Die-free assembly integrated reinforced concrete structure

Abstract

The utility model relates to a die-free assembly integrated reinforced concrete structure, which belongs to the technical field of building structures and comprises a reinforcement cage, an integrated thermal insulation layer is arranged on one side or multiple sides of the outer contour of the reinforcement cage, framework structures are arranged on multiple side faces of the outer contour of the reinforcement cage, and the integrated thermal insulation layer is connected with the reinforcement cage in a broken bridge mode. The bearing structure and the heat preservation layer are connected into a whole, a heat bridge is eliminated, and the service life of the heat preservation layer is the same as that of the structure; later external wall insulation construction is not needed, and the field workload and the construction period are greatly reduced; the exposed reinforcing steel bars ensure that the prefabricated and cast-in-place parts form vertical and longitudinal strong connection, and the strength is high; the cavity structure is convenient to transport and hoist, the surface flatness of the component is high, leveling operation is not needed, the service life of the integrated facing layer and the thermal insulation layer is consistent with that of a building, the facing layer and patterns can be selected on the outer side of the concrete formwork according to requirements, the facing layer is integrally prefabricated in a factory, and the construction period is shortened.

Description

Technical Field

[0001] This utility model relates to a formwork-free, prefabricated, integrated reinforced concrete structure, belonging to the field of building structure technology. Background Technology

[0002] In the construction industry, reinforced concrete structures are the main load-bearing components. The traditional construction method is to erect formwork on site, tie steel bars, pour concrete, and then remove the formwork after curing to the required strength.

[0003] This method involves numerous steps, a long construction period, and quality is greatly affected by environmental and human factors. To improve this, industrialized construction promotes precast concrete (PC) components, such as prefabricated concrete structures, which involve manufacturing complete concrete structures (walls, beams, columns, etc.) in a factory before transporting them to the site for hoisting. While this method reduces on-site construction work, it also presents challenges such as the heavy weight of components, high transportation and hoisting costs, complex connections between prefabricated and cast-in-place joints, and difficulty in ensuring overall integrity.

[0004] Furthermore, with the continuous improvement of building energy efficiency standards, the thermal insulation performance of building envelopes is crucial. Traditional concrete structures, due to their high thermal conductivity, are prone to forming thermal bridges in buildings, leading to heat loss and affecting energy efficiency. The conventional practice is to apply external wall insulation after the main structure is completed. However, this post-installed insulation system carries risks of detachment and fire, and has poor durability. Additionally, traditional prefabricated PC component insulation layers are often fixed using wire bracing or direct connection methods, resulting in numerous cold bridges and poor insulation performance.

[0005] Therefore, developing a new type of lightweight structural component that integrates load-bearing structure with thermal insulation and decorative functions in a factory prefabrication process has great market value and is technically necessary. Utility Model Content

[0006] Based on the shortcomings of the existing technology, the technical problem to be solved by this utility model is to provide a formwork-free, prefabricated integrated reinforced concrete structure that integrates lightweight, heat insulation, finishing layer, and prefabricated functions, facilitates industrial production, and can significantly improve construction efficiency and building energy-saving performance.

[0007] The moldless assembled integrated reinforced concrete structure of this utility model is a cavity structure, including a reinforcing cage. The reinforcing cage is arranged along the length of the cavity structure and is the load-bearing core of the cavity structure. An integrated insulation layer is provided on one or more sides of the outer contour of the reinforcing cage. A skeleton structure is also provided on multiple sides of the outer contour of the reinforcing cage. The integrated insulation layer is sandwiched between the skeleton structure and the reinforcing cage. The integrated insulation layer is fixedly connected to the reinforcing cage through the mold shell tie rod. At the same time, the integrated insulation layer and the reinforcing cage are separated by mechanical anchors. Therefore, the connection between the integrated insulation layer and the reinforcing cage is a thermal break, which fundamentally eliminates thermal bridges.

[0008] The side of the steel cage without an integrated insulation layer is solidified together with the skeleton structure and the steel cage by pouring concrete; the outside of the integrated insulation layer is equipped with a concrete formwork, which is a permanent template formed by the skeleton structure and the concrete pouring. The concrete formwork is both a forming mold and a component of the final structural parts; the skeleton structure can serve as the skeleton of the concrete formwork, and after pouring a thin layer of concrete, it can form a strong template surface layer that is crack-resistant and impact-resistant.

