CN114658208A

CN114658208A - Concrete pouring method and mold manufacturing method for pouring

Info

Publication number: CN114658208A
Application number: CN202210293090.2A
Authority: CN
Inventors: 梁恉豪; 秦川; 胡雨辰
Original assignee: Shanghai Dajie Intelligent Equipment Co ltd
Current assignee: Shanghai Dajie Intelligent Equipment Co ltd
Priority date: 2022-03-23
Filing date: 2022-03-23
Publication date: 2022-06-24
Anticipated expiration: 2042-03-23
Also published as: CN114658208B

Abstract

The invention provides a method for manufacturing a mould for concrete pouring, which comprises the following steps: s1, carrying out curvature analysis and region segmentation on the casting body by using software, wherein the segmented region is called a process region, and different molds are selected for the casting body in the process region according to the curved surface complexity of the casting body; s2, segmenting models of different process areas by using proper modulus; s3, carrying out secondary modeling on the surface unit, and outputting a processing drawing for processing; s4, each splicing unit and/or special unit corresponds to the surface module of the splicing unit and/or special unit; and S5, machining the surface module part by using numerical control equipment. According to the invention, different molds are selected according to the complexity of the curved surface, different material layers are adopted for splicing, the accurate surface of the casting body can be provided, the effect of the prepared clear water surface is better than that of the existing construction method, and the post-treatment is simple. The stacking block structure can comprehensively support various changed curved surfaces of the fitting surface layer, manual lofting is not needed, the manual workload is greatly reduced, and the construction efficiency is improved.

Description

Concrete pouring method and mold manufacturing method for pouring

Technical Field

The invention relates to the technical field of curved concrete pouring.

Background

The clear water cast-in-place concrete is a common building expression technique and can create elegant and simple effects and be perfectly strong. The later-stage modification treatment is basically not carried out after the fair-faced concrete is formed, so that the quality of the final fair-faced concrete is directly determined by the quality of the mould. In the traditional cast-in-place fair-faced concrete pouring process, particularly in the construction of double curved surfaces, because the die process is too complex and the splicing difficulty is high, the perfect effect of the fair-faced vertical surface is difficult to make, and the quality defects of wrong surface, slurry leakage, curved surface deformation and the like are generated; meanwhile, the large-curvature part of the die is mostly spliced by manual small pieces, time and labor are wasted, the construction period is shortened, and the cost is seriously floated.

Disclosure of Invention

The invention aims to overcome the defects in the prior art, and provides the concrete pouring mold and the concrete pouring method which can be applied to the variable form surface, so that the construction quality is improved, and the efficiency is greatly improved.

In order to achieve the purpose, the technical scheme adopted by the invention is as follows:

a method for manufacturing a mould for concrete pouring comprises the following steps:

s1, carrying out curvature analysis and region segmentation on the casting body by using software, wherein the segmented region is called a process region, and different molds are selected for the casting body in the process region according to the curved surface complexity of the casting body: 1.1) the small curvature part or the single curved surface part adopts the existing mould; 1.2) adopting a composite die for the large-curvature part or the double-curved-surface part; 1.3) using a fine mould for the fine crushing part and the texture part;

s2, segmenting models of different process areas by using proper modulus, wherein the segmented parts are called surface units; the parts which are complicated and can not be divided by the modulus size, such as joints, curved surface splicing positions and the like, are independently divided;

s3, carrying out secondary modeling on the surface unit, and outputting a processing drawing for processing; each surface unit is composed of a plurality of splicing units, and the parts which are separately divided in the S2 are called as special units;

s4, each splicing unit and/or special unit corresponds to the self assembly system, called surface module, the component which forms the surface module and is to be processed is called module part; in the module parts, the surface part for molding is called a surface part, the part for supporting the surface part is called a fitting part, and the rest supporting parts are called assembling parts;

s5, machining the module parts by using numerical control equipment, wherein the mould types classified according to S1 are as follows:

5.1) adopting a wood template as the surface part and the fitting part of the existing mould in the process area of 1.1);

5.2) if the process area is 1.2, the surface part of the composite die adopts a foam block, and the fitting part adopts a wood template;

5.3) if the process area is 1.3), surface parts of the fine die are printed by high polymer 3D, and fitting parts adopt wood templates;

the assembly parts of the 5.1) existing die adopt an existing supporting structure, and the assembly parts of the 5.2) composite die and the 5.3) fine die are crossed cubes.

