Construction of imitation fair-faced concrete thermal insulation wall and construction method thereof

Abstract

The present application relates to a kind of imitation fair-faced concrete thermal insulation wall structure and its construction method, wherein thermal insulation wall structure includes masonry wall layer, thermal insulation layer and imitation fair-faced concrete facing layer;Wherein, the thermal insulation layer is arranged between the masonry wall layer and the imitation fair-faced concrete facing layer, and the thermal insulation layer is respectively fixedly connected with the masonry wall layer and the imitation fair-faced concrete facing layer;The thermal insulation layer is formed by composite thermal insulation mortar, the cementitious material of the composite thermal insulation mortar includes cement and papermaking white clay, and the aggregate of the composite thermal insulation mortar includes aerogel and vitrified microsphere;The present application thermal insulation layer uses cementitious material including cement and papermaking white clay, aggregate including aerogel and vitrified microsphere composite thermal insulation mortar, reduces cracking risk and realizes waste utilization on the one hand;On the other hand, the dry density of thermal insulation mortar is reduced, and thermal insulation performance is improved;While the two form graded structure, further optimize the thermal insulation effect.

Description

Technical Field

[0001] This invention relates to the field of building wall technology, specifically to a simulated fair-faced concrete thermal insulation wall structure and its construction method. Background Technology

[0002] Fair-faced concrete walls are widely used in modern architecture due to their simplicity, naturalness, and strong texture. However, cast-in-place fair-faced concrete is heavy, has high formwork costs, and cannot provide thermal insulation, requiring an additional insulation layer, which leads to complex wall structures.

[0003] Currently, there is no wall solution that can organically integrate masonry structure, thermal insulation, and imitation fair-faced decoration in existing imitation fair-faced concrete wall technologies. At the same time, existing thermal insulation mortars mainly use cement as a binder and vitrified microspheres as aggregates. Due to the small particle size of vitrified microspheres, a large amount of binder is required, resulting in a high dry density of the thermal insulation mortar and unsatisfactory thermal insulation performance.

[0004] Therefore, there is an urgent need to develop a technology for imitation fair-faced concrete insulated walls that can effectively integrate wall structure with thermal insulation and decorative functions and has excellent thermal insulation performance. Summary of the Invention

[0005] The purpose of this invention is to overcome the defects of the prior art and provide a simulated fair-faced concrete thermal insulation wall structure and its construction method, which solves the problems that the simulated fair-faced concrete wall cannot take into account both thermal insulation performance and decorative effect, and that the existing thermal insulation mortar has a high dry density and unsatisfactory thermal insulation performance due to the large amount of vitrified microspheres used.

[0006] To achieve the above objectives, the present invention provides a simulated fair-faced concrete thermal insulation wall structure, comprising: a masonry wall layer, a thermal insulation layer, and a simulated fair-faced concrete finishing layer; wherein, the thermal insulation layer is disposed between the masonry wall layer and the simulated fair-faced concrete finishing layer, and the thermal insulation layer is fixedly connected to the masonry wall layer and the simulated fair-faced concrete finishing layer respectively. The thermal insulation layer is formed by composite thermal insulation mortar, the cementing material of which includes cement and papermaking slurry, and the aggregate of which includes aerogel and vitrified microspheres.

[0007] This technical solution integrates masonry structure, thermal insulation, and decorative functions into a three-in-one composite wall. The thermal insulation layer also serves as the base layer for the finishing layer, eliminating the need for additional leveling and bonding layers. The wall structure is simple and has good overall integrity. Furthermore, the thermal insulation layer uses a composite thermal insulation mortar with cementitious materials including cement and papermaking slurry, and aggregates including aerogel and vitrified microspheres. On one hand, it utilizes industrial waste papermaking slurry to replace part of the cement, reducing heat of hydration, minimizing the risk of cracking, and achieving waste utilization. On the other hand, it uses the ultra-low density of aerogel to reduce the dry density of the thermal insulation mortar and improve thermal insulation performance. The vitrified microspheres and aerogel form a graded structure to further optimize the thermal insulation effect. Thus, at the wall construction level, it solves the problems of existing imitation fair-faced walls being unable to simultaneously achieve thermal insulation and decorative functions, and the high dry density of existing thermal insulation mortar leading to unsatisfactory thermal insulation performance.

