Thermal-insulated exterior wall boards, dedicated molds and making methods thereof

A method of making a lightweight composite thermal-insulated exterior wall board comprising:

• a thermal-insulated core board provided with a plurality of throughout-length thermal-insulated core board ribs,
• a reinforcement mesh on both sides of the thermal-insulated core board,
• a concrete layer that is cast on the reinforcement mesh and is provided with a plurality of concrete ribs interlaced with and matching the thermal-insulated core board ribs, and
• a shear-resistant connector connected with the reinforcement mesh that is inserted between adjacent thermal-insulated core board ribs, an angle between the shear-resistant connector and a horizontal plane of the thermal-insulated core board being 45°, concrete ribs for wrapping being only provided on part of the shear-resistant connector,
• the method comprising:
• step 1:
• calculating parameters:
• according to actual project requirements, by comprehensively considering service conditions including wind loads, seismic actions and temperature stress loads, calculating and determining a size of the thermal-insulated core board and the concrete layer, and determining cross-section forms of the thermal-insulated core board ribs and the concrete ribs;
• step 2:
• making the thermal-insulated core board:
• according to the calculated size of the thermal-insulated core board and the cross-section form of the thermal-insulated core board ribs, making a thermal-insulated material into the thermal-insulated core board or customizing the thermal-insulated core board from a factory;
• step 3:
• binding a reinforcement mesh truss core board:
• inserting the shear-resistant connector between the adjacent thermal-insulated core board ribs, and determining a distance between the reinforcement mesh and the thermal-insulated core board, and then connecting the reinforcement mesh with the shear-resistant connector to form the reinforcement mesh truss core board;
• step 4:
• disposing a dedicated mold for making the lightweight composite thermal-insulated exterior wall board comprising a bottom template, two mutually parallel end templates including a first end template and a second end template, and two mutually parallel vertical templates including a first vertical template and a second vertical template, the vertical templates and the end templates being respectively connected with four sides of the bottom template:
• firstly disposing the bottom template, and then fixing the first vertical template and the first end template respectively to two mutually perpendicular sides of the bottom template;
• step 5:
• positioning the reinforcement mesh truss core board:
• firstly placing the reinforcement mesh truss core board sidewise into the bottom template and the first vertical template that have been fixed, and arranging the thermal-insulated core board ribs vertically, and then controlling a distance between the reinforcement mesh truss core board and the first vertical template according to a thickness of the concrete layer;
• step 6:
• disposing the second vertical template and the second end template on the other side:
• fixing the second vertical template on the bottom template, and under the premise of ensuring that a net size in the dedicated mold is respectively thickness, height, and width of the lightweight composite thermal-insulated exterior wall board, and finally fixing the second end template to the bottom template;
• step 7:
• pouring the concrete layer:
• pouring the concrete from top to bottom above the dedicated mold, and after pouring, leveling a surface of the concrete layer, and then curing;
• and
• step 8:
• demolding:
• after the concrete reaches an expected strength, demolding the lightweight composite thermal-insulated exterior wall board.