JP2006104808A - Embedded form and its manufacturing method - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide an embedded form and its manufacturing method for constructing a concrete structure with a coating of reformed sulfur integrated on the surface and carrying out the corrosion preventive reconstruction of an existing concrete structure. <P>SOLUTION: In this embedded form 5, a corrosion-proof material 4 formed of a solidified body of reformed sulfur is stuck in a thin film state to the surface of a thin-walled form material 1. <P>COPYRIGHT: (C)2006,JPO&NCIPI

Description

  The present invention relates to a thin-walled formwork suitable for use in, for example, construction of an anticorrosive concrete structure in a water and sewage facility or the like, and an anticorrosive reconstruction of an existing concrete structure, and a method for manufacturing the same.

  Cement concrete has been widely used as an economical structural material with long-term durability, but recently, the structure of sewerage facilities has been corroded at a relatively early stage, which is caused by bacteria in the sewerage system. It has been found that this is due to the sulfuric acid produced by the work.

  As measures to prevent these corrosions, especially in highly corrosive environments such as sewer facilities, a method of protecting the concrete structure surface by a method of forming a corrosion protection layer with concrete, a coating type lining method, a sheet lining method, etc. Has been put to practical use.

  However, in the method of forming the anticorrosion layer with concrete, the concrete itself that becomes the anticorrosion layer corrodes, and therefore periodic repair is necessary. In addition, since the thickness of the anticorrosion layer is required in addition to the necessary thickness of the structural member, the thickness of the structure becomes unnecessarily thick, and there is a problem that the structure becomes large.

  In contrast, the coating type lining method and the sheet lining method ensure the corrosion resistance of the lining material itself. However, the materials used have a very different linear expansion coefficient compared to concrete and have poor adhesion to concrete, such as low adhesion, which causes problems such as peeling, pinholes, joints, etc. Therefore, there was a problem that corrosion progressed.

  In addition, it has also been found that in waterworks facilities, concrete deterioration is likely to occur due to ozone and activated carbon for water purification.

By the way, the inventors of the present invention have a solidified body of modified sulfur obtained by adding petroleum-based olefin to sulfur, or a mixture thereof with an inorganic additive, which has excellent water barrier properties, acid resistance, alkali resistance, and concrete. It was confirmed that an inexpensive and tough anti-corrosion solidified coating was formed by coating the surface of the concrete structure.
Japanese Unexamined Patent Publication No. 60-6404 JP 2000-281425 A

  In actual construction, if the modified sulfur is heated above its melting point, it can be fluidized, and if it is cooled, a solidified film can be formed. For example, a mold is assembled facing the existing structure and melted inside it. Sulfur can be poured into the existing structure. However, in order to spread the molten sulfur to every corner of the mold, there are technically difficult aspects such as a method for transferring and supplying molten sulfur and temperature control of the mold.

  On the other hand, a method by spraying molten sulfur is also conceivable, but it is easily influenced by environmental conditions (rain, moisture, temperature, wind, etc.) such as the weather, and the spraying device may not be able to enter in a narrow field. There were also points unsuitable for on-site construction, such as the fact that the spraying surface was sprayed with heated and compressed air, so it was difficult to ensure a smooth surface, and a spraying device with strict temperature control was required. .

  The present invention solves the above-mentioned problems, and its purpose is not to rely on on-site construction that is easily affected by environmental conditions, and on the surface so that the process required for on-site coating can be shortened. The present invention provides an embedded formwork that can be used to construct a concrete structure that integrates the above film and to improve the anticorrosive property of existing concrete, and a method for manufacturing the same.

  In order to achieve the above object, the present invention is characterized in that an anticorrosive material made of a solidified modified sulfur is attached in the form of a thin film to the surface of a thin formwork material.

  The invention of claim 2 is the invention according to claim 1, wherein the modified sulfur is obtained by heating and melting a simple substance of modified sulfur obtained by adding a petroleum olefin to pure sulfur or a mixture of the modified sulfur and an inorganic and / or organic additive, It adheres to the surface of the said formwork material, It is characterized by the above-mentioned.

  The invention of claim 3 is characterized in that, in claim 2, the amount of the petroleum olefin added is 1 to 10 wt% with respect to sulfur.

