Technical field
[0001] The present invention relates to the technical field of buildings, in particular
to the formwork-free and decoration-free cast-in-place structure and a construction
method therefor.
Background art
[0002] The existing cast-in-place building mainly adopts the following method: firstly,
fixing the framework of steel reinforcement made of the reinforcing steel bars on
the construction site, then enclosing the framework by formworks made of various materials
such as steel, aluminum, wood and the like, after the formworks are completely fixed
through various reinforcement members, pouring concrete, disassembling the mold and
trimming after the concrete is solidified, and finally, carrying out heat preservation,
sound insulation and decoration construction according to requirements to become a
finished building for residential use. The existing construction method of the cast-in-place
building has the following defects: 1) a large amount of formworks must be used. The
cost of the formworks accounts for 20-30% of the cost of the building, accounts for
50% of the construction period, accounts for 30-40% of the workload of the engineering,
a large amount of use of the formworks is the main reason that the construction cost
of the existing building is too high, meanwhile, the production of various formworks
consumes a large amount of resources, according to statistics, the steel formwork
which accounts for a relatively small proportion of cast-in-place formworks in Chinese
buildings, consumes more than 3 million tons of steel each year, and the steel formworks
consume a large amount of energy from ore mining to smelting processing, and generate
a large amount of carbon emission; the aluminum formworks that have become popular
in recent years not only have high manufacturing cost, but also cause great pollution
during the mining and smelting of aluminum; the bamboo and wood formworks, which account
for a larger proportion, requires more than 10,000 hectares of forest to be cut down
each year to meet demand; the carbon emissions and pollution generated by composite
formworks are also quite serious, and the bamboo and wood formworks and the composite
formworks are low in strength and easy to be damaged, that a large amount of harmful
garbage can be generated. 2) The concrete surface after demolding must be subjected
to decoration, heat preservation and sound insulation construction to become a usable
finished building, and the prior art has the following defects: firstly, the construction
of decoration, heat preservation and sound insulation needs to spend a large amount
of manpower and material costs; secondly, existing decorative materials such as coatings,
ceramic tiles, stones and the like generally do not meet the green building material
standards, some or even completely violate the concept of green building materials.
At the same time, there are various defects in the fixed installation of the existing
thermal insulation and sound insulation materials. In summary, the existing cast-in-place
construction technology must use formworks, must perform decoration and thermal insulation
and sound insulation construction, which will have various problems such as low construction
efficiency, high construction cost, large waste, excessively high carbon emission
and the like.
Summary of the invention
[0003] The purpose of the present invention is to provide the formwork-free and decoration-free
cast-in-place structure and a construction method therefor to solve the problems raised
in the above background art.
[0004] The technical solution adopted by the present invention is that a construction method
for the formwork-free and decoration-free cast-in-place structure, comprising the
following steps:
- A. Construction preparation
- 1) cement-based artificial stone slabs, made of cement and aggregate as main raw materials,
are prepared by vibration as the basic slab preparation technology, the cement-based
artificial stone slabs are formed after curing and thickness determination, a front
surface of each of the cement-based artificial stone slabs forms a decorative layer
by one of peeling, coating, bonding, wrapping, etc.; nuts are embedded in the back
of each of the cement-based artificial stone slabs, each of the nuts is in threaded
connection with one end of an anchoring connecting rod, and an outer surface of each
of the cement-based artificial stone slabs is arranged to be covered with a protective
film for later use;
- 2) site preparation: laying out lines on site, and fixing reinforcing steel bars to
form a metal framework at a construction site;
- B. Construction and installation
- 1) the multiple cement-based artificial stone slabs enclose on one or more surfaces
of a periphery of the metal framework, and the metal framework outside the one or
more enclosed surface is enclosed by a formwork; an anchoring portion is provided
on the main body of the anchoring connecting rod on the back of each of the cement-based
artificial stone slabs, the anchoring portion is of any geometric shape larger than
a cross-sectional area of the anchoring connecting rod, and supporting fixing frames
are provided on an outside of each of the cement-based artificial stone slabs and
the formwork; and
- 2) pre-embedding water and electricity pipelines and switch sockets before concrete
pouring if they are required to be pre-embedded;
- C. Concrete pouring
- 1) pouring the concrete on a top portion of the enclosed metal framework, and inserting
a slender vibrating rod to vibrate until the pouring is completed to form reinforced
concrete;
- D. Cleaning completion
4) dismantling the supporting fixing frames and the enclosed formwork at the construction
site;
5) grouting slab joints between the slabs with structural adhesive; and
6) cleaning and tearing off the protective film to obtain the formwork-free and decoration-free
cast-in-place structure.
[0005] Preferably, in Step 1) of the construction preparation Step A, if the cement-based
artificial stone slabs are ultra-high-performance artificial stone slabs, raw materials
of the artificial stone slabs are configured according to an ultra-high performance
standard, and slab preparation technology thereof is prepared by adding intense pressure
and vacuumizing as main technical means on the basic technical means of vibration.
