Modular prefabrication and indoor and outdoor synchronous construction process of fiberboard thermal insulation wall suitable for severe cold regions

Abstract

The application discloses a fiberboard thermal insulation wall modular prefabrication and indoor and outdoor synchronous construction process suitable for severe cold regions, relates to the thermal insulation wall installation technical field and comprises the following steps: step one, modular splitting and prefabrication, according to the building module, the wall system is split into multiple independent prefabricated module units, the fiberboard thermal insulation wall modular prefabrication and indoor and outdoor synchronous construction process suitable for severe cold regions realizes the outdoor fiberboard closure in advance through three core steps of steel skeleton installation, outer side plate closure, rock wool filling and inner side plate closure, forms a closed cavity which is completely isolated from the outdoor harsh environment in the wall body after the completion of the steel skeleton and the outer side moisture-proof fiberboard installation, gets rid of the plight that the traditional masonry and external thermal insulation process is seriously restricted by climate conditions, completely eliminates a large number of wet operation links such as mortar mixing, leveling and plastering, thermal insulation board sticking and the like in the traditional process, and further improves the construction efficiency of the thermal insulation wall.

Description

Technical Field

[0001] This invention relates to insulation wall installation technology, specifically to a modular prefabrication and simultaneous indoor and outdoor construction process for fiberboard insulation walls applicable to extremely cold regions. Background Technology

[0002] The construction industry is currently accelerating its transformation towards "prefabricated" and "green" construction. Traditional masonry wall construction has significant drawbacks: First, the construction process is cumbersome, requiring the wall masonry to be completed first, followed by separate splicing, fixing, and sealing of the insulation layer, with an overall cycle of 20-30 days per 100m. 2 First, the process is inefficient; second, the amount of on-site wet work (such as mortar mixing and plastering) is large, which easily generates construction waste and is affected by manual operation, resulting in large quality fluctuations; third, under extreme weather conditions (severe winter cold and summer rainstorms), the construction of the insulation layer is easily affected by freeze-thaw cycles and rainwater soaking, forcing work to stop and delaying the construction period; fourth, the separate design of the wall and the insulation layer is prone to insulation layer detachment and sealing failure during long-term use, resulting in high maintenance costs.

[0003] To address the aforementioned pain points, a modular prefabrication and simultaneous indoor and outdoor construction process for fiberboard insulation walls suitable for frigid regions was developed. Through on-site prefabrication and rapid on-site assembly, the quality of wall construction is improved, costs are reduced, and efficiency is increased. Summary of the Invention

[0004] The purpose of this invention is to provide a modular prefabrication and simultaneous indoor and outdoor construction process for fiberboard insulation walls suitable for extremely cold regions, in order to solve the problems of cumbersome construction processes and long construction periods in the existing technology.

[0005] To achieve the above objectives, the present invention provides the following technical solution: a modular prefabrication and simultaneous indoor and outdoor construction process for fiberboard insulation walls suitable for extremely cold regions, comprising the following steps:

[0006] Step 1: Modular Disassembly and Prefabrication. Based on the building module, the wall system is divided into multiple independent prefabricated modular units. The modular units include: multiple standardized hot-dip galvanized square steel frame modules, multiple standardized outer moisture-proof fiberboard modules, multiple standardized inner moisture-proof fiberboard modules, and multiple standardized rock wool insulation board modules. All modules are produced in a standardized manner in the factory or on-site prefabrication area.

[0007] Step 2: Main structure pretreatment and measurement layout. After the main structure (beams, columns, floor slabs) of the building is completed, the installation area is cleaned, and the steel frame module is accurately laid out according to the detailed design drawings to determine the installation position of the steel frame module, ensuring that the layout error is controlled within ±2mm.

[0008] Step 3: On-site installation of steel frame modules. The prefabricated hot-dip galvanized square steel frame modules are fixed to the main structure using expansion bolts to form the main load-bearing frame of the wall, and its verticality and horizontality are adjusted to meet the requirements.

[0009] Step 4: Outdoor fiberboard module enclosure installation. On the outdoor side of the steel frame module, the outer moisture-proof fiberboard module is fixed with self-tapping screws to form an outdoor enclosure. After this step is completed, a closed cavity is formed inside the wall that is isolated from the outdoor environment, thus allowing indoor work to continue when the outdoor temperature is not lower than -15℃ or in rainy or snowy weather.

[0010] Step 5: Simultaneous filling of indoor insulation material. Inside the building, the rock wool insulation board module is filled into the closed cavity formed by the steel frame module and the outer moisture-proof fiberboard module. The filling density is checked by sampling and opening inspection to ensure that it is not less than 95%.

[0011] Step Six: Indoor Fiberboard Module Sealing Installation. After the rock wool insulation board module is filled, the inner moisture-proof fiberboard module is fixed to the indoor side of the steel frame module using self-tapping screws, thus forming a complete prefabricated wall with integrated structure and insulation.

[0012] Step 7: Sealing the joints and overall acceptance. Seal all the joints between the fiberboard modules and test and accept the flatness, verticality, heat transfer coefficient and structural connection strength of the formed wall.

