烧结页岩空心砖自保温系统研究与应用
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摘要
墙体自保温技术是国内学者近年来提出的一个新技术方向，随着外墙保温系统应用中存在问题的暴露，特别防火问题的出现，逐渐得到关注。墙体自保温系统耐候性、耐久性好，与建筑物同寿命，防火、抗冲击性能佳，系统安全、可靠，施工便捷，综合经济性较好。在当前国家全面推进建筑节能的背景下，开展墙体自保温系统研究对支撑建筑节能工作开展具有重要的现实意义。
目前热桥占墙体比例和墙体组成材料与墙体热工性能的关系缺乏基础性研究。本文分析了热桥比例对墙体平均传热系数的影响，热桥比大于0.172时，热桥必须进行保温处理后墙体平均传热系数才能≤1.5W/(m~2·K)，而经调研分析重庆地区当前框架结构和框剪结构建筑热桥占墙体最小比例为0.257，所以墙体自保温系统应以砌体部分为研究对象。配砖和砌筑砂浆等墙体组成材料对砌体热工性能有显著影响。当空心砖当量导热系数为0.25W/(m·K)时，与实心配砖和普通砌筑砂浆组成砌体的传热系数K≤1.2W/(m~2·K)，而与多孔配砖和保温砌筑砂浆组成的砌体传热系数K≤1.0W/(m~2·K)。因此，节能型烧结页岩空心砖的当量导热系数应低于0.25W/(m·K)。
目前烧结空心砖的孔洞结构不合理，且烧结砖几乎没有应用气孔形成剂，其热工性能亟需进一步提高。本文采用数值模拟软件FLUENT计算不同孔洞结构时烧结页岩空心砖的当量导热系数，揭示孔型、矩形孔长宽比、孔排列数、孔洞率、孔排列方式等对烧结空心砖热工性能的影响。结果表明，长边垂直于热流方向的矩形孔有利于提高烧结空心砖的热工性能，其长宽比在3:1～6:1之间为宜；孔洞率相同时，空心砖孔排数增多，空心砖的当量导热系数减小，空气间层宽度减小到10mm左右时，间层内空气的热导率几乎与静止空气的热导率相同，因而烧结空心砖的孔宽宜在10mm左右；孔列数增加，孔肋变薄，每增加一列孔，空心砖的当量导热系数减小5%左右；空心砖的孔洞率与导热系数成反比，在满足烧结空心砖成型性能和强度时，应尽可能增大其孔洞率；交错排列可使孔肋延长线系数变大，有利于提高空心砖的热工性能。
在分析锯末、造纸污泥和煤矸石的热解特性以及对混合料塑性指数影响基础上，研究了气孔形成剂掺量对烧结页岩砖性能的影响。结果表明，锯末、造纸污泥掺量增加，烧结页岩砖体积密度和抗压强度逐渐下降，孔隙率和吸水率逐渐增大，锯末和造纸污泥适宜掺量分别为6%和7%；煤矸石成孔能力较弱，可作为烧结页岩砖的内燃料，减少燃煤用量。相同密度等级的烧结页岩空心砖抗压强度高于微孔砖，但微孔砖显气孔率较高、导热系数较低。对于优化设计出的9排孔烧结空心砖，在设置阻断砌筑砂浆灰缝热桥凹槽的基础上，通过在原料中掺入气孔形成剂和优化生产工艺，可得到节能型烧结页岩空心砖，其当量导热系数小于0.25W/(m·K)，满足墙体自保温体系的要求。
在孔洞结构优化的基础上，采用泡沫混凝土填充烧结页岩空心砖制备复合型烧结页岩空心砖以进一步提高其热工性能。填充用泡沫混凝土干表观密度为224kg/m~3，导热系数为0.063W/（m·K），吸水率为11.02%。发明的灌注设备结构简单、耗能低、高效，从根本上解决了复合空心砖浆料灌注问题，并已申请国家发明专利。根据复合空心砖各组成材料的厚度及导热系数，确定了泡沫混凝土最佳灌注厚度及位置并对砖结构进行了优化，制备出了干表观密度867kg/m~3、当量导热系数0.24W/（m·K）、吸水率18%、抗压强度5.35MPa复合空心砖，并已获得国家实用新型专利。
理论计算和实验测试了砌筑砂浆和配砖对烧结页岩空心砖自保温系统热工性能的影响，并在实际工程中利用热流计法实测了烧结页岩空心砖自保温墙体的传热系数和利用红外热像仪分析墙体内表面温度分布。保温砌筑砂浆砌体的传热系数比水泥砌筑砂浆砌体的传热系数降低13%；多孔配砖墙体内表面温度比实心配砖高0.5℃左右，保温砌筑砂浆砌筑的墙体的温度比普通水泥砂浆砌筑的墙体的温度高0.4℃左右。利用防护热箱法测试结果表明，玻化微珠砌筑砂浆砌筑的烧结页岩空心砖自保温墙体传热系数比水泥砌筑砂浆砌筑时降低了20%，选择12孔配砖的烧结页岩空心砖自保温墙体传热系数比实心配砖降低8%左右，因而烧结页岩空心砖自保温系统应选用砌筑型玻化微珠砂浆和多孔配砖。利用建筑节能分析软件分析了不同类型烧结空心砖砌体、不同类型砌筑砂浆、配砖对自保温墙体热工性能和建筑能耗的影响，结果表明保温砌筑砂浆和多孔配砖与节能型烧结页岩空心砖组成的自保温墙体的当量导热系数为0.32W/(m·K)、保温砌筑砂浆和多孔配砖与和复合烧结页岩空心砖组成的自保温墙体的当量导热系数为0.31W/(m·K)，满足夏热冬冷地区建筑节能65%的设计标准要求。
Thermal-insulation exterior wall system contains exterior insulation wall system,interior insulation wall system, self-insulation wall system nowadays while exteriorinsulation wall is widely used at home and abroad, whereas it has some disadvantages,namely, complex and long construction process, shorter longevity compared with mainstructure, low engineering quality, high cost, easy peeling of decorative materials,content of combustible organic materials etc.. However, self-thermal insulation wallsystem has superior properties to a certain extent, it is apparent that the weatherabilityand durability are greater compared with other insulation wall systems, and its longevityis more or less the same with the building structure, moreover, it has some excellentproperties of fireproof performance, shock resistance, easy construction process and lowcost, thus the investigation of self-insulation wall system impede the development andapplication of building energy saving.
