Brief introduction of LY permanent composite external formwork cast-in-place concrete thermal insulation structure system
LY permanent composite external formwork cast-in-place concrete thermal insulation structure system is a thermal insulation structure system formed by taking cement-based double-sided composite thermal insulation board as permanent external formwork, pouring concrete inside, wrapping anti-crack mortar outside, and firmly connecting double-sided composite thermal insulation formwork with concrete through connectors. The system belongs to cast-in-place reinforced concrete composite thermal insulation structure system, and is suitable for cast-in-place concrete structural engineering such as frame structure, shear wall structure, column and beam of industrial and civil buildings.
LY permanent composite external formwork consists of insulation board, insulation transition layer, internal and external bonding enhancement layer and ribs. The product has the excellent characteristics of light weight, good thermal insulation effect, convenient construction, good fire prevention performance, no potential safety hazard and the same life as the building.
During the construction of the composite external formwork insulation system, the composite insulation board is used as the permanent external formwork, and the cast-in-place concrete wall and the permanent external formwork are cast into a whole and connected by anchor bolts, which is more safe and reliable. After pouring, the mortar protective layer is applied outside to meet the requirement of building energy saving 65%.
The thermal insulation system has the following characteristics:
1) The design and construction process is simple, and it is easy to popularize and apply in a large area. The load-bearing structure form of cast-in-place concrete frame (frame-shear wall) structure remains unchanged, and the beams, columns and shear walls are still designed according to the current standards and specifications. The design standard and calculation software are complete, the construction technology is mature, and it is easy to popularize and apply in a large area.
2) Meet the technical requirements of integration, and achieve the purpose of building thermal insulation and structural longevity. The permanent composite thermal insulation external formwork is poured together with the cast-in-place concrete members of the frame (frame-shear wall) structure, such as beams, columns and shear walls, and is firmly connected with connectors with "sheep"-shaped angle nuts (tensile bearing capacity ≥0.5Mpa), so as to meet the technical requirements of synchronous design, synchronous construction and synchronous acceptance, and realize the purpose of building thermal insulation and structural life.
3) Multi-layer structure design, high strength and good thermal insulation performance. The permanent composite thermal insulation external formwork is composed of extruded thermal insulation board, reinforcing ribs, internal and external bonding reinforcing layers and thermal insulation transition layers. It has high mechanical strength, can be directly used as external formwork, and has good thermal insulation performance, which meets the standard requirement of building energy saving of 65%.
4) It has good fireproof performance. The two main facades inside and outside the insulation layer are covered with cement polymer mortar protective layer, which can effectively avoid the occurrence of fire in the construction process. After the construction project is completed, the protective layer of cement mortar outside the insulation layer reaches more than 30mm, which greatly improves the fire protection performance.
5) Factory prefabrication is adopted to ensure the engineering quality of products. The permanent composite thermal insulation external formwork is all prefabricated in the factory, so there is no chance of counterfeiting during use, and the phenomenon of cutting corners is put an end to. In the process of concrete pouring, the product quality of permanent composite thermal insulation external formwork is verified on site, which effectively prevents the use of counterfeit and shoddy products in construction projects.
6) creatively set the thermal insulation transition layer to avoid the common quality defects such as hollowing and cracking of the plastering layer. In the structural design of permanent composite thermal insulation external formwork, the thermal insulation transition layer is set, which relieves the strain of thermal insulation formwork caused by environmental changes and avoids the common quality defects such as hollowing and cracking of plastering layer.
7) Thermal insulation and formwork are integrated, and the project cost is low. The permanent composite thermal insulation external formwork can be directly used as the external formwork of cast-in-place concrete structure engineering, which combines thermal insulation and formwork, reduces the construction process and formwork consumption, and does not need other thermal insulation treatment, thus improving the construction efficiency and reducing the comprehensive construction cost.
Production example
Brief introduction to the production line of composite external wall insulation board;
The production line of composite external wall insulation board (flame retardant insulation board) is a new product successfully developed by our company after repeated tests with reference to advanced technology and experience at home and abroad. It is an important invention to realize the factory production of external insulation board. This production line consists of five parts: automatic mixing system, automatic plate making machine, automatic cutting saw, automatic palletizing system and drilling assembly.
