A recycled concrete self-insulation house building and a construction method thereof

Abstract

The application discloses a kind of recycled concrete self-insulation house building and its construction method. With brick mixed building waste residue as raw material, prepare recycled sand powder and micro powder, prepare recycled sand powder structure concrete and multi-density foam concrete. Single-layer block core column composite enclosure or double-layer block sandwich insulation composite enclosure is used, and the thickness and thermal index of outer wall are matched for four climate zones, including hot summer and warm winter, hot summer and cold winter, cold and severe cold, integrated self-insulation wall, floor and roof insulation system. Precast block + cast-in-place composite structure is used, combined with dry laying mortar-free, cast-in-place core column and sandwich forming method, realize load-bearing, insulation, A-grade fireproofing, crack resistance, sound insulation, frost resistance and other multifunctional integration. The solid waste content is more than 70%, low-carbon construction, solves the problems of external insulation flammable falling, poor durability, weak climate adaptation and other problems, suitable for farmhouses, rural buildings, affordable housing, public buildings and energy-saving reconstruction, with significant ecological and economic benefits.

Description

Technical Field

[0001] This invention relates to the fields of green recycled building material preparation, prefabricated house construction, and building energy-saving envelope construction technology, specifically to a self-insulating recycled concrete house building and its construction method. Background Technology

[0002] With the nationwide advancement of livable rural housing, prefabricated rural buildings, and low-carbon urban and rural construction, low-energy consumption, low-cost, easy-to-construct, and durable complete housing construction technologies have become an industry necessity. Simultaneously, urban renewal, demolition of old buildings, and urban and rural renovation generate massive amounts of brick-and-mortar construction waste. Solid waste storage and landfilling lead to land occupation and secondary pollution, making resource utilization and high-quality utilization a mandatory policy requirement. Deeply integrating construction solid waste recycling technology with whole-house self-insulating housing systems creates an integrated regenerative energy-saving construction solution for walls, floors, and roofs.

[0003] Existing resource utilization methods are limited to simple backfilling or low-end products, with a low proportion of high-value and building-integrated applications. Traditional housing construction generally adopts a model of adding organic insulation boards to the main structure, which suffers from common problems such as low fire resistance, insulation layer detachment and cracking, short service life, and high maintenance costs. Aerated concrete wall materials have low strength and obvious problems such as shrinkage and cracking. The whole house lacks a systematic self-insulating design, resulting in large heat loss from the floor and roof, and high overall energy consumption.

[0004] Traditional building materials are highly dependent on high-carbon resources such as natural sand, gravel, and clay. Cement products have a high carbon emission intensity. Under the constraints of energy consumption control and the promotion of low-carbon building materials policies, the industry urgently needs to transform and upgrade. Existing recycled concrete technologies are mostly limited to single wall components and have not formed an integrated whole-house enclosure solution that includes walls, floors, and roofs. The thermal structure is also simple and cannot cover the energy-saving design requirements of multiple climate zones across the country, making it difficult to meet the market demand for the mass standardization and rapid implementation of prefabricated rural houses.

[0005] Therefore, developing a self-insulating recycled concrete house construction method and its construction method, which uses recycled solid waste raw materials as the core, features standardized structure, modular construction, whole-house self-insulation, and applicability to multiple climate zones, fills the gap in the technology of integrated application of recycled low-carbon building materials for whole-house construction, and has significant engineering value, policy value, and industrial implementation value. Summary of the Invention

[0006] This invention addresses the shortcomings of existing conventional building insulation systems, such as significant deficiencies, low solid waste resource utilization rates, fragmented application of recycled building materials, lack of whole-house energy-saving structures, poor adaptability to prefabricated construction, and difficulty in universal application across multiple climate zones. It provides a self-insulating recycled concrete building system and its construction method. This invention uses recycled sand powder and recycled micro-powder prepared from brick and concrete waste as basic raw materials to create a composite system of recycled concrete load-bearing and insulation. Through differentiated structural design, it achieves adaptability to four major climate zones across China, integrating self-insulating functions across walls, floors, and roofs. It is accompanied by a simple and standardized construction method, suitable for the mass promotion of prefabricated rural housing, new urban and rural buildings, and renovations. It addresses multiple requirements including structural safety, energy conservation and low carbon emissions, solid waste disposal, cost-effectiveness, and durable service.