The thermal bridge to exterior wall ratio and the relationship between wallmaterials and average heat-transfer coefficient of walls are lack of basic researches. Theeffect of thermal bridge to exterior wall ratio on average heat-transfer coefficient of wallwas analyzed in this investigation. The results demonstrate that the average heat-transfercoefficient of wall is less than1.5W/(m~2·K) with the insulation treatment of thermalbridge while thermal bridge to exterior wall ratio is equal to0.172. The survey showsthe minimum thermal bridge to exterior wall ratio of frame structure or frame-shear wallstructure is0.25in Chongqing, therefore, the masonry is mainly studied in the research.Through the test, it presents the effect of equipped of brick and masonry mortar onthermal performance is significant. The thermal conductivity of masonry composedwith hollow brick, solid equipped of brick and ordinary masonry mortar is less than orequal to1.2W/(m~2·K), whereas it is less than or equal to1.0W/(m~2·K) when themasonry is composed with hollow brick, multi-hole equipped of brick and masonrymortar, while the thermal conductivity of hollow brick is equal to0.25W/(m~2·K).Therefore, the reasonably thermal conductivity is less than0.25W/(m~2·K).
The early research shows it is unreasonable for hole type of hollow brick of whichthe thermal performance is not suitable enough without using of pore-forming agent.The equivalent thermal conductivities of fired-shale hollow bricks with varied holetypes were tested by using of simulation software FLUENT in the investigation. It reveals the effects of hole type, length-width ratio, arrangement type and quantity ofholes, hole ratio on thermal performance of hollow brick. According to the result thethermal performance is improved when the longer edge of the rectangular holeperpendicular to the thermal flow direction with a suitable length-width ratio rangingfrom3/1to6/1. It is reasonable for a value of the hole width equal to10mm as theincreasing of quantity of lateral holes with the same hole ratio of brick, i. e. the thermalconductivity of hollow brick decreases considerably and the thermal conductivity of airin holes is more or less the same with that of stationary air while the width of hole isequal to10mm. Besides, the thermal conductivity of hollow brick with increasing ofquantity of longitudinal holes reduces5%compared with ordinary hollow brick.Moreover, stagger arrangement of varied types of holes is gainful for improving thethermal performance of brick.