[0009] The steel cage is a spatial skeleton structure formed by several stirrups arranged along the length of the cavity structure and several longitudinal steel bars parallel to the length of the cavity structure. The stirrups are used to fix the cross-sectional shape of the cavity structure, and the longitudinal steel bars are the main load-bearing bars. The concrete mold shell is prefabricated with a decorative layer on the outside.

[0010] The technical solution of this utility model is to provide a formwork-free assembled integrated reinforced concrete structure. An integrated insulation layer is set between the skeleton structure and the steel cage. The connection between the integrated insulation layer and the steel cage is a broken bridge. A concrete formwork is poured on the outside of the integrated insulation layer. A precast decorative layer is placed on the outside of the concrete formwork to achieve load-bearing, insulation and decoration functions. No external wall insulation and decoration construction is required, which improves construction efficiency.

[0011] Preferably, the longitudinal reinforcing bars protrude from the end face of the concrete formwork and are exposed on the outside of the cavity structure, so that the connecting ends of the reinforcing bars extend into the cavity of the adjacent concrete component and overlap with the adjacent reinforcing cage. This facilitates the continuous casting of the concrete cavity component and enables tight interlocking and force transmission through these exposed reinforcing bars, ensuring the integrity of the structural components under stress. This connection method truly achieves the equivalence of the precast and cast-in-place parts in terms of mechanical properties in terms of connection principle.

[0012] Preferably, the stirrup is formed by continuously bending a single steel bar to form a closed stirrup ring, and the stirrup is connected to the longitudinal steel bar by binding or welding.

[0013] Preferably, the integrated insulation layer is made of insulation board, including but not limited to extruded polystyrene board (XPS), molded polystyrene board (EPS), rock wool board, rigid polyurethane foam insulation board, and foam glass board; several molded shell tie rods are fixed on the integrated insulation layer, and the molded shell tie rods are specifically L-shaped steel bars. The molded shell tie rods are firmly connected to the steel cage by welding. The integrated insulation layer is also reinforced and fixed by mechanical anchors connected to the skeleton structure.

[0014] Preferably, the stirrup is rectangular, trapezoidal, or octagonal in shape.

[0015] Preferably, the materials of the finishing layer include, but are not limited to, facing bricks, stone, metal sheets, real stone paint, and terrazzo.

[0016] The advantages of this utility model compared with the prior art are:

[0017] 1. Integrated structure and insulation: The load-bearing structure and insulation layer of this utility model are connected as one, which fundamentally eliminates thermal bridges, has a high energy-saving coefficient, and the insulation layer and structure have the same lifespan, making it safe and reliable.

[0018] 2. Highly efficient construction: This utility model eliminates the need for subsequent external wall insulation construction, significantly reducing on-site work and construction period, and has a high degree of industrialization;

[0019] 3. Good integrity: The exposed steel bars ensure that the precast and cast-in-place parts form a strong vertical and longitudinal connection, and the stress performance is the same as that of cast-in-place parts, with high strength;

[0020] 4. High overall benefits: The cavity structure of this utility model is relatively lightweight, making transportation and hoisting operations convenient. The surface of the components has high flatness, eliminating the need for leveling operations. The integrated finishing layer and insulation layer have the same lifespan as the building.

[0021] 5. Factory prefabrication of finishing layer: The outer side of the concrete formwork can be finished with materials such as brick, stone, real stone paint, terrazzo, etc., according to the project design requirements. The finishing layer is prefabricated in the factory, eliminating the need for on-site construction, improving efficiency and shortening the construction period. Attached Figure Description

[0022] Figure 1 This is a structural schematic diagram of Example 1;

[0023] Figure 2 This is an exploded view of Example 1;

[0024] Figure 3 This is a top view of Embodiment 1;

[0025] Figure 4 This is a structural schematic diagram of Example 2;

[0026] Figure 5 This is an exploded view of Example 2;

[0027] Figure 6 This is a schematic diagram of the structure of Example 3;

[0028] Figure 7 This is an exploded view of Example 3;

[0029] Figure 8 This is a structural schematic diagram of Example 4.

