JPH0242325B2 - - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION "Field of Industrial Application" The present invention relates to a method for producing a lightweight cellular concrete panel having through holes in the surface direction of the panel that serve as spaces for wiring, piping, heating ventilation passages, etc.

``Prior art'' When forming lightweight aerated concrete panels (hereinafter referred to as concrete panels) used in the panel construction method through factory production, a considerable amount of foam is added to concrete slurry (fluid mixture), and the foam is placed in a forming form. It is known to carry out a method in which the framework is covered with a framework provided in the interior, and the framework is first hardened, and after being removed from the mold, it is pressurized and heated in an autoclave, and then steam-cured.

By the way, when it becomes necessary to install electrical wiring or various types of piping along the walls of a house constructed using the concrete panels, conventionally, the internal space of the steel frame to which the concrete panels are attached is used. It was by the same means. This is because it is difficult to form long holes for electrical wiring or piping inside the concrete panel along the width direction or the surface direction such as the vertical direction. The reason for this is that the framework is installed inside the concrete panel, and this framework becomes an obstacle to the formation of through holes.If long through holes are cut, there is a risk of cracking in the concrete panel, and the wiring This is because it is difficult to form through holes that face in the required direction according to the direction of the pipes and pipes by cutting from the outside of the concrete panel.

Therefore, conventionally, in houses using this type of concrete panel, wiring and piping cannot be installed directly inside the concrete, which creates restrictions on the positions where outlet boxes and gas pipe outlets can be formed. There was a problem.

In addition, when forming the concrete panel,
When pouring the aerated concrete slurry into the forming formwork, it is possible to expose the ends in advance and install wiring and piping, but since the location of the concrete panels in the building is unspecified, factory-produced panels In addition to being extremely wasteful, there is a problem in that the wiring and piping parts may be damaged by steam curing under high temperature and pressure in an autoclave, making it impractical.

``Object of the Invention'' The present invention has been made in view of the above-mentioned circumstances, and it is possible to simultaneously form through holes along the surface direction of the concrete panel inside the concrete panel at the time of panel molding, and thereby, The purpose of the present invention is to provide a method for obtaining a concrete panel that allows internal wiring and piping.

"Means for Solving the Problems" The present invention covers the outer periphery with a melting tube that melts at the temperature during autoclave curing, and has a diameter that is approximately the same as the diameter of the through hole necessary for wiring, piping, etc. A flexible rod is prepared, and a conditioning material made of mortar or the like that is compatible with the lightweight aerated concrete slurry is interposed between it and the framework in the molding cavity before the aerated concrete slurry is poured. The panel base is formed by pouring aerated concrete slurry, and the rods are pulled out before or after autoclaving to form through holes.

"Operation" By inserting a flexible rod and pouring concrete slurry, it is possible to form a hole of any shape, and the flexible rod makes it easy to pull out.

"Embodiment" Figures 1 to 6 show an embodiment of the present invention, and 1 in Figure 1 shows a box-shaped molding frame with an open top. Molding cavity S
As shown in FIG. 2, etc., a frame 2 is disposed, which is constructed by arranging antirust-treated steel angle members 2a and steel reinforcing bars 2b. The above-mentioned forming cavity S is a concrete panel (lightweight cellular concrete panel) P manufactured by the method of the present invention.
The frame 2 is formed into a flat rectangular parallelepiped by having a pair of lattice-structured reinforcing bars 2b facing each other and connecting the ends of the reinforcing bars 2b to angle members 2a. This frame 2 is buried in the concrete panel P to reinforce the concrete panel P.

To manufacture concrete panel P, first,
Set the internal wiring position or internal piping position of the concrete panel P in advance,
In order to form a through hole T that fits the position, flexible rods 3 having a rectangular or circular cross section are prepared (two rods are shown in the drawing). This rod 3 has a core material 3A such as wire.
It consists of an inner peripheral part 3B that covers this core material 3A, and a melting tube 3c that covers the outer periphery of this inner peripheral part 3B, the length of which is equivalent to the length of the through hole T. It is set. The inner peripheral portion 3B is made of a flexible material such as rubber, foamed polyethylene, foamed polystyrene, foamed polystyrene, etc., and is preferably made of a material whose volume decreases at the steam curing temperature in the autoclave device 7, which will be described later. It is formed. In addition, melting tube 3c
is made of a material that melts at a steam curing temperature (for example, 150 to 180°C) in an autoclave device 7, which will be described later, and a thickness of about 0.3 mm is sufficient. The outer diameter of the melting tube 3c is made substantially the same as the inner diameter of the through hole T, and the melting tube 3c
A mold release agent is applied to the inner surface of c as necessary. Then, these rods 3 are installed at the positions where the through holes T are to be formed. For this installation, as shown in Fig. 3, each part of the rod 3 is tied to a predetermined position of the reinforcing bar 2b of the frame 2 using threads 4 so that the rod 3 does not move when pouring concrete slurry. In order to avoid contact between the rod 3 and the reinforcing bars 2b, an adjusting member 5 is interposed between the rod 3 and the reinforcing bars 2b during binding. The conditioning material 5 is preferably made of mortar or the like, which is compatible with the concrete slurry described later. Note that the end portion 3a of the rod 3 is installed at a position close to the inner surface of the mold frame 1.

