JP3414442B2 - Method for manufacturing thin ALC panel - Google Patents

Description

Description: BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for producing a thin lightweight cellular concrete panel having a panel thickness of, for example, 20 to 50 mm (hereinafter referred to as an ALC panel). . [0002] Conventionally, there has been known a method of manufacturing a thin ALC panel having a panel thickness of 20 to 50 mm using a metal lath or a welding wire mesh as a reinforcing material. This is done by injecting the mortar slurry into the mold and removing the support rod holding the reinforcing material in the mold while the mortar slurry retains fluidity after foaming of the mortar slurry is completed. This is a production method that makes the mortar slurry solid by self-disintegration. According to this manufacturing method, a punching hole does not remain inside the ALC panel, so that even a thin plate having a panel thickness of 20 to 50 mm has sufficient strength for practical use. [0003] However, in the above-mentioned manufacturing method, there is a problem that a striped pattern appears on the surface of the obtained panel along the position where the support bar exists, and the appearance of the product is poor. Therefore, an object of the present invention is to prevent a heavier pattern appearing on the surface of a thin ALC panel. [0004] In view of the above problems, the behavior of the mortar slurry in the mold in the above manufacturing method was analyzed, and the mortar slurry injected into the mold was heated by the heat of hydration reaction. As the temperature rises and the heat is radiated to the outside at the side of the mold, a temperature difference occurs between the center and the side of the mortar slurry of the mold. If the difference occurs and the reinforcing material density differs between the mortar slurry center part and the side part, the mortar slurry flows from the mold center part toward the side part due to the difference in the rise resistance of the mortar slurry, and the like. It was found that this phenomenon continued even after the support rod was removed. When the support rod is pulled out, air bubbles around the support rod are caught in the support rod and come out together, and the part where the support rod is pulled out has a heavy portion containing no air bubbles and having a large specific gravity. become. Then, due to the flow of the mortar slurry, the heavier portion moves and appears as a stripe pattern on the cut surface of the panel, resulting in a phenomenon in which the appearance of the product panel deteriorates. Therefore, according to the present invention, when the distance from the side surface of the support rod to the cut surface of the panel is set to be equal to or longer than the horizontal flow distance of the mortar after the removal of the support rod, the heavy portion does not appear on the surface of the panel. They found that it would be a product with an appearance. That is, the gist is that a plurality of reinforcing materials are supported at both sides by support rods and vertically arranged at predetermined intervals in a mold, and mortar slurry is injected into the mold to foam and maintain fluidity. In a method of manufacturing a thin ALC panel by extracting the support rods in between to make the extraction holes of the support rods solid by the self-disintegration of the mortar slurry, the distance from the side surface of the support rods to the panel cut surface is reduced. The flow length of the mortar after removal of the support rod is equal to or longer than the horizontal flow distance. The present invention will be described with reference to the drawings. FIG. 1 is a longitudinal sectional view showing a state in which a reinforcing material is arranged on a mold, and FIG. 2 is a transverse sectional view showing a panel cut surface in a state in which the reinforcing material is arranged. In the figure, a support bar fixing frame 2 is provided on a mold 3, and a plurality of support bars 1 are arranged on the support bar fixing frame 2. For example, the support rod 1 is passed through a support rod fixing frame 2 at an upper portion thereof and is fixed at that portion, and is disposed at a predetermined interval in the mold. The support rods 1 consist of a pair, and the interval between them is such that one reinforcing member can be exactly inserted and supported.
I support. As the reinforcing member 4, for example, a metal lath, a welding wire mesh, or the like can be used. FIG. 3 is an enlarged view of a cross section showing a panel cut surface. In the figure, a reinforcing material 4 is arranged between a pair of support rods 1 and a panel cut surface C corresponding to the panel thickness of this product.