[0006] Preferably, in Step 1) of the construction preparation Step A, the anchoring connecting
rod passes through a thermal insulation material layer, or a sound insulation material
layer, or a composite material layer composed of the thermal insulation material layer
and the sound insulation material layer, and protrudes from one of the outer ends
of the thermal insulation material layer, the sound insulation material layer, or
of the composite material layer composed of the thermal insulation material layer
and the sound insulation material layer.
[0007] Preferably, in Step 1) of the construction preparation Step A, the cement-based artificial
stone slabs are arc-shaped or rectangular cement-based artificial stone slabs.
[0008] Preferably, in Step 1) of the construction preparation Step A, a mesh is provided
in each of the cement-based artificial stone slabs.
[0009] Preferably, in Step 1) of the construction and installation Step B, all the peripheries
of the metal framework are enclosed by the cement-based artificial stone slabs.
[0010] Preferably, in Step 1) of the construction and installation Step B, the anchoring
portion and the anchoring connecting rod are of an integrated structure.
[0011] Preferably, in Step 1) of the construction and installation Step B, the anchoring
portion on the main body of the anchoring connecting rod is connected with the metal
framework.
[0012] Preferably, in Step 1) of the construction and installation Step B, the anchoring
portion is further interconnected with the anchoring connecting rod screwed on the
back of another one of the cement-based artificial stone slabs arranged oppositely
or with the anchoring portion on the anchoring connecting rod.
[0013] Preferably, in Step 1) of the construction and installation Step B, the supporting
fixing frames are triangular supporting frames fixed to the ground, and the triangular
supporting frames are formed by lap joint according to height requirements and are
tightly attached to the surface of each of the cement-based artificial stone slabs.
[0014] Preferably, in Step 1) of the construction and installation Step B, the supporting
fixing frames are supporting frames or ones formed by fixedly connecting a plurality
of horizontal and vertical plane reinforcement members with each other, and each of
the plane reinforcement members is a square tube or a channel steel or lumber.
[0015] Preferably, in Step 2) of the construction and installation Step B, further comprises
erecting a full-hall supporting scaffold, after leveling, laying the cement-based
artificial stone slabs on a top portion of the scaffold, and then horizontally placing
a framework of steel reinforcement above the cement-based artificial stone slabs,
and tying and fixing the placed framework of steel reinforcement with the surrounding
framework of steel reinforcements.
[0016] The artificial stone slabs of the present invention is made of cement-based materials
as the main material, and can adopt the ultra-high performance of the highest standard
in the field of concrete as the preparation standard. By adopting the slab preparation
method of vibration, intense pressure and vacuumizing, a whole sheet interconnected
stainless steel mesh and nuts that can be connected externally are implanted when
preparing the slabs. After completing the slab preparation, its surface adopts various
finishes formed by the principle of natural stone peeling, so it can fully achieve
the service life of more than 100 years of natural stone. When the cement-based artificial
stone slab is used as the base slab, the surface can be wrapped with extremely thin
metal to achieve any metal finishing effect; wrapping soft finishes such as fabrics
and leather can achieve all finishing effects of these materials; the surface of the
cement-based artificial stone slab adopts coating treatment to achieve any finishing
effect. The excellent performance of the cement-based artificial stone slab itself
can reach the highest fireproof, waterproof, and anti-corrosion standards, and can
effectively prevent alkali efflux and water seepage. Even if fabrics, wallpaper, etc.
are re-pasted on the surface of the slab, the attached finish can achieve an extremely
long service life. Therefore, cement-based artificial stone slabs can completely replace
existing decorative materials such as coatings, ceramic tiles, stones and the like,
can achieve all the decorative effects of these materials inside and outside the building,
and can completely solve the various defects commonly found in these materials.
[0017] The cement-based artificial stone slab, which has ultra-high strength and ultra-high
durability, is combined with a slab preparation method that can make it more dense
and have a lower water-cement ratio, and the stainless steel mesh that is interconnected
throughout the slab and the nuts that have extremely high hanging strength after forming
an integrated body, so that the cement-based artificial stone slab can have extremely
high bending, tensile and impact resistance, so it can fully withstand the impact
and expansion force generated when pouring concrete, and can completely replace the
existing steel, aluminum, wood and other formworks. The strong screw-on hanging force
of the embedded nuts on the back of the slab easily and flexibly clamp the thermal
insulation material and sound insulation material of any material on the back of the
slab through the screw-on embedded anchoring connecting rod. The multifunctional slab
formed by physical clamping can solve the various defects of the existing thermal
insulation and decorative integrated slabs that are mainly bonded by chemical glue.