The surface parts and fitting parts of the existing mould in the 1.1 process area of the step S5 adopt wood templates, and solid wood, laminated wood, density boards and other materials can be processed and used. For better curved surface splicing, V-shaped grooves can be cut on the wood template, so that the bending and splicing are ensured to be easy.

The surface part of the 1.2 process area composite die in the step S5 adopts a foam block, and the foam block is preferably formed by cutting and surface milling EPS, polyurethane or PIR foam. The wood template selection and processing mode adopted by the fitting part is the same as the wood template selection and splicing mode of the fitting part in the 1.1 process area.

And the wood template material selection and processing mode adopted by the 1.3 process area fitting part of the step S5 is the same as the material selection and splicing mode of the 1.1 process area fitting part wood template. The polymer 3d printing material can be selected from pla, photosensitive resin, silica gel and the like.

Further, the surface parts are pretreated before splicing, and different pretreatment modes are respectively used according to the material types of the surface parts. The printing material can be textured according to the requirement. The foam material is paved with a hardening material with the thickness of 1-10mm according to the pouring pressure intensity of concrete and the vibration requirement, and the hardening material is made of hard materials such as putty, gypsum, epoxy resin and the like. Furthermore, in order to adapt to stress influences such as cement expansion and the like during pouring, gaps of 1-3mm are arranged at intervals on the laid hardened material layer, and sealing materials are filled in the gaps, wherein the sealing materials are made of hard materials such as atomic ash, white carbon black, wood powder and epoxy resin mixture; and may be flexible material such as polyurea, polyurethane, etc. If the gap at the joint with a relatively large curvature exceeds 3mm, the gap is filled with a material such as wood fiber or glass fiber by bottoming in advance. And (4) leveling and trimming the bottoming part into a concave shape, then filling and polishing the bottoming part in the concave shape by using a sealing material, and smoothing the bottoming part. And after the seam splicing treatment is finished, the whole inspection, repair and polishing are carried out, so that the surface quality of the die is ensured to meet the requirements. In addition, if a textured cement surface is required, the surface of the hardened material layer can be textured.

Further, the assembly part cross cube in step S5 is formed by all criss-cross adjacent vertical plates, the vertical plates are wooden templates with a thickness of 20-40mm, and the distance between two opposite vertical plates is 150-300 mm. Furthermore, a mortise and tenon structure is arranged on the vertical plate and used for being accurately butted with the fitting part.

Furthermore, the assembling parts also comprise a supporting frame, and the crossed cube is fixed on the supporting frame. Furthermore, the supporting frame comprises an upright post, a cross beam, supporting ribs, a bottom plate and a back plate, wherein the upright post and the cross beam form a fixed frame of the peripheral space of the die; the assembling parts are fixedly connected with the bottom plate and the back plate, and the vertical plate positioned on the fixing surface is in butt joint with the bottom plate or the back plate through a mortise and tenon structure.

The assembling part is arranged between the fitting part and the bottom plate and the back plate, and the vertical plate of the assembling part is completely filled in a space formed between the fitting part and the bottom plate and the back plate. The vertical plate is in butt joint with the bottom plate or the back plate through the mortise and tenon structure, and then is further fixed by bolting or nails or configured with corner connectors.

Furthermore, the upright posts and the cross beams are arranged into 60-120 cm-spaced coil buckle scaffold, and at least two supporting ribs are arranged in the scaffold unit cells.

Furthermore, the bottom plate, the back plate and the supporting ribs are firmly fixed in a nailing mode, and a total station is used for calibrating positions before fixing.

Furthermore, the cross section of the supporting rib is higher than 60 mm; the bottom plate and the back plate adopt wood templates with the thickness of 20mm-40mm, and the size of the bottom plate and the size of the back plate are more than 60 x 60 cm.

Further, a double-sided mold needs to be manufactured, and the middle channel is used for concrete pouring. Furthermore, in order to resist the concrete expansion, a plurality of split bolts are transversely inserted into the double-faced mold.

A concrete pouring method comprises the following steps:

1) the mould is spliced by adopting the mould manufacturing method for concrete pouring of the patent;

2) laying or brushing a demoulding material on the pouring surface of the mould;

3) and pouring concrete in the channel between the single-sided mould pouring surface or the double-sided mould.

The invention has the beneficial effects that:

according to the method for manufacturing the mold for concrete pouring, the curvature analysis and the area division are carried out on the poured body by software, then different molds are selected for the divided poured body according to the complexity of the curved surface, and finally different material layers are adopted for splicing, so that no matter the curvature of a single surface or a double surface changes, an accurate surface of the poured body can be provided, the surface staggering and slurry leakage are not easy to occur, the manufactured clear water surface has a better effect than the existing construction method, and the post-treatment is simple.

