阅读说明：本技术 一种大尺寸uhpc双面镂空雕花构件及制作工艺 (Large-size UHPC double-sided hollowed-out carved component and manufacturing process thereof ) 是由 冯斌 洪安享 黄轩 黄涛 杨世斌 陈雄 韩立波 韩建 李庆达 齐圣鑫 于 2021-09-03 设计创作，主要内容包括：本发明公开了一种大尺寸UHPC双面镂空雕花构件及制作工艺,分为UHPC背板和UHPC正板,UHPC背板上设置第一雕花面和第一接合面,UHPC正板上设置第二雕花面和第二接合面；第一接合面内设置有第一预埋件,并且设置有用于插入第二接合面的连接件；通过第一接合面与第二接合面的结合,以及连接件插入未凝固的UHPC正板相接,从而形成构件本体；第一雕花面和第二雕花面则分别设有装饰层,形成正反两个装饰面,解决了现有大尺寸UHPC装饰构件无法实现正反两面均为装饰面的问题。相对于单面浇筑,一面采用人工雕刻的方法,操作简便,节省人工,具有良好的经济效益。相对于传统UHPC装饰构件,本实施例的大尺寸UHPC双面镂空雕花构件的建筑效果较为突出,具有良好的社会效益。(The invention discloses a large-size UHPC double-sided hollowed-out carved component and a manufacturing process thereof, wherein the large-size UHPC double-sided hollowed-out carved component is divided into an UHPC back plate and an UHPC front plate, a first carved surface and a first joint surface are arranged on the UHPC back plate, and a second carved surface and a second joint surface are arranged on the UHPC front plate; a first embedded part is arranged in the first joint surface, and a connecting part used for being inserted into the second joint surface is arranged; combining the first joint surface and the second joint surface, and inserting a connector into the uncured UHPC positive plate to be connected, thereby forming a component body; first carving face and second carving face then are equipped with the decorative layer respectively, form two positive and negative decorative surfaces, have solved current jumbo size UHPC decorative component and can't realize that the positive and negative two sides is the problem of decorative surface. Compared with single-side pouring, the method has the advantages that one side is manually carved, the operation is simple and convenient, the labor is saved, and the economic benefit is good. Compared with the traditional UHPC decorative component, the large-size UHPC double-sided hollow-out carved component has more outstanding building effect and good social benefit.)

1. A large-size UHPC double-sided hollow carved component is characterized by comprising a UHPC back plate and a UHPC front plate which are formed by die casting;

the UHPC back plate comprises a first carved surface and a first joint surface which are oppositely arranged; the UHPC positive plate comprises a second engraved surface and a second joint surface which are oppositely arranged;

decorative layers are arranged on the first carved surface and the second carved surface;

the first joint surface is jointed with the second joint surface and used for realizing the connection of the UHPC back plate and the UHPC front plate and forming a component body;

a first embedded part is arranged inside the UHPC back plate, and a second embedded part is arranged inside the UHPC front plate; a raised connecting piece is arranged on the first joint surface, is connected with the first embedded part and is used for being inserted into the second joint surface;

wherein, when the UHPC back plate is jointed with the UHPC front plate, the UHPC front plate is in a semi-solidification state.

2. The large-scale UHPC double-sided openwork engraved element of claim 1, wherein said connecting elements are reinforcing bars.

3. The large-size UHPC double-sided hollowed-out engraved member of claim 1, wherein the first embedded part and the second embedded part are screw steel frames embedded in the UHPC back plate and the UHPC front plate respectively.

4. The large-size UHPC double-sided hollowed-out engraved element of claim 1, wherein at least one first nut is embedded in the UHPC back plate, and at least one corresponding second nut is embedded in the UHPC front plate;

the first nut is connected with the first embedded part, and the second nut is connected with the second embedded part; the first nut and the corresponding second nut are coaxial and matched to form a screw hole.

5. The large-size UHPC double-sided hollowed-out engraved member as claimed in claim 1, wherein said UHPC back plate and said UHPC front plate are provided with corresponding drainage holes.

6. The large-size UHPC double-sided hollow-out engraved element of claim 1, wherein the thickness of said decorative layer is 5mm, and the material of said decorative layer is decorative concrete.

