JPH04191004A - Manufacture of cellular concrete panel - Google Patents

Abstract

PURPOSE:To manufacture a cellular concrete panel of good coating properties by adding metal salt of higher aliphatic acid to a release agent and adjusting the viscosity of cellular concrete slurry to a specified value by means of flow value. CONSTITUTION:A pattern sheet 13 is placed with its release agent 12 side facing up in a mold 11 for forming. The release agent 12 is composed of oil, and aluminum stearate as metal salt of higher aliphatic acid is added to the release agent 12. Light cellular concrete slurry 17, the ratio of water/cement of which is adjusted to make the flow value 150-170mm is placed in a mold 11. The concrete slurry 14 is cured for the given time and then hardened primarily, and a formed panel is autoclave cured in an autoclave. Cells 16 in the slurry 14 are brought into contact with the release agent 12 and broken on the surface side of a panel 15, and the width of an opening 18 of a recess 17 is largest, and the width gets narrower as it goes inwardly. A coating material 19 infiltrates well into the recess 17, and films of uniform thickness are formed continuously.

Description

DETAILED DESCRIPTION OF THE INVENTION [Industrial Field of Application] The present invention relates to a method for manufacturing aerated concrete panels having patterns formed on their surfaces.

[Background Art] In recent years, lightweight aerated concrete panels have been used as wall panels for prefabricated unit houses.

Lightweight aerated concrete panels like this with patterns formed on the surface are made by placing a patterned sheet coated with a release agent in a molding frame, and then using a slurry mainly made of cement and silica sand. Add foam to the foam and pour it into the formwork,
- It is manufactured by curing and curing to form a panel, after which the panel is placed in an autoclave and steam-cured under high temperature and high pressure.

The manufactured panels are painted or coated to make them waterproof.

[Problems to be Solved by the Invention] In the production of the above-mentioned conventional lightweight cellular concrete panels, when pouring concrete slurry into formwork, air bubbles in this concrete slurry are released into the release material applied to the patterned sheet. If it comes into contact with it, it may break partially.

As a result, on the surface of the panel after being demolded, fine depressions due to partially broken air bubbles are formed on the entire surface of the panel.

Such depressions may be of various shapes, or may be only a part of the upper surface of the bubble 1 or a broken depression 2, as shown in FIG.
In the case of , the width of the opening 3 is narrower and wider near the center of the interior. When painting the formed panel 4, as shown in FIG. 7, the paint 5 applied to such depressions 2 caused the following problems after drying.

That is, as shown in FIG. 8, when the coating film 6 is thin,
During drying, holes 7 are formed in the coating film 5 on the openings 3, and since the film 5 is not formed inside, in these depressions 2, moisture can enter the interior and the waterproofing effect of the coating cannot be obtained. It is to disappear.

Moreover, as shown in FIG. 9, if the coating film 6 is thick,
During drying, the coating film 6 on the opening 3 swells, impairing the appearance, and if the coating film 6 in the swollen portion is torn, a waterproofing problem also arises.

SUMMARY OF THE INVENTION An object of the present invention is to provide a method for manufacturing aerated concrete panels that provides good paintability.

"Means for Solving the Problems" The present invention provides a method for producing aerated concrete panels in which aerated concrete slurry is poured into a molding frame coated with a mold release agent, in which the mold release agent is coated with a higher fatty acid. metal salt is added thereto, and the viscosity of the aerated concrete slurry is adjusted to a flow value of 150-170 mm.

Examples of the metal salts of higher fatty acids include aluminum stearate, zinc stearate, calcium stearate, barium stearate, and magnesium stearate.

The amount of the higher fatty acid metal salt added to the mold release agent is determined to be an appropriate amount such that when the bubbles come into contact with the mold release agent, most of the bubbles are destroyed and a nearly flat depression is formed.

The flow value is based on a cement paste (Portland cement) hardness (consistency) test method specified in JIS R5201.

If the flow value is less than 150 mm, the bubbles near the slurry surface will not be destroyed well;
Moreover, if it is larger than 170 cm, even the air bubbles inside the slurry will be destroyed.

The flow value of the slurry can be adjusted by, for example, adjusting the water/cemen ratio; adding a viscosity modifier to the foaming agent;
■This can be done by increasing the slurry temperature, etc.

For example, when forming a pattern on a panel through a pattern sheet, the release agent is applied to the pattern sheet I. For flat panels, it is applied directly into the formwork.

The cellular concrete 1-panel includes a pressure-cured cellular concrete panel and an autoclave-cured cellular concrete panel.

[Function] By adding the metal salt of higher fatty acid according to the present invention to the mold release agent, the air bubbles in the slurry that come into contact with the mold release agent during slurry pouring are almost completely destroyed, forming almost flat depressions. arise. As a result, during painting, the paint completely penetrates into the recesses, so waterproofing failures due to incomplete painting will not occur. In addition, since the viscosity of the aerated concrete slurry is adjusted to a flow value of 150 to 170, the collapse of the bubbles when the slurry comes into contact with the mold release agent is caused by the bubbles in the slurry in the part that came into contact with the mold release agent. It does not affect air bubbles inside the retaining panel.

