JP2916565B2 - Method for producing molded article for fireproof coating - 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 manufacturing a fire-resistant coated molded article excellent in fire resistance, formability and workability, which is applied to a steel frame of a building or the like.

[0002]

2. Description of the Related Art Conventionally, as a method of applying a fireproof coating to a steel frame or the like of a building, a material mainly composed of cement and a fire-resistant fibrous substance such as rock wool or glass fiber is applied to a site. In general, a method of directly spraying the coating portion on the coating portion, or a method of attaching a calcium silicate-based refractory molded plate to the coating portion on site is generally adopted.

[0003]

However, these methods have various disadvantages. In the spraying method, the coating material powder is scattered at the time of spraying, and the adhesive strength of the coating material to a coating portion such as a steel frame surface. Is insufficient, causing peeling. Further, in order to obtain fire resistance that can withstand practical use, it is necessary to increase the thickness of the coating material to some extent, and it takes a long time for the spraying operation, resulting in poor workability.

[0004] On the other hand, in the forming plate method, although there is no problem regarding dust scattering, adhesive force or working time unlike the spraying method, since the forming plate is generally a flat shape, the shape according to the shape of the covering portion is not considered. It has the drawback that it takes time and effort to process it. A general method for producing a calcium silicate-based molded plate is a method in which a calcium silicate slurry is compression-press-molded. In this molding method,
The production efficiency is not so good because the molding is performed by the batch method using the molding frame.

[0005] For this reason, continuous molding has been practiced using an extruder. But in this case,
Since the flowability of the calcium silicate-based raw material is poor and the moldability and shape retention are inferior, the molded product is deformed and cannot have a desired shape, or a crack is formed, and a product having a free shape is formed. This results in a disadvantage that it is difficult to obtain. In addition, extrusion molding is performed by increasing the extrusion pressure or providing a vacuum chamber on the side opposite to the pressurized side because the fluidity of the raw material is poor, but extrusion molding is performed. In addition, the extruder itself becomes expensive due to the need for power for manufacturing, and the manufacturing cost is also high.

[0006] In addition, various refractory materials and various construction methods have been proposed. However, from the viewpoints of the fire resistance performance, workability, and labor saving of construction, there is still no satisfactory material. An object of the present invention is to provide a fire-resistant coated molded article excellent in fire resistance performance, workability, and moldability with good productivity at low cost.

[0007]

Means for Solving the Problems The present inventors have conducted intensive studies for the purpose of solving the above-mentioned problems, and as a result,
The fireproofing material matrix such as cement, fibrous material having fire resistance, such as rock wool or compositions of glass fibers was large amount, by molding into a shape corresponding to the more coating site extrusion forming shape It has been found that a fire-resistant coated molded article having excellent fire resistance and workability can be manufactured with high productivity, and the present invention has been accomplished.

The object of the present invention is to provide a method for producing a fire-resistant coated molded article by molding a composition comprising a base material of a fire-resistant coated article and a fire-resistant fibrous substance as main components.
Said refractory coating molding selected from cement, gypsum and lime
A composition comprising a body matrix and 60 to 80% by weight of the refractory fibrous substance based on the total amount of the composition;
It can be achieved by a process for preparing extruded to fire protection moldings, characterized in Rukoto. Various types of cement, gypsum, and lime can be used as the base material of the fire-resistant coated molding used in the present invention. More specifically, as cements, alumina cement, Portland cement,
Silica cement, fly ash cement, blast furnace cement, phosphate cement, water glass, oxychloride cement, or a mixture thereof can be used. As the gypsum, natural gypsum, chemical gypsum or dihydrate, hemihydrate and anhydrous salt of these gypsums can be appropriately selected and mixed for use. As the limes, quick lime, slaked lime, dolomite plaster and the like can be used.