  The invention of claim 4 is the invention according to claim 2 or 3, wherein the inorganic additive has an average particle diameter of 0.1 mm or less and is added and mixed in an amount of 0 to 80 wt% with respect to the total amount including the modified sulfur. It is characterized by.

  The invention of claim 5 is characterized in that, in claim 2 or 3, the organic additive is a short vinylon fiber mixed and dispersed in a range of 0.5 to 1.5 wt% with respect to the total amount of modified sulfur. Buried formwork.

A sixth aspect of the present invention is characterized in that in the first to fifth aspects, the mold material is a mold material that satisfies the following conditions.
(1) Allowable bending stress: 135 kgf / cm ² or more (2) Young's modulus: 70000 kgf / cm ² or more (3) Adhesion with sulfur solidified body: 1.0 N / mm ² or more (4) Adhesion with concrete : 1.0 N / mm ² or more (5) The molten sulfur at 140 ° C. should not be altered or deformed until it reaches room temperature within 60 minutes.

  The invention of claim 7 is characterized in that, in claims 1 to 6, irregularities are formed on the surface of the mold material between the adhesion surface of the mold material and modified sulfur and / or the adhesion surface of the mold material and concrete. It is characterized by being formed.

  The invention of claim 8 is that, in claims 1 to 6, a nonwoven fabric is interposed between the bonding surface of the mold material and modified sulfur and / or the bonding surface of the mold material and concrete. It is a feature.

  A ninth aspect of the present invention is characterized in that, in the first to sixth aspects, a plurality of anchor members are integrally projected on the mold member between the mold member and the bonding surface of the concrete. Is.

  The invention of claim 10 is a method for manufacturing an embedded mold according to any one of claims 1 to 9, wherein the modified sulfur is sprayed on the surface of the mold material in a molten state, and then sprayed. The melted sulfur is cooled and individualized, and the anticorrosive material is deposited in a thin film.

  As described above, according to the present invention, a solidified coating of modified sulfur can be integrally formed on the surface of the concrete structure at the same time as the concrete structure, thereby obtaining an anticorrosive structure. It is also suitable for remodeling the existing concrete structure.

  In the invention according to claim 2, the surface of the structure is protected and the durability is greatly improved by the characteristics such as mechanical strength, water imperviousness, acid resistance, alkali resistance, salt resistance, and low water absorption of the modified sulfur itself. It becomes possible to improve.

  In the invention according to claim 3, when the amount of petroleum olefin added is less than 1 wt% with respect to sulfur, the reforming reaction becomes excessive when it exceeds 10 wt%. By setting it in the range of 10 wt%, a sufficient reforming effect can be obtained without becoming excessive.

  In the invention described in claim 4, the adhesion to the mold material is improved by mixing the inorganic additive in an appropriate ratio.

  In invention of Claim 5, the crack suppression effect becomes a high thing.

  In the invention of claim 6, it is durable to the temperature characteristics of the melt-modified sulfur, and the formwork itself has good adhesion to the modified sulfur and concrete, and has a certain thickness. It can sufficiently withstand the setting pressure.

  In the inventions of claims 7 and 8, the adhesion between the mold material and the modified sulfur and concrete is further improved by the unevenness and the anchor effect of the nonwoven fabric.

  In the invention according to claim 9, the adhesion between the formwork and the concrete is improved.

  In invention of Claim 10, the embedded formwork of Claims 1-9 can be manufactured.

  DESCRIPTION OF EXEMPLARY EMBODIMENTS Hereinafter, preferred embodiments of the invention will be described in detail with reference to the accompanying drawings. First, a method for molding an embedded form will be described with reference to FIGS. 1 and 2.

  FIG. 1 shows a method of adhering modified sulfur to the mold material 1 by a spraying method (including a method of spraying, including pouring or coating), as shown in (a), A frame material 2 having a thickness corresponding to the sulfur stacking thickness t is attached around the required form and width dimensions of the mold material 1, and then the molten sulfur injection nozzle 3 is placed on the mold material 1 at a predetermined distance from the mold material 1. It is sprayed on the mold material 1 by reciprocating on the mold material 1 at a predetermined speed while injecting molten sulfur maintained at a melting point of 110 ° C. or more and a transformation temperature of 160 ° C. or less. The molten sulfur thus obtained is successively laminated to a predetermined thickness while being cooled and solidified, and then the frame material 2 is removed, thereby integrating the modified sulfur layer 4 that becomes a corrosion-proof material having a predetermined thickness as shown in FIG. Is formed into a flat plate-like embedded form 5.

