JPH10158077A - Production of lightweight cellurar concrete panel - Google Patents

Abstract

PROBLEM TO BE SOLVED: To prevent defects in a half-hardened panel when the panel is transferred for the production of a panel having a high density part inside by pressing the panel during the panel is half hardened, by attaching a base plate and side plates to a half-hardened panel having specified compression strength and then pressing with a pressing die. SOLUTION: A bottom plate 3 and side plates 2 which regulate the thickness of the product are attached to faces of a half-hardened panel except for the pressing surface. Then the panel is pressed by a pressing die 4. This panel has 1.9 to 5.0kgf/cm<2> compressive strength, preferably 2.2 to 4.5kgf/cm<2> , and more preferably 2.5 to 4.0kgf/cm<2> and is prepared, for example, by aerating a mortar slurry containing silica stone, lime stone, cement, dry gypsum, aluminum powder and water, injecting the slurry into a die, ageing and cutting when the injected slurry is hardened to such hardness proper for cutting.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for producing lightweight cellular concrete in which a high specific gravity portion formed by pressing during semi-curing exists inside a panel.

[0002]

2. Description of the Related Art In recent years, there has been an increasing demand for lightweight cellular concrete panels which are excellent for design students, and various methods for forming a pattern on the surface of the lightweight cellular concrete panel have been proposed. Among them, there is a method of cutting a semi-cured cellular mortar block into a panel shape and pressing a mold having an uneven pattern against the panel surface to form a pattern (Japanese Patent Publication No. 5-34121). According to this method, a freely designed pattern can be provided on the panel surface. Further, when the uneven pattern is pressed against the panel surface, a high specific gravity portion is formed inside the panel, so that there is an advantage that the high specific gravity portion reinforces the panel.

[0003] However, in the above method, the hardness of the semi-cured panel at the time of forming the concavo-convex pattern is limited to a relatively low level. There is a restriction that the pressing process must be performed in the state. For this reason, in the step of transferring the panel cut from the cellular mortar block to the step of pressing the panel, or the step of transferring the pressed panel to the curing step, or the like, in the step of moving the semi-cured panel, the panel is damaged or broken. There is a problem that occurs frequently, which causes a significant decrease in productivity.

SUMMARY OF THE INVENTION It is an object of the present invention to provide a method capable of preventing a defect in a moving step of a semi-cured panel and producing a lightweight cellular concrete having a high specific gravity portion formed therein by pressing with high productivity. Is what you do.

[0005]

SUMMARY OF THE INVENTION The present invention is a method of manufacturing a lightweight cellular concrete panel in which a high specific gravity portion formed by pressing during semi-curing exists inside the panel.
A semi-cured panel having a compressive strength in the range of 9 kgf / cm2 to 5.0 kgf / cm2 is applied to a surface other than the surface for pressing the backing plate and the side plate for defining the product thickness, and then pressed by a pressing die. This is a method for manufacturing lightweight cellular concrete panels.

Further, the compressive strength of the semi-cured panel is 2 to 1
The above-mentioned manufacturing method of pressing with a pressing die at a pressure of 0 times is more preferable.

[0007]

BEST MODE FOR CARRYING OUT THE INVENTION The semi-cured panel used in the present invention can be obtained, for example, by cutting a semi-cured cellular mortar block using the following raw materials into a panel shape. As a method of cutting the semi-cured cellular mortar block into a panel shape, a method used for cutting ordinary lightweight cellular mortar can be used. For example,
Use a method of cutting a semi-cured lightweight cellular mortar block with a wire material such as a piano wire or the like to obtain a plurality of panel-shaped semi-cured products using a plurality of strained wiring materials. You can also.

The raw material of the cellular mortar block is not particularly limited as long as it is generally used as lightweight cellular concrete. For example, a mortar slurry containing silica stone, cement, quicklime, water as a main raw material, gypsum, crushed debris, and the like added as necessary, and further mixed with air bubbles can be used. As a method of mixing air bubbles into the foam mortar block, a method of mixing a foaming agent into a mortar slurry to cause foaming may be used, or a method of mixing air bubbles previously foamed into the mortar slurry may be used.