7. The large-scale UHPC double-sided openwork engraved element of claim 1, wherein said element body has dimensions of 5000 x 2050 x 200 mm.

8. A manufacturing process of a large-size UHPC double-sided hollowed-out carved component is characterized by being used for manufacturing the large-size UHPC double-sided hollowed-out carved component as claimed in any one of claims 1 to 7, and comprising the following specific steps of:

step S1: manufacturing an upper die and a lower die corresponding to the UHPC back plate and the UHPC front plate;

step S2: preparing a UHPC back plate in an upper plate die and demoulding;

step S3: spraying a decorative layer in the lower die, pouring a UHPC material, hoisting the UHPC back plate to the position above the lower die, and closing the die;

step S4: and (5) integrally demolding.

9. The process for making a large-sized UHPC double-sided openwork engraved element of claim 8, wherein said step S2 comprises:

step S201: spraying a decorative layer in the upper die;

step S202: pre-burying a first embedded part and a connecting part in the upper piece die;

step S203: and pouring a UHPC material, and demolding after molding.

10. The process for making a large-sized UHPC double-sided openwork engraved element of claim 8, wherein said step S3 comprises:

step S301: pouring UHPC material until the blind hole of the overflow trough reserved on the joint line is found out, and leveling the height;

step S302: slowly hanging the UHPC back plate to be aligned downwards, and finding the position of a mold closing clamp;

step S303: after the condition that the workpiece is not wrong is confirmed, the sling chain is loosened, the UHPC back plate is pressed on the UHPC front plate, the fixture nut is fixed, the local thickness can be finely adjusted by a shim, the state of the overflow groove is observed, and the wet materials including four sides are uniformly extruded by all the overflow grooves;

step S304: and (5) checking, and partially grouting when the local overflow is insufficient.

Technical Field

The invention belongs to the technical field of building curtain wall decoration, and particularly relates to a large-size UHPC double-sided hollowed-out carved component and a manufacturing process thereof.

Background

With the development of building curtain walls and the requirements of modern public buildings and (ultra) large buildings, ultra-high performance concrete (UHPC for short) is gradually applied to the decoration of building outer walls. The ultra-high performance concrete has ultra-high durability and ultra-high mechanical properties. Compared with traditional concrete, UHPC is a building material with high strength, high compactness, excellent durability and high toughness. The building exterior wall can be processed into a specific specification and a specific shape, and the appearance of the building exterior wall is changed through an artistic form, so that the building exterior wall has stereoscopic impression. The common UHPC component is formed by pouring through a mould, generally has an outer vertical surface single-side decoration effect, and does not provide a mature solution for the research at present to realize that the front and back surfaces of the UHPC hollowed-out carved component are both decoration surfaces. Therefore, there is a need to develop a process for manufacturing a UHPC hollowed-out carved decorative component with front and back surface veneers.

Because UHPC fretwork carving component two-sided visual, middle pattern is intricate and complicated, if adopt two-sided mould fixed, by the mode of the direct casting in top, the side pressure is too big, the mould probably warp, probably because local nonconnection leads to the hole risk of appearing and even breaking in the middle of moreover. The method of single-side pouring and reverse-side manual carving is adopted, so that the problem that manual carving cannot meet the specification and smoothness of lines exists.

Disclosure of Invention

The invention aims to solve the technical problem of providing a large-size UHPC double-sided hollowed-out carved component and a manufacturing process thereof, and aims to solve the problem that the front side and the back side of the conventional large-size UHPC decorative component cannot be decorated.

In order to solve the problems, the technical scheme of the invention is as follows:

the invention relates to a large-size UHPC double-sided hollow carved component, which comprises a UHPC back plate and a UHPC front plate which are formed by pouring a die;

the UHPC back plate comprises a first carved surface and a first joint surface which are oppositely arranged; the UHPC positive plate comprises a second engraved surface and a second joint surface which are oppositely arranged;

decorative layers are arranged on the first carved surface and the second carved surface;

the first joint surface is jointed with the second joint surface and used for realizing the connection of the UHPC back plate and the UHPC front plate and forming a component body;

a first embedded part is arranged inside the UHPC back plate, and a second embedded part is arranged inside the UHPC front plate; a raised connecting piece is arranged on the first joint surface, is connected with the first embedded part and is used for being inserted into the second joint surface;

wherein, when the UHPC back plate is jointed with the UHPC front plate, the UHPC front plate is in a semi-solidification state.

