JPH0345302A - Manufacture of concrete panel using large-sized tile as concrete shuttering - Google Patents

Abstract

PURPOSE:To reduce a working space and improve waterproofing properties and peeling resistance, by a method wherein a large-sized tile and outer frame which is arranged on its circumference and comprised of a metal or ceramics are both put into a high-temperature and high-pressure iron pot for ripening. CONSTITUTION:A large-sized tile 1 is laid on the bottom and an outer frame 2 comprised of a metal or ceramics is arranged on the circumference of the said large-sized tile. In this instance, iron reinforcing rods 3, 3 are fitted to length and breadth of the outer frame 2 beforehand and ready mixed concrete is placed into a space surrounded by the large-sized tile 1 and outer frame 2. When the same is ripened by heating and pressing the same by putting into a high-temperature and high-pressure iron pot as it is fitted with the large-sized tile 1 and outer frame 2 after the same is left as it is for such an extent of time during which the concrete is semi-ripened, a concrete panel whose one side is the large-sized tile and the other side is obtained by leaving the concrete as it is placed is obtained. With this construction, since it is unnecessary to remove the concrete shuttering, labor can be saved and it becomes unnecessary to prepare a large quantity by concrete shutterings.

Description

DETAILED DESCRIPTION OF THE INVENTION (Field of Industrial Application) The present invention relates to a concrete panel using large tiles and a method for manufacturing the same.

In the present invention, the term "large tile" refers to a plate-shaped building material for decorative windows, such as walls, made of ceramics, ceramics, etc., with a long side of 60 centimeters or more.

Not only for prefabricated buildings, but also for regular wooden buildings, steel-framed concrete buildings, and reinforced concrete buildings, there is a shortage of construction workers for not only exterior and interior walls, but also walls such as bathrooms, toilets, living rooms, and kitchens. Panels of a predetermined size that are pre-produced at a factory are installed.

Regarding tiles made of unidirectional porcelain or ceramics, the manufacturing technology has significantly advanced in recent years, and recently, lightweight and large-sized ceramic tiles with long sides of 3000 mm or more and thicknesses of up to about 3 mm have been developed.

In some cases, these large tile boards have various paintings and designs drawn on them, and the colors can be chosen within a fairly flexible range. Because there are fewer joints, it is less likely to get dirty, and it also looks colder than a conventional wall made of small tiles connected by joints.
In addition to the interior and exterior of ordinary buildings, it is also used on walls in a fairly wide range of areas such as living rooms, offices, and bedrooms, and its uses are expanding.

However, when carrying such large tiles to a construction site and installing them on concrete walls, it takes a lot of effort to transport and protect them, compared to conventional small tiles. It has to be cured, and for the same reason, there is a high probability of breakage during transportation, and in the event of breakage, the damage is large.As with conventional tiles, it requires considerable effort to install on site. Currently, the use of large tiles is slowing down in terms of construction, as it requires skill and skill.

In order to solve this problem, it may be possible to combine large tiles with concrete to form a panel-shaped wall surface in advance, and then transport these panels to the construction site and install them on the building wall. . But for that,
As with conventional concrete panels, we would have created a concrete panel by pouring concrete into a formwork, then removed the mold, and then attached large tiles to the surface of the panel, which would have been twice the effort. Therefore, a manufacturing method and structure for panels that take advantage of the characteristics of large tiles are awaited.

Particularly for large tiles with long sides of 60 cm or more, if the concrete that makes up the panel develops cracks later on, the gap between the joints is large.
The cracks tend to cause cracks on the tile surface without escaping into the joints, so it is necessary to take measures to prevent this, and on the other hand, since the tiles are large, they cannot be used as they are as concrete formwork. It is necessary to take advantage of the characteristics that can be achieved.