The influence of sawdust, paper sludge, coal gangue on plasticity index of mixtureand the influence of dosage of pore-forming agent on property of hollow brick werediscussed in the research. It presents the volume densities and the compressive strengthsof bricks lose with the increasing dosages of sawdust, paper sludge, coal gangue,whereas the porosities and water absorption rates improve gradually while the dosagesof sawdust and paper sludge are6%and7%respectively. The suitable value ofequivalent thermal conductivity should be less than0.25W/(m~2·K) to satisfy the needsof building energy saving according to optimizing the hole type of hollow brick with9holes.
Furthermore, the thermal performance of hollow brick filled with foam concrete asthe insulation material is improved of which the dry apparent density is224kg/m~3,thermal conductivity is0.063W/(m~2·K) and the water absorption ratio is equal to11.02%. Moreover, the compound hollow brick is prepared according to optimizing thehole type, of which the dry apparent density is867kg/m~3, thermal conductivity is0.21W/(m~2·K), the water absorption ratio is equal to18%and the compressive strength is5.35MPa.
The effects of masonry and equipped of brick on thermal performance ofself-thermal insulation hollow brick were tested in order to obtain the heat-transfercoefficient of hollow brick and the surface temperature of interior wall. It presents theheat-transfer coefficient of insulation masonry decreases13%compared with which ofordinary masonry whereas the heat-transfer coefficient of fired-shale hollow brickreduces12%in comparison with that of compound hollow brick, and the surface temperature of interior wall of multi-hole equipped of brick is about0.5℃highercompared with that of solid brick whereas the temperature of insulation masonry mortaris about0.4℃higher compared with that of cement mortar. According to the result, thethermal conductivity of hollow brick wall built with glazed hollow bead mortar loses20%compared with which built with cement mortar, meanwhile, it reduces8%whenequipped of brick of12holes is used instead of solid brick. The thermal performanceand building energy consumption of varied types of hollow brick masonry, masonrymortar and multi-hole brick were tested in the investigation. It demonstrates theequivalent thermal conductivities of hollow brick wall and compound hollow brick wallare0.32W/(m~2·K) and0.31W/(m~2·K) respectively, and it suits the65%of energysaving design.
