1. Construction of Masonry Walls Without Scaffold Holes
Process:
Begin by welding a T-shaped flat iron to the end of the steel pipe crossbar on the scaffold. The masonry height should reach the installation point, which is typically selected at the intersection of vertical mortar joints and horizontal joints. When supporting the scaffold, position the T-shaped flat iron flat against the wall. Mortar can be omitted at the placement location to facilitate easy assembly and disassembly.
2. Innovative Technology for Constructing Columns and Ring Beams Without Eye Formwork Supports
Process 1:
This method uses pre-embedded Φ14 tension bolts, externally threaded with Φ15 PVC plastic pipes, within the “GZ” formwork section to secure the formwork. This replaces the traditional frame holes left in the masonry, improving the overall wall masonry quality. The “GZ” template consists of 12mm thick full-face plywood reinforced with three wooden ribs measuring 50mm × 80mm on each side, forming a fixed template. Tension bolts are pre-embedded in the “GZ” section, and four sets of 50mm × 80mm short wooden blocks lock each layer externally at the ends, while 100mm × 100mm wooden blocks support the inner corners. This technique is ideal for “one”-shaped, L-shaped, and T-shaped brick concrete structure corners.
Process 2:
(1) Use standardized steel formwork, secured with short steel pipes and specially designed through-wall bolts. These bolts consist of a Φ12 steel bar welded on one end to a steel pipe sleeve or straight stopper and threaded on the opposite end.
(2) During wall construction, pre-embed plastic pipes at designated frame holes. After construction, remove the plastic pipes to create reserved holes.
(3) When installing the formwork, insert specially made Φ12 bolts into the reserved holes and tighten the threaded ends with nuts.
Process 3:
Supporting Formwork of Ring Beam Hard Frame:
(1) At the brick layer under the ring beam, embed Φ16 PVC plastic pipes during wall construction. After completion, gently rotate and extract the pipes to form Φ16 installation holes spaced 800-1000mm apart.
(2) Attach a special support tool made from ∠40 × 4 angle steel, securing it by threading a Φ14 bolt into the installation holes.
(3) Install ordinary composite steel formwork, tighten bolts, and adjust the formwork flatness.
Column Formwork Construction:
(1) Leave Φ16mm installation holes with Φ16 PVC plastic pipes at the horizontal mortar joints, 240mm from the structural column, spaced vertically no more than 800mm apart.
(2) After reinforcing bars pass inspection, install the composite formwork.
(3) Fix a special mold made from ∠50 × 5 angle steel, securing it with Φ14 through-wall bolts.
Process 4:
Cut PVC pipes to match wall thickness and install rubber plugs on both ends, ensuring the outer dimensions match the concrete component cross-section. When supporting formwork, thread tension bolts to secure it. After pouring concrete and removing the formwork, extract the rubber plugs and fill the holes with 1:2 cement mortar for a smooth finish. Alternatively, prefabricate a 5mm thick flat iron with one end bent into a 5cm long 90-degree hook. When supporting wall formwork or scaffolding, insert the flat iron into brick joints embedded in the wall, achieving the same effect as wall anchors.
Advantages:
- Eyeless support mold process requires fewer shaping molds, increasing mold turnover, reducing costs, and simplifying installation and removal.
- Leaving no holes in the masonry enhances the overall wall strength.
- The concrete surface is flat, smooth, and color-consistent, effectively eliminating common defects like concrete slurry leakage and wall contamination.
- Removing the traditional eye lifting process reduces labor costs and helps shorten the construction schedule.
3. Application of Fixed Formwork for Frame Beam, Column, and Slab Junctions
Method 1:
Use composite small steel formwork combined with irregular angle formwork to support beam, column, and slab joints. Place sponge strips at formwork joints and customize irregular corner templates based on specific site conditions.
Method 2:
Employ customized bamboo plywood templates for shaping.
4. Concrete Flanging in Bathrooms and Overall Cast-in-Place Concrete Floor Construction
To enhance bathroom waterproofing, use a suspended formwork technique and pour the concrete flange integrally with the floor.
5. Application of Sponge Strips in Formwork Engineering
Process:
Before installing structural column and ring beam formwork in brick concrete structures, apply soft or hard foam sponge strips with double-sided adhesive tape on both sides of the structural column and the wall below the ring beam.
Advantages:
This effectively prevents wall contamination caused by concrete slurry overflow.
6. Construction Method for Inclined Top Brick Masonry on Infill Walls
Process:
Pre-cut the top bricks to ensure flat upper and lower contact surfaces. When laid diagonally, the bricks form a 60-degree angle with the horizontal plane.
Advantages:
- Flat contact surfaces maintain a consistent horizontal mortar joint thickness of approximately 10mm, avoiding common issues with excessive mortar thickness.
- The 60-degree angle leads to more compact masonry and better integration.
- Prevents quality problems such as seamless joints between the plastered infill wall and frame beam.
- Facilitates neat, visually appealing construction.
7. Cutting or Prefabrication Methods for Irregular Bricks in Masonry
Process:
The seven quarter head bricks are typically prefabricated at the brick yard or cut on-site with a toothless saw. The bottom brick of the protruding part of the “horse toothed” brick is also cut at a 45-degree angle using a toothless saw.
Advantages:
Cutting the bottom brick at a 45-degree slope facilitates concrete pouring and compaction, enhancing the wall’s visual quality.
8. Application Technology of Bark Number Poles in Masonry Construction
Process:
Bark number poles are made of 3cm × 5cm planed wood squares with an adjustable base. The poles have clear markings indicating gray joints, reinforcement locations, and structural changes, and are firmly fixed in place.
9. Use of Precast Concrete Blocks for Door and Window Wooden Bricks
Traditionally, door and window frames are fixed by embedding wooden bricks in walls. Since most walls use porous bricks, wooden bricks are not securely fixed. This method replaces wooden bricks with precast concrete blocks of the same cross-section. During wall construction, place the precast concrete blocks where wooden bricks would typically be, and fix door and window frames to these blocks.
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