[0008] Furthermore, the weight ratio of the papermaking sludge to the cement in the cementitious material is 9:41.

[0009] By adopting this technical solution, at this ratio, papermaking bleach can effectively reduce the heat of hydration of cement and reduce the risk of cracking of the insulation layer, while avoiding the impact on the bonding strength and hardening performance of cementitious materials due to excessive dosage. This achieves a balance between waste utilization and obtaining mechanical properties, while ensuring the connection stability between the thermal insulation layer and the masonry wall layer and the finishing layer.

[0010] Furthermore, the volume ratio of the vitrified microspheres to the aerogel in the aggregate is 6.5:3.5.

[0011] By adopting this technical solution, at this ratio, the gaps between coarse aerogel particles can be effectively filled by vitrified microspheres, while fine aerogel powder can fill the gaps between vitrified microsphere particles, forming a reasonable particle size distribution structure. This results in dense and fine pores inside the thermal insulation mortar, effectively improving the thermal insulation performance of the mortar. At the same time, the two complement each other in terms of mechanical properties, and the overall strength is better than when used alone.

[0012] Furthermore, the thermal insulation layer is a three-layer composite structure consisting of a bottom thermal insulation mortar layer, a middle thermal insulation mortar layer, and a top thermal insulation mortar layer; wherein, The surface insulation mortar layer contains polypropylene fibers and is embedded with alkali-resistant fiberglass mesh.

[0013] By adopting this technical solution, the three-layer troweling construction ensures the overall density and interlayer bonding of the thermal insulation layer; the surface layer serves as a crack-resistant protective layer, with polypropylene fibers preventing the propagation of micro-cracks in the mortar, and alkali-resistant fiberglass mesh acting as a skeleton to bear tensile stress and prevent cracks from forming. Together, they constitute a dual crack-resistant system of "fiber-mesh material", forming a flexible transition interface on the surface of the thermal insulation layer, which significantly enhances the crack resistance of the wall.

[0014] Furthermore, the polypropylene fiber content in the surface insulation mortar layer is 0.2%, the thickness of the surface insulation mortar layer is 5mm, and the overlap width of adjacent alkali-resistant fiberglass meshes is not less than 100mm.

[0015] By adopting this technical solution, the 0.2% polypropylene fiber content can provide crack resistance enhancement without excessively affecting the mortar fluidity; the 5mm surface layer thickness can ensure the effective embedding of fibers and mesh fabric without being too thick and affecting thermal insulation; the overlap width of not less than 100mm ensures the continuous stress of the mesh fabric at the splice, and avoids the overlap becoming a weak link in crack resistance.

[0016] This invention also provides a construction method for a simulated fair-faced concrete insulated wall structure, comprising the following steps: S1, Masonry wall layer; S2. Prepare composite thermal insulation mortar, wherein the cementitious material of the composite thermal insulation mortar includes cement and papermaking white mud, and the aggregate of the composite thermal insulation mortar includes aerogel and vitrified microspheres. S3. Apply the composite thermal insulation mortar in layers to the surface of the masonry wall layer to form a thermal insulation layer; S4. Apply a simulated fair-faced concrete finish to the surface of the thermal insulation layer.

[0017] By adopting this technical solution, a targeted construction process is provided for the construction of simulated fair-faced concrete insulated walls.

[0018] Furthermore, in step S2, the weight ratio of papermaking sludge to cement in the cementitious material is 9:41, and the volume ratio of vitrified microspheres to aerogel in the aggregate is 6.5:3.5.

[0019] By adopting this technical solution, the material ratio of composite thermal insulation mortar is limited at the construction method level, ensuring that the thermal insulation layer constructed according to this method has excellent thermal insulation performance and mechanical properties.