After the installation of the rod 3 is completed, aerated concrete slurry (a conventionally known slurry made by adding a considerable amount of foam to a fluid mixture whose main ingredients are cement and silica sand) is poured into the molding cavity S of the molding form 1. and leave it for the specified time. Note that by pouring the aerated concrete slurry, the rod 3 is completely buried in the aerated concrete slurry. If the poured aerated concrete slurry is left to stand, it will gradually harden, but before it completely hardens, the ends 3a of the rods 3 will bend to the ends of the panels as shown in FIG. If the rod 3 is installed close to the rod 3, drill a hole 8 in the semi-hardened aerated concrete slurry around it.
Each end 3a of is left exposed. After this operation, the aerated concrete slurry is completely hardened (primary hardening) to form a panel base P ₁ , and this panel base P ₁ is removed from the forming form 1 . Here, a through hole T into which the rod 3 is inserted is formed inside the panel base _P1 .

Next, a plurality of panel substrates _P1 formed by performing operations similar to those described above are put together and pre-cured by the pre-curing device 6. This pre-curing device 6 holds the panel substrate _P1 in a steam atmosphere under normal pressure.

After pre-curing for a predetermined period of time, the panel substrate _P1 is carried into the autoclave device 7,
High temperature (e.g. 150-180℃) and high pressure (e.g. 10Kg/
cm ² ) in a steam atmosphere for several hours (for example, 6 hours) to convert the panel substrate P ₁ into a concrete panel P. At this time, the panel base
As P ₁ is heated, the melting tube 3c on the outer periphery of the rod 3 melts and is fused and impregnated into the surrounding concrete panel P. This impregnation occurs because there are many air bubbles inside the concrete panel P, and the molten tube 3c penetrates into these air bubbles. When the molten tube 3c is fused and impregnated into the concrete panel P, a gap D is created between the inner peripheral part 3B of the rod 3 and the inner peripheral surface of the through hole T, as shown in FIG. .

When the steam curing process is completed, take out the concrete panel P from the autoclave device 7 and open the hole 8.
When the end of the rod 3 inside is pulled and the threads 4 are torn off and the rod 3 is pulled out as shown in FIG. 6, a through hole T appears inside the concrete panel P. Note that when the rod 3 is pulled out, the melting tube 3c is melted away and a gap D is formed between the outer peripheral surface of the inner peripheral portion 3B of the rod 3 and the inner peripheral surface of the through hole T. Furthermore, since the inner circumferential portion 3B itself is melted and shrunk by heating at the steam curing temperature, the mold release effect is good and the rod 3 can be easily pulled out. Note that a part of the adjustment material 5 is exposed at several places on the inner circumferential surface of the through hole T, but the adjustment material 5 is made of a material that is compatible with the aerated concrete slurry and is therefore integrated into the concrete panel P. . In addition, without using this adjustment material 5, the rod 3 is directly attached to the reinforcing bar 2b,
If they are tied together to form a concrete panel, the reinforcing bars 2b will be exposed on the inner peripheral surface of the through hole T, which will cause a problem in terms of rust prevention of the reinforcing bars 2b. Therefore, the adjustment material 5 prevents the reinforcing bars 2b from being exposed and ensures an appropriate cover thickness.

The through hole T formed as described above can be used as a space for electrical wiring such as indoor electrical wiring or TV wiring, or as a space for flexible gas pipes, refrigerant distribution pipes for air conditioners, hot water pipes for central heating, etc. It can be used as a space for piping. A part of the molten tube 3c melted as described above hardens to cover the inner peripheral surface of the through hole T, and in order to smooth the inner peripheral surface of the through hole T, wiring and piping are provided in the through hole T. In this case, the wire rod tube slides easily within the through hole T, improving work efficiency.

Moreover, since the rod 3 is flexible, it can be bent freely in a desired direction when tying it to the reinforcing bars 2b. Therefore, the through holes T can be formed to suit various wiring routes or piping routes. Further, in the above case, the rod 3 is pulled out after the autoclave, but if it has excellent mold releasability and is convenient for the panel manufacturing process, it may be pulled out before the autoclave. It can be achieved.

Further, in this example, if the core material 3A is formed into an irregular shape such as a spiral shape or a zigzag shape at a proper location, the grip on the inner circumferential portion 3B will be better. In addition, in consideration of pulling out after autoclaving, the rod 3 is preferably one that shrinks at the autoclave temperature, as described above, but it is not limited to this, as long as it is made of silicone rubber or other material with good mold release properties.
There is no problem even if the core material 3A is omitted.