The connecting piece of the large-size UHPC double-sided hollowed-out carved component is a plurality of reinforcing steel bar claws.

According to the large-size UHPC double-sided hollowed-out carved component, the first embedded part and the second embedded part are threaded steel frames which are embedded in the UHPC back plate and the UHPC front plate respectively.

According to the large-size UHPC double-sided hollowed-out carved component, at least one first nut is embedded in a UHPC back plate, and at least one corresponding second nut is embedded in a UHPC front plate;

the first nut is connected with the first embedded part, and the second nut is connected with the second embedded part; the first nut and the corresponding second nut are coaxial and matched to form a screw hole.

According to the large-size UHPC double-sided hollowed-out carved component, the UHPC back plate and the UHPC front plate are provided with corresponding drain holes.

According to the large-size UHPC double-sided hollowed-out carved component, the thickness of the decorative layer is 5mm, and the decorative layer is made of decorative concrete.

The large-size UHPC double-sided hollow carved component has the advantages that the size of a component body is 5000 × 2050 × 200 mm.

The invention relates to a manufacturing process of a large-size UHPC double-sided hollowed-out carved component, which is used for manufacturing any one of the large-size UHPC double-sided hollowed-out carved components and comprises the following specific steps:

step S1: manufacturing an upper die and a lower die corresponding to the UHPC back plate and the UHPC front plate;

step S2: preparing a UHPC back plate in an upper plate die and demoulding;

step S3: spraying a decorative layer in the lower die, pouring a UHPC material, hoisting the UHPC back plate to the position above the lower die, and closing the die;

step S4: and (5) integrally demolding.

The invention discloses a manufacturing process of a large-size UHPC double-sided hollowed-out carved component, wherein the step S2 comprises the following steps:

step S201: spraying a decorative layer in the upper die;

step S202: pre-burying a first embedded part and a connecting part in the upper piece die;

step S203: and pouring a UHPC material, and demolding after molding.

The invention discloses a manufacturing process of a large-size UHPC double-sided hollowed-out carved component, wherein the step S3 comprises the following steps:

step S301: pouring UHPC material until the blind hole of the overflow trough reserved on the joint line is found out, and leveling the height;

step S302: slowly hanging the UHPC back plate to be aligned downwards, and finding the position of a mold closing clamp;

step S303: after the condition that the workpiece is not wrong is confirmed, the sling chain is loosened, the UHPC back plate is pressed on the UHPC front plate, the fixture nut is fixed, the local thickness can be finely adjusted by a shim, the state of the overflow groove is observed, and the wet materials including four sides are uniformly extruded by all the overflow grooves;

step S304: and (5) checking, and partially grouting when the local overflow is insufficient.

Due to the adoption of the technical scheme, compared with the prior art, the invention has the following advantages and positive effects:

according to the embodiment of the invention, the large-size UHPC decorative component is divided into the UHPC back plate and the UHPC front plate, the UHPC back plate is provided with the first engraved surface and the first joint surface, and the UHPC front plate is provided with the second engraved surface and the second joint surface; a first embedded part is arranged in the first joint surface, and a connecting part used for being inserted into the second joint surface is arranged; the first joint surface and the second joint surface are combined, and the connector is inserted into the uncured UHPC front plate to be connected, namely the UHPC back plate and the UHPC front plate are respectively poured, and a UHPC front plate wet operation mode is adopted during die assembly, so that a component body is formed; first carving face and second carving face then are equipped with the decorative layer respectively to form two positive and negative decorative surfaces of component body, solved current jumbo size UHPC decorative component and can't realize that the positive and negative two sides is the problem of decorative surface. Compared with single-side pouring, the method has the advantages that one side is manually carved, the operation is simple and convenient, the labor is saved, and the economic benefit is good. Compared with the traditional UHPC decorative component, the large-size UHPC double-sided hollow-out carved component has more outstanding building effect and good social benefit.

