JP2012136886A - Method for manufacturing autoclaved lightweight concrete panel - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a method for manufacturing an autoclaved lightweight concrete panel, which achieves firm fixation by adjusting relative displacement of a net-like reinforcement member with respect to a reinforcing bar mat, and which enables the manufacture of a high-quality panel by effectively preventing a rustproof coated film of the reinforcing bar structure from causing a loss.SOLUTION: Reinforcing bar structure 5 is formed by connecting a reinforcing bar mat 7 and a net-like reinforcement member 9 in a separated state via an attachment member 11. In this case, the attachment member 11 passes through a mesh 9a of the net-like reinforcement member 9, and an arm portion 11b is supported by the reinforcing bar mat 7. In this state, a locking portion 11a is tilted in such a manner that the arm portion 11b serves as a supporting point. Thus, the displacement of the net-like reinforcement member 9 with respect to the reinforcing bar mat 7 is adjusted. After the adjustment of the displacement, the arm portion 11b is fixed to the reinforcing bar mat 7. Consequently, the reinforcing bar mat 7 and the net-like reinforcement member 9 are connected together in the separated state.

Description

  The present invention relates to a method of manufacturing a lightweight cellular concrete panel in which a reinforcing bar mat having main bars and auxiliary bars and a net-like reinforcing member such as a metal lath are embedded.

  2. Description of the Related Art Conventionally, there has been proposed a structure in which a reinforcing bar structure including a reinforcing bar mat composed of main and auxiliary bars and a net-like reinforcing member such as a metal lath is embedded in a lightweight cellular concrete panel (hereinafter referred to as “ALC panel”).

  ALC panels used for building walls, floors or roofs often have large and small through holes and openings for facilities such as water supply and drainage, air conditioning and ventilation. On the other hand, in the interior of the ALC panel, a large number of main bars and auxiliary bars are embedded in order to develop the bending strength of the panel, and reinforcing bar mats provided with main bars and auxiliary bars by drilling through holes for equipment piping If it is cut, there is a risk that the panel bending strength may be lowered. Therefore, it is difficult to provide a large number or large holes at arbitrary positions. An ALC panel that solves this problem is proposed in Japanese Patent Application Laid-Open No. 2010-59715.

  Japanese Patent Application Laid-Open No. 2010-77624 proposes an ALC panel that solves the problem that chipping is likely to occur when perforating or notching the outer edge of the reinforcing bar mat of the ALC panel. Yes.

  In order to solve the problem that the base material on the back side is peeled off when the drill blade is cut through when drilling the ALC panel, an ALC panel in which a reinforcing mesh made of reinforcing bars is stretched with a wire mesh is disclosed in Japanese Utility Model Laid-Open No. 06-077842. Has been proposed.

  In order to further enhance the design and durability of the ALC panel, the surface is covered with a cover plate such as a decorative plate. In that case, the storage and transportation are not hindered, and the construction is performed. Japanese Patent Laid-Open No. 6-114822 has proposed an ALC panel devised to significantly reduce the man-hours and time required.

  It is assumed that the reinforcing bar structure used for the ALC panel described above is manufactured by directly contacting and fixing a mesh reinforcing member to a reinforcing bar mat composed of a main bar and a secondary bar. The two members can be welded together, or a part of the net-like reinforcing member, or the two members can be joined together using another member.

  The ALC panel is manufactured by forming a reinforcing bar structure, surrounding the reinforcing bar structure with a raw slurry of lightweight cellular concrete, and further foam-curing the raw material slurry. Here, the reinforcing bar structure needs rust prevention treatment to prevent rusting. Therefore, in the manufacturing process of the ALC panel, the reinforcing bar structure is subjected to rust prevention treatment before the reinforcing bar structure is surrounded by the raw material slurry. This rust prevention treatment is generally performed by immersing the reinforcing bar structure completely in an immersion tank filled with the rust prevention liquid, attaching the rust prevention liquid to the surface of the reinforcing bar structure, and drying it. It is executed by forming a rust-proof coating film having a thickness.