[0013] Furthermore, the hot-dip galvanized square steel frame module in step one uses hot-dip galvanized square steel with specifications of 120mm×40mm×4mm (length×width×wall thickness) and a zinc layer thickness ≥85μm, which is connected by welding or bolts, and its dimensional error is controlled within the design allowable range; the density of the outer / inner moisture-proof fiberboard module is 600-800kg / m³. 3 The thickness is 12mm, the moisture content is ≤12%, and the flexural strength is ≥15MPa; the thermal conductivity of the rock wool insulation board module is ≤0.04W / (m·K), and the bulk density is 100-120kg / m³. 3 The fire resistance rating is Class A.

[0014] Furthermore, in step three, the expansion bolts are M16×150mm in size, with a tensile strength ≥400MPa and an installation spacing ≤600mm; in steps four and six, the self-tapping screws are M5×12mm in size, with a zinc plating thickness ≥10μm and an installation spacing ≤250mm, to ensure connection strength.

[0015] Furthermore, in step four, after installing the outer moisture-proof fiberboard module, sealant or sealing strips are used to initially seal the gaps between it and the steel frame, as well as between it and adjacent fiberboards, to further enhance the airtightness of the enclosed cavity, prevent the infiltration of cold outdoor air, and ensure the ambient temperature for indoor side filling operations in severe cold weather.

[0016] Furthermore, the filling process of the rock wool insulation board module further includes: adapting the rock wool board to make its size precisely match the internal space of the steel frame module; using layered laying or mechanical extrusion during filling to ensure that there are no gaps between the rock wool module and the steel frame and the outer fiberboard; and filling local gaps with rock wool strips of the same material to ensure the continuity of the overall insulation layer.

[0017] Furthermore, after step six is ​​completed, if the wall is partially damaged, the maintenance and replacement method is as follows: only the inner fiberboard module of the damaged area is removed, the damaged rock wool module is taken out and replaced, and the removed fiberboard module is restored in its original position without dismantling or modifying the entire wall.

[0018] Furthermore, the outer surface of the outer moisture-proof fiberboard module is prefabricated with a waterproof coating or finishing layer, reducing on-site secondary decoration work; the inner surface of the inner moisture-proof fiberboard module is prefabricated with an interface agent or leveling layer, providing a direct working surface for interior decoration.

[0019] Furthermore, the construction process also includes a temperature monitoring and protection measure: when the outdoor temperature is below -15℃, a temporary hot air curtain or electric heating device is installed on the indoor side to maintain the temperature of the filling operation area at no less than -10℃, and the sealant and self-tapping screws used are subjected to low-temperature adaptability treatment, thereby extending the lower limit of the construction environment to -25℃.

[0020] Compared with existing technologies, the modular prefabrication and simultaneous indoor and outdoor construction process for fiberboard insulation walls suitable for extremely cold regions provided by this invention has the following advantages:

[0021] Through three core steps—steel frame installation, outer panel sealing, rock wool filling, and inner panel sealing—the outdoor fiberboard is sealed first. After the steel frame and outer moisture-proof fiberboard are installed, a completely sealed cavity is formed inside the wall, completely isolated from the harsh outdoor environment. This solves the problem of traditional masonry and external insulation processes being severely restricted by climate conditions. In traditional processes, when the temperature is below 5°C or during rain or snow, the hardening of masonry mortar, the pasting of insulation boards, and the application of finishing mortar cannot be carried out, forcing construction to stop for 3-4 months every winter in cold regions, resulting in a large amount of idle resources. The process of this invention allows for the safe transfer of construction work to the indoor side for continuous filling of insulation materials and sealing of inner panels in environments where the outdoor temperature is not lower than -15°C or even extended to -25°C with auxiliary heating. Example 1 successfully achieved a 1000m 2 The main wall construction was completed in just 53 days, avoiding the three-month winter downtime of traditional methods; Example 2 further demonstrated this by completing emergency repairs of a border outpost in an ultra-low temperature environment of -35℃, from demolition to completion in only 15 days. Compared to traditional methods, this method achieves faster construction per 100m... 2 The previous method required a 20-30 day cycle. This invention improves construction efficiency by more than 50%, truly enabling uninterrupted construction of building envelopes in frigid regions throughout the year, providing a fundamental guarantee for on-time project delivery.

