JP5143653B2 - Manufacturing method of concrete secondary product and concrete secondary product - Google Patents
Manufacturing method of concrete secondary product and concrete secondary product Download PDFInfo
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- JP5143653B2 JP5143653B2 JP2008187659A JP2008187659A JP5143653B2 JP 5143653 B2 JP5143653 B2 JP 5143653B2 JP 2008187659 A JP2008187659 A JP 2008187659A JP 2008187659 A JP2008187659 A JP 2008187659A JP 5143653 B2 JP5143653 B2 JP 5143653B2
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- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B28/00—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements
- C04B28/02—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements containing hydraulic cements other than calcium sulfates
- C04B28/08—Slag cements
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- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
- C04B2111/10—Compositions or ingredients thereof characterised by the absence or the very low content of a specific material
- C04B2111/1037—Cement free compositions, e.g. hydraulically hardening mixtures based on waste materials, not containing cement as such
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02W—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO WASTEWATER TREATMENT OR WASTE MANAGEMENT
- Y02W30/00—Technologies for solid waste management
- Y02W30/50—Reuse, recycling or recovery technologies
- Y02W30/91—Use of waste materials as fillers for mortars or concrete
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Description
本発明は、材料にセメントを含まないコンクリート二次製品の製造方法及びそのコンクリート二次製品に係り、特に製造過程において即時に脱型することが可能な技術に関する。 The present invention relates to a method for producing a concrete secondary product that does not include cement in the material, and the concrete secondary product, and more particularly to a technique that allows immediate demolding in the production process.
コンクリートとは、結合材、水、骨材及び必要に応じて加える混和材料を材料とし、これらを練混ぜその他の方法によって混合したもの、または硬化させたものをいう。ここで、混和材料とは、結合材、水、骨材以外の材料で、コンクリートなどに特別の性質を与えるために、打込みを行う前までに必要に応じて加える材料である。また、結合材とは、水と反応し、コンクリートの強度発現に寄与する物質を生成する材料で、例えば、セメント、高炉スラグ微粉末及びフライアッシュなどが含まれる。なお、セメントとは、水と反応して硬化する鉱物質の微粉末である。また、高炉スラグ微粉末とは、溶鉱炉で銑鉄と同時に生成する溶融状態の高炉スラグを水によって急冷し、これを乾燥・粉砕したものをいうが、これにせっこうを添加してもよい。フライアッシュとは、微粉炭燃焼ボイラの燃焼ガスから集じん器で捕集されるアッシュである。 Concrete means a binder, water, aggregate, and an admixture added as necessary, and these are kneaded and mixed by other methods or hardened. Here, the admixing material is a material other than the binder, water, and aggregate, and is added as necessary before placing in order to give special properties to concrete and the like. The binding material is a material that reacts with water to generate a substance that contributes to the development of the strength of concrete, and includes, for example, cement, blast furnace slag fine powder, fly ash, and the like. Cement is a fine powder of mineral that hardens by reacting with water. The blast furnace slag fine powder is obtained by rapidly cooling a molten blast furnace slag produced simultaneously with pig iron in a blast furnace with water, drying and pulverizing it, and gypsum may be added thereto. Fly ash is ash collected by the dust collector from the combustion gas of the pulverized coal combustion boiler.
製鋼所において製鋼工程で排出される高炉スラグ微粉末及び石炭火力発電所から排出されるフライアッシュ等は、廃棄物の有効利用を促進する観点から、結合材として積極的に使用が試みられてきた。しかし、これら高炉スラグ微粉末またはフライアッシュをセメントと併用する形で使用したコンクリートは開発されたものの、結合材としてセメントを全く含まないコンクリート組成物は開発されていない。なぜなら、高炉スラグ微粉末やフライアッシュはそれ自体では水硬性がない。しかし、フライアッシュはセメントと併用することでセメント水和物と徐々に反応し、硬化体を形成する(ポゾラン作用)。また,高炉スラグ微粉末はセメントのアルカリ成分を刺激剤として、水硬性を示す性質を持つ(潜在水硬性)。 Blast furnace slag fine powder discharged from the steelmaking process in steelworks and fly ash discharged from coal-fired power plants have been actively used as binders from the viewpoint of promoting the effective use of waste. . However, although concrete using these blast furnace slag fine powder or fly ash in combination with cement has been developed, a concrete composition containing no cement as a binder has not been developed. This is because blast furnace slag fine powder and fly ash are not hydraulic by themselves. However, fly ash reacts gradually with cement hydrate when used in combination with cement to form a hardened body (pozzolanic action). In addition, blast furnace slag fine powder has the property of exhibiting hydraulic properties using the alkaline component of cement as a stimulant (latent hydraulic property).
