions in building construction, municipal engineering, and industrial projects.

[0051] It can be poured as soon as there is leftover material from the pump truck, without the need for special arrangements for concrete production. It can flexibly match the pace of on-site construction and is not limited by the prefabrication cycle. It is especially suitable for projects with tight deadlines and construction scenarios in remote areas and where off-site prefabrication conditions are insufficient.

[0052] The support blocks are made of concrete of the same strength grade as the wall. The molded support blocks are made of the same material as the cast-in-place wall concrete. After pouring, they can be perfectly bonded to the wall concrete. There is no shrinkage difference, and shrinkage cracks and water seepage channels will not be formed, which ensures the impermeability of the wall. It is especially suitable for wall projects with strict impermeability requirements such as fire water tanks, integrated pipe corridors, and underground silos.

[0053] In one embodiment of the present invention, the pre-embedded reinforcing bar 2 is bent in the middle at a bending angle of 90°, and the straight sections at both ends are each 30mm long.

[0054] The 90° bend in the middle of the embedded bar significantly improves the mechanical anchorage force between the bar and the precast concrete. Compared with straight bars, the bent bar can form a two-way limit, ensuring that the rigid connection between the support block and the connecting bar is always effective.

[0055] The straight extension section of 30mm at each end meets the weld length requirements for double-sided lap welding with the connecting rib, ensuring that the mechanical properties of the welded joint meet the standards and that there will be no problems such as weld cracking or falling off. At the same time, the standardized extension length facilitates batch welding operations on site without the need for repeated alignment adjustments.

[0056] The 90° bending structure allows the embedded bars to form a three-dimensional anchorage within the support block, which can withstand impact forces from all directions. During the concrete pouring and vibration process, the embedded bars will not be displaced or rotated due to the disturbance of the vibrator, ensuring that the positioning benchmark of the support block remains stable and preventing the failure of the internal support.

[0057] Standardized bending dimensions allow for batch bending using on-site rebar processing equipment, resulting in high processing accuracy and speed. It eliminates the need for individual bar layout, significantly improving the pre-processing efficiency of embedded rebars and meeting the batch prefabrication needs of large-scale projects.

[0058] This invention also provides a construction method for positioning internal supports in cast-in-place concrete wall formwork, comprising the following steps:

[0059] S1. Waste material preparation: Collect waste steel bar ends, waste formwork, and leftover materials from concrete pump trucks at the construction site;

[0060] S2. Mold making: Use discarded templates to cut and assemble a cube mold with a wall thickness of 50mm×50mm×50mm;

[0061] S3. Precast support block: The bent and shaped embedded bars are placed into the mold, the remaining concrete from the pump truck is poured, and the mold is removed after 7 days of curing to obtain the support block with the embedded bars.

[0062] S4. Positioning and installation: Weld the connecting bar to the two pre-embedded bars, and then weld and fix the overall internal support to the wall steel reinforcement skeleton.

[0063] S5. Formwork erection: The formwork on both sides of the wall is tightly attached to the outer surface of the support block and reinforced by back bracing and tie rods.

[0064] The entire process uses solid waste from the construction site as raw material, realizing the classification, recycling and on-site utilization of construction solid waste from the material preparation stage. There is no need to purchase any special internal support materials, which greatly reduces project measures costs and reduces the amount of solid waste transported out. It fully complies with the policy requirements of green construction and carbon emission reduction, and can help the project obtain green construction demonstration project certification.

[0065] Mold making and support block prefabrication are completed on-site, without the need for off-site prefabrication plants or special production equipment. They are not limited by off-site processing cycles and can be flexibly matched with the on-site construction rhythm, significantly shortening the material preparation cycle. Compared with purchasing finished internal supports, the material preparation cycle can be shortened, making it especially suitable for projects with tight deadlines.

[0066] Standardized construction steps enable assembly line operations. From material preparation and prefabrication to installation, all are routine processes that construction workers are proficient in, requiring no additional technical training. This significantly reduces labor input and improves construction efficiency compared to traditional internal support installation, thus greatly shortening the total construction period of the wall.

[0067] The construction sequence of first welding the entire internal support, then fixing it to the steel reinforcement frame, and finally attaching it to the formwork, achieves the pre-positioning of the internal support, avoiding the tedious process of repeatedly correcting the verticality and adjusting the position during the traditional internal support installation. The positioning accuracy is greatly improved, significantly improving the quality of wall formation and reducing the cost of later repairs and rework.

[0068] The entire process incorporates multiple quality control measures, including mold size deviation, concrete curing strength, welding quality, and installation and fixing requirements. This ensures the construction quality of the internal supports from the source, eliminates common quality problems such as formwork displacement, bulging, and uneven wall thickness, and improves the first-time acceptance rate of the main structure construction.

[0069] In one embodiment of the present invention, the internal supports are arranged at 600mm×600mm intervals. The wall thickness is 250mm, and the internal support spacing is still arranged at 600mm×600mm, which is suitable for the construction of pipe gallery walls, water tank walls, etc.

[0070] The above description is merely a preferred embodiment of the present invention; however, the scope of protection of the present invention is not limited thereto. Any equivalent substitutions or modifications made by those skilled in the art within the scope of the technology disclosed in the present invention, based on the technical solution and its improved concepts, should be covered within the scope of protection of the present invention.

Claims

1. A positioning internal brace for cast-in-place concrete wall formwork, characterized in that, include: The support block is a solid cube made of waste concrete, and the thickness of the support block is the same as the thickness of the wall to be poured. The embedded bar is a waste steel bar end, which is embedded inside the support block and extends outward from the outside of the support block at both ends. Connecting ribs are welded to the extended ends of two pre-embedded ribs to achieve overall positioning of the internal support; Two support blocks with multiple positioning supports are attached to two wall formworks, and the connecting bars are located between the two wall formworks.

2. The internal support for positioning cast-in-place concrete wall formwork according to claim 1, characterized in that, The dimensions of the support block are 50*50*50mm.

3. The internal support for positioning cast-in-place concrete wall formwork according to claim 1, characterized in that, The length of the embedded bar is 100mm, and the diameter of the embedded bar is greater than or equal to 16mm.

4. The internal support for positioning cast-in-place concrete wall formwork according to claim 1, characterized in that: The support block was cast from leftover concrete from the pump truck at the construction site, and the casting mold was made by cutting and making discarded templates on site.

5. The internal support for positioning cast-in-place concrete wall formwork according to claim 1, characterized in that: The embedded reinforcement bar is bent in the middle at a 90° angle, and the straight sections at both ends are 30mm long.

6. A construction method for positioning internal supports of cast-in-place concrete wall formwork, characterized in that: Includes the following steps: S1. Waste material preparation: Collect waste steel bar ends, waste formwork, and leftover materials from concrete pump trucks at the construction site; S2. Mold making: Use discarded templates to cut and assemble a cube mold with a wall thickness of 50mm×50mm×50mm; S3. Precast support block: The bent and shaped embedded bars are placed into the mold, the remaining concrete from the pump truck is poured, and the mold is removed after 7 days of curing to obtain the support block with the embedded bars. S4. Positioning and installation: Weld the connecting bar to the two pre-embedded bars, and then weld and fix the overall internal support to the wall steel reinforcement skeleton. S5. Formwork erection: The formwork on both sides of the wall is tightly attached to the outer surface of the support block and reinforced by back bracing and tie rods.

7. A construction method for positioning internal supports of cast-in-place concrete wall formwork according to claim 6, characterized in that: The internal supports are arranged at 600mm×600mm intervals.

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