The refractory fibrous substance used in the present invention is preferably an inorganic fiber. Typically, in addition to rock wool and glass fiber, ceramic fibers such as alumina fiber, zirconia fiber, silica fiber, magnesia fiber, etc. Fiber can be used. These refractory fibrous substances are added in an amount of 5% based on the total amount of the composition including the base material for the fire-resistant coated molded article and various admixtures described below.
0% by weight or more, preferably 60% by weight to 80% by weight. When the amount of the refractory fibrous substance is less than 50% by weight, the fire resistance is insufficient, and when the amount is more than 80% by weight, the fluidity is reduced, the material is clogged inside the molding machine, and cracks occur in the molded product. Problems occur.

Furthermore, method for producing the refractory coating moldings in the present invention, a composition composed mainly of the fire protection moldings matrix and refractory fibrous material is intended to more molded extrusion forming shape However, various substances are mixed with the composition at the time of molding. For example, an impact-resistant reinforcing material made of organic fibers such as pulp and polypropylene acrylic, a thickener and a binder made of a water-soluble resin such as methyl cellulose, polyvinyl alcohol resin, SBR latex, and an acrylic resin emulsion, lignin sulfonate, Superplasticizers such as polycarboxylates, curing accelerators such as calcium chloride and tin chloride, fillers such as calcium carbonate, talc and silica, lightweight aggregates such as perlite and permiculite, aluminum hydroxide, magnesium hydroxide, etc. Including various types of substances added to ordinary cement production, including fire-resistant improvers composed of high-water-absorbing resins and other inorganic materials having water of crystallization and high water-absorbing resins, the above-mentioned fire-resistant fibrous substances The composition may be blended to the extent that the blending ratio is not impaired, for example, 1 to 5% by weight based on the total amount of the composition.

[0011] Water is added to a composition containing the above-mentioned fire-resistant coated molded base material, the refractory fibrous substance and, if necessary, various admixtures, and the mixture is extruded to form a uniformly dispersed molding material. Thus, a fire-resistant coated molded article having a shape corresponding to the shape of the coated portion can be obtained.

[0012]

The present invention will be described in more detail with reference to the following examples. Note that the present invention is not limited to these, and various modifications are possible. [Examples 1 to 5 and Comparative Examples 1 to 4] Cement is used as a base material of a fire-resistant coated molded product, rock wool is used as a fire-resistant fibrous substance, and pulp and methyl cellulose having a fiber length of 1 mm or less are shown in Table 1 below. 65 parts of water was added to the composition blended in the proportions described above, and the mixture was uniformly dispersed to obtain a molding material.

[0013]

[Table 1]

The obtained molding material is introduced into an extruder, and molded under the conditions of a pressure of 5 kg / cm ² , an extrusion speed of 8 m / min and a degree of reduced pressure shown in Table 1, to obtain a shape shown in FIG. A fire-resistant coated molded article was prepared. The moldability of the fire-resistant coated molded article thus obtained was evaluated based on (1) the state at the time of molding and (2) the degree of deformation of the product.

The evaluation method is as follows: (1) The condition at the time of molding is visually evaluated, and there is no abnormality (symbol A), the extrusion speed fluctuates and meandering of the product is recognized (symbol B), and And the product was clogged (crack C). (2) the degree of deformation of the products is determined by measuring the angle theta ₁ and theta ₂ in FIG. 1, deviation Δθ from vertical ₁ (= 90-theta ₁₎
And Δθ ₂ (= 90−θ ₂ ).