When the foam mortar slurry thus obtained is poured into a mold in which reinforcing bars are arranged in advance, cured, and has a hardness suitable for cutting, it is removed from the mold to obtain a semi-cured cellular mortar block. be able to. This semi-cured block is cut into a predetermined thickness to form a panel to obtain a semi-cured panel. The semi-cured panel is moved into a plurality of side plates 2 surrounding the semi-cured panel 1 as shown in FIG. 1 by a vacuum transfer device (not shown), and is further shown in FIG. A surface other than the upper surface is fixed as in such a cross section. Thereafter, a high specific gravity portion 5 is formed by pressing the upper surface with a pressing die 4 having an uneven surface provided on the panel surface, and crushing bubbles near the uneven portion formed by the pressing die 4 therein.
A lightweight cellular concrete panel having a black portion (shown in the figure) is obtained, and the presence of the high specific gravity portion 5 can prevent a decrease in the strength of the entire panel.

Since the hydration reaction of a semi-cured panel progresses in a relatively short time, the pressure required for pressing changes, and it is difficult to determine the product thickness by the pressure at the time of pressing. Since the thickness is determined by the size of the side plate, it is possible to mold the semi-cured panel with high thickness accuracy. For example, as shown in FIG. 1, the height of the side plate 2 is set to be equal to the sum of the thickness of the product and the thickness of the die 4, and the semi-cured panel 1 placed in a portion surrounded by the four side plates 2 Can be formed by sandwiching the plate 3 and the pressing die 4 from above and below. At this time, the mold is lowered at a position where the surface (not shown) for pressing the die 4 hits the upper surface of the side plate 2 (the position where the upper surface of the die 4 becomes the same surface as the upper surface of the side plate 2 as shown in FIG. 1). Stops, and a product having a predetermined thickness is manufactured with good reproducibility.

In the above example, the pressing die 4 has a size that fits within the quadrilateral surrounded by the four side plates 2, but the pressing die 4 is smaller than the quadrilateral surrounded by the four side plates 2. If the size is increased, the lowering of the pressing die 4 stops at a position where the lower surface of the pressing die 4 comes into contact with the upper surface of the side plate 2, so that a product having a thickness equal to the height of the side plate 2 can be accurately formed. The high specific gravity portion in the present invention is a portion formed by crushing bubbles when pressed, has the same composition as other portions except for the presence or absence of bubbles, and is completely integrated with the surroundings.

The pressing die pressed against the semi-cured panel is not particularly limited as long as a high specific gravity portion is formed inside the panel by pressing. A mold in which a plurality of linear irregularities for forming ribs are continuous, or a mold having many square, circular, or hemispherical convex portions can be used.

[0013] The compressive strength of the semi-cured panel when it is transferred and pressed against the mold is 1.9 kgf / cm2 to 5 kgf / c as measured by the measurement method specified in JIS A5416.
m2. This value corresponds to a value of 3.8 kg / cm2 to 10.0 kg / cm2 measured by a penetration resistance hardness tester (Yamanaka soil hardness tester having a diameter of 20 mm and a length of 35 mm). When the compressive strength of the mortar is lower than 1.9 kgf / cm2, the semi-cured mortar in the transfer step before and after the pressing step is severely chipped and cracked, and when it is higher than 5 kgf / cm2, the mortar hardens. Therefore, the mortar hardening after pressing is reduced, and the strength of the high specific gravity portion formed by pressing is extremely reduced. Therefore, the bending strength of the cured panel is reduced. Moreover, stress distortion at the time of pressing tends to remain inside the panel, and the resulting lightweight cellular concrete panel tends to crack over time.

Further, in order to prevent chipping in the transfer process and stably produce a highly durable panel, 2.2 k
It is preferable to use a semi-cured panel having a compressive strength of gf / cm2 to 4.5 kgf / cm2.
More preferably, it is f / cm2 to 4.0 kgf / cm2. The pressure at the time of pressing the semi-cured panel by the pressing die needs to be 2 to 10 times the compressive strength of the semi-cured panel.
If the pressing pressure is less than twice the compressive strength of the semi-cured panel, predetermined molding cannot be performed. Pressing with a pressure exceeding 10 times the compressive strength is not preferable because large equipment is required.

[0015]

EXAMPLES The method for producing lightweight cellular concrete according to the present invention will be described below with reference to examples, but the present invention is not limited to these examples.

[0016]

Example 1 53 parts by weight of silica, 7.5 parts by weight of quicklime, 37 parts by weight of cement, 2.5 parts by weight of dry gypsum, containing 70 parts by weight of water and 0.060 parts by weight of aluminum powder based on 100 of these solids The lightweight cellular concrete mortar to be used is preliminarily placed in a 560 × 1780 mm metal lath mesh (mesh size 1).
(6 × 32 mm, thickness 0.8 mm) was injected into a mold uniformly arranged at a pitch of 50 mm to obtain a cured mortar block in the latter half of curing. This mortar block was cut with a piano wire, and a metal lath net was placed at the center of 50 × 60.
A test specimen of 0 × 1800 mm was obtained.