1, automatic plate making machine:
This machine adopts automatic multi-pass rolling, net laying and non-woven fabric laying to make board, which is formed at one time. The board making speed is fast, the board is smooth and flat, the specifications can be adjusted at will, and the thickness is uniform. In the mortar state, this machine arranges the mesh from top to bottom in turn, and the composite production and EPS polystyrene board or XPS extruded board can be formed on the same machine at one time, forming a three-dimensional connection structure of mortar mesh in the composite board. Due to advanced technology and unique technology, not only the production efficiency is doubled, but also the cost of board making is greatly reduced, and the comprehensive quality, mechanical strength and bonding fastness of the surface layer of insulation board are greatly improved, which fundamentally overcomes the shortcomings of repeated labor, complicated procedures, weak bonding and high construction cost brought by the on-site construction of traditional polystyrene board and extruded board.
The unique technology of this machine is the first in China, and the advanced technology occupies a leading position in China. It is the best choice to realize the mechanized, standardized and large-scale production of composite polystyrene, insulation board or composite extruded insulation board (XPS).
2. Technical parameters:
Overall dimensions: length 45m× width 5.0m× height 5.0m.
Installed power: 40kw
Specification: length 2.4m× width 0.6m× thickness 20- 100mm.
Work efficiency: shift output is 1000— 1500m2.
3. Automatic stirring system:
Automatic batching of water and additives, automatic mixing of sand and cement, automatic spiral distribution and blanking are realized through automatic hoist and computer automatic batching system. Automatically stir10–15m3 mud every hour. The installed power is 40kw.
4, automatic cutting saw:
It consists of a longitudinal cutting saw, a transverse cutting saw and a carriage. The cutting saw can cut at will, and the cutting sizes are 600×2400mm, 600×900mm and 600× 1200mm. Product specifications can be cut as required, and the installed power is 20kw.
5. Group drilling:
It consists of a motor and a drilling and milling head, which can drill and mill 16 countersunk holes on the insulation board at one time, and the holes are evenly distributed, which is convenient for the fixation and installation of anchor nails in construction. In the process of construction, the construction process is simplified and the engineering efficiency is improved.
Second, the production conditions and benefit analysis:
1, production conditions
① Site: 500m2 production workshop, 300m2 material warehouse and finished product warehouse (shed)/1000m2.
② Water consumption: 14m? /d .
③ Power: the installed capacity is 40kw.
④ Personnel: 8- 12 workers are needed.
2. Cost accounting:
Cost accounting and benefit analysis (calculated according to the thickness of 40 ~ 60 mm and energy saving of 65%)
(1) raw material price
Ordinary Portland cement: 0.5 yuan quartz sand: 0.4 yuan
Admixture: 1.3 yuan grid cloth: 1.5 yuan/㎡ insulation board 15- 18 yuan/㎡.
The raw material cost per square meter is 18-2 1.7 yuan/㎡.
(2) Water and electricity charges: calculated according to the local average water and electricity charges, 0.2 yuan/㎡.
(3) Salary: The annual output of 500,000 square meters requires 8 workers, calculated at the average price 1 yuan/m2.
(4) Management expenses: 4 management personnel, and the expenses are 0.7 yuan/㎡.
(5) Sales expenses: calculated by 2 yuan per square meter.
(6) Depreciation: calculated per square meter 1 yuan.
(7) Workshop rent: calculated at 0.8 yuan per square meter.
The cost per square meter is 25-27.4 yuan/m2.
According to the annual output of 500,000 square meters, taking 40 ~ 60 mm as an example, the price of each place is 55 ~ 68 yuan/㎡.
The total annual output value is 500,000 ㎡× (55 ~ 68 yuan)/㎡ = 27.5 million ~ 34 million yuan.
The total cost is 500,000 yuan1321× (21~ 25)/m2 =10.5 million ~125,000 yuan.
Total annual profits and taxes = (275,000 ~ 340,000) ten thousand yuan -( 1050 ~ 1250) ten thousand yuan =1200 ~ 210.5 million yuan.
(8) Annual tax payment = (27.5 ~ 34 million) 10,000 yuan × 6% =165 ~ 2.04 million yuan.
The annual after-tax profit is about1500 ~19.5 million yuan.