Simultaneously, this patent is fixed cross riser built-up connection on scaffold frame basis, forms stable heap square block structure, as long as the square has piled up and just can comprehensively support the curved surface of the various changes of fitting surface course together, need not to carry out artifical laying-out, has reduced manual work volume by a wide margin, has improved the efficiency of construction.

In addition, the classified mold parts and the matched structures can realize high-degree machining, and the precision guarantee is further improved.

The following description of embodiments of the invention is provided with reference to the accompanying drawings:

drawings

Fig. 1 is a schematic diagram of process zoning of a cast body according to curvature. The area A and the area B are relatively gentle, and the existing wood mold is adopted for the part with small curvature; the area B is a large-curvature part and adopts a composite die.

FIG. 2 is a schematic view of a surface element division of a casting body. C is a surface unit, and D is a modulus dividing line.

Fig. 3 is an assembled side view of the splice unit. E is a splicing unit.

Fig. 4 is a partial sectional view of a concrete casting mold according to an embodiment of the present invention.

Fig. 5 is a partial sectional view of a concrete casting mold according to an embodiment of the present invention in a double-sided mold.

Fig. 6 is a standard view of a cross-sectional structural part when the concrete casting mold according to the embodiment of the present invention is a double-sided mold.

Fig. 7 is a flow chart of a concrete pouring method according to an embodiment of the present invention.

Reference numerals:

1 fitting part, 101V-groove

2 surface parts

3 hardened material layer, 301 gap, 302 sealing material

4 pairs of pull bolts, 5 casting bodies and 6 binding agents

7 assemblage part, 701 riser

8 support frame, 801 upright post, 802 cross beam, 803 support rib, 804 bottom plate and 805 back plate

Detailed Description

The specific embodiments described herein are merely illustrative of the principles of this patent and are not intended to limit the scope of the disclosure. It should be noted that, for convenience of description, only some structures related to the technical solution of the present disclosure are shown in the drawings, not all structures.

Before discussing exemplary embodiments in greater detail, it should be noted that the structures of the device components and/or the modules themselves mentioned in the embodiments, if not specified in detail, are those understood or commercially available products by those skilled in the art in light of the present disclosure.

In the method for manufacturing a concrete casting mold according to the present embodiment, a concrete casting mold shown in fig. 1 and 2 is taken as an example, Step 1: using software such as Rhino, CATIA and the like to carry out curvature analysis, carrying out region segmentation according to the following recommended standard, calling the segmented region as a process region, and selecting different molds for the casting body in the process region according to the curved surface complexity of the casting body: 1.1) the small curvature part (curvature radius is more than 200mm) or the single curved surface part adopts the existing mould; 1.2) a large curvature part (the curvature radius is less than 200mm, or within the range of 600 × 600mm curved surface, one or more trend bends of more than 120 degrees exist in the UV ray) or a double curved surface part adopts a composite die; 1.3) use of fine molds for the overly complicated, finely divided portions and textured portions.

The numerical values in brackets are only a recommended example, the division of the process area does not need to be strictly selected according to a certain curvature point value, and the skilled person can reasonably divide the process area according to the form, quality requirement, cost and the like of the cast body to be constructed.

Step 2: dividing the models of different process areas by using a proper modulus, wherein the divided parts are called surface units; and the parts which are complicated and cannot be divided by using the modulus size, such as joints, curved surface splices and the like, are separately divided.

Step 3: and carrying out secondary deepening modeling on the surface unit, and outputting a processing drawing for processing. For the deeply modeled model in this Step, each surface unit is composed of a plurality of splicing units, and the separately divided parts in Step2 are called special units.

The skilled person can flexibly select the module of step S2 and the splicing unit/special unit composition of step S3 for different process areas, ease of mold manufacture and installation. For example, smooth surfaces can be made of large blocks, and large undulations need to be made of a plurality of blocks in a subdivision mode, while internal corners and folding corners cannot be unified into a standard, namely, different curved surfaces have different subdivision quantities. The preferable scheme when the curved surface trend or the turning exceeds 90 degrees within the range of 1000 multiplied by 1000mm is to further divide, then process and splice on site according to the module parts corresponding to the splicing units and/or the special units.