[0007] To achieve the above objectives, the present invention provides the following technical solution: a self-insulating building constructed from recycled concrete, wherein the overall building envelope system is constructed in an integrated manner from recycled concrete self-insulating walls, recycled concrete floor insulation layer, and recycled concrete roof insulation layer; the recycled concrete self-insulating walls include two structural forms: single-layer block composite self-insulating walls and double-layer block sandwich self-insulating walls; the total thickness of the recycled concrete self-insulating exterior walls is 300-600mm, and the thickness of the self-insulating interior walls is 100-240mm; the building floor and roof are uniformly cast using multi-grade recycled sand and powder foam concrete, forming a continuous, thermal bridge-free self-insulating enclosure system for the entire building.

[0008] The single-layer block composite self-insulating wall is integrally combined with recycled sand and powder concrete hollow blocks and recycled sand and powder foam concrete cast-in-place core columns; the double-layer block sandwich self-insulating wall is a composite load-bearing and heat-insulating integrated structure with recycled sand and powder foam concrete insulation core in the middle of inner and outer double-layer recycled concrete hollow blocks.

[0009] The recycled sand and powder concrete hollow blocks are made from brick and concrete demolition waste and decoration waste. The recycled sand and powder are produced by crushing, screening, purifying, grinding and grading. They are then mixed with silicate cement, functional admixtures and mixing water, and molded and cured according to standard conditions. The recycled sand and powder foamed concrete is precisely proportioned according to different usage conditions such as wall core columns, sandwich panels, floors and roofs. It is then mechanically foamed, uniformly mixed and poured on site.

[0010] 1. Mix proportion of recycled sand and powder structural concrete Raw material proportions per cubic meter: P·O 42.5 cement 230~270kg, recycled micro powder 90~110kg, recycled sand powder 680~730kg, mixing water 165~175kg, polycarboxylate superplasticizer 1.2%~1.4%, crack-resistant and waterproof admixture 3%~4%; water-cement ratio 0.46~0.53, sand ratio 40%~44%, solid waste comprehensive admixture ≥70%; 28-day compressive strength ≥5MPa, drying shrinkage ≤0.45mm / m, freeze-thaw resistance grade ≥F50.

[0011] 2. Proportioning of Graded Recycled Sand and Powder Foamed Concrete Special for 600 grade wall core columns: cement 210~240kg / m³, recycled micro powder 70~85kg / m³, recycled sand powder 530~560kg / m³, thermal conductivity ≤0.12W / (m·K); Special for 800-1000 grade floor and roof insulation: cement 260-310kg / m³, recycled micro powder 80-95kg / m³, recycled sand powder 580-640kg / m³; 1200-grade exterior wall sandwich insulation: cement 310~340kg / m³, recycled micro powder 85~100kg / m³, recycled sand powder 630~660kg / m³.

[0012] 3. Standardized structure and thermal parameters of the four major climate zones In hot-summer and warm-winter regions: 300mm single-layer self-insulating exterior wall, K≤0.90W / (m²·K), R≥1.10m²·K / W; Hot-summer and cold-winter regions: 400mm double-layer sandwich exterior wall, K≤0.70W / (m²·K), R≥1.45m²·K / W; Cold regions: 500mm thickened sandwich wall, K≤0.55W / (m²·K), R≥1.80m²·K / W; Extremely cold regions: 600mm ultra-thick sandwich exterior wall, K≤0.40W / (m²·K), R≥2.50m²·K / W.

[0013] Interior walls: Load-bearing interior walls are 190-240mm thick, and non-load-bearing partition walls are 100-120mm thick, all with recycled sand and powder foamed concrete core columns; the thickness of recycled foamed concrete for floors and roofs is 50-150mm.