The appearance of a new product with advanced significance will certainly produce great economic benefits. In today's fierce market competition, success always comes first. Science and technology are people-oriented, and Luyuan is honesty-oriented. Luyuan people are willing to work together with people of insight in the world to create good results.
Configuration table of wallboard machine
Remarks on equipment name and quantity
Platform frame 13 sets
3 sets of feeding platforms
4 sets of hoppers
4 sets of mop bracket finale
6 sets of scrapers
3 sets of mixers
2 sets of palletizers
1 pallet truck
7 sets of power distribution cabinets
Four-sided cutting saw 1 set
Cluster drilling 1 set
Technical parameters and production conditions
Overall dimensions: length 45m× width 5.0m× height 5.0m stacking space 1000 (m? )
The mass of the whole machine is 28T and the operation shed is 500 (m? )
The production capacity is1000-1500m2. Material space 300 (m? )
Host power 40 kW office building 50 (m? )
Cutting size is 600×600mm, 600×900mm, 600× 1200mm, 7 people are equipped with forklifts.
Implement the standard JC/T920-2003. Water consumption 14m? /d
The product size is1.2m× 0.6m× 20-100mm.
The demoulding time is 24 hours.
The use time is 7 days.
Second, the production technology research
Selection of raw materials
1) thermal insulation material
The thermal insulation material of the composite thermal insulation outer mold is XPS board. XPS board has low thermal conductivity, high compressive strength and impact resistance, low water absorption and excellent aging resistance, so it is a good lightweight thermal insulation material at present.
2) Cementing materials
Ordinary portland cement is selected as the main cementing material for bonding strengthening layer, bonding layer, thermal insulation transition layer and reinforcing rib. Ordinary Portland cement has wide sources, low price, good water resistance, high strength and excellent durability.
3) Aggregate
Artificial sand and natural sand mixed in a certain proportion are selected as bonding enhancement layer, bonding layer, thermal insulation transition layer and reinforced sand.
4) Vitrified microbeads
The light filling material of the thermal insulation transition layer is vitrified beads.
5) Rubber powder
The adhesive strength and water resistance of polymer mortar were improved by selecting 5044N rubber powder produced by WACKER Company in Germany.
6) Additives
In order to effectively improve the physical and mechanical properties of each layer of composite insulation, additives such as water reducer, waterproof agent and polymer are added.
7) alkali-resistant glass fiber grid cloth
Alkali-resistant glass fiber grid cloth is selected on both sides of the composite thermal insulation template to improve its mechanical strength such as impact resistance and bending load resistance.
2. Production technology and equipment
Preparation proces of 1) composite thermal insulation template
A. Preparation of polymer cement dry powder mortar: raw materials such as cementing materials, aggregates and rubber powder are measured, mixed, stirred and stored.
B, preparation of thermal insulation mortar dry powder: raw materials such as cementing materials, vitrified beads and rubber powder are measured, mixed and stirred, and stored.
C) The preparation process of the composite thermal insulation template mainly includes: cutting the extruded board, grooving, spraying the interface agent, laying the bonding enhancement layer on the inner side of the thermal insulation, and curing for 7 days; Laying adhesive layer, reinforcing rib, thermal insulation transition layer and external adhesive strengthening layer on the outer side of the insulation board in turn, and leaving the factory after natural curing for 7 days.
2) production equipment for composite thermal insulation formwork
The molding equipment of composite thermal insulation formwork is mainly composed of electronic metering device, dry mortar mixer, mortar mixer, working frame, leveling device, conveying device and cutting machine. Dry mortar mixer and mortar mixer adopt automatic batching and electronic metering, which has high degree of automation and accurate metering; The molding equipment has the characteristics of reasonable structural design, convenient production and operation, short molding cycle, high production efficiency and good product quality.
3. Product standards and performance indicators testing
According to the current energy-saving design standard of residential buildings in our province, the national technical specification for building formwork safety (JJ162-2008) and the integrated technical requirements, the enterprise standard "Composite external formwork cast-in-place concrete thermal insulation structure system" (Q/1500SCJ002-2010) was formulated.