JP 2010-59715 A JP 2010-77624 A Japanese Utility Model Publication No. 6-078432 JP-A-6-114822

  In the reinforcing bar structure used in the conventional ALC panel, the reinforcing bar mat and the net-like reinforcing member are in contact with each other and partially fixed by welding or the like. In this type of reinforcing bar structure, a rust-proof coating film is not substantially formed at the contact portion between the two. Here, in the manufacturing process of the ALC panel, when the above-mentioned raw material slurry is foam-cured, stress is applied to the reinforcing bar structure from the outside, the contact part is partially separated, and the anticorrosive coating film may be damaged. There is sex. On the other hand, in order to prevent the loss of the anticorrosive coating, measures such as performing welding on the entire surface of the contact part or fastening the substantially whole can be considered. This results in an increase in the number of processes and an increase in cost, which is not practical.

  Furthermore, the number and position of the main reinforcement and the secondary reinforcement in the reinforcing bar mat change due to the change in the longitudinal and short dimensions of the ALC panel and the change in strength performance required for the ALC panel. On the other hand, the relative position of the mesh reinforcing member with respect to the main reinforcing bar and the auxiliary reinforcing bar of the reinforcing bar mat is actually shifted due to a change in the opening of the mesh reinforcing member such as a metal lath or an error in the position of the opening. . A specific method for forming a reinforcing bar structure by accurately fixing the mesh reinforcing member to the reinforcing bar mat while absorbing the relative displacement is not described in the prior art, and is effective. An efficient method has not been established.

  The present invention aims to solve the above-mentioned problems, and adjusts the relative displacement of the mesh reinforcing member with respect to the reinforcing bar mat to firmly fix it, and also causes defects in the anticorrosive coating film of the reinforcing bar structure. An object of the present invention is to provide a method for manufacturing a lightweight cellular concrete panel that can effectively prevent high-quality panels by preventing the above-described problem.

  The present invention relates to a lightweight cellular concrete panel manufacturing method in which a reinforcing bar structure provided with a reinforcing bar mat is surrounded by a raw material slurry in a panel shape, and the raw material slurry is foamed and cured. The reinforcing member includes a reinforcing bar structure forming step of forming a reinforcing bar structure by arranging the reinforcing bar and the mesh reinforcing member in a state of being spaced apart from each other while the reinforcing member is opposed to the reinforcing member. In the reinforcing bar structure forming step, the engaging portion bent in a letter shape, and a pair of arms protruding from both ends of the engaging portion and disposed opposite to each other on the same axis across the engaging portion, The attachment member is passed through the mesh of the mesh reinforcement member, and the arm portion is supported by the reinforcement rod mat, and the locking portion is tilted with the arm portion as a fulcrum to adjust the displacement of the mesh reinforcement member with respect to the reinforcement rod mat. The mesh reinforcing member is supported by the locking portion, and after adjusting the positional displacement of the mesh reinforcing member with respect to the reinforcing bar mat, the arm portion is fixed to the reinforcing bar mat and the reinforcing bar mat and the net reinforcing member are coupled in a separated state. It is characterized by that.

  In the present invention, the reinforcing bar mat and the mesh-like reinforcing member are joined together with the attachment member interposed therebetween, and as a result, the reinforcing bar structure is formed. That is, in the present invention, as a premise, since the reinforcing bar mat and the net-like reinforcing member are separated from each other, a rust-preventing coating film is formed over substantially the entire surface of the reinforcing bar structure when the rust-proofing process is performed. Therefore, stress is applied to the reinforcing bar structure when the raw material slurry is foam-cured. For example, even if the separation width between the reinforcing bar mat and the net-like reinforcing member is changed, the rust preventive coating film is not lost. As a result, according to the present invention, it is possible to effectively prevent the loss of the anticorrosive coating film having the reinforcing bar structure. Further, in the present invention, the relative displacement of the mesh reinforcing member with respect to the reinforcing bar mat can be adjusted by tilting the locking portion with the arm portion of the mounting member as a fulcrum, and the mesh reinforcing member is firmly attached to the reinforcing bar mat. Can be fixed. That is, according to the present invention, the relative displacement of the net-like reinforcing member with respect to the reinforcing bar mat is adjusted and firmly fixed, and defects generated in the anticorrosive coating film of the reinforcing bar structure are effectively prevented and increased. Quality panels can be manufactured.