一方で、加圧流動床式複合発電(Pressurized Fluidized Bed Combustion,PFBC)方式の石炭火力発電所から排出されるPFBC灰を、セメントと共に結合材として利用するコンクリート組成物が開発された。PFBC灰は一般的なフライアッシュと異なり自硬性を有するが、結合材として単体で用いた場合の硬化体の強度は小さいため、これまでに開発されたPFBC灰を用いるコンクリート組成物においても、結合材としてセメントを全く含まない物は存在しない。 On the other hand, pressurized fluidized bed type combined cycle (Pressurized Fluidized Bed Combus t ion, PFBC) the PFBC ash discharged from coal fired power plant system, the concrete composition utilizing as a binder have been developed with the cement. Unlike general fly ash, PFBC ash is self-hardening, but the strength of the cured body when used alone as a binder is small, so even in concrete compositions using PFBC ash developed so far, There is no material that does not contain cement at all.
これに対し、本出願人は、セメントを含まないコンクリート組成物について出願している(特願2007−069048)。本発明は、かかるセメントを含まない材料を用いるとともに、製造過程において即時に脱型することが可能なコンクリート二次製品の製造方法及びそのコンクリート二次製品を提供することを目的とする。 On the other hand, the present applicant has applied for a concrete composition not containing cement (Japanese Patent Application No. 2007-069 0 48). It is an object of the present invention to provide a method for producing a concrete secondary product that uses such a cement-free material and that can be instantly demolded during the production process, and the concrete secondary product.
上記の目的を達成するため、本発明は、
細骨材、粗骨材、水、及び結合材を含むコンクリートからコンクリート二次製品を製造する方法であって、前記結合材は、PFBC灰及び高炉スラグ微粉末からなり、スランプ値が実質的にゼロとなるように前記コンクリートを配合し、練り混ぜられた前記コンクリートを、前記コンクリート二次製品の成形用の型枠に打設し、前記型枠に打設したコンクリートを締め固め、前記コンクリートを養生することなく、前記締め固められたコンクリートの前記型枠を取り外し、前記型枠が取り外されたコンクリートに対し、20℃で少なくとも24時間の前養生を行った後、前記コンクリートを蒸気養生することを特徴とする。
In order to achieve the above object, the present invention provides:
A method for producing a secondary concrete product from concrete including fine aggregate, coarse aggregate, water, and a binder, wherein the binder comprises PFBC ash and blast furnace slag fine powder, and the slump value is substantially The concrete is mixed so that it becomes zero, and the mixed concrete is placed in a mold for molding the concrete secondary product, the concrete placed in the mold is compacted, and the concrete is Removing the mold of the compacted concrete without curing, subjecting the concrete from which the mold has been removed to precuring at 20 ° C. for at least 24 hours, and then steam curing the concrete It is characterized by.
ここでいうスランプ値が実質的にゼロとは、未固結状態のコンクリートを、上端の内径が10cm、下端の内径が20cm、高さが30cmの鋼製中空のコーンにつめ、コーンを引き抜いた後に、頂面中央部が最初の高さからどのくらい下がるかの変位を測定するスランプ試験(JIS A 1101)において、当該変位が生じないことを意味する。 Here, the slump value is substantially zero. Concrete in an unconsolidated state is packed into a hollow steel cone having an inner diameter of the upper end of 10 cm, an inner diameter of the lower end of 20 cm, and a height of 30 cm, and the cone is pulled out. Later, in the slump test (JIS A 1101) for measuring the displacement of how much the center of the top surface is lowered from the initial height, this means that the displacement does not occur.