(Means and effects for solving the problems) The present invention solves the problems of the conventional concrete panels and provides a method for manufacturing concrete panels that takes advantage of the advantages of large tiles, and a method for manufacturing concrete panels that takes advantage of the advantages of large tiles. The purpose is to provide concrete panels with tiles that are lightweight and have high peelability, which cannot be obtained by using tiles. A frame is placed, fresh concrete is poured into the area surrounded by the large tiles and the outer frame, and when the concrete is semi-ripened, the outer frame is placed in a high-temperature/high-pressure cooker and subjected to heating and pressure treatment. A method for manufacturing a concrete panel using a large tile as a formwork, characterized by aging the concrete in a mold, and a structure of a panel with large tiles made by such a manufacturing method, which allows the manufacturing process to be completed. In addition to the large amount of concrete I and formwork, the space for curing the unaged concrete placed in the formwork, and the space required for the surface treatment process,
This is a manufacturing method that is very advantageous in terms of cost, and the structure of this product is highly waterproof, convenient to use, and has a high resistance to peeling between concrete and large tiles.

(Example) The present invention will be described in detail below using examples shown in the drawings.

FIG. 1 is a partially cutaway perspective view showing the state before concrete pouring in the present invention, and as shown in the same figure,
A large tile 1 is laid on the bottom, and an outer frame 2 made of metal or ceramics is placed around the large tile.Reinforcing bars 3.3' are attached vertically and horizontally to the outer frame 2 in advance. I'll keep it.

There is no need to limit the method for installing reinforcing bars 3.3'.
If the outer frame 2 is made of metal, welding is possible, or if it is made of ceramics, a fastening hole may be provided in advance and one end of the reinforcing bar may be passed through the fastening hole and bolted. When the outer frame 2 is made of metal, the metal is usually steel, but if necessary, commonly used metals such as aluminum alloy and stainless steel may be used. Rebar 3.3'
The same applies to the material. In the embodiment shown in the drawings, a retaining element 4 is provided in advance on the back surface of the large tile. Further, as shown in the figure, there are bolt holes 5.5' at key points of the outer frame 2 for connection with adjacent panels.
An example is shown in which an embankment wall 6.6' is provided to prevent fresh concrete from entering around the bolt hole 5.5'. The reinforcing bar coupling element 4 and bolt hole 5 will be described later.

FIG. 2 is a plan view of FIG. 1, and ready-mixed concrete is poured into the space surrounded by the large tiles 1 and the outer frame 2 arranged in this way. As for ready-mixed concrete, it is not limited to normal concrete, but also various types as necessary, such as foamed concrete mixed with a foaming agent (IJ-1-1), lightweight concrete mixed with slaked lime, silica sand, etc., or GRC mixed with glass fiber, etc. Needless to say, you can choose concrete.

In this way, ready-mixed concrete is poured into
After leaving the concrete to mature for a period of time, usually about one day, the semi-ripened concrete I panel is placed in a high-temperature, high-pressure oven with the large tiles 1 and outer frame 2 still attached. It is then aged by heating and pressure.

In order to speed up the maturation of the concrete, the concrete may be stored in a room with a high room temperature of, for example, about 30 degrees Celsius, even during the above-mentioned half-ripening process.

The method of aging in a high-temperature, high-pressure cooker as described above is
Known as an autoclave, concrete is matured by heating it at about 170 degrees Celsius at 10 atmospheres and baking it for about 20 hours, but this level of heating causes almost no damage to the metal parts. Experiments have shown that as long as ordinary metal materials such as aluminum alloy, stainless steel, or brass are used, there is no risk of damage to the outer frame or reinforcing bars due to heating.

Further, even when the surface of a large tile is processed in advance by painting or the like, it is desirable to use a paint or glaze that will not be damaged by the above-mentioned high temperatures.

According to this example, a concrete panel with large tiles on one side and exposed concrete on the other side can be made, but this one side may also be a concrete panel with concrete I or exposed concrete, or it can be painted with mortar after the above process. , tiling or brickwork, painting, or other surface treatments may be applied.

