CN115199027A - 一种超低能耗建筑保温一体化免拆模板与安装工艺 - Google Patents

一种超低能耗建筑保温一体化免拆模板与安装工艺 Download PDF

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CN115199027A
CN115199027A CN202210715333.7A CN202210715333A CN115199027A CN 115199027 A CN115199027 A CN 115199027A CN 202210715333 A CN202210715333 A CN 202210715333A CN 115199027 A CN115199027 A CN 115199027A
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孙生根
徐伟
孙伟华
顾伟英
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Shanghai Collodin Material Technology Development Suqian Co ltd
Shanghai Collodin Material Technology Development Co ltd
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Abstract

本发明公开了一种超低能耗建筑保温一体化免拆模板与安装工艺。所述免拆模板包括保温层和轻质无机保护层相互粘结构成的面板，面板上设有植筋孔。安装工艺为：在钢筋龙骨外侧设置免拆模板，在植筋孔内安装黑铁套管，黑铁套管的一端向内侧延伸，另一端设于保温层内；在钢筋龙骨上浇筑混凝土；从外侧向植筋孔内灌胶，插入玻纤复合材料杆至胶液充分填充植筋孔与黑铁套管内空隙；待胶液充分干燥即可。为了满足建筑保温的需求，同时降低外页墙板的重量，本发明采用复合材料杆植筋的方法，实现复合材料杆与各层材料实现可靠的剪切粘结，达到墙体各层间正粘与复合材料杆与各层间剪粘，并且保证两种连接方式不产生内应力。

