CN105484424A - 一种基于发泡水泥外保温处理的装配式复合墙板及其制造方法 - Google Patents
一种基于发泡水泥外保温处理的装配式复合墙板及其制造方法 Download PDFInfo
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Abstract
本发明一种基于发泡水泥外保温处理的装配式复合墙板及其制造方法，装配式复合墙板包括复合墙板；涂覆在复合墙板一面上的聚合物粘结砂浆；设置于聚合物粘结砂浆上的发泡水泥；涂抹在发泡水泥上的聚合物抗裂砂浆以及压入在聚合物抗裂砂浆中的耐碱玻璃网格布；本发明复合墙板使用新型生态混凝土材料，能有效的缓解传统原材料的消耗问题，具有节能保温、防火抗震、生态环保等优点，同时复合墙板采用工厂预制生产，有利于建筑构件部品化，现场施工装配化，大大提高施工效率，缩短工期，具有质量稳定性好，结构整体性强，建造快捷、一体化施工的优点，也无冷热桥现象产生，能很好的适应我国夏热冬冷地区的节能要求。
Description
技术领域
本发明属于建筑技术领域，特别涉及一种基于发泡水泥外保温处理的装配式复合墙板。
背景技术
在我国新型城镇化进程不断推进的背景下,建筑物能耗量在社会的总能耗量中所占的比例不断上升，已经严重制约了经济的发展，建造更经济实惠、节能环保、可持续发展的住宅，是提高我国城镇化水平的重要有效措施，因此建筑节能刻不容缓，而外墙节能对整个建筑物的耗能量起着支配性作用。装配式混凝土节能与结构一体化符合我国“十二五”规划中提出的资源节约、环境友好的社会要求，是实现建筑节能减排及住宅产业化的有效途径之一。目前传统的外墙保温发展面临诸多问题，一方面承重墙体与保温系统并未完全一体化施工，传统外墙外保温系统通过粘贴式或机械固定在外墙主体结构上，系统受力复杂，施工工艺较复杂，需要二次施工，成本较高，工程质量也难以控制。另一方面我国传统的外墙外保温体系采用的保温材料主要是发泡聚苯乙烯(EPS)或挤塑聚苯乙烯((XPS)等有机材料，这些材料普遍具有易燃、易老化、耐久性差等问题，且一旦燃烧就会释放出有毒气体，危害人体健康，造成环境污染。同时墙体所用的材料为传统混凝土材料，使得我国的能源和原材料消耗过大，因此寻找新型生态混凝土墙体材料已成为现在亟需解决的问题。最后，传统装配式剪力墙结构整体性差，连接方式需要进一步改进。
发明内容
为了克服上述现有技术的缺点，本发明的目的在于提供一种基于发泡水泥外保温处理的装配式复合墙板，基于马牙槎连接，采用发泡水泥，发泡水泥是一种无机硅酸盐材料，其具有轻质、保温隔热、防火、抗震、耐久、隔音等优点，属于无机材料，具有不燃性，是一种绿色、环保的新型建筑节能材料，与传统有机保温材料相比具有巨大优势；通过调整发泡水泥的厚度，能够适应我国夏热冬冷地区的热工设计，满足建筑节能要求。发泡水泥外保温装配式复合墙板与传统外保温墙板相比，该墙板具有节能保温、经济实用、生态环保、整体性强、取材方便、施工速度快、工业化程度高等特点。
为了实现上述目的，本发明采用的技术方案是：
一种基于发泡水泥外保温处理的装配式复合墙板，包括：
复合墙板1；
涂覆在复合墙板一面上的聚合物粘结砂浆2；
设置于聚合物粘结砂浆2上的发泡水泥3；
涂抹在发泡水泥3上的聚合物抗裂砂浆4；
以及，压入在聚合物抗裂砂浆4中的耐碱玻璃网格布5。
所述复合墙板1由嵌有生态块材11的钢筋混凝土框格构成，厚度200mm，复合墙板1的侧面为马牙槎结构。
所述生态块材11是轻质多孔混凝土砌块，每立方中水泥：废矿渣：石灰的重量比为90：275：135，水料比0.6。
所述聚合物粘结砂浆2是郑州华荣建筑材料有限公司的华荣牌聚合物干粉粘结砂浆，厚度为10mm；所述聚合物抗裂砂浆4是郑州华荣建筑材料有限公司的华荣牌聚合物干粉抗裂砂浆，厚度为10mm。
所述发泡水泥3厚度为40mm。
所述发泡水泥3配合比为水泥：粉煤灰：矿粉：硅粉：发泡剂：稳泡剂：聚丙烯纤维：水＝1.04kg：0.5kg：0.5kg:10g:3.5L:2.25L:6.1g:480g。