すなわち、本発明に係るコンクリート二次製品の製造方法によれば、材料をスランプ値が実質的にゼロとなるように配合することから、材料を型枠に打ち込み締め固めた後、直ぐに脱型しても、コンクリートは変形することなく、成形された形を留めて自立するので、コンクリートを脱型した状態で養生することができる。このように、一つの製品を成形するために必要な型枠の使用時間を短縮することができることから、生産性を向上させることができる。また、少なくとも24時間の前養生を行った後に蒸気養生を行っているので、製造されるコンクリート二次製品に関し、所定の設計基準強度以上の強度を発現させることができる。 That is, according to the method for producing a concrete secondary product according to the present invention, the material is blended so that the slump value becomes substantially zero. However, since concrete does not deform, it retains its formed shape and becomes self-supporting, so it can be cured in a state in which the concrete is removed. As described above, since the use time of the mold necessary for molding one product can be shortened, productivity can be improved. Moreover, since the steam curing is performed after performing the pre-curing for at least 24 hours, the strength of the concrete secondary product to be produced can be expressed more than a predetermined design standard strength.
本発明において、前記コンクリートの配合は、前記PFBC灰及び高炉スラグ微粉末を含む結合材に対する前記水の質量比である水結合材比を40%以下とするとともに、全骨材量に対する細骨材量の絶対容積比である細骨材率を50%以上とすることとしてもよい。本構成によれば、具体的に材料をかかる配合にすることにより、スランプ値を実質的にゼロになるようにすることができる。 In the present invention, the mixing ratio of the concrete is such that the water binder ratio, which is the mass ratio of the water to the binder containing the PFBC ash and blast furnace slag fine powder, is 40% or less, and the fine aggregate with respect to the total aggregate amount. The fine aggregate ratio that is the absolute volume ratio of the amount may be 50% or more. According to this configuration, the slump value can be made substantially zero by specifically blending the materials.
また、水結合材比を40%以下とすることから、通常よりも水の割合が少ないコンクリートとなるので、固結時における強度の発現が良好になる。 In addition, since the water binder ratio is 40% or less, the ratio of water is less than usual, so that the strength is improved when consolidated.
また、全骨材量に対する細骨材量の絶対容積比である細骨材率を50%以上とすることから、通常よりも空隙が多いコンクリートとなるので、保水性及び透水性を備えるポーラスブロックとして適する。 Also, since the fine aggregate ratio, which is the absolute volume ratio of the fine aggregate amount to the total aggregate amount, is 50% or more, the concrete has more voids than usual, so a porous block having water retention and water permeability. Suitable as
本発明において、前記PFBC灰と前記高炉スラグ微粉末との質量比を、25:75〜75:25とすることとしてもよい。 In the present invention, a mass ratio between the PFBC ash and the blast furnace slag fine powder may be set to 25:75 to 75:25.
本発明において、前記PFBC灰及び高炉スラグ微粉末を含む結合材に占める前記高炉スラグ微粉末の含有率を、50質量%以下とすることとしてもよい。 In the present invention, the content of the fine blast furnace slag powder in the binder containing the PFBC ash and fine blast furnace slag powder may be 50% by mass or less.
本発明において、前記コンクリートに混和剤をさらに配合することとしてもよい。 In the present invention, an admixture may be further added to the concrete.
また、本発明は、請求項1から5の何れか1項のコンクリート二次製品の製造方法で製造されたことを特徴とするコンクリート二次製品である。
Moreover, this invention is a concrete secondary product manufactured with the manufacturing method of the concrete secondary product of any one of
本発明によれば、セメントを含まない材料を用いるとともに、製造過程において即時に脱型することが可能なコンクリート二次製品の製造方法及びそのコンクリート二次製品を提供できる。 ADVANTAGE OF THE INVENTION According to this invention, while using the material which does not contain cement, the manufacturing method of the concrete secondary product which can be demolded immediately in a manufacturing process, and its concrete secondary product can be provided.
