JP3336375B2 - Concrete roof tile - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a concrete roof tile formed by molding concrete containing at least fiber.

[0002]

2. Description of the Related Art JI has been used as a roof tile for a conventional house.
Residential roofing asbestos slate shown in SA 5423, JI
There are thick slate shown in SA 5402, and clay straw shown in JIS A 5208. Cosmetic asbestos slate for residential roofs is made of cement mixed with asbestos and water and has a thickness of about 4 to 7 mm and a weight of about 60 to 90 kg / 3.3 m ² when laid. There is an advantage that the cutting property and the workability are good. Thick slate is made by mixing cement and sand and water, pressing it into a predetermined shape and curing it.It is about 11 to 16 mm thick, thick, thick and heavy, When laying, there is an advantage that the space between the roof tile and the base plate becomes large, so that heat is hardly transmitted, and that the base plate is hard to rot because sufficient ventilation can be provided. Straw clay is a material obtained by shaping a raw material clay into a predetermined shape and firing it. The thickness is about 14 to 20 mm, which is advantageous in that it is thick, heavy, and durable. .

[0003]

However, the cosmetic asbestos slate for the roof of a house has a small thickness and no weight.
Also, when laying, there is a problem that heat is easily transmitted because the space between the slate and the base plate is narrow, and furthermore, the base plate is liable to rot because the ventilation is not sufficiently performed due to the small thickness. In addition, the use of asbestos may cause health problems. Further, the thick slate has a weight of about 130 to 160 kg / 3.3 m ² when laid, and has a problem that the workability and the cutting property are poor. Further, there is a problem that the durability of the clay is slightly lower than that of the straw. Furthermore, clay straw has such a problem that the weight at the time of laying is as heavy as about 150 to 200 kg / m ^2, and the cutability is poor and the workability is slightly inferior.

As described above, the conventional tiles have advantages and disadvantages, but when they are used in a general house or the like, they are mainly used to take advantage of the advantages. We must accept the disadvantages that accompany it, and for that reason, there is no feeling of weight, poor workability, poor cutting performance, poor durability, poor ventilation, the base plate is easily rotted and heat insulation He always had the problem of poor sex.

[0005] In addition, thick slate and clay straw have relatively small tile sizes of less than about 370 x 360 mm for non-standard products and less than about 485 x 350 mm for non-standard products. Since the number of sheets to be constructed is as large as about 25 to 50 sheets / 3.3 m ² (3.3 m ² = 1 tsubo), it takes a long time to construct the tiles, which deteriorates the workability and the construction of the tiles per unit area As the number of tiles increases, the area of the overlapping portion of adjacent tiles increases, and there is a problem that the weight of the tiles per unit area increases.

The present invention solves the above-mentioned various problems of the conventional tiles by minimizing the problems of the conventional tiles and maximizing their advantages. The purpose is to provide a concrete tile that can be used.

Another object of the present invention is to increase the size of a tile as much as possible without using asbestos having a health problem, thereby improving the workability of the tile and reducing the weight per unit area. .

[0008]

According to the first aspect of the present invention, at least a hydraulic binder, water, an AE agent,
Agent, AE water reducing agent, high performance AE water reducing agent or surfactant, etc.
And approximately 5% to 40% of sand in absolute volume,
Hydraulic containing approximately 0.5% to 1.5% fiber by volume
Press-forming the binder composition to a thickness of approximately 7 mm
The concrete roof tiles have a thickness of 11 mm and a surface area of 1300 cm ² or more .

According to a second aspect of the present invention, there is provided the
Synthetic resin foam in concrete roof tiles
The body contains approximately 1 to 10% in absolute volume .

[0010] The means of claim 3 is described in claim 1 or 2.
In the concrete roof tile, the fiber is
It is in the place where it was made into fiber .

According to a fourth aspect of the present invention, there is provided any one of the first to third aspects.
The concrete tile according to any one of claims 1 to 3, wherein the fiber is pulled.
Strength is 10 × 10 ³ (kgf / cm ² ) or more, Young's modulus is 3 ×
10 ⁴ (kgf / cm ² ) or more and elongation at break of 3%
The reason is that the fiber has the above physical properties .