  In the above, the formwork material 1 is high toughness (span 250 mm, displacement amount is 5 mm or more) and thickness is a thin plate material, board, panel, etc. of 3 to 20 mm, and the spraying thickness of the sulfur layer 4 is 3 Set to ~ 30 mm.

  In addition, as shown in a part of (b) in an enlarged manner on both sides of the mold material 1, for example, a depth of about 0.5 mm and an eye roughness of 1 to Concavities and convexities 1a such as a mesh shape of about 3 mm are formed, thereby increasing the effect of joining to the sulfur layer 4 and improving the effect of joining to concrete in a state of being integrated with concrete described later. .

Formwork material 1 has bending strength and Young's modulus comparable to those of plywood usually used as a wooden formwork. Specifically, allowable bending stress level (JIS A 1408 “Bending and impact test method for building boards”) : 135 kgf / cm ² or more, Young's modulus (JIS A 1408 “Bending and impact test method for building boards”): 70000 kgf / cm ² or more, and in addition to this, the adhesion force to the solidified sulfur ( “Kenken-type adhesive strength test”: 1.0 N / mm ² or more, adhesion to concrete (“Kenken-type adhesive strength test”): 1.0 N / mm ² or more, molten sulfur at 140 ° C. for 60 minutes The material is selected from materials that do not deteriorate or deform before reaching room temperature.

  In addition to slate boards used as building interior and exterior materials, fiber reinforced gypsum boards, calcium silicate boards, and fiber reinforced cement boards developed as embedding form materials, surface treatment Heat resistant plastic plates, FRP plates, etc. can also be used.

  Sulfur materials used for spraying are either sulfur recovered as a by-product during the petroleum refining process or modified sulfur consisting of natural pure sulfur and petroleum-based olefins such as olefin polymers, or addition of inorganic or organic substances. A mixture with the material is heated and melted.

  Examples of petroleum olefins include olefin compounds such as dicyclopentadiene (DCPD), tetrahydroindene (THI), or cyclopentadiene and oligomers thereof (2 to 5 mer mixture), dipentene, vinyltoluene, and dicyclopentene. Or a mixture of two or more thereof. The proportion of the petroleum olefin used is usually 0.01 to 30% by mass, particularly preferably 0.1 to 20% by mass, based on the total amount of sulfur and petroleum olefin.

  Examples of the inorganic additive include aggregates such as coal ash and cinnabar, and the average particle diameter of these additives is 0.1 mm or less, and 20 to 80 wt% is added to and mixed with the total amount including modified sulfur. Is preferable in order to improve the adhesion to the mold material.

  The reason for this limitation is that the adhesiveness to the mold material 1 with the blending ratio of the additive exceeds 20% is sufficient for the quality standard of the cross-section repair material (mortar construction) and the standard value of the anticorrosion coating method in the standard state. It is because it exceeds.

Further, the adhesion strength increases as the compounding ratio increases from 20%, but the adhesive force tends to decrease conversely at a compounding ratio exceeding the upper limit of 80%.
Therefore, although it is set as the above compounding ratio, Preferably it exceeds the said quality specification value in the range of 25 to 60%, and especially 50% of additive material shows the highest adhesiveness with respect to 50% of modified sulfur.

  Examples of the organic additive include polypyropylene, carbon, aramid, polyethylene, vinylon, and the like, and in particular, vinylon short fibers mixed and dispersed in a range of 0.5 to 1.5 wt% with respect to the total amount of modified sulfur are used. It is preferable. By mixing such short fibers, the cracking phenomenon of the sulfur layer 4 can be prevented in advance.