所述水泥为P.O42.5级，粉煤灰为Ⅱ级，发泡剂为质量浓度30％的H2O2。
本发明还提供了所述基于发泡水泥外保温处理的装配式复合墙板的制备方法，包括如下步骤：
步骤1，制备复合墙板1：首先组装马牙槎专用钢模板，绑扎肋格钢筋网片，在网片内放置生态块材11，以生态块材为内膜，钢模板为外膜，用混凝土浇筑肋梁12、肋柱13；
步骤2，制备发泡水泥3：首先水泥、粉煤灰、矿粉、硅粉、稳泡剂、聚丙烯纤维和水搅拌均匀，并控制料浆温度40℃，持续3min，随后在高速搅拌的同时，迅速加入发泡剂，持续搅拌约30min；
步骤3，保温层施工：在复合墙板1上，首先涂抹聚合物粘结砂浆2，然后将拌合均匀的发泡水泥3料浆浇筑在聚合物粘结砂浆22表面，并控制厚度为40mm，待强度达到设计值的75％以上后拆模养护；最终，养护至规定龄期即28天后，形成气—固结构的发泡水泥，然后用工具将其表面平整，再涂抹聚合物抗裂砂浆4，最后把耐碱玻璃网格布5压入聚合物抗裂砂浆4。
所述生态块材11的制备过程是：
将水泥、废矿渣和石灰按比例计量后混合均匀，然后加水计量后混合搅拌1min，打浆混合均匀后，加入铝粉，搅拌60S，注入试模，放入恒温养护桶发气经停2～2.5h，然后送入蒸压室蒸压养护，铝粉用量为胶凝材料重量的1.2‰。过程中可加入胶凝材料重量的0.9‰的减水剂。
所述步骤2中，各材料的配合比为水：水泥：EPS颗粒：玻化微珠：硫酸钙晶须：胶粉：纤维素醚＝1.04kg：1kg:3.5L:2.25L:9g:15g:6g。
与现有技术相比，本发明的有益效果是：
1、本发明复合墙板使用新型生态混凝土材料，能有效的缓解传统原材料的消耗问题，具有节能保温、防火抗震、生态环保等优点。
2、本发明复合墙板采用工厂预制生产，有利于建筑构件部品化，现场施工装配化，大大提高施工效率，缩短工期。
3、发泡水泥外保温处理的装配式复合墙板与传统的外墙外保温连接方式相比，具有质量稳定性好，结构整体性强，建造快捷、一体化施工的优点，也无冷热桥现象产生，能很好的适应我国夏热冬冷地区的节能要求。
附图说明
图1是本发明装配式复合墙板结构示意图。
图2是本发明复合墙板结构示意图。
具体实施方式
下面结合附图和实施例详细说明本发明的实施方式。
如图1所示，本发明一种基于发泡水泥外保温处理的装配式复合墙板，包括：复合墙板1、涂覆在复合墙板一面上的聚合物粘结砂浆2、设置于聚合物粘结砂浆2上的发泡水泥3、涂抹在发泡水泥3上的聚合物抗裂砂浆4以及压入在聚合物抗裂砂浆4中的耐碱玻璃网格布5。
本实施例中，复合墙板1厚度200mm，聚合物粘结砂浆2厚度10mm，发泡水泥3厚度40mm，聚合物抗裂砂浆4厚度10mm。
如图2所示，复合墙板1以截面和配筋较小的钢筋混凝土框格，内嵌以工农业废料为主的生态块材组成，在竖向及水平荷载作用下，复合墙板中的钢筋混凝土框格与填充体两两相互作用、相互约束、共同受力，充分发挥各自性能；同时，内填墙体材料，因地制宜、就地取材、生态节能。墙板侧面做成马牙槎，墙板水平方向主要是通过马牙槎与后浇竖向边缘构件紧密咬合连接，水平钢筋预留足够的锚固长度与边缘构件纵筋嵌套，并在连接处一一点焊实现可靠锚固。竖向接方式为底部坐浆连接，铺设砂浆厚度均匀，墙板安装后灰缝应填塞密实，填塞后的灰缝应表面光洁平整。
本发明装配式复合墙板的制备包括如下步骤：
步骤一：复合墙板1的生产：
首先组装马牙槎专用钢模板，绑扎肋格钢筋网片，在网片内放置生态块材，以生态块材为内膜，钢模板为外膜，用混凝土浇筑肋梁、肋柱，最后标准养护1～2d，形成带马牙槎的复合墙板1。
步骤二：发泡水泥3的制备：
发泡水泥的最优配合比为水泥(P.O42.5级)：粉煤灰(Ⅱ级)：矿粉：硅粉：发泡剂(30％H2O2)：稳泡剂：聚丙烯纤维：水＝1.04kg：0.5kg：0.5kg:10g:3.5L:2.25L:6.1g:480g。发泡水泥的制作方法如下:首先将胶凝材料、添加剂等除发泡剂以外的其他材料加水搅拌均匀，并控制料浆温度40℃，这一过程一般持续约3min左右；随后在高速搅拌的同时，迅速加入发泡剂，持续搅拌约30，即可形成发泡水泥料浆。