[0022] This invention employs a modular disassembly and standardized factory prefabrication strategy. All hot-dip galvanized square steel frames, inner and outer moisture-proof fiberboards, and rock wool insulation modules are manufactured with high precision in the factory or on-site processing area, with dimensional errors strictly controlled within the design tolerances. On-site construction requires only dry assembly, fixing the steel frame with expansion bolts, installing the fiberboard with self-tapping screws, and directly filling the insulation modules, completely eliminating the numerous wet work steps in traditional processes such as mortar mixing, leveling and plastering, and insulation board pasting. This technical approach brings three core benefits: First, significantly improved quality stability, eliminating common quality problems such as hollow areas, cracking, and insufficient bonding area caused by differences in manual operation experience. Example 1 shows a measured wall heat transfer coefficient of 0.38 W / (m²). 2 ·K) Self-tapping screw pull-out force is 0.65kN, which is superior to the national standard. Secondly, structural safety is fundamentally improved. The steel frame load-bearing system, combined with screw mechanical connections, completely eliminates the safety hazards of traditional external insulation systems caused by freeze-thaw cycles leading to aging of the bonding mortar and high-altitude detachment of insulation boards. Thirdly, maintenance convenience is significantly optimized. When the wall is partially damaged, only the inner fiberboard of the corresponding area needs to be removed, the damaged rock wool module replaced, and the wall restored in situ. There is no need for large-scale demolition and redoing of the insulation layer as in traditional processes. Life cycle accounting shows that every 1000m²... 2The wall can save 321,300 yuan in maintenance costs, and the maintenance frequency is reduced from major repairs every 10 years in the traditional solution to only once every 25 years, resulting in outstanding comprehensive economic benefits. Attached Figure Description

[0023] To more clearly illustrate the technical solutions in the embodiments of this application or the prior art, the drawings used in the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments recorded in this invention. For those skilled in the art, other drawings can be obtained based on these drawings.

[0024] Figure 1 This is a flowchart illustrating the modular prefabrication and simultaneous indoor and outdoor construction process of fiberboard insulation walls applicable to extremely cold regions, as described in this invention. Detailed Implementation

[0025] To enable those skilled in the art to better understand the technical solution of the present invention, the present invention will be further described in detail below with reference to the accompanying drawings.

[0026] Example 1: Construction Example of a Standard Industrial Plant in Extremely Cold Regions

[0027] Please see Figure 1 As shown in the figure, this embodiment takes a fine chemical project as an example to illustrate in detail the application of the process of the present invention in a standard cold-region industrial plant.

[0028] Project Overview: Located in Qitaihe City, Heilongjiang Province, where winter temperatures can drop to -30℃, the project requires completion of the main structure and enclosure structure by the end of October. The total building area is 23,222.79 m². 2 The exterior wall area is approximately 10,000 square meters. 2 The present invention employs the "modular prefabrication and simultaneous indoor and outdoor construction process for fiberboard insulation walls suitable for extremely cold regions".

[0029] Specific implementation steps:

[0030] Modular Decomposition and Detailed Design: First, using ANSYS finite element software, the wall structure was modularly decomposed based on architectural drawings and local extreme wind and snow loads. The width of the standard wall panel module was determined to be 1200mm (corresponding to the steel frame spacing), with the height depending on the floor height. The grid layout of the hot-dip galvanized square steel frame (12×4mm, 85μm zinc layer) was designed to be 600mm×600mm. Specifications, connection nodes, and fabrication drawings for all modules were finalized at this stage.

[0031] Factory prefabrication:

[0032] Steel frame production: In the supporting factory, hot-dip galvanized square steel is cut and welded into standard frame modules according to detailed drawings. Dimensional errors (length, width, and height error ±2mm) and diagonal error ±3mm are strictly checked. Weld joints are ground smooth and treated with anti-corrosion coating.

[0033] Fiberboard module production: Purchase density 700kg / m 3 The 12mm thick high-density moisture-proof fiberboard is CNC-cut into standard panels (e.g., 1190mm × 2390mm) to match the steel frame, with precise drilling to pre-drill holes for self-tapping screws. The outer fiberboard surface is pre-coated with a layer of highly weather-resistant acrylic waterproof coating at the factory.

[0034] Rock wool module production: Modules with a thermal conductivity of 0.038 W / (m·K) and a bulk density of 120 kg / m³... 3 Class A fireproof rock wool boards are pre-cut into small pieces according to the internal clearance dimensions of the steel frame (570mm×570mm) and sealed in moisture-proof packaging to prevent moisture damage during transportation.

[0035] On-site construction:

[0036] Steel frame installation: After the main structure is completed, surveyors use high-precision laser levels and theodolites to accurately lay out lines on the beams and columns. Installers hoist the prefabricated steel frame modules into place and securely connect them to the concrete beams and columns using M16×150mm expansion bolts (600mm spacing, at least 16 fixing points per module). After installation, flatness is checked using a 2m straightedge and feeler gauge (≤3mm), and verticality is checked using a laser plumb line (≤1mm / m). Any areas that do not meet the standards are adjusted using 0.5-2mm galvanized steel shims.

[0037] External Fiberboard Sealing (August 21 - September 1): During this stage, outdoor temperatures have begun to drop, but the advantages of this invention are realized. Construction workers attach prefabricated fiberboard modules to the steel frame from the outdoor side, securing them with an electric drill and M5×12mm self-tapping screws (200mm spacing). A 3-5mm V-shaped gap is left between the boards, and building weather-resistant sealant is immediately embedded. At this point, the wall forms a completely sealed "cavity," effectively isolating it from the zero-degree outdoor environment.

[0038] Simultaneous construction on the indoor side (September 2nd - September 22nd): After the outer enclosure was completed, construction moved entirely indoors. Snow had begun falling outside, but no additional heating was needed indoors for subsequent work. Workers tightly filled the pre-cut rock wool modules into the cavities of the steel frame, ensuring complete filling without any settling. Any gaps were filled with rock wool strips (fill density ≥98%). Subsequently, the inner fiberboard modules were installed, also secured with self-tapping screws, with the screw heads recessed 0.5mm into the board surface, and then leveled with putty.