[0012] The means of claim 5 is the method of claim 1, 2 or 4.
In the concrete tile according to any one of the above, the fiber
It is in the place of vinylon fiber .

[0013] The means of claim 6 is any of claims 1 to 5
The concrete tile according to any of the above items,
0cm ² or more .

According to a seventh aspect of the present invention, there is provided any one of the first to sixth aspects.
5. The concrete tile according to claim 1, wherein the hydraulic connection
The material is cement .

[0015] The means of claim 8 is any of claims 1 to 7.
Fly ash for concrete tiles described in
And / or a blast furnace slag of about 10 to 50 weights of cement
% By weight .

[0016]

[0017]

[0018]

[0019]

[0020]

Embodiments of the present invention will be described below. Examples of the sand used in the present invention include river sand, sea sand, mountain sand, crushed sand, silica sand, blast furnace slag sand, and the like made of rock by natural action, and the particle size is preferably 5 mm or less, particularly 2.5 mm or less. The use of fine sand is preferred, and the specific gravity may be, for example, in the range of about 2.6, and the type is not particularly limited. About 5 to 40% of such sand mixed in absolute volume means that if it is 5 % or less, the drying shrinkage ratio becomes large, and the roof tiles are likely to be warped or deformed. This is because the formability and surface properties of the tile are deteriorated, and additionally, the reinforcing hardening of the fibers mixed together is reduced. About 20-30% of sand
Within this range, the moldability and surface properties are particularly good, and the reinforcing hardening of the fibers is not reduced, which is particularly effective.

Examples of the fiber to be mixed include alkali-resistant glass fiber, vinylon fiber, nylon fiber, polypropylene fiber and the like. These fibers may be mixed or used alone according to the tile design. Cases arise. The length of the fiber is preferably about 5 mm to 20 mm on average, but is not particularly limited. Such fibers are mixed at about 0.5 to 1.5% in absolute volume, and this makes it possible to obtain a concrete roof tile which is strong and has high bending strength. If it is 0.5% or less, the bending strength becomes small, and if it is 1.5% or more, the formability and surface properties of the tile deteriorate, and the effect of reinforcing the fiber is reduced. . Approximately 0.8 in absolute volume of mixed fiber
If the content is in the range of from 1.2 to 1.2%, the formability and surface properties of the tile are particularly good, and the effect of reinforcing fibers is most obtained, so that it is particularly preferable.

Among the above-mentioned fibers, alkali-resistant glass fibers have higher flexural strength than nylon fibers and polypropylene fibers, and have alkali resistance.
It is preferably used because it is nonflammable. Vinylon fibers are also preferably used because they have high bending strength, are more resistant to alkali than alkali-resistant glass fibers, and have good adhesion to hydraulic binders, especially cement. You. Table 1 shows data comparing the tensile strength, Young's modulus and elongation at break of the alkali-resistant glass fiber and vinylon fiber.

[0023]

[Table 1]

As is clear from Table 1, both the alkali-resistant glass fiber and the vinylon fiber have sufficiently high tensile strength and Young's modulus, and therefore, when a load in the thickness direction is applied to a concrete tile containing these fibers, Is difficult to bend,
In addition, it is not easily broken, and has an effect of improving the bending strength of the tile. On the other hand, with respect to the elongation at break, the alkali-resistant glass fiber is relatively small at 2%, while the vinylon fiber is sufficiently large at 5%. It can be understood that it can withstand greater deformation in the thickness direction than a concrete roof tile containing, and has good deformation followability.

Here, the amount of deformation of each tile in the thickness direction due to an external load increases as the size of the tile increases and the number of sheets used per unit area decreases. When fibers are used, there is a certain limit to enlarging the size of concrete tiles due to poor deformation followability, whereas when vinylon fibers are included in concrete tiles, such restrictions are few. It can be seen that this has the effect of suppressing a decrease in strength due to the enlargement of the tile, and inhibiting the breakage of the large tile. In addition, nylon fibers and polypropylene fibers have deformation followability,
The effect of improving the bending strength described above is extremely poor.

