Prefabricated Special-Shaped Assembled Houses

Prefabricated special-shaped assembled houses are an efficient solution for constructing buildings with complex shapes using a modular approach. Their core lies in achieving precise prefabrication and rapid assembly of special-shaped components through innovative formwork technology.

1. Prefabrication Technology for Special-Shaped Components

The key to prefabricated special-shaped assembled houses lies in the manufacturing of components with complex shapes. For example, the prestressed fish-belly integral prefabricated roof truss for the skylight of the medical technology building at a certain central hospital is entirely prefabricated using UHPC (Ultra-High Performance Concrete). Its chord members are designed in a spindle shape with a cross-sectional thickness of 250mm, incorporating complex geometric forms that combine curved and flat surfaces. This design breaks through the regular constraints of traditional concrete components but also poses higher demands on formwork technology: traditional steel formwork is difficult to meet the construction requirements for special-shaped components due to its high manufacturing difficulty, long cycle time, and high cost.

2. Innovative Application of Polymer Material 3D-Printed Formwork

To address the limitations of traditional formwork, such projects adopt a polymer material 3D-printed formwork solution. Its core advantages include:

• Modular Disassembly: The formwork is disassembled into components with a maximum size of 2m, with each piece weighing less than 25kg, allowing for manual operation without the need for lifting equipment and significantly enhancing construction flexibility.
• Anti-Deformation Design: Stability during concrete pouring is ensured through methods such as upper-edge fixation, mid-span formwork fixation, U-clip restraint, and right-angle fastener connections, preventing deformation that could affect component precision.
• Surface Treatment Process: A combination of grinding and filling is used to treat the inner surface of the formwork, eliminating the layered textures from 3D printing and ensuring a smooth surface for the concrete after molding, meeting both architectural aesthetic and functional requirements.

3. Construction Process and Modular Advantages

The construction process for prefabricated special-shaped assembled houses covers formwork design, assembly, reinforcement, and inner surface treatment, culminating in the completion of the overall structure through on-site assembly. This process embodies two core advantages of modular construction:

• Efficiency: 3D-printed formwork can be manufactured quickly, shortening the production cycle for special-shaped components; modular design reduces on-site work volume, enhancing construction efficiency.
• Flexibility: The standardized and lightweight design of formwork components allows them to adapt to the needs of components with various complex shapes, providing technical support for the diversification of architectural design.

In conclusion, through material and process innovations, prefabricated special-shaped assembled houses achieve high-precision, low-cost manufacturing of components with complex shapes, offering an important path for modern architecture to develop towards personalization and efficiency.