以下、本発明の好ましい実施形態について図面に基づき詳細に説明する。
本実施形態に係るコンクリート二次製品は、材料として、細骨材、粗骨材、水、及び結合材を含む。
Hereinafter, preferred embodiments of the present invention will be described in detail with reference to the drawings.
The concrete secondary product according to the present embodiment includes fine aggregate, coarse aggregate, water, and a binder as materials.
細骨材とは、10mm網ふるいを全部通り、5mm網ふるいを質量で85%以上通る骨材をいうが、川砂、砕砂など、特に限定されない。粗骨材とは、5mm網ふるいに質量で85%以上とどまる骨材をいうが、砕石、人工骨材など、特に限定されない。 The fine aggregate is an aggregate that passes through a 10 mm mesh screen and passes through a 5 mm mesh screen by 85% or more, but is not particularly limited, such as river sand and crushed sand. Coarse aggregate is an aggregate that remains 85% or more by mass on a 5 mm mesh screen, but is not particularly limited, such as crushed stone and artificial aggregate.
結合材とは、上述の通り、水と反応してコンクリートの強度発現に寄与する物質を生成する材料であり、一般的にはセメントが挙げられるが、本実施形態に係るコンクリート二次製品では、結合材として、PFBC灰及び高炉スラグ微粉末からなる材料を用いる。 As described above, the binder is a material that reacts with water to generate a substance that contributes to the development of the strength of concrete, and generally includes cement, but in the concrete secondary product according to the present embodiment, As the binder, a material composed of PFBC ash and blast furnace slag fine powder is used.
ここで、PFBC灰とは、加圧流動床式複合発電(Pressurized Fluidized Bed Combusion,PFBC)方式の石炭火力発電所から排出される灰をいう。また、高炉スラグ微粉末とは、溶鉱炉で銑鉄と同時に生成する溶融状態の高炉スラグを水によって急冷し、これを乾燥・粉砕したものをいう。 Here, PFBC ash refers to ash discharged from a pressurized fluidized bed combined power generation (PFBC) type coal-fired power plant. Moreover, the blast furnace slag fine powder means a product obtained by rapidly cooling a molten blast furnace slag generated simultaneously with pig iron in a blast furnace with water, and drying and pulverizing it.
これらコンクリート二次製品の材料は、実質的にゼロスランプになるように配合する。ゼロスランプとは、スランプ試験による変位量(スランプ値)が0cmとなることをいう。スランプ試験とは、未固結のコンクリートを、上端の内径が10cm、下端の内径が20cm、高さが30cmの鋼製中空のコーンにつめ、コーンを引き抜いた後に、頂面中央部が最初の高さからどのくらい下がるかの変位を測定する試験である(JIS A 1101)。したがって、ゼロスランプとは、コーンを引き抜き後でもコンクリートがその形を留めて自立し、変形しないことを意味する。 The material of these concrete secondary products is blended so as to be substantially zero slump. Zero slump means that a displacement amount (slump value) by a slump test becomes 0 cm. In the slump test, unconsolidated concrete is packed into a steel hollow cone with an inner diameter of the upper end of 10 cm, an inner diameter of the lower end of 20 cm, and a height of 30 cm. This is a test for measuring the displacement of how much the height falls (JIS A 1101). Therefore, zero slump means that even after the cone is pulled out, the concrete remains in its shape and does not deform.
具体的な配合条件として、水結合材比を40質量%以下、及び全骨材量に対する細骨材量の絶対容積比を表す細骨材率を50%以上にすることが好ましい。ここで、水結合材比とは、水と結合材とのフレッシュコンクリート組成物中の比である。また、PFBC灰と高炉スラグ微粉末との質量比は25:75〜75:25、結合材に占める前記高炉スラグ微粉末の含有率が50質量%以下にすることが好ましい。 As specific blending conditions, the water binder ratio is preferably 40% by mass or less, and the fine aggregate ratio representing the absolute volume ratio of the fine aggregate amount to the total aggregate amount is preferably 50% or more. Here, the water binder ratio is the ratio of water and binder in the fresh concrete composition. Moreover, it is preferable that the mass ratio of PFBC ash and blast furnace slag fine powder is 25: 75-75: 25, and the content rate of the said blast furnace slag fine powder which occupies for a binder is 50 mass% or less.