Based on such findings, the present inventor has made it possible to reduce the number of works per unit area by increasing the size of the tiles by adding vinylon fibers to the concrete tiles, thereby improving the workability. Along with this, we succeeded in reducing the weight of the tile per unit area by reducing the area of the overlapping part of adjacent tiles. Here, in the case of enlarging a concrete tile using vinylon fiber, specifically, for example, the surface area, that is, the product of the vertical size and the horizontal size of the tile is 1300 cm ² or more, more preferably 1700 cm ² or more.
² or more, more preferably 2000 cm ² or more. Incidentally, even fibers other than vinylon fibers, for example, have a tensile strength of 10 × 10 ³ (kgf / cm ² ) or more, a Young's modulus of 30 × 10 ⁴ (kgf / cm ² ) or more, and an elongation at break. If the fiber has a physical property of a rate of 3% or more, it can be adopted as a reinforcing fiber for enlarging a tile.

On the other hand, when the surface area of the tile is relatively small, for example, when the surface area is about 1700 cm ² or less, the amount of deformation of the tile in the thickness direction due to an external load is relatively small. Even with fiber,
Since the problem of tile breakage is unlikely to occur, a sufficient reinforcing effect can be obtained by mixing alkali-resistant glass fibers into concrete tiles. Of course, even when vinylon fibers are mixed into such a concrete tile having a relatively small surface area, a sufficient reinforcing effect can be obtained, and therefore, the vinylon fibers have a good reinforcing effect regardless of the size of the tile. .

Examples of the hydraulic binder include cement, blast furnace slag, gypsum, adhesives, etc. Among them, cement is most preferable because it has high strength, excellent water resistance, and is relatively inexpensive. As the cement, Portland cement such as ordinary Portland cement, early-strength Portland cement, ultra-high-strength Portland cement, moderate heat Portland cement, or mixed cement such as blast furnace cement, silica cement, fly ash cement, or ultra-high-strength cement , Expanded cement, special cement such as cosmetic cement (white cement, color cement, etc.), or alumina cement, etc., which are preferably used depending on the application.

The proportion of water to be added to the hydraulic binder, that is, the ratio of the water binder is suitably in the range of approximately 25 to 50% by weight. If the content is 25% or less, the viscosity of the hydraulic binder composition increases, and molding becomes impossible. On the contrary, 50%
When the ratio exceeds, fibers and sand tend to separate and the bending strength tends to decrease. On the other hand, when the content exceeds about 33%, warpage and deformation tend to occur easily when sand is not introduced. Therefore, the ratio of the water binder without sand is approximately 25 by weight.
The optimum range is from 30 to 33%, and the most ideal state is when the water binder ratio is in the range from 27 to 31%. When the water binder is mixed at a ratio of about 35% or less, the dispersion of the hydraulic binder deteriorates, and sufficient mixing cannot be performed. Therefore, an admixture such as a surfactant is required. In the ideal state, the amount of the admixture mixed is about 0.5 to 1% of the binder weight.
5% by weight. As an admixture, for example, if an AE agent, a water reducing agent, an AE water reducing agent, a high-performance AE water reducing agent, a surfactant or the like is mixed, the bending strength is improved by, for example, about 10%, and the quality is stabilized. And more preferable results can be obtained. The water binder ratio is about 25 to 33 by weight.
%, Good properties can be obtained without the addition of sand. However, the addition of sand results in a lower drying shrinkage, less warpage and the like, and an improvement in flexural strength and cost. It is also advantageous and preferable.

A concrete roof tile is obtained by molding and processing the hydraulic binder composition obtained by adding water to such sand, fiber, hydraulic binder, etc. in an uncured state.
The forming process in this case is usually pressure forming, and specifically, press forming is suitable. This is because it is not possible to easily form a thin product having a complicated shape such as a box shape by extrusion molding or paper forming. That is, the concrete roof tile has a relatively small average thickness of about 7 to 11 mm excluding the protrusions, and its outer shape is also as shown in FIG.
A lower projection 2 is provided at the lower part of the front end of the concrete roof tile 1 so as to make the appearance of the roof tile thicker. This is because it cannot be formed into a complicated uneven shape or a box shape such as providing a lower projection 4 which is hooked on a roof tile on a floor board (not shown). In addition, the shape of the other parts of the concrete roof tile 1 may be flat or corrugated.

