JP2678704B2 - Method for manufacturing lightweight cellular concrete panel with double-sided pattern - Google Patents

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 a lightweight cellular concrete panel suitable for use as walls of various parts of a building, walls, staircase walls, balcony walls and the like.

[0002]

2. Description of the Related Art Concrete panels are often used for outer walls and partition walls of buildings, or for walls near site boundaries. As the concrete panel, an ordinary mixture or a lightweight cellular concrete panel, a so-called ALC panel or the like is used. In many cases, it is desired that both sides of the concrete panel used in each of the above-mentioned areas be patterned, and methods for obtaining the double-sided patterned concrete panel are roughly classified into a vertical placing method and a flat placing method. In the vertical pouring method, the flat box-shaped formwork consisting of the formwork panel 2 surface engraved with each pattern on both sides of the concrete panel and the peripheral members is placed in the vertical position, and the concrete slurry is poured from the upper opening. Thus, a concrete panel with a double-sided pattern corresponding to the engraved pattern can be obtained. The flat-casting method is one in which a bat-shaped mold made up of one panel for a formwork in which a pattern on one side of a concrete panel is engraved and peripheral members is placed flat, and concrete slurry is placed on it. A concrete panel with a single-sided pattern corresponding to the engraved pattern on one surface of the panel is obtained, and a pattern is engraved on the other surface without the pattern by a separately prepared machining process or the like to obtain a double-sided patterned concrete panel.

[0003]

However, each of the methods for obtaining a double-sided patterned concrete panel from lightweight cellular concrete has many drawbacks. That is, it is difficult to obtain a lightweight cellular concrete panel having a uniform density, composition and the like by the vertical casting method. This is because in the case of a lightweight cellular concrete panel, since the casting height is high, the air bubbles below are crushed and the concrete density is different depending on the site, so that the heterogeneity of the concrete slurry is likely to occur. The other flat-placing method requires engraving of a pattern on one side without a pattern by post-processing, which is extremely disadvantageous in terms of processing equipment, labor, time, etc., and is accompanied by processing of cutting chips. .
It is an object of the present invention to provide a lightweight cellular concrete panel with a double-sided pattern, in which the double-sided pattern can be easily and surely applied without any problem in homogeneity, and a method for producing the same.
Hereinafter, the lightweight cellular concrete panel is simply referred to as "concrete panel" in the present specification.

[0004]

A method for producing a double-sided patterned concrete panel according to the present invention is one in which a concrete mold is engraved on one side of a double-sided patterned concrete panel and one of the flat frames is filled with concrete slurry. The reinforcement bar that is configured to the required thickness is embedded in the slurry by half the thickness and cured to a semi-cured state.
The concrete slurry is cast into the other formwork of the flat plate engraved with the pattern form on the other side of the double-sided patterned concrete panel, and the concrete cured to the semi-cured state is applied to the upper surface of the other formwork. The upper surface of the one of the inserted molds is inverted and closely adhered to continue concrete curing, and after the concrete is hardened, both molds are removed.

[0005]

[Operation] In the method for producing a concrete panel with double-sided pattern, concrete slurry is cast into two flat molds in which respective pattern molds are engraved to form two panel members, respectively, and these are adhered to each other. The two-sided pattern can be obtained at the same time as the casting operation and the material can be made uniform. The double-sided patterned concrete panel obtained in this way is obtained by adhering two panel members with a pattern on one side in close contact with each other on the other side of the pattern, A pattern is provided. At this time, the reinforcement-like reinforcing bar unit remarkably reinforces the bonding strength of the two panel members against the close integration.

At the time of the close integration, concrete slurry is cast into one of the two frame members forming one of the panel members, the reinforcing bar arrangement unit is arranged, and the concrete is semi-cured. By curing up to this point, the concrete will not fall off even if the concrete slurry is cast and the upper surface of the other formwork is reversed. Further, when the protruding portion of the reinforcing bar arrangement unit on the upper surface of the concrete in a semi-hardened state is embedded in the concrete slurry of the other form, the concrete slurry is immediately after being placed, for example, in the reinforcing bar arrangement unit. Even if the member locally cuts the concrete slurry, the concrete slurry is immediately restored and integrated, and evenly adheres to the surface of the reinforcing bar unit and hardens.