[0039] Verification of technical effects:

[0040] Construction period: The main construction period of the 1000㎡ wall (from the installation of the steel skeleton to the completion of the fixation of the inner panel) only takes 53 days. If the traditional process is adopted, construction cannot be carried out at all during this period due to the arrival of winter. Even compared with the traditional process in summer construction (about 28 days / 100m 2 ), the process of the present invention realizes "peak-shifting construction", ensures the continuity of construction throughout the year, and saves at least 3 months of ineffective construction period.

[0041] Quality: After completion inspection, the average heat transfer coefficient of the wall is 0.38W / (m 2 ·K), and the air infiltration rate is 0.25m³ / (m 2 ·h), both of which are better than the design requirements. For the sampling pull-out test, the average pull-out force of the self-tapping screws is 0.65kN, far higher than the standard of 0.5kN. The flatness and perpendicularity of the wall surface are 100% qualified.

[0042] Benefit: Compared with the traditional scheme, the direct cost is saved by about 2.6%, and the life-cycle cost (25 years) is reduced by 27.3%.

[0043] Embodiment 2: Application example in ultra-low temperature environment and emergency repair conditions

[0044] Please refer to Figure 1 As shown, this embodiment aims to demonstrate the outstanding advantages of the present invention in extremely low temperature (below -25°C) and building emergency repair scenarios.

[0045] Project overview: At a border post, the winter temperature is often below -35°C. The original brick-concrete wall has serious cracks due to frost heaving and the insulation has failed. Emergency repair needs to be carried out within 12 months to restore its living function. The task requires that the construction period does not exceed 15 days.

[0046] Specific implementation steps:

[0047] Quick assessment and customized prefabrication: The dimensions of the damaged wall were measured on-site and the data was immediately transmitted to the rear processing center. The processing center completed the production of the required steel skeletons, inner and outer fiberboards, and rock wool modules of specific sizes within 2 days. To improve efficiency, high-strength bolt connections were used instead of welding for the connection nodes of the steel skeletons, facilitating rapid on-site assembly.

[0048] On-site demolition and preparation (the 3rd day): Indoors, workers quickly demolished the inner lining and some bricks of the original damaged wall and cleared the installation space. At the same time, four high-power industrial hot air curtain machines were installed indoors to raise the temperature of the core operation area to above -10°C.

[0049] Steel frame and outer panel installation (days 4-6): Following the standard procedure of this invention, quickly complete the installation of the steel frame and outer fiberboard. Due to the extremely cold outdoor environment of -35°C, the outer panel fixing work is compressed into the two hours of noon when the temperature is highest each day. Workers wear low-temperature protective equipment and use low-temperature special self-tapping screws and sealant (embrittlement temperature below -40°C).

[0050] Indoor heating and simultaneous construction (days 7-12): After the outer side panels are sealed, the indoor environment is quickly isolated from the outdoors. The hot air curtain machine is stopped, and a lower-power far-infrared heater is used to maintain the local working point temperature at around -5℃. Workers can then comfortably complete the installation of rock wool filling and inner fiberboard in a much more comfortable environment. Because the rock wool modules are pre-cut and sealed for moisture protection in the factory, they maintain good flexibility and filling performance even at low temperatures.

[0051] Quick Finishing (Days 13-15): Complete the sealing of all board joints and reinforce the sealing of the connection nodes between the wall and the original structure to ensure airtightness.

[0052] Technical effectiveness verification:

[0053] Environmental adaptability: The process of this invention has successfully challenged the extreme low temperature environment of -35℃, realizing winter emergency repairs that are impossible with traditional processes, ensuring the normal use of border outposts, and generating huge social benefits.

[0054] Construction efficiency: From demolition to completion, it took only 15 days, providing the fastest solution for the restoration of the outpost. The modular maintenance approach was perfectly embodied here, eliminating the need for large-scale modifications to the entire building.

[0055] Example 3: Functional Optimization Example for High Humidity Environments

[0056] Please see Figure 1 As shown, this embodiment aims to propose an improvement solution to address the weakness of the present invention (fiberboard is susceptible to moisture in high humidity environments) and demonstrate its application in a specific scenario.

[0057] Project Overview: A seafood processing workshop in Liaoning Province has an indoor temperature of 20-25℃ and a relative humidity as high as 85% year-round. The building's exterior walls not only need excellent thermal insulation performance, but also superior moisture-proof and corrosion-resistant properties.

[0058] Specific implementation steps:

[0059] Material upgrades and optimizations:

[0060] Steel frame: The standard hot-dip galvanized square steel is upgraded to zinc-aluminum alloy coated (55% Al-Zn) square steel, which has 2-4 times the corrosion resistance of ordinary hot-dip galvanized steel and can better resist rust in high humidity environments.