As a method of press molding, a method of kneading a hydraulic binder composition with a water binder ratio of about 40% and subjecting the mixture to pressure dehydration molding, or a method of reducing the water binder ratio to about 25% is used. There is dry press molding which is small and does not dehydrate, and any method may be used. However, pressure dehydration molding is more preferable in terms of watertightness.

The reason why the average thickness of the concrete roof tile excluding the protrusions is set to a thickness of about 7 to 11 mm is 7 mm
If it is less than the above, the bending strength becomes small, and it becomes difficult to form the roof tile. Although there is a method of improving the formability by reducing the amount of sand to be added, the disadvantage that warpage or deformation tends to occur as described above appears, which is not preferable. On the other hand, if it is 11 mm or more, the weight becomes large, which is not preferable in workability, transportation work and the like.

After press molding, the concrete tile is cured by a normal curing process performed on a normal concrete product, for example, by curing in the air, in water, in steam, or in an autoclave. Complete. Furthermore, on the obtained concrete tile,
In order to improve the appearance of the surface, painting or the like with an acrylic or acrylic silicone paint may be performed.

When the synthetic resin foam is mixed with the hydraulic binder composition at about 1 to 10% in absolute volume, the weight of the concrete tile can be reduced and the resistance to freezing and thawing is improved, which is preferable. . If it is 1% or less, both weight reduction and freeze-thaw resistance are not sufficient, and if it is 10% or more, the bending strength becomes small. Various known materials can be used as the raw material of the synthetic resin foam in this case,
There is no particular limitation. Also, synthetic resin foam is
Although it may be a crushed product or an irregular shape obtained by crushing a foamed synthetic resin, a spherical or substantially spherical shape, that is, a so-called bead, has less weight and volume measurement errors, and a concrete roof tile mixed with this. It is preferable because the variation in the specific gravity is reduced and a tile with stable quality can be obtained.
Further, when stress is applied to the concrete tile mixed with the synthetic resin foam, if beads are used, the beads can be dispersed, and a high-strength concrete tile can be obtained. Are concentrated on the stress, and the strength is weakened.

The average diameter of the synthetic resin foam is from 0.1 to 2.
The range is preferably 0 mm, more preferably 0.1 to 1.5 mm. If it is less than 0.1 mm, it becomes too small, and when kneading with water and a hydraulic binder, the fluidity of the kneaded material tends to decrease, and it is difficult to sufficiently secure the mixing amount of the synthetic resin foam. However, it is likely that it is difficult to sufficiently reduce the weight of the roof tile containing this. On the other hand, if the average diameter is 2.0 mm or more, the number of synthetic resin foams per unit volume of the tile tends to be limited, and the strength tends to be weak. The average diameter when the synthetic resin foam is a pulverized product or an irregular shape is represented as an average value of a maximum length and a minimum length.

The synthetic resin used as a raw material of the synthetic resin foam includes styrene resins such as polystyrene, olefin resins such as polypropylene and polyethylene, various copolymers such as acrylonitrile-styrene copolymer and styrene-ethylene copolymer. Polymers (of course, random, block,
Grafts, etc.), polyvinyl chloride, polyvinyl chloride resins such as polyvinylidene chloride, etc.
Among them, when polystyrene is used, the strength is strong,
It is most desirable because of its low cost. As the specific gravity, a true specific gravity of about 0.07 to 0.12% is appropriate.

In addition to the above-mentioned natural sand, fly ash and blast furnace slag (particle size of 5 mm or less, specific gravity of, for example, about 2.0 to 2.6) may be used alone or mixed. About 10 to 50% by weight of cement
It may be mixed. It is preferable because the alkalinity of the cement is reduced by mixing these, and the cement is made weakly alkaline. When fly ash or the like is mixed in cement, the fluidity is improved, the surface becomes beautiful, and even when a synthetic resin foam is mixed, there is an advantage that it does not easily appear on the surface of the tile. Further, the long-term strength is improved, and a strong roof tile is obtained.