  FIG. 2 shows another embodiment of the method for manufacturing the embedded mold 5. This method is a molding method by pouring molten sulfur. In this method, a planar heater 7 connected to a power source is laid on an installation mount 6 as shown in FIG. The frame material 1 is installed on the upper surface, the periphery is surrounded by the frame material 2, and the granular or molten modified sulfur material heated to 50 ° C. to 140 ° C. through the hose 9 is placed on the mold material 1 Then, as shown in (b), the mount 6, the heater 7, and the iron plate 8 are connected to the vibrator 11 through the clamp 10 and heated while applying lateral vibration, so that the sulfur is melted and averaged. The thickness is smoothed to form a thin modified sulfur layer 4. Thereafter, by cooling and demolding the frame member 2, as shown in (c), the embedded mold 5 having the same composition as that of FIG. 1 can be obtained.

  In addition, it can replace with the vibrator 11 and the method of heating by installing the installation mount 6 on a vibrator and driving a vibrator can also be employ | adopted.

  Next, a method for molding an anticorrosive concrete structure using the above-described embedded form 5 will be described with reference to FIGS.

FIG. 3 shows a construction example of a concrete structure having anticorrosion properties on both sides, and as shown in (a), a buried form 5 in which a pair of modified sulfur layers 4 are arranged facing the outer surface. Are separated by a predetermined distance via a plurality of separators 20, and concrete is placed between both molds 5 via a reinforcing bar (not shown). As shown in FIG. The anticorrosive concrete structure 22 in which the embedded form 5 is integrated is constructed.
In this case, since the formwork 1 in contact with the concrete surface has good adhesion to the concrete as described above and has irregularities (see the enlarged view in FIG. 1B), it is firmly attached. Sex can be obtained.

FIG. 4 shows an example in which the adhesion between the embedded form 5 and the concrete casing 21 is further strengthened, and a nonwoven fabric 23 is previously attached to the surface of the formwork 1 in contact with the concrete.
In this example, due to the tangled effect caused by the impregnated concrete impregnated into the nonwoven fabric 23, the adhesion of the embedded form 5 to the concrete frame 21 can be improved.

  FIG. 5 shows another example of adhesion strengthening. An anchor body 24 (for example, Resicon Z: manufactured by Okabe Co., Ltd.) used for fastening the formwork material at an appropriate interval on the surface of the formwork material 1 in contact with the concrete. The anchor effect of these anchor bodies 24 can improve the adhesion of the embedded form 5 to the concrete frame 21.

  FIG. 6 shows a construction example of a concrete structure imparted with anticorrosion property only on one side, and the embedded form 5 is disposed on one side requiring anticorrosion property as shown in (a), An ordinary mold 25 is arranged on the surface that does not require anticorrosion, and a frame is formed between these molds via a plurality of separators 20, and concrete is placed between both molds 5 and 25 via unillustrated reinforcing bars. By providing, the anticorrosion structure 26 which built the embedding formwork 5 into the single side | surface of the concrete housing 21 as shown in (b) is constructed | assembled. The normal mold 25 is demolded after curing.

  FIG. 7 shows an example of construction applied to the surface repair of an existing concrete structure. As shown in (a), the surface corrosion portion of the existing concrete structure 30 is suspended to a predetermined depth d, and then, The embedded form 5 is arranged with a space on the surface of the structure 30 through a plurality of separators 20 whose one ends are anchored in the structure 30, and then embedded with the structure 30 as shown in FIG. By placing concrete between the embedded molds 5, the surface of the structure 30 can be repaired, and at the same time, anticorrosion is improved.

  In each of the above construction examples, the mold is usually removed from the mold, but in the case of the buried mold 5, the separator 20 is integrated into the structure with the separator 20 being joined. Post-processing of the protruding end from the mold 5 is required.

  FIG. 8 shows the processing procedure. As shown in (a), the steel rod screwed to the outside of the P-con 40 in contact with the back of the embedded form 5 is removed, and as shown in (b). The sulfur layer 4 around the through-hole 5a formed in the embedded mold 5 is largely cut off, and as shown in (c), the screw 41 is screwed into the P-con 40 and joined to the separator 20, and then the head of the screw 41 By filling the periphery with molten sulfur 42, the pores of the separator mark can be completely closed.