Description

一种超低能耗建筑保温一体化免拆模板与安装工艺
技术领域
本发明涉及一种超低能耗建筑墙体保温一体化免拆模板为用于浇筑超低能耗建筑结构墙、柱的免拆模板与安装工艺，属于建筑工程领域。
背景技术
建筑保温工程中可以采用外墙外保温、外墙内保温和夹心保温三种形式。这在以往的建筑建造过程中均有应用。
采用外墙外保温具有保温效果好，冷桥少的特点。但是外保温的防火与脱落问题构成了新的安全隐患。外墙外保温采用保温性能较高的有机材料时，由于材料不合格或者使用不当常有火灾发生。外墙外保温采用防火性能为A级的保温材料时，由于保温材料隔热性能较差，因此保温层厚度增加，这又带来了保温层脱落的新问题。
采用外墙内保温时，由于保温材料被混凝土分割，且位于墙体内部，因此相关的火灾和脱落造成的安全问题得以缓解。然而保温层在墙体内部也导致了楼层间的混凝土部位均为冷桥，实际保温效果差的问题。
采用夹心保温时，可以避免上述外墙外保温和外墙内保温的缺点。但是这种新的形式会导致保温层总体重量增加显著。采用夹心保温时，悬挑部分墙体重量增加约为130kg/m2，为了确保建筑总体承重的安全性和外墙悬挑部分的安全性。会造成结构加大，建筑的造价较高的问题。
以上的建筑保温均为基于普通节能建筑计算。对于节能要求更高的超低能耗建筑，建筑保温工程则面临着新的压力。
传统的建筑采用有机保温材料时，保温层的厚度约为30mm～50mm，采用无机材料时，则需70mm～100mm。对于超低能耗建筑而言，采用有机保温材料时，保温层的厚度约为60mm～240mm，全部采用无机材料则很难实现保温要求。同时，超低能耗建筑保温对于冷桥的规范排除了单一采用外墙内保温的建筑保温形式。
对于外墙外保温而言，更加厚的保温层意味着火灾和保温层脱落的风险均显著增加。对于夹心保温而言，则会使外墙悬挑的尺寸显著增加，造成悬挑结构的受力结构需要显著加大以满足安全性要求。这些无疑都是对传统的保温结构的巨大挑战。
发明内容
本发明所要解决的技术问题是：如何通过墙体保温一体化免拆模板构造与应用工艺设计，降低系统内应力，减低系统对面板强度的依赖，从而实现低密度低强度面板代替高密度高强度面板达到减重的目的。
为了解决上述技术问题，本发明提供了一种超低能耗建筑保温一体化免拆模板，其包括保温层和轻质无机保护层相互粘结构成的面板，面板上设有植筋孔。优选地，所述保温层的材料采用聚苯乙烯泡沫或聚氨酯硬泡，优选采用聚氨酯硬泡，其厚度为40～300mm，可依据保温性能确定。主体保温材料表面可设无机界面层以便粘结。优选地，所述轻质无机防护层的材料采用纤维增强发泡水泥制备而成的板材，其厚度为45～60mm，优选为50mm。优选地，所述粘结采用保温材料胶粘剂。优选地，所述植筋孔的位置为孔心距面板板边的距离不超过300mm，且相邻植筋孔的间距不超过600mm，开孔直径比玻纤复合材料杆的直径大1～4mm。本发明还提供了上述超低能耗建筑保温一体化免拆模板的安装工艺，包括以下步骤：步骤1)：绑扎钢筋龙骨；步骤2)：在钢筋龙骨内侧设置内模板，并通过内侧模板支架支撑内模板；步骤3)：在钢筋龙骨外侧设置所述超低能耗建筑保温一体化免拆模板，并通过外侧模板支架支撑该超低能耗建筑保温一体化免拆模板；步骤4)：在植筋孔内安装黑铁套管，黑铁套管的一端向内侧延伸，另一端设于保温层内并与植筋孔紧配；步骤5)：在黑铁套管内插入对穿螺栓，对穿螺栓两侧螺母分别与内侧模板支架、外侧模板支架的主梁连接固定；步骤6)：在钢筋龙骨上浇筑混凝土形成墙体；步骤7)：拆除内侧模板支架、外侧模板支架和内模板，使浇筑时应力充分释放；步骤8)：拆除对穿螺栓，并将黑铁套管向内侧延伸的一端采用泡沫条填充，并用封堵将端头填塞密实；步骤9)：从外侧向植筋孔内灌胶，通过反复插捣，插入玻纤复合材料杆至胶液充分填充植筋孔与黑铁套管内空隙；待胶液充分干燥即可。优选地，所述步骤4)中，黑铁套管插入保温层中的深度为10mm。优选地，所述步骤9)中胶液的灌注量为植筋孔与黑铁套管内剩余容积的2/3。
优选地，所述步骤9)中，玻纤复合材料杆插入墙体部分的长度为30～240mm，优选为50～150mm。上述工艺完成后，墙体从室内到室外依次为结构墙体、保温层、轻质无机保温防护层，各层间通过正粘连接。除了常规的层层粘结外，层间还通过玻纤复合材料杆与胶粘剂将各层材料串联，并通过剪切粘结形式与各层材料牢靠连接，达到了节能性、保温性和安全性的统一，又通过降低外页板重量达到降低结构重量和悬挑重量，达到通过降低荷载而减少建筑成本的经济效益。
其与传统的保温结构的显著区别在于：其一，外页板相对于夹心保温外墙板重量显著减轻，从130kg/m2下降至30kg/m2，显著降低了悬挑结构的重量；其二，外页墙板、保温层以及内页墙体通过高刚度、高强度的结构杆件连接，确保建筑保温与结构一体，无保温层脱落风险。
为了满足建筑保温的需求，同时降低外页墙板的重量，本发明采用复合材料杆植筋的方法，实现复合材料杆与各层材料实现可靠的剪切粘结，达到墙体各层间正粘与复合材料杆与各层间剪粘，并且保证两种连接方式不产生内应力，达到墙体各层成为一个整体的目的。
附图说明
图1为本发明提供的建筑保温一体化免拆模板的主视图；
图2为图1的侧视图；
图3为浇筑前黑铁套管的位置示意图；
图4为建筑保温一体化免拆模板安装完成后的示意图。
具体实施方式
为使本发明更明显易懂，兹以优选实施例，并配合附图作详细说明如下。
实施例
如图1、2所示，为本发明提供的一种超低能耗建筑保温一体化免拆模板，其包括保温层1和轻质无机保护层2相互粘结构成的面板，面板上设有多个植筋孔3。所述保温层1的材料以有机保温材料为主，并可在保温材料表面设置无机材料界面层以便粘结；有机保温材料包括聚苯乙烯泡沫和聚氨酯硬泡材料等隔热性能优异的材料，优选为采用导热系数更低的聚氨酯硬泡材料，无机材料界面层可选纤维增强涂层毡等材料；保温层1的厚度为40～300mm。所述轻质无机防护层2的材料采用纤维增强加气混凝土板、加气蒸养混凝土板等轻质无机板材，其密度不超过700kg/m3，其厚度对应防火规范的要求，优选为50mm。所述粘结采用保温材料胶粘剂(如水泥基胶粘剂或环氧树脂胶粘剂)。所述植筋孔3的位置为孔心距面板板边的距离不超过300mm，且相邻植筋孔3的间距不超过600mm，开孔直径比玻纤复合材料杆4的直径大1～4mm，玻纤复合材料杆4的直径以悬挑强度和悬挑刚度计算获得。
上述超低能耗建筑保温一体化免拆模板的安装工艺，包括以下步骤：
步骤1)：绑扎钢筋龙骨；
步骤2)：在钢筋龙骨内侧设置内模板，并通过内侧模板支架支撑内模板；
步骤3)：在钢筋龙骨外侧设置所述超低能耗建筑保温一体化免拆模板，并通过外侧模板支架支撑该超低能耗建筑保温一体化免拆模板；
步骤4)：在植筋孔3内安装黑铁套管5，黑铁套管5的一端向内侧延伸，另一端设于保温层1内并与植筋孔3紧配，黑铁套管5插入保温层1中的深度a为10mm，如图3所示；
步骤5)：在黑铁套管5内插入对穿螺栓，对穿螺栓两侧螺母分别与内侧模板支架、外侧模板支架的主梁连接固定；
步骤6)：在钢筋龙骨上浇筑混凝土形成墙体8；
步骤7)：拆除内侧模板支架、外侧模板支架和内模板，使浇筑时应力充分释放；
步骤8)：拆除对穿螺栓，并将黑铁套管5向内侧延伸的一端采用泡沫条7填充，并用封堵6将端头填塞密实；
步骤9)：从外侧向植筋孔3内灌胶，胶液的灌注量为植筋孔3与黑铁套管5内剩余容积的2/3，通过反复插捣，插入玻纤复合材料杆4至胶液充分填充植筋孔3与黑铁套管5内空隙，玻纤复合材料杆4插入墙体8部分的长度为50～150mm；待胶液充分干燥即可。安装完成如图4所示。
上述步骤4)中，黑铁套管的设置与传统的墙板浇筑工艺具有显著的不同。传统工艺中，黑铁套管贯穿墙体布置，这样就会造成黑铁套管位置在浇筑完成后与建筑内外页连成一体，导致该部位在支撑模板去除后变形与其他无拉筋连接位置不一致，产生需要无机保护层承担的弯曲应力。本发明黑铁套管只与保温层紧配，并无粘结等连接作用，在浇筑完成，支撑模板拆除后，保温材料整体同步变形释放应力。为了实现这一作用，黑铁套管需与保温层紧配，而本身并无粘结等作用相连，如图3所示。
上述步骤7)中，由于模板的支护，造成支撑部分和非支撑部位的材料应力存在差异。采用本工艺在浇筑完成后，首先拆除内侧模板支架、外侧模板支架和内模板，使材料因浇筑支护产生的应力全部释放，然后再进行玻纤复合材料杆植入连接操作。
上述步骤9)中，后插入玻纤复合材料杆可以保证杆体在植入过程中，墙体的保温材料和面板材料无内应力。在玻纤复合材料杆植入后，胶液对黑铁套管和外模板有效粘结。玻纤复合材料杆使保温材料层层正粘和玻纤复合材料杆对各层的剪粘同时起作用，且不产生内应力。