[0038]

Embodiments of the present invention will be described below.
First, Tables 2 and 3 show examples of mixing per liter of volume in Comparative Examples and Examples of the present invention. In addition, EP in Table 3
S indicates expanded polystyrene and the shape is a bead. An AE water reducing agent was used as an admixture. The length of the alkali-resistant glass fiber was in the range of 12 to 14 mm. In addition, river sand having an average diameter of 2.5 mm or less was used as sand, ordinary Portland cement was used as a binder, and tap water was used as water.

[0039]

[Table 2]

[0040]

[Table 3]

Table 4 shows the performance test results of the roof tiles of Comparative Examples 1 to 6, and Table 5 shows the performance test results of Examples 1 to 9.

[0042]

[Table 4]

[0043]

[Table 5]

As is clear from Table 4, Comparative Examples 1 to 6
Are all outside the scope of the present invention and are not suitable for use, as noted below in Table 4. On the other hand, as is clear from Table 5,
All of Examples 1 to 9 were satisfactory and almost satisfactory. The weight at the time of laying the concrete roof tile of this example was about 90 kg / 3.3 m ² , which was about 40% smaller than that of the conventional thick slate. Although the concrete tiles of Examples 1 to 9 described above have good bending strength, the concrete tiles containing alkali-resistant glass fibers have poor deformation followability as described above. If it is larger than the above, breakage may occur. In the above example and comparative example, the size of the tile was set to 48
Although the size was 5 mm × 350 mm, the concrete roof tile containing alkali-resistant glass fiber as in the above example was 485 mm × 35 mm.
It is preferable to use it with a size of about 0 mm or less or a size of 1700 cm ² or less in surface area.

Next, another embodiment of the present invention will be described. Table 6 shows a formulation example per 1 liter volume of the comparative example, and Table 7 shows a formulation example per 1 liter volume of the example of the present invention. In these Examples 10 to 16, by adding vinylon fiber, the size of the tiles was made larger than those of Examples 1 to 9 to make the surface area 2017 cm ^2, and the tiles of Comparative Examples 7 to 16 were also made. Has the same surface area. The experimental conditions were the same as those of Comparative Examples 1 to 6 and Examples 1 to 9 described above.
The one having a length of 6 mm was used.

[0046]

[Table 6]

[0047]

[Table 7]

Next, the performance test results of the tiles of Comparative Examples 7 to 16 in Table 6 are shown in Table 8, and Examples 10 to 16 in Table 7 are shown.
Table 9 shows the performance test results of the roof tiles.

[0049]

[Table 8]

[0050]

[Table 9]

As apparent from Table 8, Comparative Examples 7 to 1
6 were all out of the scope of the present invention and were not suitable for use, as described below these tables. On the other hand, as is clear from Table 9, each of Examples 10 to 16 of the present invention could be used satisfactorily or almost satisfactorily. The concrete roof tiles containing vinylon fibers are not only large in surface area as in Examples 10 to 16, but also excellent when the surface area of the roof tile is reduced to the same extent as in Examples 1 to 9. The bending strength can be obtained.

[0052] Concrete roof tiles of this invention, at the same time taking full advantage of the advantages of the prior tile, which was to not leave as much as possible shortcomings, in particular, as claimed in claim 1
In addition, hydraulic binder, water, admixture, sand, and fiber
By mixing at a predetermined mixing ratio, the drying shrinkage of the obtained concrete tile was reduced, warpage and deformation were prevented, the formability and surface properties of the tile were improved, and the toughness was also increased. A tile can be obtained. Also,
As a result that strength can be improved by mixing fibers,
Since it can be formed thin, the thickness is about 7 mm to 11 mm.
mm for good bending strength and press forming
Work efficiency is improved, work efficiency is improved, and overall weight is moderate.
Can be, it is possible to improve the transport costs and workability. In addition, to make the surface area 1300 cm ² or more
Since the size of each tile becomes larger,
If the number of roof tiles is reduced and the workability is improved,
In addition, since the area of the overlap between adjacent tiles is reduced,
There is an advantage that the weight of the tile per unit area is reduced.

[0053]

[0054]

[0055]

[0056]

When the synthetic resin foam is contained in an amount of about 1 to 10% in absolute volume as described in the second aspect , not only an appropriate weight reduction and resistance to freezing and thawing can be obtained, but also the bending strength is improved. It does not drop.