  And in this invention, you may provide the rust prevention process which immerses a reinforcing bar structure in a rust prevention liquid and performs a rust prevention process.

  According to the present invention, the relative displacement of the mesh reinforcing member with respect to the reinforcing bar mat is adjusted and firmly fixed, and the defects generated in the anticorrosive coating film of the reinforcing bar structure are effectively prevented and high quality is achieved. Lightweight cellular concrete panels can be manufactured.

It is a top view of the lightweight cellular concrete panel manufactured by the manufacturing method concerning the embodiment of the present invention. It is sectional drawing along the II-II line of FIG. It is a perspective view which expands and shows the site | part which couple | bonds a reinforcing bar mat and a mesh-shaped reinforcement member in the state spaced apart via the attachment member. The reinforcement reinforcement | strength formation process of the manufacturing method which concerns on this embodiment is shown, (a) is a perspective view which shows the state which has arrange | positioned the mesh reinforcement member between a pair of reinforcement reinforcement mats, (b) is a reinforcement reinforcement mat. It is a perspective view which shows the state which connected the reinforcement reinforcement mat and the mesh reinforcement member via the attachment member while arrange | positioning a mesh reinforcement member facing it. The state which adjusts the relative position shift of a reinforcement reinforcement mat and a net-like reinforcement member with an attachment member is shown, (a) is a figure showing typically the state before adjustment, and (b) is the state after adjustment. It is a figure which shows a state typically.

Preferred embodiments of the present invention will be described below with reference to the drawings.
(First embodiment)

  First, a lightweight cellular concrete (hereinafter referred to as “ALC”) panel 1 manufactured by the manufacturing method according to the present embodiment will be described with reference to FIGS.

  As shown in FIGS. 1 to 3, the ALC panel 1 includes a panel main body 3 formed into a rectangular plate shape by ALC and a reinforcing bar structure 5 embedded in the panel main body 3. The reinforcing bar structure 5 includes a pair of reinforcing bar mats 7 and a net-like reinforcing member 9 disposed between the pair of reinforcing bar mats 7 so as to be separated from the reinforcing bar mats 7.

  The reinforcing bar mat 7 intersects (perpendicular to) the two parallel main bars 7 a extending along the longitudinal direction of the panel body 3 and the main bar 7 a, and extends along the short direction of the panel body 3. And five accessory muscles 7b. The pair of reinforcing bar mats 7 are arranged in parallel along the panel surface of the panel body 3.

  Of the five accessory bars 7 b of the reinforcing bar mat 7, the two accessory bars 7 b are desirably arranged in the vicinity of both ends in the longitudinal direction of the panel body 3. By disposing the secondary muscles 7b at both longitudinal ends of the panel body 3, the main muscles 7a are sufficiently fixed to the panel body 3 made of ALC, and the attachment strength of the fastener attached to the end of the ALC panel 1 is increased. Can be secured.

  The mesh reinforcing member 9 is a planar mesh member made of metal lath, wire lath, or the like, and a wire mesh, lath mesh, expanded metal, or the like can be used. For example, the wire diameter of the iron wire used for the wire mesh and the thickness of the lath mesh or the expanded metal may be determined in consideration of the reinforcing effect and workability at the time of drilling, and about 0.6 mm to 1.2 mm. preferable. The size of the mesh may be determined in consideration of the adhesion of the mesh reinforcing member 9 to the panel body 3 (ALC base material) or the interval between the through holes and the openings, and is preferably about 10 mm to 60 mm.

  When the mesh reinforcing member 9 is a lath mesh, flat laths such as No. 3 and 4 or corrugated laths such as No. 1 and 2 can be employed. The size of the mesh (mesh) in the mesh direction is 26 mm to 32 mm (the major axis of the rhombus), and the size of the mesh (mesh) in the minor direction is 13 mm to 16 mm.

  The net-like reinforcing member 9 is sandwiched between the pair of reinforcing bar mats 7 and is spaced from the reinforcing bar mats 7 with a certain distance Da, Db (see FIG. 2) between them. Opposed.

  The reinforcing bar structure 5 includes a mounting member 11 that joins the reinforcing bar mat 7 and the net-like reinforcing member 9 with a predetermined distance Da, Db, and further, a reinforcing bar is provided at the upper end of the reinforcing bar structure 5. A suspension spacer (not shown) is fixed.