目前热桥占墙体比例和墙体组成材料与墙体热工性能的关系缺乏基础性研究。本文分析了热桥比例对墙体平均传热系数的影响，热桥比大于0.172时，热桥必须进行保温处理后墙体平均传热系数才能≤1.5W/(m~2·K)，而经调研分析重庆地区当前框架结构和框剪结构建筑热桥占墙体最小比例为0.257，所以墙体自保温系统应以砌体部分为研究对象。配砖和砌筑砂浆等墙体组成材料对砌体热工性能有显著影响。当空心砖当量导热系数为0.25W/(m·K)时，与实心配砖和普通砌筑砂浆组成砌体的传热系数K≤1.2W/(m~2·K)，而与多孔配砖和保温砌筑砂浆组成的砌体传热系数K≤1.0W/(m~2·K)。因此，节能型烧结页岩空心砖的当量导热系数应低于0.25W/(m·K)。
目前烧结空心砖的孔洞结构不合理，且烧结砖几乎没有应用气孔形成剂，其热工性能亟需进一步提高。本文采用数值模拟软件FLUENT计算不同孔洞结构时烧结页岩空心砖的当量导热系数，揭示孔型、矩形孔长宽比、孔排列数、孔洞率、孔排列方式等对烧结空心砖热工性能的影响。结果表明，长边垂直于热流方向的矩形孔有利于提高烧结空心砖的热工性能，其长宽比在3:1～6:1之间为宜；孔洞率相同时，空心砖孔排数增多，空心砖的当量导热系数减小，空气间层宽度减小到10mm左右时，间层内空气的热导率几乎与静止空气的热导率相同，因而烧结空心砖的孔宽宜在10mm左右；孔列数增加，孔肋变薄，每增加一列孔，空心砖的当量导热系数减小5%左右；空心砖的孔洞率与导热系数成反比，在满足烧结空心砖成型性能和强度时，应尽可能增大其孔洞率；交错排列可使孔肋延长线系数变大，有利于提高空心砖的热工性能。
在分析锯末、造纸污泥和煤矸石的热解特性以及对混合料塑性指数影响基础上，研究了气孔形成剂掺量对烧结页岩砖性能的影响。结果表明，锯末、造纸污泥掺量增加，烧结页岩砖体积密度和抗压强度逐渐下降，孔隙率和吸水率逐渐增大，锯末和造纸污泥适宜掺量分别为6%和7%；煤矸石成孔能力较弱，可作为烧结页岩砖的内燃料，减少燃煤用量。相同密度等级的烧结页岩空心砖抗压强度高于微孔砖，但微孔砖显气孔率较高、导热系数较低。对于优化设计出的9排孔烧结空心砖，在设置阻断砌筑砂浆灰缝热桥凹槽的基础上，通过在原料中掺入气孔形成剂和优化生产工艺，可得到节能型烧结页岩空心砖，其当量导热系数小于0.25W/(m·K)，满足墙体自保温体系的要求。
在孔洞结构优化的基础上，采用泡沫混凝土填充烧结页岩空心砖制备复合型烧结页岩空心砖以进一步提高其热工性能。填充用泡沫混凝土干表观密度为224kg/m~3，导热系数为0.063W/（m·K），吸水率为11.02%。发明的灌注设备结构简单、耗能低、高效，从根本上解决了复合空心砖浆料灌注问题，并已申请国家发明专利。根据复合空心砖各组成材料的厚度及导热系数，确定了泡沫混凝土最佳灌注厚度及位置并对砖结构进行了优化，制备出了干表观密度867kg/m~3、当量导热系数0.24W/（m·K）、吸水率18%、抗压强度5.35MPa复合空心砖，并已获得国家实用新型专利。
理论计算和实验测试了砌筑砂浆和配砖对烧结页岩空心砖自保温系统热工性能的影响，并在实际工程中利用热流计法实测了烧结页岩空心砖自保温墙体的传热系数和利用红外热像仪分析墙体内表面温度分布。保温砌筑砂浆砌体的传热系数比水泥砌筑砂浆砌体的传热系数降低13%；多孔配砖墙体内表面温度比实心配砖高0.5℃左右，保温砌筑砂浆砌筑的墙体的温度比普通水泥砂浆砌筑的墙体的温度高0.4℃左右。利用防护热箱法测试结果表明，玻化微珠砌筑砂浆砌筑的烧结页岩空心砖自保温墙体传热系数比水泥砌筑砂浆砌筑时降低了20%，选择12孔配砖的烧结页岩空心砖自保温墙体传热系数比实心配砖降低8%左右，因而烧结页岩空心砖自保温系统应选用砌筑型玻化微珠砂浆和多孔配砖。利用建筑节能分析软件分析了不同类型烧结空心砖砌体、不同类型砌筑砂浆、配砖对自保温墙体热工性能和建筑能耗的影响，结果表明保温砌筑砂浆和多孔配砖与节能型烧结页岩空心砖组成的自保温墙体的当量导热系数为0.32W/(m·K)、保温砌筑砂浆和多孔配砖与和复合烧结页岩空心砖组成的自保温墙体的当量导热系数为0.31W/(m·K)，满足夏热冬冷地区建筑节能65%的设计标准要求。
Thermal-insulation exterior wall system contains exterior insulation wall system,interior insulation wall system, self-insulation wall system nowadays while exteriorinsulation wall is widely used at home and abroad, whereas it has some disadvantages,namely, complex and long construction process, shorter longevity compared with mainstructure, low engineering quality, high cost, easy peeling of decorative materials,content of combustible organic materials etc.. However, self-thermal insulation wallsystem has superior properties to a certain extent, it is apparent that the weatherabilityand durability are greater compared with other insulation wall systems, and its longevityis more or less the same with the building structure, moreover, it has some excellentproperties of fireproof performance, shock resistance, easy construction process and lowcost, thus the investigation of self-insulation wall system impede the development andapplication of building energy saving.