Table 1 also shows the evaluation results on the moldability. As is evident from Table 1, it is found that those containing 65% by weight or more of the refractory fibrous substance (rock wool) have good moldability. [Examples 6 to 10 and Comparative Examples 5 and 6] Cement and gypsum as a base material of a fire-resistant coated molded product, rock wool as a fire-resistant fibrous substance and glass fiber having a fiber length of 13 mm, and pulp having a fiber length of 1 mm or less as a binder To a composition prepared by mixing methylcellulose and aluminum hydroxide as a fire resistance improver in the proportions shown in Table 2 below, add 65 parts or 60 parts of water with respect to the total amount of the composition, and uniformly disperse the molding material. I got

[0017]

[Table 2]

The obtained molding material was introduced into an extruder, and the pressure was 5 kg / cm ² , the extrusion speed was 10 m / min, and Table 2 was used.
Was formed under the conditions of the degree of reduced pressure shown in Table 2 to prepare a fire-resistant coated molded plate having a thickness of 25 mm. In addition, sonotrite-based calcium silicate, a typical product of fire-resistant molded articles,
What was formed into a 25 mm thick flat plate was Comparative Example 6. Table 2 also shows the physical properties and mechanical strengths of the fire-resistant coated molded plate and the sonotrite-based calcium silicate plate.

The fire resistance of the fire-resistant molded article thus obtained was evaluated based on (1) weight loss, (2) volume shrinkage, and (3) back surface temperature. The evaluation method is
Regarding (1) weight reduction and (2) volume shrinkage, the refractory coated molded plate was heated in an electric furnace at 1000 ° C. for 1 hour, and after cooling, the weight and volume were measured. Was compared. (3) Regarding the back surface temperature, one side of the fire-resistant coated molded plate was set at 1000 ° C.
Is the maximum temperature of the back surface when heated for 1 hour.

Table 2 also shows the evaluation results regarding the fire resistance. As is clear from Table 2, the refractory fibrous material (rock wool or a mixture of rock wool and glass fiber) was added to 6
It can be seen that those blended at 5% by weight or more have good fire resistance. Further, the nail indentation load was measured using the same fire-resistant coated molded plate. The measuring method was such that a load required for pushing a nail having a diameter of 1.8 mm and a length of 32 mm at a speed of 20 mm / min was measured. As is evident from Table 2, the fire-resistant coated molded plate manufactured according to the present invention has a significantly smaller nail pushing load than the conventional example, which is advantageous in performing a construction work.

[0021]

As described above, according to the production method of the present invention, a fire-resistant coated molded article excellent in fire resistance, workability and workability can be obtained with good productivity and at low cost. In other words, the fire-resistant coated molded article produced according to the present invention contains a large amount of fibrous substances, and thus has high shape retention during molding. Therefore, even when molded into a complicated shape, the molded article may be deformed. Since it can be easily formed into a shape corresponding to the shape of the coated portion, workability and workability can be remarkably improved as compared with a calcium silicate-based formed body.

The fire-resistant coated molded article produced by the present invention is mainly composed of a fibrous substance, and has excellent strength, especially impact resistance, so that damage due to handling during construction can be prevented. Further, since the voids are formed inside the molded article due to the entanglement of the fibers of the fibrous substance, the heat conductivity can be reduced and the heat resistance can be improved. In addition, shrinkage and cracking of the fire-resistant coated molded article during heating are small, and it is possible to prevent the fire-resistant coated molded article from falling off from the coated portion.

In addition, the composition comprising the base material of the fire-resistant coated molded article according to the present invention and a large amount of a fire-resistant fibrous substance as the main components:
Since there is no need to evacuate during molding, an expensive device such as a vacuum device is not attached to the extrusion molding device, and the manufacturing cost can be reduced.

[Brief description of the drawings]

FIG. 1 is a view showing a molded shape used for evaluating the moldability of a fire-resistant coated molded article produced according to the present invention.

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Claims (1)

(57) [Claims] 1. A method for producing a fire-resistant coated molded article by molding a composition comprising a fire-resistant coated molded article base material and a refractory fibrous substance as main components, wherein the composition comprises cement, gypsum and
Said fire protection moldings matrix selected from fine lime, together and a 60% to 80% by weight of said refractory fibrous material with respect to the total amount of the composition, that you extruding the composition A method for producing a fire-resistant coated molded product.