[0007]

EXAMPLE FIG. 1 is a perspective view including a partially broken surface of a double-sided patterned concrete panel obtained in this example, FIG. 2 is a vertical cross-sectional view as seen from the direction of arrow XX in FIG. 1, and FIG. Is an explanatory view showing an embodiment of the method for producing a double-sided patterned concrete panel of the present invention, and FIG. 4 is an explanatory view of a production line for a double-sided patterned concrete panel incorporating the production method of FIG. In the figure, 1 is a double-sided concrete panel, 11a, 11
Reference numeral b is a panel member, 12 is a pattern, 2 is a reinforcing bar arrangement unit, 3a and 3b are molds, and 31a and 31b are pattern molds. As shown in FIG. 1 and FIG. 2, the concrete panel 1 with double-sided pattern of the present embodiment has two panel members 11a and 11b whose thicknesses are approximately halved and overlap each other, and is further integrated into two panel members 11a and 11b. A reinforcing bar arrangement unit 2 having an area that extends over almost the entire area of the integrated surface and extending across the thickness direction of both members is embedded and embedded.

The reinforcing reinforcing bar unit 2 has a flat box-like shape by connecting a pair of mesh reinforcing bars 21 in which reinforcing bars are arranged in a matrix in the vertical and horizontal directions with flat steel plates 22 at intervals. By arranging this reinforcing bar arrangement unit 2 at the center of the thickness of the double-sided patterned concrete panel 1, when the two panel members 11a and 11b whose thickness has been halved are closely adhered and integrated, both members are strengthened. Reinforce the connection. Double-sided concrete panel 1
As shown in FIG. 3, the manufacture of the two panel members 11
The molds 3a and 3b corresponding to a and 11b are placed flat, and the concrete slurry 13 is placed on each of the molds 3a and 3b.
Is performed, the reinforcing bar arrangement unit 2 is embedded at a timing of a specific condition described later, and the molds 3a and 3b are united. Specifically, pattern dies 31a and 31b for predetermined patterns 12 formed on the two panel members 11a and 11b, respectively, are formed in advance on the bottom surfaces of the respective molds 3a and 3b and, if necessary, on the side surfaces. The pattern-shaped engraving may be performed directly on the mold, or as a separate member, a sheet or plate to be laid inside the mold may be prepared and engraved on this sheet or the like. These pattern type 31
a and 31b are completed concrete panels with double-sided pattern 1
They may be the same or different on the front and back depending on the usage status of.

The molds 3a, 3b are constructed so that they can be disassembled on the bottom and the periphery, and the vertical and horizontal dimensions are the standard dimensions of the double-faced concrete panel 1 to be manufactured, and the peripheral height is the thickness of the two panel members 11a, 11b. The total height of the perimeters of the molds 3a and 3b is set to the completed thickness of the double-sided patterned concrete panel 1. It should be noted that, on the periphery of one of the molds 3a and the periphery of the reinforcing bar arrangement unit 2, the relative position of the two,
A supporting mechanism for the relative height is regulated, and a positioning mechanism that combines a nut 23 and a bolt 24 is arranged in the periphery so that it can be used also for a construction mounting hardware of the completed double-sided patterned concrete panel 1. The one mold 3a prepared as described above is placed horizontally, and the concrete slurry 13 supplied from the slurry supply tank 4a is placed therein,
Immediately, the reinforcing bar arrangement unit 2 is embedded to a half thickness and positioned, and the concrete slurry 13 is cured until it becomes a predetermined semi-hardened concrete 14.

The predetermined semi-hardened state is the time when the concrete 14 inside and the reinforcing bar arrangement unit 2 do not fall out under the condition that one of the molds 3a in which the concrete slurry 13 is cast is inverted by 180 °. Although it depends on the shape and size of the patterned concrete panel 1, the shape and size of the reinforcing bar arrangement unit 2, the property of the concrete 14, and the like, the time value can be set experimentally in advance.
For example, a conventionally known lightweight aerated concrete material containing cement and silica sand as a main material and a foaming agent and the like is manufactured for a partition, and has a thickness of 80 m / m, a length and a width of 900.
For a mm panel, about 50 minutes after casting was sufficient. Immediately before the concrete 14 becomes the predetermined semi-hardened state, the concrete slurry 13 supplied from the slurry supply tank 4b is placed in the other horizontally placed mold 3b, and the one mold 3a is immediately inverted by 180 °. Then, the mold 3b is overlaid and brought into close contact. With this operation, one mold 3
Half of the reinforcing bar arrangement unit 2 protruding above the concrete 14 a is embedded in the concrete slurry 13 of the form 3 b, and the concrete slurry 13 is hardened in this state. In the above process, the reinforcing bar arrangement unit 2 is buried in the concrete slurry 13 twice in each half of the height, but in any case, since it is the concrete slurry immediately after being placed, it has high fluidity and is not buried. Even if the concrete slurry 13 is cut by the member of the reinforcing bar arrangement unit 2 without causing resistance, the member surface of the reinforcing bar arrangement unit 2 is uniformly restored by being restored immediately and fully integrated to leave no defect. cover.