Is indicated by a one-point diagonal line. The distance D from the side surface of the support rod 1 to the panel cutting surface C is set to be equal to or longer than the horizontal flow distance of the mortar after the support rod is removed. In the manufacturing method of the present invention, first, a siliceous raw material, a calcareous raw material, a foaming agent, and water are mainly placed in a mold 3 in which a plurality of reinforcing members 4 supported on both sides by a support rod 1 and held at predetermined intervals are set. Inject mortar slurry as a component. Next, the support rod 1 is withdrawn while the mortar slurry foams and retains fluidity, and the withdrawal hole of the support rod 1 is filled with the mortar slurry by self-disintegration to make it solid. After the mortar slurry has reached a semi-cured state, it is released from the mold, cut at a panel cut surface C so as to have a predetermined size, and further autoclaved to obtain a thin ALC panel. In such a method for manufacturing a thin ALC panel, a heavy pattern can be prevented by setting the distance from both sides of the support rod to the panel cut surface to be equal to or longer than the horizontal flow distance of the mortar after the support rod is extracted. It is. Hereinafter, the production method of the present invention will be specifically described using examples. Example 1 A metal lath having a wire diameter of 1 mm was used as a reinforcing material, and both sides of each reinforcing material were supported vertically by supporting rods, and 37.5.
They were arranged in parallel in the mold at intervals of mm. The supporting rod has a cross section of 6 x 13 mm to obtain an appropriate second moment of area,
A prism made of carbon steel having a length of 800 mm was used. The width of the support rod is set 13 mm side in parallel with the reinforcement,
It was set so that the distance from the side surface of the support rod to the panel cut surface was 11 mm. The mortar slurry is composed of 33 parts by weight of Portland cement, 7 parts by weight of quicklime, 42 parts by weight of powdered silica, 18 parts by weight of mortar collected waste, and 0.03 parts of aluminum metal powder.
A composition mainly composed of 7 parts by weight and 73 parts by weight of water was prepared by stirring. The mortar slurry was poured into a mold, and after a lapse of 30 minutes, the support rod was withdrawn while the mortar slurry maintained its fluidity, and the withdrawal hole of the support rod was made solid by the self-collapse property of the mortar slurry. Next, after the mortar slurry reached a semi-cured state, it was removed from the mold and 37.5 pieces with a piano wire.
The product was cut at the panel cut surface at an interval of mm and further autoclaved to obtain a product. A small piece of plastic was floated on the upper surface of the mortar, and the horizontal flow distance of the mortar slurry was measured. As a result, the flow distance of the mortar slurry immediately after the set rod was pulled out was 6 mm. In this case, the distance from the side surface of the support rod to the panel cut surface is 11 mm,
No heavier pattern appeared on the surface of the product, and the appearance was excellent. Comparative Example 1 A product was obtained in the same manner as in Example except that the cross section of the support rod was set to 12 × 13 mm and the distance from the side surface of the support rod to the cut surface of the panel was set to 5 mm. As a result, in this case, the horizontal flow distance of the mortar after removal of the support rod is larger than the distance from the side surface of the support rod to the panel cut surface, and a heavier pattern appears on the product surface along the position where the support rod exists. The appearance was bad. In the above embodiment, a rectangular support rod is used. However, the shape of the support rod is not limited to a square, and a suitable magnitude of the second moment of area of the support rod can be secured. Any shape can be used as long as the distance from the panel cut surface can be ensured. As described above, according to the method of the present invention, the distance from the side surface of the support rod to the cut surface of the panel is maintained without removing the support hole from the mortar after the support rod is removed. Since the flow distance is equal to or longer than the horizontal flow distance, the appearance of a heavier pattern on the panel surface can be prevented. Since the distance from the side of the support rod to the panel cut surface was set to be equal to or longer than the horizontal flow distance of the mortar after the support rod was removed,
It is possible to obtain a thin ALC panel which does not show a heavier pattern on the product surface and has excellent product appearance.

[Brief description of the drawings] FIG. 1 is a longitudinal sectional view showing a manufacturing state of the present invention. FIG. 2 is a cross-sectional view showing a manufacturing state of the present invention. FIG. 3 is an enlarged cross-sectional view of a support rod portion of the present invention. [Explanation of symbols] 1 support rod 2 Support rod fixing frame 3 Formwork 4 Reinforcement C Panel cut surface D Distance from side of support rod to panel cut surface

──────────────────────────────────────────────────続 き Continued on front page (58) Field surveyed (Int. Cl. ⁷ , DB name) C04B 38/00-38/10

Claims (1)

(57) [Claims 1] A plurality of reinforcing members are supported at both sides thereof by support rods, vertically arranged at predetermined intervals in a mold, and mortar slurry is poured into the mold. A method for manufacturing a thin ALC panel by extracting the support rod while maintaining the fluidity by foaming the support rod to make the extraction hole of the support rod solid by the self-disintegration of the mortar slurry, thereby manufacturing a thin ALC panel. A method for manufacturing a thin ALC panel, comprising: setting a distance from a panel to a panel cut surface to be equal to or longer than a horizontal flow distance of the mortar after the support rod is removed.