At the same time, it is also extremely difficult to achieve with existing steel, aluminum,
wood and other formworks. The heat insulation and sound insulation materials are clamped
and exposed out of one end of the external anchoring connecting rod, and different
anchoring portions shall be arranged according to requirements, when used as a formwork
to enclose the framework of steel reinforcement, it can be interconnected with the
framework of steel reinforcement, or it can be interconnected with the opposite cement-based
artificial stone slab, or it can be directly suspended inside or outside the framework
of steel reinforcement, and after the artificial stone slab is completely fixed from
the periphery by a reinforcement method that is basically same as that of the existing
formwork, the expansion force generated by the pouring concrete will be borne and
blocked by the peripheral reinforcement. After the concrete is poured, the anchoring
portion of the anchoring connecting rod extending at one end of the framework of steel
reinforcement will be completely covered, and after the poured concrete is completely
solidified, the anchoring portion will be completely wrapped, so that the anchoring
portion arranged to be larger than the cross section of the anchoring connecting rod
can generate a great drawing force, and meanwhile, the cement-based artificial stone
slab completely screwed and interconnected with the anchoring connecting rod can be
completely integrated with the cast-in-place reinforced concrete structure. The cement-based
artificial stone slab with the trinity of decoration, heat preservation and sound
insulation can directly realize the finished building of the trinity function of the
cast-in-place building based on the above principle after replacing the formwork for
casting.
[0018] The present invention adopts cement-based artificial stone slabs to replace the cast-in-place
buildings formed by formwork, which can not only reduce the various formwork costs
of the existing cast-in-place construction, but also can directly reduce the construction
of formwork, demoulding, finishing and decoration, insulation and sound insulation
required in the later stage. Not only does it greatly reduce various expenses, but
it can also make all cast-in-place buildings directly realize green energy-saving
buildings with exquisite internal and external decoration, efficient two-way thermal
insulation function, and extremely quiet and healthy indoor environment. Meanwhile,
the cement-based ultra-high-performance artificial stone slabs configured with the
highest technical standards of cement concrete can fully reach the performance limit
of existing cement concrete after adopting the existing ultra-high performance slab
preparation methods such as vibration, high pressure and vacuum-pumping, which are
extremely difficult to implement. After replacing the formwork and becoming a whole
with the entire reinforced concrete structure, the cement-based artificial stone slabs
with ultra-high strength above C150 can be used as the overall surface layer of the
existing mainly C30 and C40 reinforced concrete structures, which can completely block
various erosions and damages caused to the reinforced concrete structure by various
harmful substances such as ultraviolet rays and rainwater. Therefore, the service
life of the reinforced concrete structure completely protected by cement-based artificial
stone slabs can be greatly improved compared with that of the reinforced concrete
structure with formwork cast-in-place in the prior art.
[0019] The cement-based artificial stone slabs of the present invention adopts waste natural
stone as processing scraps, or miscellaneous stones and gravels widely existing in
nature that may even affect the growth of crops as main materials, and industrial
waste silica fume, mineral powder, fly ash and the like combined with cement as cementitious
materials. The production does not require high-temperature firing, does not produce
chemical odor, and the waste produced by processing can be reused or made into other
building materials, which can fully meet the highest environmental protection standards
of zero pollution and zero emission. The cement-based artificial stone slab that does
not contain any harmful substances can meet the highest health requirements when used,
and can also achieve a variety of beneficial functions such as sterilization, self-cleaning,
and air purification after nano or surface nano treatment. The ultra-high strength
and ultra-high durability it has can also exceed the high strength and high durability
standards of the highest requirements of green building materials, and the slab can
be reprocessed into a brand-new facing slab after being dismantled, and it can also
be reprocessed into a new product after being broken, which can fully meet the highest
standards of green building materials. The present invention adopts the cement-based
artificial stone slabs to replace cast-in-place buildings with formwork, which can
directly realize green buildings with high efficiency and energy saving. Therefore,
the present invention is an innovative technology that benefits the nation and the
people.
Description of drawings
[0020]
Figure 1 is a structural diagram of the present invention;
Figure 2 is another structural diagram of the present invention;
Figure 3 is an enlarged view of Part A in Figure 2;
Figure 4 is an enlarged view of Part B in Figure 2;
Figure 5 is an enlarged view of Part C in Figure 2;
Figure 6 is a schematic diagram of a cast-in-place framework structure of the present
invention;
Figure 7 is a cast-in-place schematic diagram of adding a cast-in-place floor slab
to a cast-in-place structure of the present invention;
Figure 8 is a schematic diagram a cast-in-place shear wall structure with doors or
windows of the present invention.
[0021] In the drawings: 1- cement-based artificial stone slab; 2- mesh; 3- nut; 4- anchoring
connecting rod; 5- thermal insulation material layer; 6- sound insulation material
layer; 7- metal framework; 8- reinforced concrete; 9- anchoring portion; and 10- floor
slab.
Embodiments
[0022] Hereinafter, the technical solutions in the embodiments of the present disclosure
will be clearly and completely described with reference to the accompanying drawings
in the embodiments of the present invention. Obviously, the described embodiments
are only part of the embodiments of the present invention, not all of the embodiments.
Based on the embodiments of the present invention, all other embodiments obtained
by those of ordinary skill in the art without creative work shall fall within the
protection scope of the present invention.