Step 4: each splicing unit and/or special unit corresponds to an own assembly system, called a surface module, and the parts which form the surface module and need to be processed are called module parts; in the module part, a surface portion for molding is called a surface part, a portion for supporting the surface part is called a fitting part, and the remaining supporting members are called assemblage parts. In the software, the surface module is spliced and the outline and the shape of the supporting backboard, which can be fixed by the cube, are designed in a stacking cube mode.

The component constitution and the structural mode of the surface module are obtained through the steps, and the subsequent steps of processing and installing the components are carried out.

Step 5: machining the assembly parts by using numerical control equipment, wherein the types of the moulds classified according to Step1 are as follows:

5.1) adopting a wood template as the surface part and the fitting part of the existing mould in the process area of 1.1); 5.2) if the process area is 1.2, the surface part of the composite die adopts a foam block, and the fitting part adopts a wood template; 5.3) if the process area is 1.3), surface parts of the fine die are printed by high polymer 3D, and fitting parts adopt wood templates; the assembly parts of the 5.1) existing die adopt an existing supporting structure, and the assembly parts of the 5.2) composite die and the 5.3) fine die are crossed cubes.

The surface parts and fitting parts of the existing mould in the 1.1 process area of Step5 adopt wood templates, solid wood, glued wood, density boards and other materials can be processed and used, and the materials of the wood template boards are mainly carved with outlines. And V-shaped grooves are cut on the wood template, so that the wood template can be bent and spliced easily.

The surface part of the 1.2 process area composite die of Step5 adopts a foam block, and the foam block can be formed by cutting and surface milling EPS, polyurethane or PIR foam. The wood template selection and processing mode adopted by the fitting part is the same as the wood template selection and splicing mode of the fitting part in the 1.1 process area.

The wood template material selection and processing mode adopted by the fitting part in the 1.3 process area of Step5 is the same as the material selection and splicing mode of the wood template of the fitting part in the 1.1 process area. The polymer 3D printing material can be LA, photosensitive resin, silica gel and the like.

The surface parts are pretreated before splicing, and different pretreatment modes are respectively used according to the material types of the surface parts. The foam material is paved with a hardening material with the thickness of 1-10mm according to the pouring pressure intensity of concrete and the vibration requirement, and the hardening material is made of hard materials such as putty, gypsum, epoxy resin and the like. In order to adapt to stress influences such as cement expansion and the like during pouring, gaps of 1-3mm are arranged at intervals on the paved hardened material layer, and sealing materials are filled in the gaps, wherein the sealing materials are made of hard materials such as atomic ash, white carbon black, wood powder and epoxy resin mixture; and may be flexible material such as polyurea, polyurethane, etc. If the gap at the joint with a relatively large curvature exceeds 3mm, the gap is filled with a material such as wood fiber or glass fiber by bottoming in advance. And (4) leveling and trimming the bottoming part into a concave shape, then filling and polishing the bottoming part in the concave shape by using a sealing material, and smoothing the bottoming part. And (4) after the seam splicing treatment is finished, carrying out integral inspection, repairing and polishing to ensure that the surface quality of the mold meets the requirement, and finally paving or brushing a demolding material to wait for pouring.

If a textured cement surface is required to be formed, a corresponding texture is made on the surface of the hardened material layer.

The assembly part cross cube of Step5 is composed of all criss-cross adjacent vertical plates, the vertical plates are preferably wooden templates with the thickness of 20-40mm, and the distance between two opposite vertical plates is 150-300 mm. For the accurate butt joint with the fitting part, processing mortise and tenon structure on the riser.

Most construction sites of the assembly parts need support frames for fixing, namely, the crossed cubes are fixed on the support frames. One of the preferable schemes of the supporting frame is as follows: the die comprises upright columns, cross beams, support ribs, a bottom plate and a back plate, wherein the upright columns and the cross beams form a fixed frame of a peripheral space of the die; the assembling parts are fixedly connected with the bottom plate and the back plate, and the vertical plate positioned on the fixing surface is in butt joint with the bottom plate or the back plate through a mortise and tenon structure.

The assembling part is arranged between the fitting part and the bottom plate and the back plate, and the vertical plate of the assembling part is completely filled in a space formed between the fitting part and the bottom plate and the back plate. The vertical plate is in butt joint with the bottom plate or the back plate through the mortise and tenon structure, and then is further fixed by bolting or nails or configured with corner connectors. The bottom plate, the back plate and the supporting ribs are firmly fixed in a nailing mode, and the total station is used for calibrating the position before fixing, fine-tuning and firmly fixing.