Tested by Shandong Construction Engineering Quality Supervision, Inspection and Testing Center, the mechanical properties and weatherability of the permanent composite thermal insulation external formwork and FS composite external formwork thermal insulation system meet the requirements of relevant national standards and enterprise standards, and the specific technical indicators are as follows:
Table 1 System parameters of self-insulation structure
Table 2 Performance index of self-insulation structural system
case study
Project index
The surface density of Ly composite insulation external mold, kg/m? ≦35
Pit impact strength, j ≧ 10.0
Bending failure load, N≥2000
Tensile bond strength (with XPS board) MPa original strength ≧ 0.20
Water resistance ≧ 0.20
Freeze-thaw resistance ≧ 0.20
The density of thermal insulation layer (XPS) is 30-35.
Compressive strength, MPa≧0.20
Thermal conductivity w/(m k) ≦ 0.030
The combustion performance is not lower than B 1 class.
Research on design technology
1. Design requirements of self-insulation structural system
1) The engineering design of composite thermal insulation formwork thermal insulation system shall conform to the following principles:
A, the cast-in-place concrete members of frame structure and shear wall structure are designed according to the current Code for Design of Concrete Structures (GB 500 10-2002) and Code for Seismic Design of Buildings (GB 500110) and other relevant standards and specifications.
B, beam, column, shear wall and other external protective structures are designed with cast-in-place permanent composite external formwork, and the external protective filler wall is made of self-insulation blocks, which are at the same vertical elevation as the external side of the composite thermal insulation formwork.
C new wall materials such as aerated concrete block and lightweight aggregate concrete hollow block are selected for indoor partition design.
2) The energy-saving design and thermal calculation of the composite external formwork insulation system construction project should be designed according to the provisions of Shandong Province's Energy-saving Design Standard for Residential Buildings DJB-036 and Energy-saving Design Standard for Public Buildings DJB-037.
3) The design of self-insulation masonry matched with composite thermal insulation formwork in the enclosure structure shall comply with the provisions of the relevant national and Shandong masonry design codes.
4) The composite external formwork insulation system and main wall surface of the external wall filler wall should be designed according to the common plastering practice of the external wall, and 20mm thick anti-crack plastering mortar should be adopted.
5) The strength calculation of composite thermal insulation formwork should consider the pressure measurement standard value of newly poured concrete acting on the formwork. The calculated lateral pressure of fresh concrete is the smaller value in the following formula:
F = 0.22 RC tβ 1β2√~ V F = RC H
Among them, the RC gravity density of concrete is 24,000 kn/m3.
T-initial setting time of new concrete, when the data is insufficient, take 200, (t+15);
T—— the temperature when the concrete enters the mould;
V -- concrete pouring speed, m/h;
H-the total height from the position where the lateral pressure of concrete is calculated to the top surface of newly poured concrete; β1-positive coefficient of additive effect, and1.00 is taken when no additive is added; 1.200 when admixtures with retarding effect are mixed;
β 2-correction coefficient of concrete slump, when the slump is less than 30mm, take 0.85; When the slump is 50mm~90mm, take1.0; When the slump is110mm ~150mm, take 1. 150.
6) The deformation value of composite thermal insulation formwork is 1/400 of the calculated span of formwork components.
2. Structural design of nodes of self-insulation structure system
1) Before plastering construction, anti-cracking measures should be taken for the splicing of composite thermal insulation formwork and the junction with self-insulation masonry.
2) In addition to the main wall, thermal bridge parts such as masonry parapets, doors and windows, balconies, awnings, air conditioning partitions, protruding waistlines, etc. Should be insulated from the mud system.
3) Structure of special parts of composite external mold insulation system.
& lt 1 & gt； Splicing of composite thermal insulation formwork.
The intersection of<2> composite insulation board and self-insulation masonry.
Design and construction of<3> Yin-Yang angle.
Design structure of<4> door and window openings.
Fourth, the construction technology research
Technical requirements for construction
1) During the construction of composite external formwork insulation system, the corresponding quality management system, construction quality and inspection system should be established on site, and a special construction scheme should be prepared to train and make technical disclosure to the construction personnel.