[0030] In the diagram: 1. Reinforcing cage; 11. Longitudinal reinforcement; 12. Stirrups; 2. Finishing layer; 3. Skeleton structure; 4. Mechanical anchors; 5. Integrated insulation layer; 51. Formwork tie rods; 6. Concrete formwork. Detailed Implementation

[0031] Example 1

[0032] like Figure 1-3 As shown, when this cavity structure is used as a column, it is achieved through the following technical solution: The cavity structure includes a reinforcing cage 1, which is embedded along the length of the cavity structure and serves as the load-bearing core. The reinforcing cage 1 has an integrated insulation layer 5 on one or more sides of its outer contour, and multiple sides of the reinforcing cage 1 also have a frame structure 3, which is a wire mesh or tensile fiber. The integrated insulation layer 5 is sandwiched between the frame structure 3 and the reinforcing cage 1, and is fixedly connected to the reinforcing cage 1 via a molded tension member 51. Simultaneously, the integrated insulation layer 5 and the reinforcing cage 1 are separated by mechanical anchors 4, preventing direct contact between the integrated insulation layer 5 and the reinforcing cage 1 to prevent flame retardant corrosion. The contact part between the mechanical anchors 4 and the integrated insulation layer 5 is made of plastic, thus the connection between the integrated insulation layer 5 and the reinforcing cage 1 is a thermal break, fundamentally eliminating thermal bridging.

[0033] The side of the steel cage 1 without the integrated insulation layer 5 is solidified together with the skeleton structure 3 and the steel cage 1 by pouring concrete; the outer side of the integrated insulation layer 5 is provided with a concrete formwork 6, which is a permanent template formed by the skeleton structure 3 and the concrete pouring. The concrete formwork 6 is both a forming mold and a component of the final structural component; the skeleton structure 3 can serve as the skeleton of the concrete formwork 6, and after pouring a thin layer of concrete, it can form a strong template surface layer that is crack-resistant and impact-resistant.

[0034] The steel cage 1 is formed by a number of stirrups 12 arranged along the length of the cavity structure and a number of longitudinal steel bars 11 parallel to the length of the cavity structure to form a spatial skeleton structure. The stirrups 12 are used to fix the cross-sectional shape of the cavity structure, and the longitudinal steel bars 11 are the main load-bearing bars.

[0035] In this embodiment, the longitudinal reinforcing bars 11 protrude from the end face of the concrete formwork 6 and are exposed on the outside of the cavity structure. This allows the connecting ends of the reinforcing bars to extend into the cavity of the adjacent concrete component and overlap with the adjacent reinforcing cage 1, facilitating continuous casting of the concrete cavity component. These exposed reinforcing bars enable tight interlocking and force transmission, ensuring the overall structural integrity. This connection method truly achieves mechanical performance equivalence between the precast and cast-in-place parts in terms of connection principle. The portion of the longitudinal reinforcing bars 11 exposed on the outside of the cavity structure is tapered inward by a certain distance, greater than the thickness of the concrete formwork 6, so that the longitudinal reinforcing bars 11 can avoid the concrete formwork 6 and smoothly penetrate into the next layer of components during assembly.

[0036] The stirrup 12 is formed by continuously bending a single steel bar to form a closed stirrup ring. The stirrup 12 is connected to the longitudinal steel bar 11 by binding. The integrated insulation layer 5 is made of extruded polystyrene board (XPS). Several mold shell tie members 51 are fixed on the integrated insulation layer 5. The mold shell tie members 51 are specifically steel bars bent into an L shape. The mold shell tie members 51 are firmly connected to the steel cage 1 by welding. The integrated insulation layer 5 is reinforced and fixed by mechanical anchors 4 connected to the frame structure 3.

[0037] The stirrup 12 is rectangular in shape; the outer side of the concrete formwork 6 is prefabricated with a decorative layer 2. When the decorative layer 2 is made of stone, brick or metal sheet, it is fastened into the concrete by embedded parts to form an embedded mechanical connection process; when the decorative layer 2 is made of terrazzo, a grinding and polishing process is used; when the decorative layer 2 is made of real stone paint, a spraying process is used.

[0038] The construction process in this embodiment is as follows:

[0039] 1. Factory prefabrication: In the factory, the outer formwork of the steel cage 1 with the integrated insulation layer 5 installed is erected, and then concrete is poured on the side of the steel cage 1; after the concrete wraps around the skeleton structure 3 and solidifies, a strong permanent concrete shell 6 is formed that is permanently composite with the integrated insulation layer 5, forming a cavity structure.