[0061] Fiberboard: High density (850kg / m²) selected 3 The fiberboard is made of moisture-proof material and undergoes deep waterproofing treatment on both its inner and outer surfaces: the exterior side is sprayed with polyurea elastomer coating, and the interior side is covered with a 0.2mm thick PET polyester film to effectively block moisture penetration. A waterproof sealant is also applied to the edges of the boards during prefabrication.

[0062] Connectors: All self-tapping screws and expansion bolts are made of 304 stainless steel to prevent electrochemical corrosion.

[0063] Insulation layer: The rock wool modules are replaced with graphite polystyrene boards (GEPS) with a closed-cell structure. Their water absorption rate is much lower than that of rock wool, making them more suitable for high-humidity environments, while maintaining A2 fire resistance.

[0064] Construction process adjustments:

[0065] Enhanced airtightness: At the connection between the steel frame and the main structure, as well as at the joints between the inner and outer fiberboards, in addition to using sealant, an extra layer of butyl rubber waterproof tape is applied for double sealing to ensure more than 99% airtightness and prevent indoor humid and hot air from seeping into the interior of the wall and forming condensation.

[0066] Adding a moisture-proof vapor barrier layer: Before installing the inner fiberboard, a 0.3mm thick PE moisture-proof vapor barrier film is laid on the inside of the steel frame and fixed to the steel frame before installing the inner fiberboard. This forms a dual protection system of "external rain protection and internal vapor barrier".

[0067] Technical effectiveness verification:

[0068] Performance: After a complete production cycle (12 months), an endoscopic inspection of the interior walls revealed no rust on the steel frame, mold growth on the fiberboard, or water accumulation in the insulation layer. The wall's heat transfer coefficient remained stable, and there were no condensation or mold issues on the workshop walls.

[0069] Value: This embodiment demonstrates that by optimizing the selection of core materials and adding auxiliary functional layers, the application scenarios of this invention can be expanded from ordinary industrial buildings in frigid regions to special corrosive environments such as oceans, high humidity, and chemical plants, demonstrating strong technical scalability and market value.

[0070] Comparison Example

[0071] Specific construction steps

[0072] Foundation and main structure construction: Complete the construction of the reinforced concrete frame or shear wall main structure and reserve wall tie bars.

[0073] Wall construction: Use sintered porous bricks or solid bricks, and M5 or M7.5 cement mortar for masonry. During construction, structural columns, ring beams, lintels for doors and windows must be installed according to specifications. After completion, the wall must be cured for at least 7 days until the mortar strength reaches the design requirements. (100m) 2 The construction of the wall typically takes 10-15 days (including curing).

[0074] Wall leveling treatment: Clean and moisten the surface of the masonry wall. Apply a 1:2.5 cement mortar for overall leveling, with a thickness controlled at 15-20mm. The leveling layer needs to be cured for 7-10 days to prevent hollow areas and cracks.

[0075] Thermal insulation layer construction (external wall thermal insulation system): Bonding mortar preparation: On-site mixing of polymer bonding mortar and cement in proportion.

[0076] Insulation board bonding: Use the dot-frame method or strip bonding method to bond the insulation board (commonly EPS board, thickness 80-120mm) on the leveling layer, and the bonding area should not be less than 40%.

[0077] Anchor fixing: After the bonding mortar has initially set (usually 24 hours), drill holes in the insulation board and install plastic expansion anchors (no less than 6 per square meter). The anchors should penetrate the wall base layer to a depth of no less than 50mm.

[0078] Grinding and joint treatment: Grind the uneven areas of the insulation board and fill the joints with polyurethane foam.

[0079] Finishing layer construction: Apply the first coat of finishing mortar (2-3mm thick) to the surface of the insulation board, and then press in the alkali-resistant fiberglass mesh. After the first coat of finishing mortar has dried (at least 24 hours), apply the second coat of finishing mortar (1-2mm thick) to completely cover the mesh.

[0080] Finishing layer construction: Apply exterior wall paint or stone paint according to design requirements. Detail treatment: Waterproof sealing and reinforced mesh treatment are applied to door and window openings, inside and outside corners, plinths, eaves, and other areas.

[0081] Main technical defects of the comparison example

[0082] Construction is severely constrained by weather conditions: the hydration reaction of masonry mortar and plastering mortar stops when the temperature is below 5°C, making construction impossible; the bonding of insulation boards and plastering mortar also cannot be carried out when the temperature is below 5°C or in rainy or snowy weather.

[0083] In frigid regions, exterior wall construction is completely impossible for 3-4 months during winter, which significantly extends the overall project duration and results in a large amount of idle and wasted manpower and machinery.

[0084] The process is complicated and the construction period is long: from masonry to finishing, it requires more than 10 steps, including "masonry → curing → leveling → curing → pasting insulation board → curing → anchoring → plastering → curing → finishing".

[0085] The construction period for each 100 square meters of wall is as long as 20-30 days, and each process must be maintained at intervals, making continuous operation impossible.

[0086] Poor quality stability and high rate of common defects: The amount of wet work on site is large, and the material ratio, mixing and application quality are significantly affected by the operator's skill level, which can easily lead to problems such as insufficient mortar fullness, hollow cracking of leveling layer, and substandard bonding area of ​​insulation board.