In addition, when the concrete panel P is installed as a wall of a house, one opening of the through hole T opens slightly above the floor, and the other opening of the through hole T opens near the ceiling. Through hole T opens to
If a ventilation fan and a heater are further provided inside the through hole T, the through hole T can be used as a heating air passage.

In this case, indoor air is drawn into the hole T through the opening above the hole T, heated by the heater, and then heated air is blown out from the opening below the hole T. It can heat the room while circulating air. In this case, since the concrete panel P has a large heat capacity, the concrete panel P can be used as a heat storage wall,
For example, if heat is stored in the concrete panel P during the day, heat radiation will gradually occur from the concrete panel P at night, and the heating effect can be exerted for a long time. In addition, since the concrete panel P is an insulator, the heater can be installed safely.
The concrete panel P can be used as a heater storage body, resulting in effective space utilization. Further, the shape of the adjusting member 5 may be arbitrary as long as it avoids direct contact between the rod 3 and the reinforcing bar 2b, for example, it may be in the shape of a block. Furthermore, the melting tube 3c can be replaced with a coating layer formed on the outer surface of the inner peripheral portion 3B.

"Effects of the Invention" As explained above, the present invention provides a flexible tube whose outer periphery is covered with a melting tube that melts at the temperature during autoclave curing, and whose diameter is approximately the same as that of the required through hole. A rod is prepared, and this rod is supported by the framework in the molding frame with a conditioning material made of lightweight aerated concrete slurry and compatible mortar interposed between it and the framework, and placed in the desired position. Next, aerated concrete slurry is poured into the molding form and cured to form the panel base, and then the rods are pulled out before or after steam curing at high temperature and pressure in an autoclave. Therefore, since a through hole is formed, a long through hole can be formed along the surface direction of the concrete panel. Therefore, according to the method of the present invention, it is possible to obtain a concrete panel that has a through hole for wiring or piping inside, and has the effect of making wiring or piping to the concrete panel possible. Further, the present invention is characterized in that the rods are supported by the framework with a conditioning material such as mortar that is compatible with lightweight aerated concrete slurry interposed between the framework and the rods. After the body is pulled out, a predetermined covering thickness is ensured between the through hole and the frame using an adjusting material.
Moreover, no skeleton is exposed in the through hole,
Another advantage is that the frame will not corrode and the strength of the concrete panel will not be compromised.

Furthermore, in the present invention, the installation of the rod is a work of attaching various parts of the rod to a framework with adjustment material interposed, so the rod is routed in various directions to form a freely shaped through hole. Even if the rod is installed using a frame, the rod can always be supported within the formwork by attaching it using the framework, which has the advantage of simplifying the installation process and improving work efficiency. be. Further, since the rod has flexibility, it can be easily pulled out from the through hole, and there is an effect that a through hole that matches the routing route of wiring and piping can be easily formed. Furthermore, the melting tube provided on the outer periphery of the rod is melted by heating with an autoclave device, and is fused and impregnated into the concrete panel, so that the outer periphery of the inner periphery of the rod and the inner periphery of the through hole are bonded. Since a gap is formed between them, the rod can be easily pulled out. Note that a portion of the molten coating tube covers the inner circumferential surface of the through hole, making the inner circumferential surface of the through hole smooth and preventing the wire rod or tube from slipping when wiring or piping is installed in the through hole. This has the effect of improving workability.

[Brief explanation of drawings]

Figures 1 to 6 show one embodiment of the present invention. Figure 1 is a schematic perspective view showing the manufacturing process of a concrete panel, and Figure 2 is a plan view showing how the rods are attached to the frame. , FIG. 3 is a sectional view of the panel base, FIG. 4 is a cross-sectional view of the panel base, FIG. 5 is a sectional view of the concrete panel, and FIG. 6 is a sectional view showing the rod in a pulled out state. 1... Molding formwork, S... Molding space, 2... Frame, P... Lightweight aerated concrete panel (concrete panel), P ₁ ... Panel base, 3... Rod body, 7... Autoclave device, T...Through hole, 3
a...End part, 3A...Core material, 3B...Inner peripheral part, 3
C...Melting tube.

Claims (1)

[Scope of Claims] 1. A framework is placed in a molding cavity within a molding frame, and a foamed concrete slurry is poured into the molding cavity to cover the framework and hardened to form a panel base within the molding frame. A method for manufacturing a lightweight cellular concrete panel in which the panel base is removed from the molding form and steam-cured at high temperature and pressure in an autoclave, the outer periphery being covered with a melting tube that melts at the temperature during autoclave curing. In addition, prepare a flexible rod having approximately the same diameter as the diameter of the required through hole, and use mortar, etc. that is compatible with the lightweight foamed concrete slurry in the molding cavity before pouring the foamed concrete slurry. The above-mentioned rods are supported by the framework with a conditioning material consisting of: A method for manufacturing a lightweight aerated concrete panel having through holes, the method comprising: pulling out a rod to form through holes in the surface direction of the panel.