次に、このような材料からなるコンクリート二次製品の製造方法について説明する。なお、上記材料からなるコンクリート二次製品としては、例えば、ブロック類、まくら木、又は無筋コンクリート管等が挙げられる。 Next, the manufacturing method of the concrete secondary product which consists of such a material is demonstrated. In addition, as a concrete secondary product which consists of the said material, blocks, a sleeper, or an unreinforced concrete pipe etc. are mentioned, for example.
図1に示すように、コンクリート二次製品の製造方法は、材料の計量工程S10、練り混ぜ工程S20、打ち込み工程S30、締め固め工程S40、脱型工程S50、及び蒸気養生工程S60を備える。 As shown in FIG. 1, the concrete secondary product manufacturing method includes a material measuring step S10, a kneading step S20, a driving step S30, a compacting step S40, a demolding step S50, and a steam curing step S60.
材料の計量工程S10では、上述した配合条件の下、さらにコンクリート二次製品の種類や形状・寸法等に適するように材料を調合する。 In the material measurement step S10, the material is mixed so as to be suitable for the kind, shape, size, etc. of the concrete secondary product under the above-described mixing conditions.
練り混ぜ工程S20では、配合された材料を、良質なコンクリートを得るために均一に練り混ぜる。練り混ぜには、例えば上記のような富配合の超硬練りコンクリートの練り混ぜに適した強制練りミキサを用いる。 In the kneading step S20, the blended materials are kneaded uniformly to obtain high-quality concrete. For kneading, for example, a forced kneading mixer suitable for kneading ultra-high kneaded concrete with a rich blend as described above is used.
打ち込み工程S30では、練り混ぜ工程S20で練り混ぜられたコンクリートを型枠へ打設する。型枠には、製造中に振動、圧力及び熱等が繰り返し作用しても、堅固で、形状及び寸法に狂いの生じない材質からなるものが望まれ、例えば、鋼製型枠を用いる。また、型枠は、この後の工程(S40)を実施するため用いられる成形機に取り付け可能であることが好ましい。型枠へのコンクリートの打ち込みは、例えば、ホッパー、コンクリートポンプ、又は自動給材機などを用いて行う。 In the placing step S30, the concrete kneaded in the kneading step S20 is placed on the formwork. The mold is desired to be made of a material that is firm and does not cause a deviation in shape and dimensions even when vibration, pressure, heat, and the like are repeatedly applied during manufacturing. For example, a steel mold is used. Moreover, it is preferable that a formwork is attachable to the molding machine used in order to implement a subsequent process (S40). The concrete is placed into the mold using, for example, a hopper, a concrete pump, or an automatic material feeder.
締め固め工程S40は、型枠に打ち込まれたコンクリートを、振動或いは加圧、又はこれらを併用して型枠内の隅々まで充填し、かつコンクリートが密実になるようするための処理であり、例えば、打ち込み工程S30でコンクリートを打ち込まれた型枠が取り付け可能な振動機、加圧成形機、遠心成形機、又は突固め機等を用いて行う。 The compacting step S40 is a process for filling the concrete that has been driven into the formwork into the corners of the formwork by vibration or pressurization, or a combination thereof, so that the concrete becomes dense, For example, it is performed using a vibrator, a pressure molding machine, a centrifugal molding machine, a tamping machine, or the like to which a form into which concrete has been placed in the placing step S30 can be attached.
脱型工程S50では、コンクリートをS40で締め固めた後、直ぐに(例えば、5秒程度後)に型枠を取り外す。上述のように、コンクリートがゼロスランプになるように材料が配合されているので、直ぐに型枠を取り外してもコンクリートは脱型後に変形することはない。 In the demolding step S50, after the concrete is compacted in S40, the mold is removed immediately (for example, after about 5 seconds). As described above, since the material is blended so that the concrete becomes zero slump, even if the mold is removed immediately, the concrete does not deform after being removed.