[0087] The insulation layer and the wall structure layer are designed separately. Under the long-term action of freeze-thaw cycles and wind pressure, the bonding mortar ages and the anchors corrode, causing the insulation board to bulge and fall off, creating serious safety hazards.

[0088] If the joints between the boards are not properly sealed, thermal bridges can easily form, leading to condensation and mold growth indoors.

[0089] Maintenance is difficult and costly: Once the insulation layer is partially damaged or hollow, it cannot be repaired locally. The damaged area and the surrounding insulation and plastering layers must be completely removed, and the area must be leveled, re-attached, and plastered again. This process generates a large amount of construction waste and requires further maintenance, which seriously affects the normal use of the building.

[0090] Low structural safety: Sintered brick walls have low shear strength and are prone to cracking under frost heave in extremely cold regions. Insulation layer weight (approximately 8-10 kg / m²). 2 The entire load, including wind load, is borne by the bonding mortar and anchor bolts, and after long-term service, it faces the risk of overall collapse.

[0091] Poor life-cycle economics: Although the initial construction cost is not high (approximately 380 yuan / m²), 2 However, the insulation layer needs to be replaced or overhauled approximately every 10 years, and requires maintenance 2-3 times within its 25-year lifespan. The total life-cycle cost far exceeds that of integrated prefabricated wall technology.

[0092] The modular prefabrication and simultaneous indoor and outdoor construction processes of fiberboard insulation walls applicable to extremely cold regions, as described in Examples 1 to 3, were compared with the control example, and the results are shown in the table below:

[0093] Comparison Dimensions Comparative example (traditional sintered brick masonry + external insulation process) Example 1 (Standard Cold Environment Construction) Example 2 (Ultra-low temperature emergency repair case) Example 3 (Optimization for High Humidity Environments) Construction environment adaptability Due to significant climate limitations, wet work and insulation layer application cannot be carried out when temperatures drop below 5°C or during rainy or snowy weather, forcing work to stop for 3-4 months during winter. Once the outer side panels are sealed, an isolation space is formed, enabling continuous construction in winter, with a minimum construction temperature of -15℃. Emergency repairs were successfully completed in an extremely cold environment of -35°C using indoor hot air curtains and special low-temperature materials. By upgrading materials and edge sealing, it can adapt to high humidity environments with a relative humidity of 85% for a long time. Construction period and efficiency <![CDATA[Many processes (such as masonry, leveling, pasting, plastering, maintenance, etc.), 100m 2 Cycle: 20 - 30 days]]> <![CDATA[The process is simplified into 3 major core steps, 1000m 2 The main body construction takes only 53 days, and the cycle is shortened by more than 50%]]> Modular rapid assembly, from dismantling to completion in just 15 days, enables emergency repairs. Despite the addition of a moisture-proof layer, the main assembly efficiency remains unchanged, still representing an efficiency improvement of over 50% compared to traditional wet construction methods. Quality stability and performance On-site wet work is frequent, and quality depends heavily on manual labor, making it prone to issues such as hollow areas, detachment, and inadequate sealing; the heat transfer coefficient also fluctuates greatly. <![CDATA[Factory prefabrication and modular assembly ensure unified quality; the measured heat transfer coefficient is 0.38 W / (m 2 ·K), and the pulling force is 0.65 kN, which is better than the national standard]]> The prefabricated modules maintain consistent quality and performance at low temperatures, and the wall's heat transfer performance meets standards after restoration. After adding double seals and a vapor barrier, there was no condensation or mold growth after one year of operation, and the performance remained stable. Structural safety and durability The insulation layer separates from the structural layer, and the bond strength decreases rapidly under freeze-thaw cycles, posing a risk of detachment from heights. The steel frame provides load-bearing support, while the fiberboard is secured with screws, eliminating the risk of detachment; it requires only one maintenance throughout its entire lifespan. Bolt and screw connections offer reliable wind and impact resistance, making them suitable for special structures such as border outposts. By using stainless steel connectors and a zinc-aluminum alloy frame, the corrosion resistance lifespan is extended from 10 years to over 25 years. Ease of maintenance Damage to the insulation layer requires extensive demolition of the wall, which is time-consuming, labor-intensive, and has a wide impact. For localized damage, only the corresponding inner panel needs to be removed and the rock wool module replaced to restore the original condition, reducing maintenance costs by 80%. Similar to Example 1, future maintenance is equally convenient after the emergency repair. Modular maintenance is available, and the moisture-proof layer can be replaced separately, making maintenance more flexible. Comprehensive economic benefits <![CDATA[1000m 2 Direct costs are approximately 380,000 yuan, and total life-cycle (25 years) costs are approximately 1,177,500 yuan. The direct cost is approximately 551,300 yuan (material costs are slightly higher), but the total life cycle cost is only 856,300 yuan, resulting in a saving of 321,300 yuan. Avoiding the need for building scrapping and reconstruction saves on investment in the main structure, resulting in significant indirect economic benefits. Extends building lifespan, reduces frequent maintenance in high-humidity environments, and shortens the investment payback period to 3-5 years.