[0020] Furthermore, the specific steps for preparing the composite thermal insulation mortar in step S2 are as follows: First, dry mix the cement and papermaking mud in proportion for 2 minutes, then add water and stir for 3 to 4 minutes, and finally add aerogel and vitrified microsphere composite aggregate.

[0021] By adopting this technical solution, it is ensured that cement and papermaking slurry are fully and evenly mixed before being combined with water, thus avoiding the problem of uneven dispersion of papermaking slurry in the slurry. The order of preparing the gel slurry first and then adding lightweight aggregates avoids the breakage of aerogel and vitrified microspheres during long-term stirring, ensuring the integrity of the aggregates and the effectiveness of the gradation structure.

[0022] Furthermore, in step S3, the layered troweling and pressing is carried out in three layers: a bottom insulation mortar layer, a middle insulation mortar layer, and a top insulation mortar layer. Polypropylene fibers are incorporated into the surface insulation mortar layer. Before initial setting, the mortar is troweled and alkali-resistant fiberglass mesh is embedded simultaneously. Spray curing is carried out after each layer is constructed.

[0023] By adopting this technical solution, the three-layer troweling ensures the compaction of each layer of mortar and the interlayer bonding force; the pre-setting troweling makes the surface of the layer dense and smooth; the simultaneous embedding of alkali-resistant fiberglass mesh ensures its synergistic work with the mortar; and the spray curing ensures the full hydration of the cementitious material, avoids drying shrinkage and cracking, and ensures the overall construction quality of the thermal insulation layer.

[0024] Furthermore, step S4 specifically includes: First, apply a natural stone powder finish base to the surface of the thermal insulation layer. After drying, apply a gray base coat and sand it with 600-grit sandpaper. Then, apply a color-matching agent and sand it with 800-grit sandpaper. Finally, roll on a fluorocarbon transparent topcoat.

[0025] By adopting this technical solution, the natural stone powder finish substrate provides a high-strength, high-hardness, and abrasion-resistant protective base layer; 600-grit polishing can eliminate brush marks; color matching agent combined with 800-grit fine polishing can simulate the natural texture of fair-faced concrete; fluorocarbon transparent topcoat gives the finish layer stain resistance, weather resistance, and self-cleaning ability.

[0026] Compared with the prior art, the present invention has the following advantages: 1. The masonry wall layer, thermal insulation layer and imitation fair-faced concrete finishing layer are fixedly connected into a three-in-one composite wall structure. The thermal insulation layer simultaneously undertakes the functions of thermal insulation and finishing base layer. No additional leveling layer or adhesive layer is required. The wall structure is simple, has good integrity, and has high construction efficiency.

[0027] 2. Papermaking sludge is mixed with cement as a cementing material. Papermaking sludge is an industrial waste that replaces part of the cement, reducing the amount of cement used, reducing the heat of hydration reaction, reducing the risk of cracking of the thermal insulation layer, and realizing the resource utilization of industrial waste, which is environmentally friendly and economical.

[0028] 3. Aerogel and vitrified microsphere composite aggregate is used; aerogel has the characteristics of high porosity and ultra-low density, which can optimize the shortcomings of excessive dry density of pure vitrified microsphere thermal insulation mortar, forming a "coarse aggregate voids - fine aggregate filling" gradation structure, forming dense and fine pores inside the thermal insulation mortar, effectively improving the thermal insulation performance of the mortar; in addition, aerogel particles are relatively brittle and have low mechanical strength. When mixed with vitrified microspheres, the two compensate for each other's defects, and the overall mechanical properties are better than when used alone.

[0029] 4. Polypropylene fibers are incorporated into the surface insulation mortar, and alkali-resistant fiberglass mesh is embedded in the surface layer. The polypropylene fibers can effectively prevent the propagation of micro-cracks, while the alkali-resistant fiberglass mesh can prevent the formation of macro-cracks. Together, they form a dual crack-resistant system of "fiber-mesh material", which significantly enhances the overall crack resistance of the insulation wall.