[0040] 2. Transportation and hoisting: Transport the lightweight cavity structure to the construction site, hoist it to the design elevation and position, and install and fix it in place;

[0041] 3. On-site pouring: Pour concrete into the upper opening of the cavity structure to fill the cavity;

[0042] 4. Curing and shaping: After the concrete has solidified, a complete reinforced concrete column with its own heat insulation function will be formed.

[0043] Example 2

[0044] like Figure 4-5 As shown, when this cavity structure is used as a beam, it is achieved through the following technical solution:

[0045] The cavity structure includes a steel cage 1, with a frame structure 3 fixedly connected to the outer sides and bottom of the steel cage 1, and an integrated insulation layer 5 sandwiched between the frame structure 3 and the steel cage 1.

[0046] The other structures of Example 2 are the same as those of Example 1.

[0047] Example 3

[0048] like Figure 6-7 As shown, when this cavity structure is used as an L-shaped wall, it is achieved through the following technical solution:

[0049] The cavity structure includes a steel cage 1, a frame structure 3 is fixedly connected to one side of the steel cage 1, and an integrated insulation layer 5 is sandwiched between the frame structure 3 and the steel cage 1.

[0050] The other structures of Example 3 are the same as those of Example 1.

[0051] Example 4

[0052] like Figure 8 As shown, this cavity structure is a schematic diagram when used as an upright wall. The other structures of Embodiment 4 are the same as those of Embodiment 3.

Claims

1. A form-free assembly integrated reinforced concrete structure, characterized by, The cavity structure comprises a reinforcing cage (1) arranged along the length direction of the cavity structure; one side or multiple sides of the outer contour of the reinforcing cage (1) are provided with an integrated thermal insulation layer (5), and multiple sides of the outer contour of the reinforcing cage (1) are further provided with a framework structure (3); the integrated thermal insulation layer (5) is clamped between the framework structure (3) and the reinforcing cage (1), and the integrated thermal insulation layer (5) is fixedly connected with the reinforcing cage (1) through a formwork tensioning piece (51); the integrated thermal insulation layer (5) and the reinforcing cage (1) are spaced through a mechanical anchor (4). The side of the reinforcing cage (1) without the integrated thermal insulation layer (5) is poured with concrete to solidify the framework structure (3) and the reinforcing cage (1) together; the outer side of the integrated thermal insulation layer (5) is provided with a concrete formwork (6), and the concrete formwork (6) is a permanent formwork formed by the framework structure (3) and the concrete pouring; the reinforcing cage (1) is formed by a plurality of stirrups (12) arranged along the length direction of the cavity structure and a plurality of longitudinal reinforcing steels (11) fixedly connected in parallel to the length direction of the cavity structure to form a spatial framework structure.

2. The no-form-fit integrated reinforced concrete structure according to claim 1, characterized in that The longitudinal reinforcing steel (11) protrudes from the end face of the concrete formwork (6) and is exposed to the outside of the cavity structure.

3. The no-form-fit integrated reinforced concrete structure according to claim 1, characterized in that The stirrup (12) is formed by continuously bending one steel bar to form a closed stirrup ring, and the stirrup (12) and the longitudinal reinforcing steel (11) are connected by binding or welding.

4. The no-form-fit integrated reinforced concrete structure according to claim 1, characterized in that The integrated thermal insulation layer (5) is made of thermal insulation board; a plurality of formwork tensioning pieces (51) are fixed on the integrated thermal insulation layer (5), the formwork tensioning pieces (51) are firmly combined with the reinforcing cage (1) by welding, and the integrated thermal insulation layer (5) is further fixed by being connected with the framework structure (3) through the mechanical anchor (4).

5. The no-form-fit integrated reinforced concrete structure according to claim 3, characterized in that The shape of the stirrup (12) is one of a rectangle, a trapezoid and an octagon.

6. The no-form-fit integrated reinforced concrete structure according to claim 1, characterized in that The outer side of the concrete formwork (6) is prefabricated with a facing layer (2), and the material of the facing layer (2) comprises face bricks, stone materials, metal plates, real stone paint and terrazzo.

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