[0094] Compared with the control example (traditional process), the three embodiments of the present invention have achieved leapfrog technological progress in severe cold and special environments through the core technical path of "modular prefabrication and simultaneous indoor and outdoor construction".

[0095] Firstly, regarding adaptability to the construction environment, the comparative example is completely constrained by climate conditions, making it impossible to work for extended periods in winter. In contrast, this invention, through the unique step of "sealing the exterior side with fiberboard first," creates an independent working space inside the wall, isolated from the harsh environment. Example 1 achieved normal construction at -15℃, and Example 2 even successfully completed emergency repairs at an ultra-low temperature of -35℃, completely breaking the age-old dilemma of the construction industry "hibernating in winter" and enabling uninterrupted construction throughout the year.

[0096] Secondly, regarding engineering quality and life-cycle performance, the comparative examples rely on wet work and manual pasting, resulting in common quality problems such as hollow insulation layers, detachment, and poor sealing. In contrast, all modules of this invention are factory-standardized prefabricated, requiring only dry assembly on-site. The measured data of Example 1 (heat transfer coefficient 0.38, pull-out force 0.65kN) comprehensively surpasses national standards, and the steel frame connection eliminates the risk of detachment. Example 3, through targeted upgrades to materials (stainless steel connectors, zinc-aluminum alloy frame, vapor barrier), further expands the application scenarios of the technology to high-humidity and corrosive environments, demonstrating strong technical adaptability and environmental robustness.

[0097] Finally, regarding economy and maintainability, although the initial material unit price of the prefabricated modules of this invention is slightly higher than that of the control example, its comprehensive advantages are significant: the construction cycle is shortened by more than 50%, directly saving labor, machinery and management costs; the modular structure makes later maintenance more convenient, and the maintenance frequency and cost are greatly reduced. The life cycle cost accounting of Example 1 shows that per 1000m²... 2 The wall can save 321,300 yuan. More importantly, the emergency repair capabilities demonstrated in Example 2 have immeasurable social benefits and avoid indirect economic losses when facing urgent tasks such as border outposts and post-disaster reconstruction.

[0098] In summary, through three embodiments targeting "standard cold-weather construction," "extreme low-temperature emergency repair," and "special high-humidity environment," this invention comprehensively verifies its significant advantages over traditional processes in terms of environmental adaptability, construction efficiency, quality performance, maintenance convenience, and overall life-cycle economic benefits, demonstrating its high value for widespread application.

[0099] Application example: Comprehensive economic benefit assessment of large-scale promotion

[0100] Background: Based on the successful application of the above embodiments, it is assumed that the technology of this invention will be widely promoted within Heilongjiang Provincial Construction and Installation Group Co., Ltd. Taking a typical annual promotion plan as an example, its overall economic benefits will be evaluated.

[0101] Project data settings: The company undertakes 20 industrial plant or public building projects annually that meet the application conditions of this invention's technology, with an average exterior wall construction area of ​​1000m² for each project.2 Calculations. The benchmark remains the traditional process of "sintered brick masonry + external wall insulation".

[0102] Cost and benefit accounting (based on the data model of identification material four):

[0103] Single project (1000m) 2 Direct economic benefits:

[0104] Direct construction cost savings: 32,625 yuan - 50,000 yuan (savings on construction delay costs) = approximately 82,625 yuan (indirect benefits from construction delay savings). For a conservative estimate, we will use a direct cost saving of 26,250 yuan.

[0105] Total lifecycle (25 years) cost savings: 321,250 yuan.

[0106] The overall benefits of promoting 20 projects annually:

[0107] Annual direct economic benefits: 20 projects × 26,250 yuan / project = 525,000 yuan. This does not include the financial cost savings due to shortened construction periods and earlier delivery.

[0108] Annual total lifecycle benefits: 20 projects × 321,250 yuan / project = 6,425,000 yuan. This reflects the long-term value brought by technology.

[0109] Total time saved: Each project saves an average of 15 days of construction time (compared to traditional summer construction methods), totaling 300 man-days saved across 20 projects, significantly improving the company's capital turnover rate and project undertaking capacity.

[0110] Resource conservation and carbon emission reduction: for each project (1000m) 2 This reduces construction waste by approximately 50 tons and water consumption by 80%. The 20 projects reduce construction waste by 1,000 tons annually, demonstrating significant water conservation and strongly supporting the company's "dual carbon" goals and social responsibility report.

[0111] Conclusion: The present invention, "Modular Prefabrication and Simultaneous Indoor and Outdoor Construction Technology of Fiberboard Insulation Wall Applicable to Severe Cold Regions," not only solves the core pain points of building construction in severe cold regions at the technical level, possessing creativity, novelty, and practicality; but also brings significant, quantifiable direct and long-term economic benefits to construction companies at the economic level, and has extremely high commercial promotion value and broad application prospects.

[0112] The foregoing has only described certain exemplary embodiments of the present invention by way of illustration. Undoubtedly, those skilled in the art can modify the described embodiments in various ways without departing from the spirit and scope of the present invention. Therefore, the foregoing drawings and descriptions are illustrative in nature and should not be construed as limiting the scope of protection of the claims of the present invention.