Embodiment 1
[0023] As shown in Figure 1, when the cast-in-place structure is a cast-in-place wallboard,
the metal framework 7 is a framework of steel reinforcement.
- A. Construction preparation
- 1) cement-based artificial stone slabs 1, made of cement and aggregate as main raw
materials, are prepared by vibration as the basic slab preparation technology, the
cement-based artificial stone slabs 1 are formed after curing and thickness determination,
a front surface of each of the cement-based artificial stone slabs 1 forms a decorative
layer by one of peeling, coating, bonding, wrapping, etc.; nuts 3 are embedded in
the back of each of the cement-based artificial stone slabs 1, each of the nuts 3
is in threaded connection with one end of an anchoring connecting rod 4, and an outer
surface of each of the cement-based artificial stone slabs 1 is arranged to be covered
with a protective film for later use;
- 2) site preparation: laying out lines on site, and fixing reinforcing steel bars to
form a framework of steel reinforcement at a construction site;
- B. Construction and installation
- 1) the cement-based artificial stone slabs 1 enclose on one surface of the framework
of steel reinforcement, and the framework of steel reinforcement outside the enclosed
surface is enclosed by a formwork; an anchoring portion 9 is provided on the main
body of the anchoring connecting rod 4 on the back of each of the cement-based artificial
stone slabs 1, the anchoring portion 9 is of any geometric shape larger than a cross-sectional
area of the anchoring connecting rod 4; and supporting fixing frames are provided
on an outside of each of the cement-based artificial stone slabs 1;
- 2) an L-shaped fixing member can be provided at a bottom portion of an outer side
of each of the cement-based artificial stone slabs 1 for reinforcement, one end of
the L-shaped fixing member is fixed to the ground with an expansion bolt, and the
other end of the L-shaped fixing member is closely attached to each of the cement-based
artificial stone slabs 1, the supporting fixing frames provided on the outer side
of each of the cement-based artificial stone slabs 1 and the formwork can be triangular
supporting frames fixed to the ground, and the triangular supporting frames are formed
by lap joint according to height requirements, multiple plane reinforcement members,
such as square tubes, channel steels, lumber and the like can be provided between
the multiple triangular supporting frames, which are closely attached to the surface
of each of the cement-based artificial stone slabs 1;
- 3) pre-embedding water and electricity pipelines and switch sockets before concrete
pouring if they are required to be pre-embedded;
- C. Concrete pouring
- 1) pouring the concrete on a top portion of the framework of steel reinforcement that
completely encloses and fixes each of the cement-based artificial stone slabs 1, and
inserting a slender vibrating rod to vibrate until the pouring is completed to form
reinforced concrete 8;
- 2) a main body of the anchoring connecting rod 4 is in the reinforced concrete 8,
and the anchoring portion 9 can be an integrated structure with the anchoring connecting
rod 4; after the reinforced concrete 8 formed by pouring is completely solidified,
the huge structural force formed by it will allow the anchoring connecting rod 4 to
engage with the anchoring portion 9 thereof, which completely fix each of the cement-based
artificial stone slabs 1 and the reinforced concrete 8 into an interconnected whole.
- D. Cleaning completion
- 1) dismantling the L-shaped fixing member, the triangular supporting frames, and the
formwork at the construction site, and repair the ground bolt holes;
- 2) grouting slab joints between the slabs with structural adhesive; and
- 3) cleaning and tearing off the protective film to obtain the decoration-free cast-in-place
wallboard building structure.
Embodiment 2
[0024] As shown in Figures 2 to 5, when the cast-in-place structure is a cast-in-place shear
wall structure, the metal framework 7 is a framework of steel reinforcement.