(Other Examples) Although the above example shows an example in which a large tile is placed below and ready-mixed concrete is poured on top of it, the present invention is not limited to this.
For example, as shown in FIG.
0, and the elevating plate is provided with a baffle plate 11.1 as shown in the figure.
1'... Attach the corresponding baffle plate 11.11'...
Prepare a structure that can be inserted into a hole appropriately drilled in the bullet 10, and arrange the bricks 2 in a plane so that they are adjacent to each other with the baffle plate 11 in between, as shown in the figure. An outer frame 2 made of metal or ceramics, similar to the above embodiment, with only one side portion missing (the third right side) is arranged, and the back side of the large tile (bottom side in the figure) is arranged.
As shown in the figure, the locking reinforcing bars 8 were engaged between the engaging elements 3 and 3' provided on the top surface of the brick, and the outer frame 2 on the right side of the figure was removed. Pour the ready-mixed concrete with the part facing up, then attach an outer frame to one side excluding the outer frame, and let the ready-mixed concrete semi-ripen with the side with the large tiles facing down, as in the previous example. After leaving it for a long time, it can be aged in a high-temperature, high-pressure oven.

In the case of this example, as shown in the right side view in Figure 4, a concrete panel is created with large tiles on one side and bricks on the other side, and between each brick there are as shown in Figure 3. Since the baffle board intervenes only in the middle, the ready-mixed concrete gets in only up to that point, making it look like joint concrete has been filled between the bricks, but anything that is pasted on one side is usually not limited to bricks. A variety of solid wall decorative materials can be used, such as sized tiles and large tiles.

The positional relationship between the large tile 1 and the outer frame 2 made of metal or ceramics may be such that the outer frame 2 surrounds the large tile 1, as shown in FIGS. 1 and 2. However, as shown in FIGS. 3 and 4, the outer frame 2 may be placed in contact with the periphery of the large tile 1, with only a part of the thickness of the outer frame 2 protruding outside the large tile l. .

(Effects of the Invention) Since the present invention is a method for manufacturing a concrete panel as described above and a concrete panel having the structure as described above, the present invention has the following effects.

First of all, in the manufacturing method of the present invention, the large tile and the metal or ceramic outer frame placed around it are put together in a high temperature and high pressure oven and aged. Since the ceramic outer frame serves as the formwork for the concrete and forms part of the finished product, it is not necessary to remove the formwork compared to conventional methods of manufacturing concrete panels. This eliminates the need to prepare large quantities of concrete formwork, improving capital turnover efficiency, and eliminating the need for extremely bulky formwork during the curing process. Since the panels after concrete pouring can be stacked as they are and left until half-ripened, it can save a lot of space in the factory.Furthermore, since the panels can be aged in a short period of time using a high-temperature, high-pressure oven, it is possible to This saves land and eliminates the conventional decorative finishing process for panels, which improves the efficiency of capital utilization and allows high-quality panels to be obtained at low cost.

However, in order to reduce waste in terms of space and capital turnover efficiency due to leaving fresh concrete poured in the formwork for a long time as mentioned above, it is necessary to ripen the fresh concrete by early demolding. There are other methods, but in order to do this, it is necessary to increase the proportion of cement in the fresh concrete or to reduce the moisture content and pour the concrete firmly, so for early demolding,
This eliminates the freedom of material selection, such as adding a foaming agent to reduce weight as in the present invention.

Since large tiles are attached to concrete panels at a factory, it eliminates the traditional work of applying mortar to concrete walls and pasting tiles at construction sites, which frees up the hands on the tile shafts, which are lacking in manpower. There's no need to bother. In addition, because the factory production ratio is high, quality control can be improved, and processes such as concrete stirring can be standardized, which also leads to labor savings and quality improvements.

Next, looking at the structure of the concrete panel of the present invention, it is a panel with a structure in which large tiles are pasted on one side and an outer frame made of metal or ceramics is placed around it. When the outer frame is made of metal, the frames are welded together, and when the outer frame is made of ceramics, connecting bolt holes 5 are provided between adjacent panels at key points of the frame as in the above embodiment. It is also possible to allow bolts to pass through the bolt holes so that adjacent panels can be connected using nuts. Of course, in addition to bolt holes, well-known coupling elements such as locking pieces can also be used as coupling elements for connecting adjacent panels. It is also easy to connect it to iron columns.