Further, the concrete slurry 13 that adheres to the semi-hardened concrete 14 is also fresh immediately after pouring, and is clean and excellent in activity, so that both are integrated and hardened with high joint strength. When the concrete slurry 13 in the mold 3b becomes hardened concrete 14 and can be demolded, the molds 3a and 3b are dismantled and removed, and curing is continued to obtain a double-sided patterned concrete panel 1. FIG. 4 shows an outline of an example of the production line for the concrete panel 1 with double-sided pattern. As the concrete slurry 13 to be placed in the molds 3a, 3b, lightweight cement concrete milk for air-contained concrete containing air bubbles and additives is supplied from the slurry supply tanks 4a, 4b, and in the same manufacturing process as in FIG. A double-sided patterned concrete panel 1 before curing is obtained.

Then, the concrete panel 1 with the double-sided pattern, in which the molds 3a and 3b are dismantled and demolded, is loaded on a carrier 5 and pre-cured in a pre-curing chamber 6 in a normal-pressure steam atmosphere. Complete curing in high-pressure steam atmosphere and remove. The double-sided patterned concrete panels 1 that have been cured are taken out one by one from the transport carriage 5, subjected to inspection and finish coating in the coating space 8, transported to the storage space 9 and stored, and shipped as required. Since the double-sided patterned concrete panel 1 according to the present embodiment is constructed and manufactured as described above, even a lightweight cellular concrete panel which is apt to cause a problem in homogeneity can have a very uniform property. In addition, the two panel members 11a and 11b
Even if it is divided into two parts and joined later, they can be strongly and surely integrated by the embedded interposition of the reinforcing bar arrangement unit 2 and the close contact at a good timing. By dividing into the two panel members 11a and 11b, it is possible to efficiently form a double-sided pattern.

The method for producing a double-sided patterned concrete panel of the present invention can be modified in various ways other than the above-mentioned embodiment. For example, the reinforcing bar arrangement unit can be mounted in advance before the concrete slurry is poured into one of the molds. In this case, the nut 23, which is a metal when mounting and mounting as a panel, is not located in the central portion of the panel thickness, but this does not cause a problem in use. Further, if the thickness of one of the molds is changed, the metal piece can be positioned at the center of the thickness by the above means. The reinforcing bar arrangement unit 2 is a pair of mesh bars 21 in the above-mentioned embodiment, but it may be composed of an extract band metal. Also,
Even in the production line, one slurry supply tank can be shared by one group, and can be placed and joined on one line.

[0014]

EFFECTS OF THE INVENTION According to the method for producing a double-sided patterned concrete panel according to the present invention, it is possible to obtain a lightweight cellular concrete panel having excellent homogeneity and capable of easily and reliably applying a double-sided pattern.

[Brief description of the drawings]

FIG. 1 is a perspective view including a partially broken surface of a double-sided patterned concrete panel obtained in this example.

FIG. 2 is a longitudinal sectional view as seen from the direction of arrows XX in FIG.

FIG. 3 is an explanatory view showing an example of a method for producing a patterned concrete panel of the present invention.

4 is an explanatory view of a production line for a concrete panel with a double-sided pattern incorporating the production method of FIG.

[Explanation of symbols]

 1 Double-sided concrete panel 3a, 3b Formwork 11a, 11b Panel member 12 Pattern 13 Concrete slurry 14 Concrete 31a, 31b Pattern type

Claims (2)

(57) [Claims] 1. A reinforcing bar arrangement unit having a required thickness, in which concrete slurry is cast into one formwork of a flat plate on which one side of a lightweight cellular concrete panel with double-sided pattern is engraved. Is buried in the slurry for about half of its thickness and cured to a semi-cured state,
The concrete slurry is cast into the other formwork of the flat plate in which the pattern form is engraved on the other side of the light-weight cellular concrete panel with the double-sided pattern, and the upper surface of the other formwork is cured to the semi-cured state. The method for producing a lightweight cellular concrete panel with double-sided pattern, wherein the upper surface of the one mold containing the concrete is inverted and closely adhered to continue concrete curing, and after the concrete is hardened, both molds are removed to form a panel. 2. The reinforcing bar arrangement unit is placed at a predetermined depth and the concrete slurry is placed on one of the flat form frames in which a pattern mold is engraved on one side of the double-sided lightweight cellular concrete panel. Doing, curing the concrete to a semi-hardened state, casting the concrete slurry into the other formwork of the flat plate engraved with the pattern mold on the other surface of the double-sided patterned lightweight cellular concrete panel, Double-sided to form a panel by continuing the concrete curing by reversing and closely adhering the upper surface of one of the molds containing the concrete that has been cured to the semi-hardened state on the upper surface of the mold and after hardening the concrete. A method for manufacturing a lightweight cellular concrete panel with a pattern.