- A. Construction preparation
- 1) different from the Embodiment 1, in the preparation of the slabs, a mesh 2 is provided
in each of the cement-based artificial stone slabs 1, the anchoring connecting rod
4 passes through a thermal insulation material layer 5, or a sound insulation material
layer 6, or a composite material layer composed of the thermal insulation material
layer 5 and the sound insulation material layer 6, and is screwed with the nuts 3
on the back of each of the cement-based artificial stone slabs 1, so that the back
of the cement-based artificial stone board 1 is covered with the thermal insulation
material layer 5, or the sound insulation material layer 6, or the composite material
layer composed of the thermal insulation material layer 5 and the sound insulation
material layer 6; the other end of the anchoring connecting rod 4 protrudes from outer
ends of the thermal insulation material layer 5, or the sound insulation material
layer 6, or the composite material layer composed of the thermal insulation material
layer 5 and the sound insulation material layer 6 according to requirements;
- 2) site preparation: laying out lines on site, and fixing reinforcing steel bars to
form a framework of steel reinforcement (such as shear wall, etc.) at a construction
site;
- B. Construction and installation
- 1) the cement-based artificial stone slab 1 covered with the thermal insulation material
layer 5, or the sound insulation material layer 6, or the composite material layer
composed of the thermal insulation material layer 5 and the sound insulation material
layer 6 is enclosed inside and outside the framework of steel reinforcement of the
shear wall, and two sides thereof are enclosed by the formwork; and a breathable waterproof
membrane can be penetrated on the anchoring connecting rod 4 on the back of the cement-based
artificial stone slab 1 according to requirements, an anchoring portion 9 is provided
on the main body of the anchoring connecting rod 4 on the back of each of the cement-based
artificial stone slabs 1, the anchoring portion 9 is of any geometric shape larger
than a cross-sectional area of the anchoring connecting rod 4; and it can also be
interconnected with the anchoring connecting rod 4 screwed on the back of another
one of the cement-based artificial stone slabs arranged oppositely or the anchoring
portion 9 on the anchoring connecting rod 4, and supporting fixing frames are provided
on an outside of each of the cement-based artificial stone slabs 1;
- 2) an L-shaped fixing member can be provided at an inner and outer bottom portion
of each of the cement-based artificial stone slabs 1 for reinforcement, one end of
the L-shaped fixing member is fixed to the ground with an expansion bolt, and the
other end of the L-shaped fixing member is closely attached to each of the cement-based
artificial stone slabs 1, the supporting fixing frames provided on the outer side
of each of the cement-based artificial stone slabs 1 and the formwork can be triangular
supporting frames fixed to the ground, and the triangular supporting frames are formed
by lap joint according to height requirements, multiple plane reinforcement members,
such as square tubes, channel steels, lumber and the like can be provided between
the multiple triangular supporting frames, which are closely attached to the surface
of each of the cement-based artificial stone slabs 1;
- 3) pre-embedding water and electricity pipelines and switch sockets before concrete
pouring if they are required to be pre-embedded;
- C. Concrete pouring
- 1) pouring the concrete on a top portion of the framework of steel reinforcement that
completely encloses and fixes each of the cement-based artificial stone slabs 1, and
inserting a slender vibrating rod to vibrate until the pouring is completed to form
reinforced concrete 8;
- 2) a main body of the anchoring connecting rod 4 is in the reinforced concrete 8,
and the anchoring portion 9 can be an integrated structure with the anchoring connecting
rod 4; after the reinforced concrete 8 formed by pouring is completely solidified,
the huge structural force formed by it will allow the anchoring connecting rod 4 to
engage with the anchoring portion 9 thereof, which completely fix each of the cement-based
artificial stone slabs 1 and the reinforced concrete 8 into an interconnected whole.
- D. Cleaning completion
- 1) dismantling the L-shaped fixing member, the triangular supporting frames, and the
formwork at the construction site, and repair the ground bolt holes;
- 2) grouting slab joints between the slabs with structural adhesive; and
- 3) cleaning and tearing off the protective film to obtain a decoration-free cast-in-place
shear wall building structure with decorative, thermal insulation, and sound insulation
functions inside and outside.
Embodiment 3
[0025] As shown in Figure 6, when the cast-in-place structure is a cast-in-place frame structure,
the mesh 2 is a stainless steel mesh, the metal framework 7 is a framework of steel
reinforcement, and the cement-based artificial stone slabs 1 are cement-based ultra-high-performance
artificial stone slabs.
- A. Construction preparation
- 1) the cement-based ultra-high-performance artificial stone slabs are made of cement
and aggregate as main raw materials and configured according to ultra-high performance
standards, the slab preparation technology thereof is based on the basic technical
means of vibration, and is prepared by adding intense pressure and vacuumizing as
the main technical means, the cement-based ultra-high-performance artificial stone
slabs are formed after curing and thickness determination; a front surface of the
cement-based artificial stone slab forms a decorative layer by one of peeling, coating,
bonding, wrapping, etc.; a stainless steel mesh is provided in the cement-based ultra-high-performance
artificial stone slab, and nuts 3 are embedded in the back of the cement-based ultra-high-performance
artificial stone slab, each of the nuts 3 is in threaded connection with one end of
an anchoring connecting rod 4, and an outer surface of each of the cement-based ultra-high-performance
artificial stone slab is arranged to be covered with a protective film for later use;
- 2) site preparation: laying out lines on site, and fixing reinforcing steel bars to
form a framework of steel reinforcement (such as columns, beams, etc.) at a construction
site;
- B. Construction and installation
- 1) cement-based ultra-high-performance artificial stone slabs are protected around
an outer periphery of the framework of steel reinforcement of the column, the cement-based
ultra-high-performance artificial stone slabs are rectangular cement-based ultra-high-performance
artificial stone slabs, the supporting fixing frames are arranged on the outsides
of the cement-based ultra-high-performance artificial stone slabs, the supporting
fixing frames are supporting frames or ones formed by fixedly connecting a plurality
of horizontal and vertical plane reinforcement members with each other, and the supporting
fixing frames are formed by lap joint according to height requirements, and each of
the plane reinforcement members is a square tube or a channel steel or lumber.