  The attachment member 11 is a substantially V-shaped member (hereinafter referred to as “V-shaped attachment member”), and protrudes from both ends of the engagement portion 11a bent into a V shape and the engagement portion 11a, and the engagement portion 11a. And a pair of arm portions 11b disposed opposite to each other on the same axis L.

  The V-shaped mounting member 11 supports the mesh reinforcing member 9 by holding the mesh reinforcing member 9 so that the locking portion 11a sandwiches the mesh reinforcing member 9, and holds it in a fixed position. Further, both ends of the arm portion 11b are in contact with and welded to the main bar 7a of the pair of reinforcing bar mats 7. In addition, although this embodiment demonstrates the aspect in which the latching | locking part 11a of the V-shaped attachment member 11 was fixed to the main reinforcement 7a of the reinforcement reinforcement mat 7, you may fix to the accessory reinforcement 7b.

  Next, a method for manufacturing the ALC panel 1 according to the first embodiment will be described with reference to FIGS. In the present embodiment, eight V-shaped attachment members 11 are used, and the V-shaped attachment members 11 are arranged at four places above and four places below the reinforcing bar structure 5. The number of V-shaped attachment members 11 in the longitudinal direction of the ALC panel 1 and the frequency of the layout, for example, prevent contact between the reinforcing bar mat 7 and the net-like reinforcing member 9 during the rust prevention treatment of the reinforcing bar structure 5. Any change can be made as long as possible, and there is no particular limitation. In addition, the frequency of the V-shaped attachment members 11 in the short direction of the ALC panel 1 and the frequency of layout, for example, can be determined by the contact between the reinforcing bar mat 7 and the mesh reinforcing member 9 during the rust prevention treatment of the reinforcing bar structure 5. Any change can be made as long as it can be prevented, and there is no particular limitation.

  The manufacturing method according to the present embodiment includes a reinforcing bar structure forming step, a rust prevention step, a foam hardening step of raw material slurry, a mortar block cutting step, and a curing step.

  In the reinforcing bar structure forming step, the reinforcing bar mat 7 and the net-like reinforcing member 9 are arranged to face each other, and the reinforcing bar mat 7 and the net-like reinforcing member 9 are connected to each other via the V-shaped attachment member 11. A reinforcing bar structure 5 is formed.

  Specifically, the V-shaped attachment member 11 is passed through the mesh 9a of the mesh reinforcing member 9, and the V-shaped attachment member 11 is inserted to a position where the mesh reinforcing member 9 is sandwiched by the locking portion 11a. Next, the arm part 11b of the V-shaped attachment member 11 is supported by the main reinforcement 7a of the reinforcing bar mat 7, and the engaging part 11a is tilted with the arm part 11b as a fulcrum, so that the mesh reinforcing member 9 is relative to the reinforcing bar mat 7. Correct misalignment.

  Specifically, the axis L of the arm portion 11b is perpendicular to the panel plate surface of the completed ALC panel 1. Then, by rotating the locking portion 11a about the axis L, the displacement in the direction along the panel plate surface of the mesh reinforcing member 9 can be absorbed, and the relative displacement of the mesh reinforcing member 9 with respect to the reinforcing bar mat 7 Can be adjusted. In this embodiment, in addition to tilting the locking portion 11a, the arm portion 11b is translated along the main bar 7a of the reinforcing bar mat 7 and adjusted to an appropriate position.

  By adjusting the relative displacement of the mesh reinforcing member 9 with respect to the reinforcing bar mat 7, the engaging portions 11 a of the plurality of V-shaped attachment members 11 are hooked on the mesh 9 a of the mesh reinforcing member 9, and the mesh reinforcing member 9. Can support. As a result, it is possible to prevent the floating portion from the mesh reinforcing member 9 from occurring in the locking portions 11a of some of the V-shaped attachment members 11.