[0030] 5. Apply a fluorocarbon transparent topcoat to the outermost side of the finish layer. The fluorocarbon topcoat gives the finish layer excellent stain resistance and weather resistance. It can be self-cleaned after being washed by rainwater, maintaining the original decorative effect of fair-faced concrete for a long time. Attached Figure Description

[0031] Figure 1 This is a schematic diagram of the main construction process of the simulated fair-faced concrete thermal insulation wall structure in this invention. Detailed Implementation

[0032] The present invention will be further described below with reference to the accompanying drawings and specific embodiments.

[0033] This invention provides a simulated fair-faced concrete thermal insulation wall structure and its construction method, comprising: a masonry wall layer, a thermal insulation layer, and a simulated fair-faced concrete finishing layer; wherein, the thermal insulation layer is disposed between the masonry wall layer and the simulated fair-faced concrete finishing layer, and the thermal insulation layer is fixedly connected to both the masonry wall layer and the simulated fair-faced concrete finishing layer; the thermal insulation layer is formed by composite thermal insulation mortar, wherein the cementitious material of the composite thermal insulation mortar includes cement and papermaking white clay, and the aggregate of the composite thermal insulation mortar includes aerogel and vitrified microspheres.

[0034] This composite wall integrates masonry structure, thermal insulation, and decorative functions into a unified whole. The thermal insulation layer also serves as the base layer for the finishing layer, eliminating the need for additional leveling and bonding layers. The wall structure is simple and has good overall integrity. Furthermore, the thermal insulation layer uses a composite thermal insulation mortar with cementitious materials including cement and papermaking mortar, and aggregates including aerogel and vitrified microspheres. On one hand, it utilizes industrial waste papermaking mortar to replace part of the cement, reducing heat of hydration, minimizing the risk of cracking, and achieving waste utilization. On the other hand, it uses the ultra-low density of aerogel to reduce the dry density of the thermal insulation mortar and improve thermal insulation performance. The vitrified microspheres and aerogel form a graded structure to further optimize the thermal insulation effect. Thus, at the wall construction level, it solves the problems of existing imitation fair-faced walls being unable to simultaneously achieve thermal insulation and decorative functions, and the high dry density of existing thermal insulation mortar leading to unsatisfactory thermal insulation performance.

[0035] The weight ratio of papermaking sludge to cement in the cementitious material is 9:41. At this ratio, the papermaking sludge can effectively reduce the heat of hydration of cement and reduce the risk of cracking of the insulation layer, and will not affect the bonding strength and hardening performance of the cementitious material due to excessive dosage. This achieves a balance between waste utilization and obtaining mechanical properties, while ensuring the connection stability between the thermal insulation layer and the masonry wall layer and the finishing layer.

[0036] The volume ratio of vitrified microspheres to aerogel in the aggregate is 6.5:3.5. At this ratio, the gaps between coarse aerogel particles can be effectively filled by vitrified microspheres, while the fine aerogel powder can fill the gaps between vitrified microsphere particles, forming a reasonable particle size distribution structure. This results in dense and fine pores inside the thermal insulation mortar, effectively improving the thermal insulation performance of the mortar. At the same time, the two complement each other in terms of mechanical properties, and the overall strength is better than when used alone.

[0037] The thermal insulation layer is a three-layer composite structure consisting of a base thermal insulation mortar layer, a middle thermal insulation mortar layer, and a surface thermal insulation mortar layer. The surface thermal insulation mortar layer contains polypropylene fibers and is embedded with alkali-resistant fiberglass mesh. The three-layer troweling construction ensures the overall compactness and interlayer bonding of the thermal insulation layer. The surface layer serves as a crack-resistant protective layer. The polypropylene fibers in the mortar prevent the propagation of micro-cracks, while the alkali-resistant fiberglass mesh acts as a skeleton to bear tensile stress and prevent crack formation. Together, they form a dual crack-resistant system of "fiber-mesh material," creating a flexible transition interface on the surface of the thermal insulation layer, which significantly enhances the crack resistance of the wall.