- 2) when cement-based ultra-high-performance artificial stone slabs are arc-shaped
cement-based ultra-high-performance artificial stone slabs, they can be reinforced
with a hoop;
- 3) erecting a full-hall supporting scaffold, after leveling, laying the cement-based
ultra-high-performance artificial stone slabs on a top portion of the scaffold, and
then horizontally placing a framework of steel reinforcement above the cement-based
ultra-high-performance artificial stone slabs to form a beam reinforcement framework,
wherein a front portion and a rear portion of the beam reinforcement framework are
enclosed by the cement-based ultra-high-performance artificial stone slabs, and a
left end and a right end of the beam reinforcement framework are respectively tied
and fixed to the top ends of the two column frameworks of steel reinforcement.
- 4) pre-embedding water and electricity pipelines and switch sockets before concrete
pouring if they are required to be pre-embedded;
- C. Concrete pouring
- 1) pouring concrete above the column metal framework, and then sequentially pouring
concrete above the beam metal framework, wherein during pouring, inserting a slender
vibrating rod to vibrate until the pouring is completed to form reinforced concrete
8;
- 2) a main body of the anchoring connecting rod 4 is in the reinforced concrete 8,
an anchoring portion 9 is provided on the main body of the anchoring connecting rod
4, the anchoring portion 9 is of any geometric shape larger than a cross-sectional
area of the anchoring connecting rod 4, and the anchoring portion 9 can be an integrated
structure with the anchoring connecting rod 4; after the reinforced concrete 8 formed
by pouring is completely solidified, the huge structural force formed by it will allow
the anchoring connecting rod 4 to engage with the anchoring portion 9 thereof, which
completely fix the cement-based ultra-high-performance artificial stone slabs and
the reinforced concrete 8 into an interconnected whole.
- D. Cleaning completion
- 1) dismantling the supporting fixing frames, the full-hall supporting scaffold, and
the formwork at the construction site;
- 2) grouting slab joints between the slabs with structural adhesive; and
- 3) cleaning and tearing off the protective film to obtain the multi-functional cast-in-place
framework structure.
Embodiment 4
[0026] The floor slabs of various cast-in-place structures are cast-in-place, and the metal
framework 7 is a framework of steel reinforcement.
- A. Construction preparation
The construction preparation is the same as that in Embodiment 1;
- B. Construction and installation
- 1) erecting a full-hall supporting scaffold, after leveling, laying the cement-based
artificial stone slab 1 covered with the thermal insulation material layer 5, or the
sound insulation material layer 6, or the composite material layer composed of the
thermal insulation material layer 5 and the sound insulation material layer 6 on a
top portion of the scaffold, and then horizontally arranging a framework of steel
reinforcement that is staggered horizontally and vertically to form a floor slab 10
(as shown in Figure 7) on the cement-based artificial stone slab 1, the ends of the
framework of steel reinforcement of the floor slab 10 are connected with the framework
of steel reinforcement of the shear wall or the framework of steel reinforcement of
the beam and column in a penetrating way, and are tied and fixed thereto;
- 2) pre-embedding water and electricity pipelines and switch sockets before concrete
pouring if they are required to be pre-embedded;
- C. Concrete pouring
- 1) pouring the stirred concrete above the floor slab framework of steel reinforcement,
wherein during pouring, inserting a slender vibrating rod to vibrate until the pouring
is completed to form reinforced concrete 8;
- 2) a main body of the anchoring connecting rod 4 is in the reinforced concrete 8,
an anchoring portion 9 is provided on the main body of the anchoring connecting rod
4, the anchoring portion 9 is of any geometric shape larger than a cross-sectional
area of the anchoring connecting rod 4, and the anchoring portion 9 can be an integrated
structure with the anchoring connecting rod 4; after the reinforced concrete 8 formed
by pouring is completely solidified, the huge structural force formed by it will allow
the anchoring connecting rod 4 to engage with the anchoring portion 9 thereof, which
completely fix the cement-based artificial stone slabs and the reinforced concrete
8 into an interconnected whole.
- D. Cleaning completion
- 1) dismantling the full-hall supporting scaffold at the construction site;
- 2) grouting slab joints between the slabs with structural adhesive; and
- 3) cleaning and tearing off the protective film to obtain a multi-faceted decoration-free
cast-in-place floor structure.
Embodiment 5
[0027] As shown in Figure 8 , when the cast-in-place structure is a cast-in-place shear
wall structure with doors or windows, the cement-based artificial stone slabs 1 are
cement-based ultra-high-performance artificial stone slabs.