Drawings

FIG. 1 is a cross-sectional view of a large-sized UHPC double-sided hollowed out engraved component of the present invention;

FIG. 2 is a schematic view of a cross-section of a mold assembly for a large-sized UHPC double-sided hollow engraved element of the present invention;

FIG. 3 is a schematic diagram of a method for manufacturing a large-sized UHPC double-sided hollowed-out engraved member of the present invention.

Description of reference numerals: 1: a member body; 101: a UHPC backplane; 102: a UHPC positive plate; 2: a decorative layer; 3: a deformed steel frame; 4: an internally threaded tube; 5: a joint line; 6: an overflow trough.

Detailed Description

The following will further explain the large-sized UHPC double-sided hollowed-out engraved component and the manufacturing process thereof according to the present invention with reference to the accompanying drawings and the specific embodiments. Advantages and features of the present invention will become apparent from the following description and from the claims.

Example one

Referring to fig. 1 and 2, in one embodiment, a large-sized UHPC double-sided hollow-carved component comprises a UHPC back plate 101 and a UHPC front plate 102 which are formed by die casting.

The UHPC backplane 101 includes a first engraved surface and a first bonding surface that are disposed opposite to each other. The UHPC positive plate 102 includes a second engraved surface and a second engaging surface that are oppositely disposed. All be equipped with decorative layer 2 on first carving face and the second carving face.

The first joint surface is jointed with the second joint surface for realizing the connection of the UHPC back plate 101 and the UHPC front plate 102 and forming the component body 1. A first embedded part is arranged inside the UHPC back plate 101, and a second embedded part is arranged inside the UHPC front plate 102. And the first joint surface is provided with a raised connecting piece, and the connecting piece is connected with the first embedded part and is used for being inserted into the second joint surface.

Wherein, when the UHPC back plate 101 is jointed with the UHPC front plate 102, the UHPC front plate 102 is in a semi-solidified state.

In the embodiment, the large-size UHPC decorative component is divided into a UHPC back plate 101 and a UHPC front plate 102, the UHPC back plate 101 is provided with a first engraved surface and a first joint surface, and the UHPC front plate 102 is provided with a second engraved surface and a second joint surface. A first embedded part is arranged in the first joint surface, and a connecting part used for being inserted into the second joint surface is arranged. The member body 1 is formed by combining the first joint surface and the second joint surface and inserting and connecting a connector into the uncured UHPC front plate 102, namely, the UHPC back plate 101 and the UHPC front plate 102 are respectively poured, and the UHPC front plate 102 is subjected to wet operation during mold closing. First carving face and second carving face then are equipped with decorative layer 2 respectively to form two positive and negative decorative covers of component body 1, solved current jumbo size UHPC decorative component and can't realize that the positive and negative two sides is the decorative cover problem. Compared with single-side pouring, the method has the advantages that one side is manually carved, the operation is simple and convenient, the labor is saved, and the economic benefit is good. Compared with the traditional UHPC decorative component, the large-size UHPC double-sided hollow-out carved component has more outstanding building effect and good social benefit.

The specific structure of the large-sized UHPC double-sided hollow-carved component of this embodiment is further described below:

in this embodiment, the connecting member is a plurality of reinforcing claws. The first embedded part and the second embedded part are respectively a deformed steel bar frame 3 which is embedded in the UHPC back plate 101 and the UHPC front plate 102. Before pouring, the deformed steel bar frame 3 is embedded in a corresponding die in advance, and then pouring of the UHPC material is carried out. In the manufacturing process of the UHPC back plate 101, the steel claw needs to be embedded into the mold before pouring, and can be fixedly arranged on the deformed steel bar frame 3.

Furthermore, at least one first nut is embedded in the UHPC back plate 101, and at least one corresponding second nut is embedded in the UHPC front plate 102. The first nut and the second nut are respectively and fixedly connected with the corresponding threaded steel frame 3, and the first nut and the corresponding second nut are coaxial and matched to form a screw hole. Specifically, eight corresponding first nuts and eight corresponding second nuts can be respectively arranged on the UHPC back plate 101 and the UHPC front plate 102, and the first nuts and the second nuts respectively penetrate through the UHPC back plate 101 and the UHPC front plate 102 in the thickness direction; when the UHPC back plate 101 and the UHPC front plate 102 are spliced and formed, the first nuts are respectively matched with the corresponding second nuts to form a screw hole which can be in threaded connection with an external threaded part. After the screw hole is connected with the external screw thread piece, the connection with a building or a building body can be realized through the external screw thread piece.