[0014] Construction methods 1. Construction of single-layer masonry block type recycled concrete self-insulating house walls S1. Base cleaning, positioning and layout, marking the building walls, structural columns and elevation control lines; S2. Dry masonry of recycled concrete hollow blocks with staggered joints, mortar-free prefabricated masonry; S3. Lay longitudinal core column steel bars and transverse tie bars to form an integral reinforcement skeleton; S4. For every 1m of masonry height, cast-in-place recycled foamed concrete core columns in layers and compact them with vibration. S5. Lay the bricks layer by layer and pour them in sections to the designed height of the building walls; S6. Natural curing, with subsequent floor and roof insulation construction carried out simultaneously.

[0015] 2. Construction of double-layer sandwich-type recycled concrete self-insulating house walls S1. Basic cleaning and precise layout to define the overall outline of the building's exterior walls; S2. Tie wire mesh is installed inside the cavity of the double-layer wall; S3. The recycled concrete blocks on both the inner and outer sides are laid in a staggered dry-laying manner. S4. Layered pouring of structural core column concrete through block holes; S5. After the core column has set, the cavity is integrally cast-in-place recycled foamed concrete insulation sandwich. S6. Overall curing and shaping to form a composite self-insulating structure for the exterior walls of the house.

[0016] 3. Construction of self-insulating flooring and roof throughout the house After the main walls of the building are completed, a recycled sand and powder foam concrete floor insulation layer and a roof insulation layer are poured on-site to provide full-area insulation and eliminate thermal bridges.

[0017] Beneficial effects: 1. This invention breaks through the limitations of a single wall structure, achieving whole-house insulation of walls, floors, and roofs, with standardized construction and dry-laid assembly. Using brick-concrete construction waste as the core raw material, it largely replaces natural aggregates and cement, resulting in high solid waste resource utilization and reduced carbon emissions from construction. The integrated rigid structure of recycled concrete eliminates organic insulation materials, ensuring the entire building envelope is Class A non-combustible and has a service life equal to the building's lifespan.

[0018] A single technical system covers all four major climate zones in China, applicable to both northern and southern regions, and suitable for both new construction and renovation. The system combines prefabricated dry-laying with on-site cast-in-place composite molding, resulting in fewer procedures, lower labor costs, and significant economic benefits when applied on a large scale. Attached Figure Description

[0019] Figure 1 This is a schematic diagram of the overall cross-sectional structure of the self-insulating house built with recycled concrete according to the present invention. Figure 2 This is a cross-sectional structural diagram of a single-layer recycled concrete self-insulating wall. Figure 3 This is a cross-sectional structural diagram of a double-layer block sandwich self-insulating wall.

[0020] Reference numerals: 1-Outer side recycled concrete block; 2-Inner side recycled concrete block; 3-Recycled foamed concrete core column; 4-Recycled foamed concrete sandwich layer; 5-Tie reinforcement; 6-Wall tie mesh; 7-Recycled concrete floor insulation layer; 8-Recycled concrete roof insulation layer. Detailed Implementation

[0021] 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.

[0022] The following is in conjunction with the accompanying drawings. Figures 1-3 The specific embodiments of the present invention will be further described in detail below: Example 1: Prefabricated farmhouses in hot-summer and warm-winter regions The exterior walls of the house are constructed with 300mm single-layer recycled concrete blocks and cast-in-place 600-grade recycled foamed concrete core columns. The entire house floor and roof are equipped with recycled insulation structures, with a solid waste content of ≥70%. The overall heat transfer coefficient meets the energy-saving requirements for buildings in southern China.

[0023] Example 2: Low-carbon and livable housing in hot-summer and cold-winter regions The exterior wall features a 400mm double-layer sandwich structure, which is suitable for the climate of the Yangtze River Basin. It provides insulation in winter and heat insulation in summer, eliminating the need for additional internal and external insulation. It is suitable for urban resettlement housing and rural improved housing.