[0058] As according to claim 3, when using the alkali resistant glass fibers as fibers, high flexural strength can be obtained, it is resistant to alkali, since it is nonflammable, particularly preferred.

As described in claim 4 , the fiber has a tensile strength of 1%.
0 × 10 ³ (kgf / cm ² ) or more, Young's modulus is 30 × 10 ⁴
(Kgf / cm ² ) or more and the property of elongation at break of 3% or more are used, and the deformation followability as well as the bending strength becomes good. There is an advantage that breakage of the tile is hardly generated even when the tiles are enlarged.

[0060] As claimed in claim 5, in the case of using a vinylon fiber as the fiber tensile strength is ^{20 × 10 3 (kgf / cm} 2)
As described above, since the Young's modulus is 50 × 10 ⁴ (kgf / cm ² ) or more, and the elongation at break is about 5%, good bending strength and deformation followability can be obtained. This is advantageous in that it is difficult to generate.

[0061] As in claim 6, by making the surface area of the concrete roof tile 1700 cm ² or more, the weight of tiles per unit area has the advantage of further reduced.

When the hydraulic binder is cement as described in claim 7 , it is most desirable because it is strong, excellent in water resistance and relatively inexpensive.

In the case where fly ash, blast furnace slag, and the like are mixed in an amount of about 10 to 50% by weight of the cement weight as described in claim 8, the alkalinity of the cement is reduced by mixing these elements to make the cement weakly alkaline. This is preferable because it is as described above. When fly ash or the like is mixed in cement, the fluidity is improved, the surface becomes more beautiful, and when a synthetic resin foam is mixed, there is an advantage that it does not easily appear on the surface of the tile. Furthermore,
There is an advantage that the long-term strength is improved and a strong tile is obtained.

[Brief description of the drawings]

FIG. 1 is a sectional view of a concrete roof tile according to an embodiment of the present invention.

[Explanation of symbols]

 1 concrete roof tile

────────────────────────────────────────────────── (5) Continuation of the front page (51) Int.Cl. ⁷ Identification code FI C04B 16:06) (56) References JP-A-59-45950 (JP, A) JP-A-2-311345 (JP, A) JP-A-2-84303 (JP, A) JP-A-60-264375 (JP, A) JP-A-61-168558 (JP, A) JP-A-8-268775 (JP, A) JP-A-3-193649 (JP, A) JP-A-63-303837 (JP, A) (58) Fields investigated (Int. Cl. ⁷ , DB name) C04B 28/02 B28B 3/02

Claims (8)

(57) [Claims] At least a hydraulic binder, water, and AE
Agent, water reducing agent, AE water reducing agent, high performance AE water reducing agent or interface
Activators and other admixtures and approximately 5% to 40% sand in absolute volume
And approximately 0.5% to 1.5% fiber in absolute volume
Press molding of a hydraulic binder composition
Migaryaku 7mm to 11 mm, der surface area 1300 cm ² or more
That concrete roof tiles. 2. A synthetic resin foam in a concrete roof tile.
The concrete roof tile according to claim 1, which contains about 1 to 10% by volume . 3. The fiber is an alkali-resistant glass fiber.
Item 3. The concrete roof tile according to item 1 or 2 . 4. A fiber having a tensile strength of 10 × 10 ³ (kgf / cm
² ) above, the Young's modulus is 3 × 10 ⁴ (kgf / cm ² ) or more, and
Fiber with physical properties of elongation at break of 3% or more
The concrete roof tile according to claim 1 . 5. The fiber according to claim 1, wherein the fiber is a vinylon fiber.
Or the concrete roof tile of any one of 4 . 6. The method according to claim 1, wherein the surface area is 1700 cm ² or more.
6. The concrete roof tile according to any one of 1 to 5 . 7. The hydraulic binder according to claim 1, wherein the hydraulic binder is cement.
A concrete roof tile according to any one of claims 1 to 6 . 8. The method for producing fly ash and / or blast furnace slag.
2. The method according to claim 1, wherein the content of the cement is approximately 10 to 50% by weight.
A concrete roof tile according to any one of claims 1 to 7 .