- A. Construction preparation
- 1) the cement-based ultra-high-performance artificial stone slabs are made of cement
and aggregate as main raw materials and configured according to ultra-high performance
standards, the slab preparation technology thereof is based on the basic technical
means of vibration, and is prepared by adding intense pressure and vacuumizing as
the main technical means, the cement-based ultra-high-performance artificial stone
slabs are formed after curing and thickness determination; a front surface of the
cement-based ultra-high-performance artificial stone slab forms a decorative layer
by one of peeling, coating, bonding, wrapping, etc.; a mesh 2 is provided in the cement-based
ultra-high-performance artificial stone slab, and nuts 3 are embedded in the back
of the cement-based ultra-high-performance artificial stone slab, each of the nuts
3 is in threaded connection with one end of an anchoring connecting rod 4, one end
of the anchoring connecting rod passes through a thermal insulation material layer
5, or a sound insulation material layer 6, or a composite material layer composed
of the thermal insulation material layer 5 and the sound insulation material layer
6, and is screwed with the nuts 3 on the back the cement-based ultra-high-performance
artificial stone slab; the other end of the anchoring connecting rod 4 protrudes from
outer ends of the thermal insulation material layer 5, or the sound insulation material
layer 6, or the composite material layer composed of the thermal insulation material
layer 5 and the sound insulation material layer 6 according to requirements, and an
outer surface of each of the cement-based ultra-high-performance artificial stone
slab is arranged to be covered with a protective film for later use;
- 2) site preparation: laying out lines on site, and fixing reinforcing steel bars to
form a framework of steel reinforcement (such as columns, beams, etc.), and reserving
positions for doors or windows (such as cast-in-place shear walls with doors or windows,
etc.) at a construction site;
- B. Construction and installation
- 1) the cement-based ultra-high-performance artificial stone slab covered with the
thermal insulation material layer 5, or the sound insulation material layer 6, or
the composite material layer composed of the thermal insulation material layer 5 and
the sound insulation material layer 6 is installed around the outer periphery of the
framework of steel reinforcement of the shear wall; and a breathable waterproof membrane
can be penetrated on the anchoring connecting rod 4 on the back of the cement-based
ultra-high-performance artificial stone slab according to requirements, an anchoring
portion 9 is provided on the main body of the anchoring connecting rod 4 on the back
of the cement-based ultra-high-performance artificial stone slab, the anchoring portion
9 is of any geometric shape larger than a cross-sectional area of the anchoring connecting
rod 4; and it can also be interconnected with the anchoring connecting rod 4 screwed
on the back of the another cement-based ultra-high-performance artificial stone slab
arranged oppositely or the anchoring portion 9 on the anchoring connecting rod 4,
and supporting fixing frames are provided on an outside of the cement-based ultra-high-performance
artificial stone slab;
- 2) an L-shaped fixing member can be provided at an inner and outer bottom portion
of the cement-based ultra-high-performance artificial stone slab for reinforcement,
one end of the L-shaped fixing member is fixed to the ground with an expansion bolt,
and the other end of the L-shaped fixing member is closely attached to the cement-based
ultra-high-performance artificial stone slab, the supporting fixing frames provided
on the outer side of the cement-based ultra-high-performance artificial stone slabs
and the formwork can be triangular supporting frames fixed to the ground, and the
triangular supporting frames are formed by lap joint according to height requirements,
multiple plane reinforcement members, such as square tubes, channel steels, lumber
and the like can be provided between the multiple triangular supporting frames, which
are closely attached to the surface of the cement-based ultra-high-performance artificial
stone slab;
- 3) the door and window portions can connect the plurality of cement-based ultra-high-performance
artificial stone slabs at the guide corners in series through long steel bars, and
then threadedly connected with the nuts 3 on the back of each of the cement-based
ultra-high-performance artificial stone slabs on both sides. Specifically, placing
the long steel bars on the back of the plurality of cement-based ultra-high-performance
artificial stone slabs, and fixing them by passing the anchoring connecting rod 4
through the screw holes on the long steel bars, and threadedly connecting them with
the nuts 3 on the back of the cement-based ultra-high-performance artificial stone
slabs on the sides, wherein the long steel bars can be bent at a certain angle as
needed to achieve different shapes and structures, and are clamped and fixed on the
opening surface of the door or window through the reinforcement members;
- 4) pre-embedding water and electricity pipelines and switch sockets before concrete
pouring if they are required to be pre-embedded.
[0028] Step C of concrete pouring and Step D of cleaning completion are all the same as
those in Embodiment 1; and finally, a cast-in-place shear wall structure with doors
or windows for decoration, heat preservation and sound insulation functions is obtained.
[0029] It will be apparent to those skilled in the art that the present invention is not
limited to the details of the exemplary embodiments described above, and that the
present invention can be embodied in other specific forms without departing from the
spirit or essential characteristics of the invention. Therefore, regardless of which
point the embodiments should be considered as exemplary and not restrictive, the scope
of the invention is defined by the appended claims rather than by the foregoing description,
and therefore, it is intended that all changes that come within the meaning and range
of equivalency of the claims shall be embraced within the present invention. Any reference
signs in the claims shall not be regarded as limiting the involved claims.