The test specimen was placed in a 60 × 600 × 1800 mm steel mold formed of four side plates on a backing plate.
Pressing was performed at a pressure of 2 mm for 10 mm. The stamping die is 10mm thick,
A straight urethane having a width of 600 mm, a length of 1800 mm, and a 1/2 taper was provided at intervals of 10 mm, and was made of hard urethane rubber. The compressive strength of mortar is 1.9kg / cm2
Met.

In the process of transferring the semi-cured panel before and after molding, no chipping or cracking of the panel was observed. A bending test was performed after curing in an autoclave. In the bending strength test, a rib was taken in the span direction and the span was 900 mm.
The test was carried out at a point loading of 2 equal parts at a head speed of 2 mm / min. Table 1 shows the results.

[0019]

[Table 1]

[0020]

Embodiments 2 to 4 The same 50 × 600 as in Embodiment 1
× 1800 mm semi-cured panels were prepared, and the compressive strength was set to 3.0, 4.0, and 5.0 kg / cm 2, respectively.
Pressing was performed at the pressure of kg / cm 2 using the same steel mold and pressing die as in Example 1. Then, after autoclaving,
I got a panel.

In any case, in the transfer process of the semi-cured panel before and after molding, no breakage or cracking of the panel was observed. After curing in an autoclave, the same bending strength test as in Example 1 was performed.

[0022]

Embodiment 5 The same 50 × 600 × 1800 as in Embodiment 1
A semi-cured panel having a thickness of 2.5 mm and a compressive strength of 2.5 kg / cm 2 was prepared, and pressed using the same steel mold and decorative mold as in Example 1 at a pressure of 6 kg / cm 2. The decorative pattern used was a brick pattern having a maximum pattern depth of 15 mm and a minimum pattern thickness of 10 mm.

In the process of transferring the semi-cured panel before and after molding, no defects or cracks were found in the panel, and after autoclaving, a panel having good design properties was obtained.

[0024]

Comparative Example 1 Same 50 × 600 × 1 as in Example 1
Prepare a 800mm semi-cured panel, compressive strength 1.0
At a pressure of 4.0 kg / cm 2 at a pressure of 4.0 kg / cm 2, pressing was performed using the same steel mold and pressing die as in Example 1. In the transfer process using a vacuum suction mat before and after molding, chipping occurred at the panel end.

Table 1 shows the results of the bending test after curing in the autoclave.

[0026]

Comparative Example 2 Same 50 × 600 × 1 as in Example 1
Prepare 800mm semi-cured panel, compressive strength 6.0
At a pressure of 13.0 kg / cm 2 at a pressure of 13.0 kg / cm 2, pressing was performed using the same steel formwork and pressing die as in Example 1. Table 1 shows the results of the bending test after autoclaving.

[0027]

Comparative Example 3 Same 50 × 600 × 1 as in Example 1
Prepare 800mm semi-cured panel, compressive strength 2.0
At a pressure of 3.0 kg / cm 2 at a pressure of 3.0 kg / cm 2, pressing was performed using the same steel mold and pressing die as in Example 1. The pressed panel was not sufficiently pressed by the pressing die, and a predetermined panel shape could not be obtained.

[0028]

According to the present invention, it is possible to prevent a defect in a moving step of a semi-cured panel and to produce a lightweight cellular concrete having a high specific gravity portion formed therein by pressing with high productivity. is there.

[Brief description of the drawings]

FIG. 1 is a schematic cross-sectional view of a method for manufacturing a lightweight cellular concrete panel of the present invention.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Semi-hardened panel 2 Side plate 3 Backing plate 4 Pressing die 5 High specific gravity part

Claims (2)

[Claims] 1. A method for producing a lightweight cellular concrete panel in which a high specific gravity portion formed by pressing during semi-curing exists inside the panel, the method comprising: 1.9 kgf / cm2 to 5.0.
Production of lightweight cellular concrete panels in which a semi-cured panel having a compressive strength in the range of kgf / cm2 is applied to a surface other than a surface for pressing a backing plate and a side plate for defining a product thickness, and then pressed by a pressing die. Method. 2. The method for producing a lightweight cellular concrete panel according to claim 1, wherein the pressing is performed with a pressing die at a pressure of 2 to 10 times the compressive strength of the semi-cured panel.