[0038] The polypropylene fiber content in the surface insulation mortar layer is 0.2%, which can provide crack resistance enhancement without excessively affecting the mortar fluidity; the thickness of the surface insulation mortar layer is 5mm, which can ensure the effective embedding of fibers and mesh cloth without being too thick and affecting the insulation; the overlap width of adjacent alkali-resistant fiberglass mesh is not less than 100mm, which ensures the continuous stress of the mesh cloth at the splice and avoids the overlap becoming a weak link in crack resistance.

[0039] Please refer to the appendix. Figure 1 The present invention also provides a construction method for a simulated fair-faced concrete thermal insulation wall structure, comprising the following steps: S1, constructing a masonry wall layer; S2, preparing a composite thermal insulation mortar, wherein the cementitious material of the composite thermal insulation mortar includes cement and papermaking clay, and the aggregate of the composite thermal insulation mortar includes aerogel and vitrified microspheres; S3, applying the composite thermal insulation mortar in layers to the surface of the masonry wall layer to form a thermal insulation layer; S4, constructing a simulated fair-faced concrete finishing layer on the surface of the thermal insulation layer.

[0040] Provides targeted construction techniques for the construction of simulated fair-faced concrete insulated walls.

[0041] In step S2, the weight ratio of papermaking slurry to cement in the cementitious material is 9:41, and the volume ratio of vitrified microspheres to aerogel in the aggregate is 6.5:3.5. This limits the material ratio of the composite thermal insulation mortar at the construction method level, ensuring that the thermal insulation layer constructed according to this method has excellent thermal insulation performance and mechanical properties.

[0042] The specific steps for preparing composite thermal insulation mortar in step S2 are as follows: First, dry mix cement and papermaking clay in proportion for 2 minutes, then add water and stir for 3 to 4 minutes, and finally add aerogel and vitrified microsphere composite aggregate. This ensures that cement and papermaking clay are fully and evenly mixed before being combined with water, avoiding the problem of uneven dispersion of papermaking clay in the slurry. The order of preparing the gel slurry first and then adding lightweight aggregate avoids the aerogel and vitrified microspheres from breaking during long-term stirring, ensuring the integrity of the aggregate and the effectiveness of the gradation structure.

[0043] In step S3, the insulation mortar is applied in three layers: a base layer, a middle layer, and a top layer. Polypropylene fibers are incorporated into the top layer of insulation mortar, which is then smoothed before initial setting and simultaneously embedded with alkali-resistant fiberglass mesh. Each layer is then spray-cured after application. The three-layer application ensures the compaction and interlayer bonding of each mortar layer. Smoothing before initial setting results in a dense and smooth surface. The simultaneous embedding of the alkali-resistant fiberglass mesh ensures its synergistic effect with the mortar. Spray curing guarantees full hydration of the cementitious material, preventing shrinkage and cracking, and ensuring the overall construction quality of the insulation layer.

[0044] The S4 steps are as follows: First, apply a natural stone powder finish base coat to the surface of the thermal insulation layer. After drying, apply a base gray paint and sand it with 600-grit sandpaper. Then, apply a color-correcting agent and sand it with 800-grit sandpaper. Finally, roll on a fluorocarbon transparent topcoat. The natural stone powder finish base coat provides a high-strength, high-hardness, and abrasion-resistant protective base layer. 600-grit sanding can eliminate brush marks. The color-correcting agent, combined with 800-grit fine sanding, can simulate the natural texture of fair-faced concrete. The fluorocarbon transparent topcoat gives the finish layer stain resistance, weather resistance, and self-cleaning ability.

[0045] The present invention has been described in detail above with reference to the accompanying drawings and embodiments. Those skilled in the art can make various modifications to the present invention based on the above description. Therefore, certain details in the embodiments should not be construed as limiting the present invention, and the scope of protection of the present invention shall be defined by the appended claims.