1. A construction method for a formwork-free and decoration-free cast-in-place structure,
comprising the following steps:
A. Construction preparation
1) cement-based artificial stone slabs (1), made of cement and aggregate as main raw
materials, are prepared by vibration as the basic slab preparation technology, the
cement-based artificial stone slabs are formed after curing and thickness determination,
a front surface of each of the cement-based artificial stone slabs (1) forms a decorative
layer by one of peeling, coating, bonding, wrapping, etc.; nuts (3) are embedded in
the back of each of the cement-based artificial stone slabs (1), each of the nuts
(3) is in threaded connection with one end of an anchoring connecting rod (4), and
an outer surface of each of the cement-based artificial stone slabs (1) is arranged
to be covered with a protective film for later use;
2) site preparation: laying out lines on site, and fixing reinforcing steel bars to
form a metal framework (7) at a construction site;
B. Construction and installation
1) the multiple cement-based artificial stone slabs (1) enclose on one or more surfaces
of a periphery of the metal framework (7), and the metal framework (7) outside the
one or more enclosed surface is enclosed by a formwork; an anchoring portion (9) is
provided on the main body of the anchoring connecting rod (4) on the back of each
of the cement-based artificial stone slabs (1), the anchoring portion (9) is of any
geometric shape larger than a cross-sectional area of the anchoring connecting rod
(4), and supporting fixing frames are provided on an outside of each of the cement-based
artificial stone slabs (1) and the formwork; and
2) pre-embedding water and electricity pipelines and switch sockets before concrete
pouring if they are required to be pre-embedded ;
C. Concrete pouring
1) pouring the concrete on a top portion of the enclosed metal framework (7), and
inserting a slender vibrating rod to vibrate until the pouring is completed to form
reinforced concrete (8);
D. Cleaning completion
1) dismantling the supporting fixing frames and the enclosed formwork at the construction
site;
2) grouting slab joints between the slabs with structural adhesive; and
3) cleaning and tearing off the protective film to obtain the formwork-free and decoration-free
cast-in-place structure.
2. The construction method for a formwork-free and decoration-free cast-in-place structure
according to claim 1, wherein in Step 1) of the construction preparation Step A, if
the cement-based artificial stone slabs (1) are ultra-high-performance artificial
stone slabs, raw materials of the artificial stone slabs are configured according
to an ultra-high-performance standard, and slab preparation technology thereof is
prepared by adding intense pressure and vacuumizing as main technical means on the
basic technical means of vibration.
3. The construction method for a formwork-free and decoration-free cast-in-place structure
according to claim 1, wherein in Step 1) of the construction preparation Step A, the
anchoring connecting rod (4) passes through one of the thermal insulation material
layer (5), a sound insulation material layer (6), or a composite material layer composed
of the thermal insulation material layer (5) and the sound insulation material layer
(6), and protrudes from one of the outer ends of the thermal insulation material layer
(5), the sound insulation material layer (6), or of the composite material layer composed
of the thermal insulation material layer (5) and the sound insulation material layer
(6).
4. The construction method for a formwork-free and decoration-free cast-in-place structure
according to claim 1, wherein in Step 1) of the construction and installation Step
B, all the peripheries of the metal framework (7) are enclosed by the cement-based
artificial stone slabs (1).
5. The construction method for a formwork-free and decoration-free cast-in-place structure
according to claim 1, wherein in Step 1) of the construction and installation Step
B, the anchoring portion (9) and the anchoring connecting rod (4) are of an integrated
structure.
6. The construction method for a formwork-free and decoration-free cast-in-place structure
according to claim 1, wherein in Step 1) of the construction and installation Step
B, the anchoring portion (9) on the main body of the anchoring connecting rod (4)
is connected with the metal framework (7).
7. The construction method for a formwork-free and decoration-free cast-in-place structure
according to claim 1, wherein in Step 1) of the construction and installation Step
B, the anchoring portion (9) is further interconnected with the anchoring connecting
rod (4) screwed on the back of another one of the cement-based artificial stone slabs
arranged oppositely or with the anchoring portion (9) on the anchoring connecting
rod (4).
8. The construction method for a formwork-free and decoration-free cast-in-place structure
according to claim 1, wherein in Step 1) of the construction and installation Step
B, the supporting fixing frames are triangular supporting frames fixed to the ground,
and the triangular supporting frames are formed by lap joint according to height requirements
and are tightly attached to the surface of each of the cement-based artificial stone
slabs (1).
9. The construction method for a formwork-free and decoration-free cast-in-place structure
according to claim 1, wherein in Step 1) of the construction and installation Step
B, the supporting fixing frames are supporting frames or ones formed by fixedly connecting
a plurality of horizontal and vertical plane reinforcement members with each other,
and each of the plane reinforcement members is a square tube or a channel steel or
lumber.
10. The construction method for a formwork-free and decoration-free cast-in-place structure
according to claim 1, wherein in Step 2) of the construction and installation Step
B, further comprises erecting a full-hall supporting scaffold, after leveling, laying
the cement-based artificial stone slabs (1) on a top portion of the scaffold, and
then placing a framework of steel reinforcement above the cement-based artificial
stone slabs (1), and tying and fixing the placed framework of steel reinforcement
with the surrounding framework of steel reinforcements.