步骤三：保温层施工：
在生产好的新型复合墙板上，首先涂抹10mm厚聚合物粘结砂浆，然后将拌合均匀的发泡水泥料浆浇筑在其表面，并控制厚度为40mm，待强度达到设计值的75％以上后拆模养护；最终，标准养护28天，形成气—固结构的发泡水泥，然后用工具将其表面平整，再涂抹10mm聚合物抗裂砂浆，最后把耐碱玻璃网格布压入抗裂砂浆，即可形成带马牙槎连接的发泡水泥外保温处理的装配式复合墙板。
Claims (10)
1.一种基于发泡水泥外保温处理的装配式复合墙板，其特征在于，包括：
复合墙板(1)；
涂覆在复合墙板一面上的聚合物粘结砂浆(2)；
设置于聚合物粘结砂浆(2)上的发泡水泥(3)；
涂抹在发泡水泥(3)上的聚合物抗裂砂浆(4)；
以及，压入在聚合物抗裂砂浆(4)中的耐碱玻璃网格布(5)。
2.根据权利要求1所述基于发泡水泥外保温处理的装配式复合墙板，其特征在于，所述复合墙板(1)由嵌有生态块材(11)的钢筋混凝土框格构成，厚度200mm，复合墙板(1)的侧面为马牙槎结构。
3.根据权利要求2所述基于发泡水泥外保温处理的装配式复合墙板，其特征在于，所述生态块材(11)是轻质多孔混凝土砌块，每立方中：水泥：废矿渣：石灰的重量比为90：275：135，水料比0.6。
4.根据权利要求1所述基于发泡水泥外保温处理的装配式复合墙板，其特征在于，所述聚合物粘结砂浆(2)厚度为10mm；所述聚合物抗裂砂浆(4)厚度为10mm。
5.根据权利要求1所述基于发泡水泥外保温处理的装配式复合墙板，其特征在于，所述发泡水泥(3)厚度为40mm。
6.根据权利要求1或5所述基于发泡水泥外保温处理的装配式复合墙板，其特征在于，所述发泡水泥(3)配合比为水泥：粉煤灰：矿粉：硅粉：发泡剂：稳泡剂：聚丙烯纤维：水＝1.04kg：0.5kg：0.5kg:10g:3.5L:2.25L:6.1g:480g。
7.根据权利要求6所述基于发泡水泥外保温处理的装配式复合墙板，其特征在于，所述水泥为P.O42.5级，粉煤灰为Ⅱ级，发泡剂为质量浓度30％的H2O2。
8.权利要求1所述基于发泡水泥外保温处理的装配式复合墙板的制备方法，其特征在于，包括如下步骤：
步骤1，制备复合墙板(1)：首先组装马牙槎专用钢模板，绑扎肋格钢筋网片，在网片内放置生态块材(11)，以生态块材为内膜，钢模板为外膜，用混凝土浇筑肋梁(12)、肋柱(13)；
步骤2，制备发泡水泥(3)：首先水泥、粉煤灰、矿粉、硅粉、稳泡剂、聚丙烯纤维和水搅拌均匀，并控制料浆温度40℃，持续3min，随后在高速搅拌的同时，迅速加入发泡剂，持续搅拌约30min；
步骤3，保温层施工：在复合墙板(1)上，首先涂抹聚合物粘结砂浆(2)，然后将拌合均匀的发泡水泥(3)料浆浇筑在聚合物粘结砂浆(2)表面，并控制厚度为40mm，待强度达到设计值的75％以上后拆模养护；最终，养护至规定龄期即28天后，形成气—固结构的发泡水泥，然后用工具将其表面平整，再涂抹聚合物抗裂砂浆(4)，最后把耐碱玻璃网格布(5)压入聚合物抗裂砂浆(4)。
9.根据权利要求8所述基于发泡水泥外保温处理的装配式复合墙板的制备方法，其特征在于，所述生态块材(11)的制备过程是：
将水泥、废矿渣和石灰按比例计量后混合均匀，然后加水计量后混合搅拌1min，打浆混合均匀后，加入铝粉，搅拌60S，注入试模，放入恒温养护桶发气经停2～2.5h，然后送入蒸压室蒸压养护，铝粉用量为胶凝材料重量的1.2‰。
10.根据权利要求8所述基于发泡水泥外保温处理的装配式复合墙板的制备方法，其特征在于，所述步骤2中，各材料的配合比为水：水泥：EPS颗粒：玻化微珠：硫酸钙晶须：胶粉：纤维素醚＝1.04kg：1kg:3.5L:2.25L:9g:15g:6g。
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