Claims (9)

1.一种超低能耗建筑保温一体化免拆模板，其特征在于，包括保温层(1)和轻质无机保护层(2)相互粘结构成的面板，面板上设有植筋孔(3)。
2.如权利要求1所述的超低能耗建筑保温一体化免拆模板，其特征在于，所述保温层(1)的材料采用聚苯乙烯泡沫或聚氨酯硬泡，其厚度为40～300mm。
3.如权利要求1所述的超低能耗建筑保温一体化免拆模板，其特征在于，所述轻质无机防护层(2)的材料采用纤维增强发泡水泥制备而成的板材，其厚度为45～60mm。
4.如权利要求1所述的超低能耗建筑保温一体化免拆模板，其特征在于，所述粘结采用保温材料胶粘剂。
5.如权利要求1所述的超低能耗建筑保温一体化免拆模板，其特征在于，所述植筋孔(3)的位置为孔心距面板板边的距离不超过300mm，且相邻植筋孔(3)的间距不超过600mm，开孔直径比玻纤复合材料杆(4)的直径大1～4mm。
6.权利要求1-5任一项所述的超低能耗建筑保温一体化免拆模板的安装工艺，其特征在于，包括以下步骤：
步骤1)：绑扎钢筋龙骨；
步骤2)：在钢筋龙骨内侧设置内模板，并通过内侧模板支架支撑内模板；
步骤3)：在钢筋龙骨外侧设置所述超低能耗建筑保温一体化免拆模板，并通过外侧模板支架支撑该超低能耗建筑保温一体化免拆模板；
步骤4)：在植筋孔(3)内安装黑铁套管(5)，黑铁套管(5)的一端向内侧延伸，另一端设于保温层(1)内并与植筋孔(3)紧配；
步骤5)：在黑铁套管(5)内插入对穿螺栓，对穿螺栓两侧螺母分别与内侧模板支架、外侧模板支架的主梁连接固定；
步骤6)：在钢筋龙骨上浇筑混凝土形成墙体(8)；
步骤7)：拆除内侧模板支架、外侧模板支架和内模板，使浇筑时应力充分释放；
步骤8)：拆除对穿螺栓，并将黑铁套管(5)向内侧延伸的一端采用泡沫条(7)填充，并用封堵(6)将端头填塞密实；
步骤9)：从外侧向植筋孔(3)内灌胶，通过反复插捣，插入玻纤复合材料杆(4)至胶液充分填充植筋孔(3)与黑铁套管(5)内空隙；待胶液充分干燥即可。
7.如权利要求6所述的超低能耗建筑保温一体化免拆模板的安装工艺，其特征在于，所述步骤4)中，黑铁套管(5)插入保温层(1)中的深度为10mm。
8.如权利要求6所述的超低能耗建筑保温一体化免拆模板的安装工艺，其特征在于，所述步骤9)中胶液的灌注量为植筋孔(3)与黑铁套管(5)内剩余容积的2/3。
9.如权利要求6所述的超低能耗建筑保温一体化免拆模板的安装工艺，其特征在于，所述步骤9)中，玻纤复合材料杆(4)插入墙体(8)部分的长度为30～240mm。
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