2) The composite insulation board should be handled with care during transportation. After the materials enter the construction site, they will be accepted on site in advance, and the samples will be re-examined as required. All kinds of materials should be classified and stacked evenly, and should not be stored in the open air, and should be rain-proof and sun-proof; In a flat and dry site, the maximum floor is no more than 20 floors; Moisture-proof, waterproof and other protective measures should be taken during storage, and the storage period and conditions should be stipulated in the instruction manual of composite products.
3) Ready-mixed mortar shall be selected for masonry mortar and plastering mortar, which shall be prepared according to the requirements of product specifications. The prepared materials should be used up within the specified time, and expired use is strictly prohibited.
4) After the composite external formwork insulation system is completed, the finished product shall be protected. Aiming at the wall defects caused by construction, such as wall bushing, foot-hand-eye, hole, etc. Thermal bridge isolation measures shall be taken according to the construction scheme, and shall not affect the thermal performance of the wall.
2. Construction process and method
1) construction process:
Composite thermal insulation external formwork typesetting → cutting → installation of connectors → elastic thread → binding of steel bars and cushion blocks → installation of composite thermal insulation external formwork → installation of internal formwork → threading of pull bolts → installation of formwork wood square blank → installation of formwork double steel pipe blank → adjustment of fixed formwork position → pouring concrete → removal of formwork blank → building of self-insulation masonry → flat-fell seam and anti-crack treatment of yin and yang angles → plastering of cement anti-crack mortar → construction of facing layer.
2) Key points of construction operation:
<1> Determine the partition scheme of clappers: Determine the partition scheme of clappers according to the size of the external wall and draw the layout plan, and try to use the main specification composite thermal insulation external formwork.
< 2 > cutting of composite thermal insulation external formwork: for the parts where the main specifications cannot be installed, it should be cut into the required size by cutting saw at the construction site in advance.
< 3 > installation of connectors: at the construction site, punch holes in the preset position of the composite thermal insulation formwork with a pistol drill, and install no less than 5 connectors per square meter. Connectors can be added to doors and windows.
〈4〉 Elastic line: Before installing the composite thermal insulation formwork, the dimensions shall be rechecked according to the design drawings and layout drawings, and the installation control line shall be designed. Pop up the installation control line of each board.
〈5〉 Binding reinforcement and cushion blocks: After the binding acceptance of external wall reinforcement, C20 cement mortar cushion blocks (3~4 blocks /m2) shall be bound on both sides of reinforcement.
< Installation of composite thermal insulation external formwork: Install the composite thermal insulation external formwork according to the block scheme in the design layout, and tie the connectors and steel bars with binding steel wires. Install the boards at the yin and yang corners of the external wall first, and then install the main wallboard.
〈7〉 Installation of external wall internal formwork: According to the requirements of concrete construction acceptance specification and building formwork safety technical specification, wood (bamboo) plywood, wood square secondary stare blankly and steel pipe main stare blankly are installed inside the external wall by traditional methods.
〈 8. Installation of counter-bolts: According to the height of each wall and column, determine the spacing of counter-bolts according to the traditional formwork construction method, drill holes in the corresponding positions of the composite thermal insulation formwork and the inner formwork with a pistol, insert the counter-bolts, and preliminarily adjust the bolts.
〈9〉 Primary and secondary stare blankly for formwork installation: vertical stare blankly (40×70mm or 50×80mm) on the outside of external wall, horizontally install two 48×3.5 steel pipes as main stare blankly, fix internal and external formwork, primary and secondary stare blankly, and adjust the width and verticality of formwork to meet the construction requirements.
<10 > Concrete pouring: Type II galvanized iron fasteners are used for concrete pouring, and a protective cap is formed at the upper mouth of the composite thermal insulation formwork. The slump of concrete should meet the requirements of pumping concrete for fluidity.
3) The dismantling time and requirements of internal and external formwork, primary and secondary formwork and primary and secondary formwork shall comply with the Code for Quality Acceptance of Concrete Engineering (GB50203-2002) and Technical Code for Safety of Building Formwork (JJ162-2008).
4) Building self-insulation masonry
The self-insulation masonry construction of the infilled wall of the external protective structure should be carried out in accordance with the relevant masonry design codes and regulations of the state and Shandong Province, and the outer side of the self-insulation block should be at the same vertical elevation as the outer side of the composite insulation template.