In other embodiments, the first and second nuts may also be internally threaded tubes 4, and in particular, in the present embodiment, M24 stainless steel internally threaded tubes 4 may be used.

In this embodiment, corresponding drainage holes may be opened below the UHPC back plate 101 and the UHPC front plate 102 for draining water between a gap formed between the component body 1 and a building body.

In the present embodiment, the size of the component body 1 is 5000 × 2050 × 200mm, the material of the decoration layer 2 is decoration concrete, and the thickness of the decoration layer 2 may be 5 mm. Namely, the thickness of the combination of the UHPC back plate 101 and the UHPC front plate 102 is 190mm, and the thickness of the combination of the UHPC back plate and the UHPC front plate is 200mm after the combination of the UHPC back plate and the UHPC front plate is added with the thickness of the decorative layers 2 on the two sides to be 5 mm. The compressive strength of UHPC is more than or equal to 120Mpa, and the flexural strength is more than or equal to 20 Mpa.

Example two

Referring to fig. 3, this embodiment provides a manufacturing process of a large-sized UHPC double-sided hollow-out carved component, which is used for manufacturing the large-sized UHPC double-sided hollow-out carved component in the first embodiment, and includes the following specific steps:

step S1: upper and lower dies corresponding to the UHPC back plate 101 and the UHPC front plate 102 are manufactured.

Step S2: a UHPC backsheet 101 is prepared in a cope mold and demolded.

Step S201: and spraying the decorative layer 2 in the upper die.

Step S202: and embedding a first embedded part and a connecting part in the upper piece die.

Step S203: and pouring a UHPC material, and demolding after molding.

Step S3: and spraying the decorative layer 2 in the lower die, pouring the UHPC material, hoisting the UHPC back plate 101 to the upper part of the lower die, and closing the die.

Step S301: pouring UHPC material until the overflow groove 6 reserved on the joint line 5 is blind, and leveling to a height.

Step S302: slowly hang UHPC backplate 101 and align downwards, find the die clamping fixture position.

Step S303: after the condition that the material is not wrong is confirmed, the sling chain is loosened, the UHPC back plate 101 is pressed on the UHPC front plate 102, the fixture nut is fixed, the local thickness can be finely adjusted by a shim, the state of the overflow grooves 6 is observed, and the wet material including four sides can be uniformly extruded by all the overflow grooves 6.

Step S304: and (5) checking, and partially grouting when the local overflow is insufficient.

Step S4: and (5) integrally demolding.

The following further explains the manufacturing method of this embodiment:

in this embodiment, step S1 may be specifically realized by three-dimensional modeling based on the drawings signed and confirmed by the owner and the designer, and then carving the mold is started after confirming the sample. The die is formed by combining four pieces, namely an upper piece, a lower piece, a left piece and a right piece, and a 15mm flange is reserved at the upper part and the lower part during die assembly. The upper and lower sheets are required to be finished on the same engraving machine, the upper sheet has the thickness of 195mm, the lower sheet has the thickness of 120mm, and the EPS adopts the bulk density of 20kg/m³The material of (1). After the carving is finished, the labels are classified, and protective measures must be made during transportation. Enclosing and blocking the mold: the side fence is made of No. 18 channel steel, cutting, polishing and straightening are conducted according to the length size, the lower side of the side fence is punched and fixed on the platform, the long side and the short side of the side fence are fixed through inclined struts, and the diagonal error is controlled to be less than or equal to 2 mm. And positioning holes are punched on the long side enclosing barrier, and each set of enclosing barrier is provided with four pull braces of the embedded nuts with unequal sides of 80 x 100mm and is fixed in number.

The side wall baffle is made of 18-number channel steel, cutting, polishing and straightening are conducted according to the length size, the lower side of the side wall is punched and fixed on the platform, the long side and the short side of the side wall are fixed through inclined struts, and the diagonal error is controlled to be less than or equal to 2 mm. And positioning holes are punched on the long side enclosing barrier, and each set of enclosing barrier is provided with four pull braces of the embedded nuts with unequal sides of 80 x 100mm and is fixed in number.