  Moreover, the process of the joining end of adjacent embedded formwork 5 cut | disconnected the sulfur layer 4 which adjoins, for example, as shown to Fig.9 (a), and was cut as shown in (b). The interior is filled with molten reformed sulfur 42 or cut into a rectangular cross section as shown in FIG. 10 (a), and the reformed sulfur 42 in the molten state is cut into the cut interior as shown in FIG. 10 (b). When filled, the gap is completely closed.

  In the above embodiment, the embedded form 5 is a flat panel, but it can of course be formed on a curved panel. For example, such a curved one is formed on the inner and outer peripheral surfaces of a concrete fume pipe. It can be used for various anticorrosion applications such as integration.

(A), (b) is sectional drawing for description which shows the example of shaping | molding of an embedded formwork. (A)-(c) is sectional drawing for description which shows the other example of a shaping | molding example of an embedded formwork. (A), (b) It is sectional drawing for description which shows the construction example of the concrete structure which formed the anticorrosion layer on both surfaces using the embedded formwork. It is sectional drawing for description which shows the case where the nonwoven fabric for joint reinforcement | strengthening is interposed between concrete and an embedded formwork. It is sectional drawing for description which shows the case where the anchor is interposed. (A), (b) is sectional drawing for description which shows the construction example of the concrete structure which formed the anti-corrosion layer in the single side | surface. (A), (b) is sectional drawing for description which shows the construction example at the time of applying to the anti-corrosion reinforcement of the existing concrete. (A)-(c) is principal part sectional explanatory drawing which shows the process sequence of a separator penetration position. (A), (b) is principal part cross-sectional explanatory drawing which shows the process of the junction part between adjacent embedding formwork. (A), (b) is principal part cross-section explanatory drawing which shows the other example of the process of the junction part between adjacent embedding formwork.

Explanation of symbols

1 Formwork material 1a Concavity and convexity 4 Modified sulfur layer (anticorrosion material)
5 Embedded form 21 Concrete frame 22 Anticorrosive concrete structure 23 Nonwoven fabric 24 Anchor

Claims (10)

  An embedded formwork characterized in that an anticorrosive material made of a modified sulfur solidified body is attached to the surface of a thin formwork material in a thin film form.   2. The modified sulfur according to claim 1, wherein the modified sulfur is obtained by heating and melting a simple substance of modified sulfur obtained by adding petroleum-based olefin to pure sulfur or a mixture of the modified sulfur and an inorganic and / or organic additive, on the surface of the mold material. An embedded formwork that is attached.   In Claim 2, The addition amount of the said petroleum olefin is 1-10 wt% with respect to sulfur, The embedded formwork characterized by the above-mentioned.   The embedded form according to claim 2 or 3, wherein the inorganic additive has an average particle size of 0.1 mm or less and is added and mixed in an amount of 0 to 80 wt% with respect to the total amount including the modified sulfur. .   4. The embedded form according to claim 2, wherein the organic additive is a vinylon short fiber mixed and dispersed in a range of 0.5 to 1.5 wt% with respect to the total amount of the modified sulfur. The embedded mold according to claim 1, wherein the mold material is a mold material that satisfies the following conditions.
(1) Allowable bending stress: 135 kgf / cm ² or more (2) Young's modulus: 70000 kgf / cm ² or more (3) Adhesion with sulfur solidified body: 1.0 N / mm ² or more (4) Adhesion with concrete : 1.0 N / mm ² or more (5) No change in quality or deformation before 140 ° C molten sulfur reaches room temperature in 60 minutes   In Claim 1-6, the unevenness | corrugation is formed in the surface of the formwork material between the adhesion surface of the said formwork material and modified sulfur and / or the adhesion surface of a formwork material and concrete. Buried formwork.   The embedded form according to claim 1, wherein a nonwoven fabric is interposed between an adhesive surface between the mold material and modified sulfur and / or an adhesive surface between the mold material and concrete.   The embedded mold according to claim 1, wherein a plurality of anchor members are integrally projected on the mold material between the mold material and the bonding surface of the concrete. It is a manufacturing method of the embedded formwork according to claim 1,
Embedding on the surface of the mold material in a state where the modified sulfur is sprayed in a molten state, the sprayed molten sulfur is cooled and individualized, and the anticorrosive material is attached in a thin film shape A method for manufacturing a formwork.

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