5) Anti-cracking treatment of flat-fell seam and Yin-Yang angle.
Composite thermal insulation formwork flat-fell seam, Yin-Yang angle and intersection with self-insulation masonry are leveled with polymer mortar, and 200mm wide alkali-resistant glass fiber grid cloth is laid to strengthen crack prevention measures.
6) Cement anti-crack mortar plastering
Composite thermal insulation formwork and self-insulation masonry shall be plastered with 20mm cement anti-crack mortar in layers to make the facade smooth and meet the requirements of composite acceptance.
7) Construction of facing layer
Paint or ceramic tile facing layer shall be constructed in accordance with Code for Acceptance of Construction Quality of Building Energy Saving Projects (GB504 1 1-2007).
Verb (abbreviation of verb) technical innovation and breakthrough
1) innovatively invented the permanent composite thermal insulation formwork and the cast-in-place concrete wall structure, and connected them firmly through the connectors with "sheep"-shaped angle nuts, which reached the technical index requirements of energy-saving structural integration and achieved the purposes of building thermal insulation and structural longevity.
2) The internal bonding enhancement layer of the permanent composite thermal insulation external formwork is polymer cement bonding mortar, which is firmly bonded with the thermal insulation board 100% and organically combined with the internally poured concrete to ensure the bonding strength and quality.
3) The permanent composite thermal insulation external formwork adopts the connector with "sheep" angle nut to pour concrete, which greatly improves the anchoring strength with the cast-in-place concrete wall and ensures the safety and reliability of the connection.
4) The common quality defects such as hollowing and cracking of plastering layer are creatively reduced.
5) The permanent composite thermal insulation external formwork is designed with multi-layer structure, with internal and external bonding reinforcing layers and ribs, which improves the mechanical properties of thermal insulation formwork such as bending, compression and impact resistance, meets the technical requirements of cast-in-place concrete formwork, and reduces the dosage of formwork.
Innovative integrated insulation, the same life as the building, saving time, safety and no hidden dangers, policy orientation, the highlight of real estate sales, doing a good job in engineering projects, and thinking for users can have the greatest benefits.
performance comparison
Ordinary external insulation (such as polystyrene board) is designed for 25 years, and it will be cracked and watered in about 10 years, and it will be overhauled by secondary insulation. During the construction period, the fire hazard is great and the responsibility is great.
The construction method of polystyrene board is manual process, which is greatly influenced by weather and climate, such as strong wind, heavy rain and freezing and melting in winter. , and cannot be constructed.
The construction period of ordinary external insulation is about 60 days, and the secondary construction can only be completed after the crane and construction elevator are dismantled, which spans three or four months, affecting the overall construction progress.
Ordinary external insulation requires a large number of hanging baskets, which is prone to safety accidents, with high accident probability, and Party A's safety responsibility is too heavy.
With the continuous improvement of national energy-saving standards, polystyrene board has been unable to achieve its due thermal insulation effect. If thermal insulation materials and construction methods are not strictly controlled, it will cause long-term safety hazards such as falling objects from high altitude. If such an incident happens, it will seriously damage the company's image and it will be difficult to repair it afterwards.
LY external insulation design for 60 years, with the same life as the building. Because it is connected with concrete and poured as a whole, it is safe and has no hidden dangers. Because it is quantitative size production, it is impossible to cut corners on the spot. The insulation effect is guaranteed, the concept is novel, and it is also the highlight of sales.
LY external model achieves Grade A fire protection, which is a key promotion project of the Provincial Construction Department and the Ministry of National Construction. In addition, the insulation block is made of inorganic materials, which is safer. There is no fire hazard during the construction and after the owner moves in. Shorten the construction period by two months, save management cost, have good thermal insulation effect, and have the same service life as the building. The implementation of integrated thermal insulation system is also the national policy and policy orientation. Due to energy saving, fast safety progress and other factors, it will definitely bring sales highlights to the company and return the company's best interests.
Accession policy
Join one in each county and develop two township agents;
The company provides equipment technical support;
The company provides product patent authorization;
The company assists in checking the wall renovation of provincial organs, the application certificate of new wall materials and energy-saving technology products in Shandong Province, the product registration certificate and other relevant certificates;
The company provides a full set of production technology and production operation training free of charge.