[Example] An example in which the present invention is applied to a method for manufacturing an autoclave-cured lightweight cellular concrete panel will be described.

First, as shown in the enlarged views of FIGS. 1 and 2, a patterned sheet 13 coated with a mold release agent 12 is placed in a molding frame 11 with the mold release agent 12 side facing upward. This mold release agent 12
The mold release agent 12 is made of oil, and aluminum stearate, which is a metal salt of higher fatty acid, is added to the mold release agent 12.

Next, as shown in the figure, a lightweight aerated concrete slurry 14 whose flow value is set to, for example, 160 mm by adjusting the water/cement ratio is poured into the formwork 11. Thereafter, the concrete slurry 14 is cured for a predetermined period of time to temporarily harden the concrete slurry 14.

Next, the molded panel is transported into an autoclave (not shown) and subjected to autoclave curing, for example, at 180° C., 110 atmospheric pressure, and for 4 hours. After completion of this autoclave curing, the panel is removed from the autoclave.

As shown in FIG. 3, on the surface side of the obtained panel 15 on which the pattern is formed, a depression 17 formed after the bubbles 16 in the slurry 14 contact with the mold release agent 12 and break is formed at the opening I8. The width is the widest, and the width gets narrower towards the inside.

Next, as shown in FIG.
Paint is applied by spray coating, etc. As shown in the figure, since the recess 17 has a shallow dish-shaped cross section, the paint 19 can easily penetrate into the inside of the recess 17.

Next, as shown in FIG. 5, the panel 15 is dried to obtain a lightweight cellular concrete panel 15 according to this embodiment.

As shown in the figure, this panel 15 has a coating film 20 formed continuously and uniformly in thickness even in the areas where the bubbles 16 or the depressions 17 are broken.

According to the method for manufacturing the autoclave-cured lightweight cellular concrete panel 15 according to the present example described above, the mold release agent 12
By adding aluminum stearate, which is a metal salt of higher fatty acids, the air bubbles 1 of the slurry 14 that came into contact with the mold release agent 12 when pouring the slurry 14 into the mold 11 are removed.
6 is almost completely broken and a nearly flat depression 17 is formed. As a result, when mounting the molded panel ■5, the paint 19
Since it completely enters into the depression I7, a continuous coating film 20 with a uniform thickness is formed after drying. Therefore, according to this embodiment, waterproofing defects due to incomplete coating do not occur, and the quality of waterproofing can be stabilized.

In addition, in this embodiment, concrete slurry 14
Since the viscosity of the slurry 14 is adjusted to around 160 mm in terms of flow value, the breakage of the bubbles 16 when the slurry 14 comes into contact with the mold release agent 12 of this example is due to the viscosity of the slurry 14 in the part in contact with the mold release agent 12. The air bubbles 16 remain in the air bubbles 16 and remain inside the panel 15.
It doesn't come close to that. Therefore, regarding the air bubbles 16 inside the panel 15, a lightweight cellular concrete panel 15 is obtained in which the air bubbles 16 are formed in the conventional number and size.

In the above example, aluminum stearate, which is a metal salt of higher fatty acid, was added to the mold release agent 12, but other materials such as zinc stearate, calcium stearate, barium stearate, magnesium stearate, etc. may be added. Further, any mixture of these may be added.

Further, in the above embodiment, an example of manufacturing an autoclave-cured cellular concrete panel 15 was described, but the cellular concrete panel of the present invention may be an ordinary pressure-cured cellular concrete panel.

Furthermore, the present invention is not limited to the case of a panel with a pattern formed thereon, but can be similarly applied to the case of a flat panel without a pattern.

[Effects of the Invention] According to the method for manufacturing a cellular concrete panel according to the present invention, the paintability of the paint is improved, so that a cellular concrete panel with excellent waterproof properties can be obtained.

[Brief explanation of drawings]

Figure 1 is a cross-sectional view showing a method for manufacturing a lightweight aerated concrete panel according to an embodiment of the present invention, Figure 2 is an enlarged cross-sectional view of the main part of Figure 1, and Figure 3 is an enlarged view of the main part of the formed panel. 4 is an enlarged sectional view of the main part of the panel immediately after painting, Fig. 5 is an enlarged sectional view of the main part of the panel after the paint has dried, and Fig. 6 is an enlarged sectional view of the main part of the panel obtained by the conventional manufacturing method. Figure 7 is an enlarged cross-sectional view of the main part of the panel immediately after painting, and Figures 8 and 9 are enlarged cross-sectional views of the main part of the panel after the paint has dried. . 11... Molding frame, 12... Mold release agent, 13...
pattern sheet, 14...slurry, 15...panel,
16... Air bubbles, 17... Hollows, 18... Openings,
19... Paint, 20... Paint film. Applicant Misawa Homes Co., Ltd.

Claims (1)

[Claims] (1) A method for producing aerated concrete panels in which aerated concrete slurry is poured into a molding frame coated with a mold release agent, wherein a metal salt of a higher fatty acid is added to the mold release agent, and the aerated concrete slurry The viscosity of the flow value is 150 to 1
A method for manufacturing an aerated concrete panel characterized by adjusting the thickness to 70 mm.