[0024] Example 3: Energy-efficient houses in cold northern regions The 500mm thickened sandwich self-insulating exterior wall has strong frost resistance and weather resistance, making it suitable for heating areas in the north and significantly reducing winter heating energy consumption.

[0025] Example 4: Near-zero energy housing in frigid regions The 600mm ultra-thick recycled concrete sandwich insulation exterior wall provides integrated insulation for the entire building, meeting the low-energy and near-zero-energy building standards in frigid regions.

[0026] Example 5: General Interior Wall and Whole House Enclosures The load-bearing interior walls and partition walls are all made of recycled concrete blocks, which are combined with recycled insulation layers on the floor and roof to form a complete energy-saving system for the house.

[0027] Although the invention has been described above with reference to embodiments, various modifications can be made and components can be replaced with equivalents without departing from the scope of the invention. In particular, features in the embodiments disclosed herein can be combined in any way, provided there is no structural conflict. The lack of an exhaustive description of these combinations in this specification is merely for brevity and resource conservation. Therefore, the invention is not limited to the specific embodiments disclosed herein, but includes all technical solutions falling within the scope of the claims.

Claims

1. A self-insulating house made of recycled concrete, characterized in that: The building envelope system is composed of recycled concrete self-insulating walls, recycled concrete floor insulation layers, and recycled concrete roof insulation layers. The recycled concrete self-insulating walls include single-layer block composite self-insulating walls and double-layer block sandwich self-insulating walls. The thickness of the recycled concrete self-insulating exterior walls is 300-600mm, and the thickness of the self-insulating interior walls is 100-240mm. The building floor and roof are integrally cast using recycled sand and powder foamed concrete.

2. A self-insulating house made of recycled concrete according to claim 1, characterized in that: The single-layer block composite self-insulating wall is formed by combining recycled sand and powder concrete hollow blocks with recycled sand and powder foam concrete core columns; the double-layer block sandwich self-insulating wall is an integrated load-bearing and heat-insulating structure with inner and outer double layers of recycled sand and powder concrete hollow blocks and a middle cast-in-place recycled sand and powder foam concrete heat-insulating core.

3. A self-insulating house made of recycled concrete according to claim 1, characterized in that: The raw material proportions for the recycled sand and powder concrete are as follows: P.O42.5 grade cement 230-270 kg / m³, recycled micro powder 90-110 kg / m³, recycled sand and powder 680-730 kg / m³, mixing water 165-175 kg / m³, polycarboxylate superplasticizer 1.2%-1.4%, functional admixture 3%-4%; water-cement ratio 0.46-0.53, and solid waste content ≥70%.

4. A self-insulating house made of recycled concrete according to claim 1, characterized in that: Recycled sand and powder foamed concrete is graded and formulated according to working conditions: Grade 600 is for core columns, Grade 800-1000 is for flooring and roofing, and Grade 1200 is for exterior wall sandwich panels.

5. A self-insulating house made of recycled concrete according to claim 1, characterized in that: The thermal performance indicators of the exterior walls are matched according to the four climate zones to achieve low energy consumption operation of the entire house.

6. A construction method for a self-insulating house made of recycled concrete, characterized in that, Includes prefabricated construction of single-layer block walls: S1. Base cleaning and building axis positioning and layout; S2. Dry masonry of recycled concrete hollow blocks with staggered joints, mortar-free assembly masonry. S3. Lay out the longitudinal reinforcement and transverse tie reinforcement of the core column; S4. Segmented and layered cast-in-place recycled foamed concrete core column; S5. Construct to the design elevation and allow to cure naturally.

7. The construction method according to claim 6, characterized in that, The construction of a double-layer sandwich exterior wall includes: laying out the cavity tie frame, dry-laying of blocks on both sides, pouring of the core column, pouring of the sandwich layer, and overall curing, to form a composite self-insulating exterior wall.

8. A self-insulating house made of recycled concrete according to claim 1, characterized in that: Load-bearing interior walls: 190-240mm thick; non-load-bearing partition walls: 100-120mm thick; recycled insulation layer for floors and roofs: 50-150mm thick.

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