蒸気養生工程S60では、脱型後のコンクリートを、蒸気により加熱することにより硬化を促進させる。具体的には、脱型されたコンクリートを、ボイラで発生させた蒸気が供給される養生室に設置して、所定時間養生させる。 In the steam curing step S60, curing is promoted by heating the concrete after demolding with steam. Specifically, the demolded concrete is placed in a curing room to which steam generated by a boiler is supplied and cured for a predetermined time.
図2は、蒸気養生の熱履歴を示すグラフである。
図2に示すように、蒸気養生は、前養生期間、温度上昇期間、等温養生期間、徐冷期間のサイクルで行われる。
FIG. 2 is a graph showing the heat history of steam curing.
As shown in FIG. 2, steam curing is performed in a cycle of a pre-curing period, a temperature rising period, an isothermal curing period, and a slow cooling period.
なお、蒸気養生については、急激に加熱したり、最高温度を高くとりすぎたり、急冷したりすることにより、ひび割れの発生や発現強度の低下などまねくことがあるため、コンクリート標準示方書[施工編]により、(1)養生室に入れ温度を均等に上昇させる、(2)練り混ぜ後2〜3時間以上前養生期間を置きその後加熱する、(3)温度上昇期間では温度上昇速度は20℃/h程度とする、(4)等温養生期間では最高温度を65℃とする、(5)徐冷期間では徐々に温度を下げ室温と大差がなくなって製品を取り出す、等が記載されている。 For steam curing, concrete heating may be caused by rapid heating, excessively high maximum temperature, or rapid cooling. ] (1) Put in the curing room to raise the temperature evenly, (2) After mixing, heat for 2 to 3 hours before curing, (3) In the temperature rising period, the temperature rising rate is 20 ° C (4) The maximum temperature is set to 65 ° C. during the isothermal curing period, (5) The temperature is gradually decreased during the slow cooling period, and the product is taken out with no significant difference from room temperature.
そして最後に、養生室から蒸気養生後のコンクリートを取り出すことにより、セメントを含まないコンクリート二次製品が製造される。なお蒸気養生後、必要に応じて後養生してもよい。 And finally, the concrete secondary product which does not contain cement is manufactured by taking out the concrete after steam curing from the curing room. After steam curing, post-curing may be performed as necessary.
次に、セメントを含まないコンクリート二次製品として、上記製造法に従ってブロックを実際に製造するとともにその強度を測定したので、以下にその詳細を説明する。 Next, as a concrete secondary product not containing cement, a block was actually manufactured according to the above manufacturing method and its strength was measured. The details will be described below.
図3は、ブロックの材料の仕様を示す表である。
図3に示すように、ブロックの材料として、水(Water, W)、PFBC灰(PFBC coal ash,P)、高炉スラグ微粉末(ground granulated blast−furnace slag,BF)、細骨材(sand,S)、粗骨材(gravel, G)、及び混和剤を用いた。具体的には、水には水道水、PFBC灰には原粉(ワンボ炭100%)、高炉スラグ微粉末にはスラグ微粉末4000、細骨材には砕砂及び高炉スラグ細骨材、粗骨材には砕石、混和剤にはバイプレスコンクを用いた。また、図4は、PFBC灰及び高炉スラグ微粉末の化学組成比を示す表である。
FIG. 3 is a table showing specifications of block materials.
As shown in FIG. 3, water (Water, W), PFBC ash (PFBC coal ash, P), blast furnace slag fine powder (ground granulated blast-furnace slag, BF), fine aggregate (sand, S), coarse aggregate (gravel, G), and admixture were used. Specifically, tap water is used for water, raw powder (100% Wambo) for PFBC ash, fine slag powder 4000 for blast furnace slag fine powder, crushed sand and blast furnace slag fine aggregate, coarse bone for fine aggregate Crushed stone was used for the material, and bipress concrete was used for the admixture. FIG. 4 is a table showing the chemical composition ratio of PFBC ash and blast furnace slag fine powder.