Claims

1. A modular prefabrication and simultaneous indoor and outdoor construction process for fiberboard insulation walls suitable for extremely cold regions, characterized in that: Includes the following steps: Step 1: Modular disassembly and prefabrication. Based on the building module, the wall system is disassembled into multiple independent prefabricated modular units, including hot-dip galvanized square steel frame modules, outer moisture-proof fiberboard modules, inner moisture-proof fiberboard modules, and rock wool insulation board modules. All modules are produced in a standardized manner in the factory. Step 2: Main structure pretreatment and measurement layout. After the main structure of the building is completed, the installation area is cleaned and the layout is accurately completed to determine the installation position of the steel frame module. The layout error is controlled within ±2mm. Step 3: On-site installation of steel frame modules. Prefabricated hot-dip galvanized square steel frame modules are fixed to the main structure using expansion bolts to form a wall load-bearing frame. The verticality and horizontality are then adjusted to meet the requirements. Step 4: Outdoor fiberboard module enclosure installation. On the outdoor side of the steel frame module, self-tapping screws are used to fix the outer moisture-proof fiberboard module to form an outdoor enclosure, creating a closed cavity inside the wall that is isolated from the outdoor environment. This allows indoor side work to continue even when the outdoor temperature is not lower than -15℃ or in rainy or snowy weather. Step 5: Simultaneous filling of indoor insulation material. Inside the building, rock wool insulation board modules are filled into the enclosed cavity, with a filling density of not less than 95%. Step Six: Indoor Fiberboard Module Sealing Installation. After the rock wool insulation board module is filled, the inner moisture-proof fiberboard module is fixed to the indoor side of the steel frame module with self-tapping screws to form a complete prefabricated wall with integrated structure and insulation. Step 7: Sealing the joints and overall acceptance. Seal all the joints between the fiberboard modules and test and accept the flatness, verticality, heat transfer coefficient and structural connection strength of the formed wall.

2. The modular prefabrication and simultaneous indoor and outdoor construction technology for fiberboard insulation walls suitable for frigid regions as described in claim 1, is characterized in that... The hot-dip galvanized square steel frame module in step one uses hot-dip galvanized square steel with specifications of 120mm×40mm×4mm and a zinc layer thickness of ≥85μm, which is connected by welding or bolting, and its dimensional error is controlled within the design allowable range; the density of the outer / inner moisture-proof fiberboard module is 600-800kg / m³. 3 The thickness is 12mm, the moisture content is ≤12%, and the flexural strength is ≥15MPa; the thermal conductivity of the rock wool insulation board module is ≤0.04W / (m·K), and the bulk density is 100-120kg / m³. 3 .

3. The modular prefabrication and simultaneous indoor and outdoor construction technology for fiberboard insulation walls suitable for frigid regions as described in claim 1, is characterized in that... In step three, the expansion bolts are M16×150mm in size, with a tensile strength ≥400MPa and an installation spacing ≤600mm. In steps four and six, the self-tapping screws are M5×12mm in size, with a zinc plating thickness ≥10μm and an installation spacing ≤250mm.

4. The modular prefabrication and simultaneous indoor and outdoor construction technology for fiberboard insulation walls suitable for frigid regions as described in claim 1, is characterized in that... In step four, after installing the outer moisture-proof fiberboard module, sealant or sealing strips are used to initially seal the gaps between it and the steel frame, as well as between it and adjacent fiberboards.

5. The modular prefabrication and simultaneous indoor and outdoor construction technology for fiberboard insulation walls suitable for frigid regions as described in claim 1, characterized in that, The filling process of the rock wool insulation board module further includes: adapting the rock wool board to make its size precisely match the internal space of the steel frame module; and using at least one of the following methods during filling: layered laying and mechanical extrusion. For local gaps, rock wool strips of the same material are used to fill them.

6. The modular prefabrication and simultaneous indoor and outdoor construction technology for fiberboard insulation walls suitable for frigid regions as described in claim 1, is characterized in that... After step six is ​​completed, if the wall is partially damaged, the maintenance and replacement method is as follows: only the inner fiberboard module of the damaged area is removed, the damaged rock wool module is taken out and replaced, and the removed fiberboard module is restored in its original position without dismantling or modifying the entire wall.

7. The modular prefabrication and simultaneous indoor and outdoor construction technology for fiberboard insulation walls suitable for frigid regions as described in claim 1, is characterized in that... The outer surface of the outer moisture-proof fiberboard module is prefabricated with at least one of a waterproof coating and a finishing layer, and the inner surface of the inner moisture-proof fiberboard module is prefabricated with at least one of an interface agent and a leveling layer.

8. The modular prefabrication and simultaneous indoor and outdoor construction technology for fiberboard insulation walls suitable for frigid regions as described in claim 1, characterized in that, The construction process also includes a temperature monitoring and protection measure: when the outdoor temperature is below -15℃, a temporary hot air curtain or electric heating device is installed on the indoor side to maintain the temperature of the filling operation area at no less than -10℃.

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