  Next, both end portions of the arm portion 11 b of the V-shaped attachment member 11 are welded to the main reinforcing bar 7 a of the reinforcing bar mat 7. As a result, the reinforcing bar mat 7 and the net-like reinforcing member 9 can be coupled with each other via the V-shaped attachment member 11, and the reinforcing bar structure 5 is completed. In the reinforcing bar structure forming step according to the present embodiment, the relative position shift of the mesh reinforcing member 9 with respect to the reinforcing bar mat 7 is adjusted, and then the reinforcing bar mat 7 and the mesh reinforcing member 9 are interposed via the V-shaped attachment member 11. Therefore, the reinforcing bar mat 7 and the net-like reinforcing member 9 can be firmly fixed.

  That is, in the reinforcing bar structure forming process according to the present embodiment, for example, the main bar 7a in the reinforcing bar mat 7 is obtained by changing the size of the ALC panel 1 in the longitudinal direction or the short side direction, changing the strength performance required for the ALC panel 1, or the like. And the number and position of the secondary reinforcing bars 7b, the change in the mesh opening of the mesh reinforcing member 9, the error of the opening position, etc. Even if misalignment occurs, the reinforcing bar structure 5 can be formed by accurately fixing the mesh reinforcing member 9 to the reinforcing bar mat 7 while absorbing the relative misalignment.

  Next, the rust prevention process which performs the rust prevention process of the reinforcing bar structure 5 is performed. In the rust prevention process, the reinforcing bar structure 5 is completely immersed in an immersion tank filled with the rust preventive liquid, and the rust preventive liquid is attached to the surface of the reinforcing bar structure 5. Here, since the reinforcing bar mat 7 and the net-like reinforcing member 9 are arranged apart from each other, the rust preventive liquid is attached to the entire surface of the reinforcing bar mat 7 and the net-like reinforcing member 9. After the rust preventive liquid is applied, the reinforcing bar structure 5 is dried to form a rust preventive coating film.

  Next, a foam curing step of the raw material slurry is performed. The reinforcing bar mat 7 on which the rust preventive coating film is formed is disposed in the mold. In this formwork, a raw material slurry in which a calcareous raw material and a siliceous raw material are pulverized, an appropriate amount of water, a foaming agent and the like are mixed is injected, and the reinforcing bar structure 5 is surrounded in a panel shape, foamed and cured, and mortar. Form a block.

  After the foam-cured mortar block is formed, the mortar block is cut into a desired dimension with a piano wire or the like (a mortar block cutting step) and subjected to autoclave curing (curing step) to complete the ALC panel 1 having a predetermined shape. .

  Next, the operation and effect of the manufacturing method according to this embodiment will be described. In this manufacturing method, as a premise, since the reinforcing bar mat 7 and the net-like reinforcing member 9 are separated from each other, a rust-preventing coating film is formed over substantially the entire surface of the reinforcing bar structure 5 when the rust-proofing process is performed. The Accordingly, stress is applied to the reinforcing bar structure 5 when the raw material slurry is foam-cured, and, for example, even if the separation width between the reinforcing bar mat 7 and the mesh reinforcing member 9 is changed, the rust preventive coating film is not lost. Therefore, according to the manufacturing method which concerns on this embodiment, the defect | deletion of the anticorrosion coating film of the reinforcement reinforcement structure 5 can be prevented effectively, and manufacture of the high quality ALC panel 1 is attained.

  In particular, according to the manufacturing method according to the present embodiment, for example, compared with an aspect in which the entire surface of the reinforcing bar mat and the net-like reinforcing member is fixed by welding or the like to prevent the rust-preventing coating from being damaged, In addition, it is possible to completely solve the concerns related to the above, and at the same time, it is possible to suppress an increase in manufacturing man-hours and to suppress an increase in manufacturing cost.

  Further, according to the manufacturing method according to the present embodiment, the net reinforcing member 9 is accurately and firmly fixed to the reinforcing bar mat 7 while reliably absorbing the relative displacement of the net reinforcing member 9 with respect to the reinforcing bar mat 7. As a result, the reinforcing bar structure 5 can be formed. As a result, a high-quality ALC panel 1 can be manufactured.

  In the above embodiment, the V-shaped attachment member 11 and the reinforcing bar mat 7 are joined by welding. However, if a sufficient fixing strength is obtained, the connection is not limited to welding, but may be performed by adhesion or the like. There may be. Further, the V-shaped attachment member 11 and the reinforcing bar mat 7 can be fixed to either the main bar 7a or the auxiliary bar 7b of the reinforcing bar mat 7, but at the time of the rust prevention treatment, In order to ensure the frequency with which the contact with the mesh reinforcing member 9 can be prevented, it is desirable to fix it to the main reinforcement 7a.