Between step S1 and step S2 in the present embodiment, step S5 may be further included: the slurry of the hollowed-out carved component is prepared, the proportioning and metering are strictly controlled according to the proportion, the aggregate error is controlled within +/-0.5%, and the condition that the water content in every 100kg of UHPC mixture cannot exceed 9.5kg is ensured. The two mixers operate simultaneously, and the forklift and the traveling crane are prepared in advance. Stirring for 5-10 min, adding according to the specified material sequence, and adding stainless steel fiber uniformly. The stainless steel mixture is stirred and then the decorative layer 2 mixture is stirred, and the stirrer and the storage tank must be washed.

In steps S2 and S3 of the present embodiment, the decoration layer 2 is formed by a spraying process. The spraying is uniform, and the thickness is controlled to be 5 mm. The individual places can be leveled by manually compacting with a trowel.

Step S3 in this embodiment specifically includes: fix well pre-buried first nut, second nut and two sets of screw-thread steel frame 3 of pre-buried in advance, two upper and lower pre-buried one set of screw-thread steel frame 3 respectively, lower piece screw-thread steel links together through fenestrate mode with pre-buried nut to reserve the reinforcing bar claw. The UHPC back plate 101 is manufactured firstly, after demolding, the UHPC back plate is fixed by a support large-angle steel through a first nut, the support angle plate faces upwards for hanging, and the first joint face faces downwards for later use.

When the UHPC front plate 102 is manufactured, the decorative layer 2 material is firstly sprayed, the structural layer stainless steel mixture is poured after leveling, after the mixture is poured to a preset height, the UHPC back plate 101 is lifted to align the direction and mould assembly, and the water drainage holes are aligned. The heights of the eight embedded nuts and the heights of the four corners are controlled during the die assembly of the upper and lower sheets, so that the upper and lower sheets are fixed after being consistent. The flatness of the four corners and each side is checked repeatedly, the sling chain is loosened after the confirmation of no error, the back sheet is pressed on the front sheet, the fixture nut is fixed, the local thickness can be finely adjusted by a thin gasket, the state of the overflow grooves 6 is observed, and the wet materials including the four sides are extruded uniformly by all the overflow grooves 6. And (5) checking, and partially grouting when the local overflow is insufficient.

In the present embodiment, step S6 may be further included between step S3 and step S4: and (5) maintaining, namely covering with a film after pouring is finished, and compacting four sides. Checking and starting the hot air blower, then installing a tarpaulin bracket, covering the tarpaulin, and ensuring that the temperature in the shed is between 40 and 50 ℃.

In this embodiment, in step S4, the member may be demolded after reaching the strength standard, and the embedded nuts are fixed by four unequal-side supporting angle steels and hoisted and transferred to the picking and chiseling workshop. The polystyrene board mould is carefully removed, the surface treatment is carried out by a carving master after the polystyrene board mould is laid flat, the redundant parts at the staggered platform and the joint are removed, and the decorative effect is processed and repaired by a carving machine. And standing the product after double-sided treatment, and continuously treating details by using a carving machine. And (5) after all the steps are finished, sand blasting treatment is carried out.

After step S4, step S7 may also be included: and (5) repairing the surface of the hollowed-out carved component, and starting repairing treatment after sand blasting treatment. And (4) repairing by using the mixture of the decorative layer 2, performing sand blasting treatment on the repaired part after the maintenance strength reaches the standard, and performing repeated repairing and sand blasting again until the repairing is basically completed. The stone protective agent is sprayed on the surface of the stone, and the stone protective agent is sprayed uniformly and has consistent color.

By the manufacturing method of the embodiment, the investment of constructors is greatly reduced by using the truck crane and the chain block, and the efficiency is greatly improved. Compared with the traditional stone relief outer wall surface construction, the manufacturing of the large-size UHPC double-sided hollow carved component saves the construction period by 50 percent (10 days).

The embodiments of the present invention have been described in detail with reference to the accompanying drawings, but the present invention is not limited to the above embodiments. Even if various changes are made to the present invention, it is still within the scope of the present invention if they fall within the scope of the claims of the present invention and their equivalents.