Claims

1. A simulated fair-faced concrete thermal insulation wall structure, characterized in that, include: The wall consists of a masonry wall layer, a thermal insulation layer, and a simulated fair-faced concrete finish layer; wherein the thermal insulation layer is disposed between the masonry wall layer and the simulated fair-faced concrete finish layer, and the thermal insulation layer is fixedly connected to both the masonry wall layer and the simulated fair-faced concrete finish layer. The thermal insulation layer is formed by composite thermal insulation mortar, the cementing material of which includes cement and papermaking slurry, and the aggregate of which includes aerogel and vitrified microspheres.

2. The simulated fair-faced concrete thermal insulation wall structure according to claim 1, characterized in that, The weight ratio of the papermaking sludge to the cement in the cementitious material is 9:

41.

3. The simulated fair-faced concrete thermal insulation wall structure according to claim 1, characterized in that, The volume ratio of the vitrified microspheres to the aerogel in the aggregate is 6.5:3.

5.

4. The simulated fair-faced concrete thermal insulation wall structure according to claim 1, characterized in that, The thermal insulation layer is a three-layer composite structure consisting of a bottom thermal insulation mortar layer, a middle thermal insulation mortar layer, and a top thermal insulation mortar layer; wherein... The surface insulation mortar layer contains polypropylene fibers and is embedded with alkali-resistant fiberglass mesh.

5. The simulated fair-faced concrete thermal insulation wall structure according to claim 4, characterized in that, The polypropylene fiber content in the surface insulation mortar layer is 0.2%, the thickness of the surface insulation mortar layer is 5mm, and the overlap width of adjacent alkali-resistant fiberglass mesh is not less than 100mm.

6. A construction method for a simulated fair-faced concrete thermal insulation wall structure as described in any one of claims 1-5, characterized in that, Includes the following steps: S1, Masonry wall layer; S2. Prepare composite thermal insulation mortar, wherein the cementitious material of the composite thermal insulation mortar includes cement and papermaking white mud, and the aggregate of the composite thermal insulation mortar includes aerogel and vitrified microspheres. S3. Apply the composite thermal insulation mortar in layers to the surface of the masonry wall layer to form a thermal insulation layer; S4. Apply a simulated fair-faced concrete finish to the surface of the thermal insulation layer.

7. The construction method of the imitation fair-faced concrete thermal insulation wall structure according to claim 6, characterized in that, In step S2, the weight ratio of papermaking sludge to cement in the cementitious material is 9:41, and the volume ratio of vitrified microspheres to aerogel in the aggregate is 6.5:3.

5.

8. The construction method of the imitation fair-faced concrete thermal insulation wall structure according to claim 6, characterized in that, The specific steps for preparing the composite thermal insulation mortar in step S2 are as follows: First, dry mix the cement and papermaking mud in proportion for 2 minutes, then add water and stir for 3 to 4 minutes, and finally add aerogel and vitrified microsphere composite aggregate.

9. The construction method of the imitation fair-faced concrete thermal insulation wall structure according to claim 6, characterized in that, In step S3, the layered troweling and pressing is carried out in three layers: bottom thermal insulation mortar layer, middle thermal insulation mortar layer and top thermal insulation mortar layer. Polypropylene fibers are incorporated into the surface insulation mortar layer. Before initial setting, the mortar is troweled and alkali-resistant fiberglass mesh is embedded simultaneously. Spray curing is carried out after each layer is constructed.

10. The construction method of the imitation fair-faced concrete thermal insulation wall structure according to claim 6, characterized in that, The S4 step is specifically as follows: First, apply a natural stone powder finish base to the surface of the thermal insulation layer. After drying, apply a gray base coat and sand it with 600-grit sandpaper. Then, apply a color-matching agent and sand it with 800-grit sandpaper. Finally, roll on a fluorocarbon transparent topcoat.

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