  In this embodiment, the mesh reinforcing member 9 is only caught on the V-shaped attachment member 11 and is not particularly welded. However, the mesh reinforcing member 9 may be firmly fixed by welding or the like.

  Further, the length of the locking portion 11a of the V-shaped attachment member 11 is particularly limited as long as it can be passed through the mesh 9a of the mesh reinforcing member 9 and the mesh reinforcing member 9 can be sufficiently sandwiched. is not. Further, the position of the locking portion 11 a with respect to the arm portion 11 b of the V-shaped attachment member 11 can be arbitrarily changed according to the position of the mesh reinforcing member 9 in the thickness direction of the ALC panel 1.

  Further, among the coupling positions of the reinforcing bar mat 7 and the mesh-shaped reinforcing member 9 by the V-shaped attachment member 11, the coupling portion existing above is applied with the engaging portion 11a of the V-shaped attachment member 11 facing downward, In the upper coupling position, it is more preferable that the engaging portion 11a of the V-shaped attachment member 11 is directed upward to prevent a problem that the mesh reinforcing member 9 is not fixed due to vibration or the like.

  Further, in this embodiment, a net-like reinforcing member 9 that overlaps substantially the entire surface of the reinforcing bar mat 7 is prepared, and the net-like reinforcing member 9 is fixed to the reinforcing bar mat 7. However, the present invention is not limited to this form. The portion for fixing the mesh reinforcing member 9 may be only a required portion of the reinforcing bar mat 7. Further, two or more main bars 7a of each reinforcing bar mat 7 may be arranged in parallel to the longitudinal direction of the ALC panel 1, and three or more of the auxiliary bars 7b are arranged in parallel to the short direction of the ALC panel 1. You may set up.

  Further, among the coupling positions of the reinforcing bar mat 7 and the mesh-shaped reinforcing member 9 by the V-shaped attachment member 11, the coupling portion existing above is applied with the engaging portion 11a of the V-shaped attachment member 11 facing downward, In the coupling position existing below, it is more preferable to construct the engaging portion 11a of the V-shaped attachment member 11 upward so that the problem that the mesh reinforcing member 9 is not fixed due to vibration or the like can be prevented.

  DESCRIPTION OF SYMBOLS 1 ... ALC panel (lightweight cellular concrete panel), 5 ... Reinforcement structure, 7 ... Reinforcement reinforcement mat, 9 ... Reticulated reinforcement member, 9a ... Mesh, 11 ... V-shaped attachment member, 11a ... Locking part, 11b ... Arm part , L ... axis.

Claims (2)

A method of manufacturing a lightweight aerated concrete panel manufactured by surrounding a reinforcing bar structure including a reinforcing bar mat in a panel shape with a raw material slurry, and foaming and curing the raw material slurry,
Reinforcing bar structure formation in which the reinforcing bar mat and the net-like reinforcing member are arranged to face each other, and the reinforcing bar mat and the net-like reinforcing member are joined in a separated state via an attachment member. With a process,
The mounting member has a locking portion bent in a V shape, and a pair of arm portions protruding from both ends of the locking portion and opposed to each other on the same axis across the locking portion,
In the reinforcing bar structure forming step, the attachment member is passed through the mesh of the mesh reinforcing member, the arm part is supported by the reinforcing bar mat, and the locking part is tilted with the arm part as a fulcrum to strengthen the reinforcement. The mesh reinforcement member is supported by the locking portion while adjusting the displacement of the mesh reinforcement member with respect to the reinforcement mat, and the arm portion is attached to the reinforcement reinforcement mat after adjusting the displacement of the mesh reinforcement member with respect to the reinforcement reinforcement mat. A method for producing a lightweight cellular concrete panel, wherein the reinforcing bar mat and the mesh reinforcing member are bonded to each other in a state of being separated from each other.   The method for producing a lightweight cellular concrete panel according to claim 1, further comprising a rust-preventing step of immersing the reinforcing bar structure in a rust-preventing liquid and performing a rust-proofing treatment.

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