In addition, since the panel is surrounded by an outer frame made of metal or ceramics, it is resistant to shock and distortion, and can withstand sufficient pressure and vibration, both during transportation and after it is installed in a structure. It is also an advantage of the panels of the invention that they are durable.

Furthermore, the adhesion between concrete and large tiles is achieved by pouring the fresh concrete and aging it at high temperature and pressure in a high-temperature, high-pressure pot. Unlike the method of attaching tiles with mortar after constructing a wall, the two are firmly connected, and it is expected that the risk of the tiles falling off the wall due to an earthquake or the like after being attached to a building will be greatly reduced.

Additionally, in general, concrete walls are constructed during the construction process by pouring raw funk 4 leet containing a large amount of water, and then the portion of the water that does not combine with the cement blooms and is pulled out. from,
Fatefully, distortion remains inside the wall surface, and this tends to cause cracks due to some external force, especially on concrete walls with 4J walls covered with large tiles.
Because the spacing between the joints is large, when cracks form in the concrete, these cracks tend to cause cracks in the large tiles themselves without reaching the joints, which can spoil the appearance and often cause water leaks. However, with the concrete panel of the present invention, the concrete is aged by heating and pressurizing it by placing it in a high-temperature, high-pressure oven together with large tiles, so there is less chance of moisture inside the concrete escaping after completion. The results show that both the concrete layer and the tile surface are much less likely to develop cracks later on. Moreover, both of them seem to last for a long time without peeling or bending.

In addition, as mentioned above, reinforcing bars are placed inside the panels in advance and then aged by heating and pressurizing them in a high-temperature, high-pressure cooker, so such panels not only maintain a great deal of strength from the reinforcing bars, but also retain the strength of the reinforcing bars and concrete. The bond between
It is not easy to leave. Furthermore, due to such a structure, there is less risk of the load being damaged during transportation, and therefore curing for transportation can be completed easily.

Furthermore, since the concrete panel of the present invention has large tiles attached to its surface, there are fewer joints compared to conventional sized tiles, resulting in a panel with a high -layer waterproofing effect.

As described above, the manufacturing method of the present invention takes advantage of the characteristics of large tiles, allows the large tiles to serve as formwork, thereby eliminating the troublesomeness of using formwork, etc. The structure of the concrete panel of the present invention is as follows:
The surface is made of large tiles that have been firmly attached using an autoclave, and there is a frame made of metal or ceramics around the panel, so it is extremely waterproof and strong. It can be said that it is excellent.

[Brief explanation of drawings]

FIG. 1 shows a state in which a frame made of metal or ceramics with reinforcing bars attached inside is arranged around a large tile in order to manufacture a concrete panel using a large tile as a formwork in which the present invention can be carried out. FIG. 2 is a plan view of FIG. 1; FIG. 3 is a conceptual side view showing a state in which large tiles, an outer frame, and bricks are combined in another embodiment; 4 is a side view of the concrete panel in the latter embodiment with the concrete portion removed. In the figure 1. ...Large tiles 2. ...Outer frame made of metal or ceramics 3.3'...Reinforcement bar No. 1 Fig. Fig. Whistle Fig. Fig. Flat bottom November 4, 1 year

Claims (2)

[Claims] (1) An outer frame made of metal or ceramics with reinforcing bars installed inside is placed around the large tile, and ready-mixed concrete is poured into the area surrounded by the large tile and the outer frame. A method for producing a concrete panel using a large tile as a formwork, characterized by aging the concrete by placing the large tile and the outer frame together in a high-temperature, high-pressure pot at a semi-ripened stage and subjecting the concrete to heat and pressure treatment. . (2) An outer frame made of metal or ceramics with reinforcing bars installed inside is placed around the large tile, concrete is poured into the area surrounded by the large tile and the outer frame, and this is pressurized and heated. Construction of a concrete panel with large tiles made by treating and aging said concrete.