The thermal bridge to exterior wall ratio and the relationship between wallmaterials and average heat-transfer coefficient of walls are lack of basic researches. Theeffect of thermal bridge to exterior wall ratio on average heat-transfer coefficient of wallwas analyzed in this investigation. The results demonstrate that the average heat-transfercoefficient of wall is less than1.5W/(m~2·K) with the insulation treatment of thermalbridge while thermal bridge to exterior wall ratio is equal to0.172. The survey showsthe minimum thermal bridge to exterior wall ratio of frame structure or frame-shear wallstructure is0.25in Chongqing, therefore, the masonry is mainly studied in the research.Through the test, it presents the effect of equipped of brick and masonry mortar onthermal performance is significant. The thermal conductivity of masonry composedwith hollow brick, solid equipped of brick and ordinary masonry mortar is less than orequal to1.2W/(m~2·K), whereas it is less than or equal to1.0W/(m~2·K) when themasonry is composed with hollow brick, multi-hole equipped of brick and masonrymortar, while the thermal conductivity of hollow brick is equal to0.25W/(m~2·K).Therefore, the reasonably thermal conductivity is less than0.25W/(m~2·K).
The early research shows it is unreasonable for hole type of hollow brick of whichthe thermal performance is not suitable enough without using of pore-forming agent.The equivalent thermal conductivities of fired-shale hollow bricks with varied holetypes were tested by using of simulation software FLUENT in the investigation. It reveals the effects of hole type, length-width ratio, arrangement type and quantity ofholes, hole ratio on thermal performance of hollow brick. According to the result thethermal performance is improved when the longer edge of the rectangular holeperpendicular to the thermal flow direction with a suitable length-width ratio rangingfrom3/1to6/1. It is reasonable for a value of the hole width equal to10mm as theincreasing of quantity of lateral holes with the same hole ratio of brick, i. e. the thermalconductivity of hollow brick decreases considerably and the thermal conductivity of airin holes is more or less the same with that of stationary air while the width of hole isequal to10mm. Besides, the thermal conductivity of hollow brick with increasing ofquantity of longitudinal holes reduces5%compared with ordinary hollow brick.Moreover, stagger arrangement of varied types of holes is gainful for improving thethermal performance of brick.
The influence of sawdust, paper sludge, coal gangue on plasticity index of mixtureand the influence of dosage of pore-forming agent on property of hollow brick werediscussed in the research. It presents the volume densities and the compressive strengthsof bricks lose with the increasing dosages of sawdust, paper sludge, coal gangue,whereas the porosities and water absorption rates improve gradually while the dosagesof sawdust and paper sludge are6%and7%respectively. The suitable value ofequivalent thermal conductivity should be less than0.25W/(m~2·K) to satisfy the needsof building energy saving according to optimizing the hole type of hollow brick with9holes.
Furthermore, the thermal performance of hollow brick filled with foam concrete asthe insulation material is improved of which the dry apparent density is224kg/m~3,thermal conductivity is0.063W/(m~2·K) and the water absorption ratio is equal to11.02%. Moreover, the compound hollow brick is prepared according to optimizing thehole type, of which the dry apparent density is867kg/m~3, thermal conductivity is0.21W/(m~2·K), the water absorption ratio is equal to18%and the compressive strength is5.35MPa.
The effects of masonry and equipped of brick on thermal performance ofself-thermal insulation hollow brick were tested in order to obtain the heat-transfercoefficient of hollow brick and the surface temperature of interior wall. It presents theheat-transfer coefficient of insulation masonry decreases13%compared with which ofordinary masonry whereas the heat-transfer coefficient of fired-shale hollow brickreduces12%in comparison with that of compound hollow brick, and the surface temperature of interior wall of multi-hole equipped of brick is about0.5℃highercompared with that of solid brick whereas the temperature of insulation masonry mortaris about0.4℃higher compared with that of cement mortar. According to the result, thethermal conductivity of hollow brick wall built with glazed hollow bead mortar loses20%compared with which built with cement mortar, meanwhile, it reduces8%whenequipped of brick of12holes is used instead of solid brick. The thermal performanceand building energy consumption of varied types of hollow brick masonry, masonrymortar and multi-hole brick were tested in the investigation. It demonstrates theequivalent thermal conductivities of hollow brick wall and compound hollow brick wallare0.32W/(m~2·K) and0.31W/(m~2·K) respectively, and it suits the65%of energysaving design.
引文
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