And selecting a modularized support member such as a steel frame or a scaffold and the like as a support frame according to the casting amount, carrying out stress calculation, and additionally arranging anti-lateral force supports such as inclined struts and the like as required. And designing a corresponding supporting frame drawing in the software model based on the spliced supporting back plate. And finally, performing field lofting, building a supporting frame according to a drawing, and installing a bottom plate and a back plate. Holes can be further reserved in the bottom plate and the back plate, so that the supporting back plate and the supporting frame can be fixed through a hoop.

When the mold is spliced, the fitting part and the assembling part are firstly spliced, the assembly is sequentially arranged at the corresponding positions on the bottom plate and the back plate, and then the surface part is adhered and fixed on the fitting part by using the adhesive. I.e. the foam blocks are adhesively secured to the wooden forms.

Preferably, the upright posts and the cross beams are arranged into 60-120 cm-spaced coil buckle scaffold, and at least two supporting ribs are arranged in the scaffold unit cells. The height of the cross section of the support rib is more than 60 mm; the bottom plate and the back plate adopt wood templates with the thickness of 20mm-40mm, and the size of the bottom plate and the size of the back plate are more than 60 x 60 cm.

Sometimes it is necessary to make two separate single-sided moulds as double-sided moulds, with intermediate channels for concrete casting. In order to resist the concrete expansion die, a plurality of split bolts are transversely inserted and arranged in the double-faced die.

And after the die is manufactured and built, pouring concrete in a channel between the single-sided die pouring surface or the double-sided die to finish concrete pouring, subsequently removing the die, and performing detail repairing on the formed pouring body where manual repairing is needed.

While the preferred embodiments of the present invention have been illustrated and described, it will be understood by those skilled in the art that various changes in form and details may be made therein without departing from the spirit and scope of the invention as defined by the appended claims.

Claims

1. A method for manufacturing a mould for concrete pouring comprises the following steps:

2. The method for manufacturing a mold for concrete pouring according to claim 1, characterized in that: and S5, adopting a wood template as the surface part and the fitting part of the existing mould in the 1.1 process area, and cutting a V-shaped groove on the wood template for bending and splicing.

3. The method for manufacturing a mold for concrete pouring according to claim 1, characterized in that: the surface part of the 1.2 process area composite die in the step S5 adopts a foam block, and the fitting part adopts a wood template.

4. The method for manufacturing a mold for concrete pouring according to claim 1, characterized in that: the 1.3 process area of the step S5 is fitted with a wood template adopted by the part, and the polymer 3d printing material is pla, photosensitive resin or silica gel.

5. The method for manufacturing a mold for concrete casting according to claim 1, wherein: and (3) paving a hardening material with the thickness of 1-10mm on the foam block, wherein the hardening material is hard materials such as atomic ash, gypsum or epoxy resin.

6. The method for manufacturing a mold for concrete pouring according to claim 5, wherein: gaps of 1-3mm are arranged at intervals in the laid hardened material layer, and sealing materials are filled in the gaps.

7. The method for manufacturing a mold for concrete pouring according to claim 1, characterized in that: the vertical plate is in butt joint with the fitting part through the mortise and tenon structure.

8. The method for manufacturing a mold for concrete pouring according to claim 1, characterized in that: the assembling parts further comprise a supporting frame, and the crossed cube is fixed on the supporting frame.

9. The method for manufacturing a mold for concrete pouring according to claim 8, wherein: the supporting frame comprises an upright post, a cross beam, supporting ribs, a bottom plate and a back plate, the upright post and the cross beam form a fixed frame of the peripheral space of the die, the upright post is provided with vertical supporting ribs, the cross beam is provided with horizontal supporting ribs, the bottom plate is fixed on the horizontal supporting ribs, and the back plate is fixed on the vertical supporting ribs; the assembling parts are fixedly connected with the bottom plate and the back plate, and the vertical plate positioned on the fixing surface is in butt joint with the bottom plate or the back plate through a mortise and tenon structure.

10. The method for manufacturing a mold for concrete pouring according to claim 9, wherein: the vertical plate is completely filled in a space formed between the fitting part and the bottom plate or the back plate, and is fixedly connected with the bottom plate or the back plate through a mortise and tenon structure.

11. A concrete pouring method comprises the following steps:

1) splicing the molds by using the method for manufacturing a mold for concrete pouring according to any one of claims 1 to 10;

3) and pouring concrete on the pouring surface of the mould.