なお、本発明に係るコンクリート二次製品は、材料として混和剤を含んでもよい。バイプレスコンクとは、ユケンケミカル株式会社により製造・販売される、非イオン系の界面活性剤と特殊化学合成品が配合された混和剤である。これを配合することにより、超硬練りコンクリート等の充填性を向上させるとともに、美観性、製品均一化、及びコンクリート強度を向上させる効果を有する。なお、混和剤は、特にバイプレスコンクに限定されない。 In addition, the concrete secondary product which concerns on this invention may also contain an admixture as a material. Bi-press concrete is an admixture that is manufactured and sold by Yuken Chemical Co., Ltd. and contains a nonionic surfactant and a special chemical synthesis product. By blending this, it is possible to improve the filling properties of super hard kneaded concrete and the like, as well as to improve aesthetics, product uniformity, and concrete strength. The admixture is not particularly limited to bipress concrete.
図5は、ブロックの材料の配合条件を示す表である。
図5に示すように、結合材(binder,B;PFBC灰及び高炉スラグ微粉末の総量)に対する水(water,W)の質量比である水結合材比(W/B)を30%、結合材に占める高炉スラグ微粉末の含有率(BF/B)を30%、コンクリート1m3を作るときに用いる水の使用量を表す単位水量(W)を90kg/m3、全骨材量に対する細骨材量の絶対容積比を表す細骨材率(sand/aggterate,s/a)を57%、結合材に対する混和剤の添加量の比率(SP)を1.5%、また細骨材の砕砂S1と高炉スラグ細骨材S2との比である細骨材混入比を2.2:1.0とした。
FIG. 5 is a table showing the blending conditions of the block material.
As shown in FIG. 5, 30% water binder ratio (W / B), which is a mass ratio of water (water, W) to binder (binder, B; total amount of PFBC ash and blast furnace slag fine powder) The content of blast furnace slag fine powder (BF / B) in the material is 30%, the unit water amount (W) representing the amount of water used when making 1 m 3 of concrete is 90 kg / m 3 , and the total amount of aggregate is fine. The fine aggregate ratio (sand / aggregate, s / a) representing the absolute volume ratio of the aggregate amount is 57%, the ratio of the admixture to the binder (SP) is 1.5%, and the fine aggregate ratio The fine aggregate mixing ratio, which is the ratio between the crushed sand S1 and the blast furnace slag fine aggregate S2, was set to 2.2: 1.0.
以上配合からなるコンクリートを、均一になるように練り混ぜ、鋼製のブロック用型枠に打ち込むとともに、コンクリートに振動及び加圧を与えて締め固め、直ぐに(5秒程度)ブロック用型枠を取り外して、型枠が取り外されたコンクリートを養生室に設置し、蒸気養生をおこなった。 The concrete with the above composition is kneaded so as to be uniform, and is poured into a steel block formwork. The concrete is then squeezed by vibration and pressure, and the block formwork is removed immediately (about 5 seconds). Then, the concrete from which the formwork was removed was installed in the curing room and steam curing was performed.
図6は、本検討で用いた蒸気養生の温度履歴を示すグラフである。
図6に示すように、温度を20℃に設定して前養生期間に2時間とり(経過時間:0〜2時間)、温度上昇速度を22.5℃/hで65℃まで室温を上昇させ(経過時間:2〜4時間)、その室温で3時間保持し(経過時間:4〜7時間)、その後15℃/hの冷却速度で20℃まで徐冷した(経過時間:7〜11時間)。
以上のような条件で蒸気養生を行った後20℃でしばらく気中養生を行い、その後養生室からコンクリートを取り出すことにより、ブロックを製造した。
そして、この製造したブロックに対し、所定材齢時における圧縮強度を測定した(JIS A 1108)。
FIG. 6 is a graph showing the temperature history of steam curing used in this study.
As shown in FIG. 6, the temperature is set to 20 ° C., the pre-curing period is 2 hours (elapsed time: 0 to 2 hours), and the room temperature is increased to 65 ° C. at a temperature increase rate of 22.5 ° C./h. (Elapsed time: 2 to 4 hours), held at that room temperature for 3 hours (elapsed time: 4 to 7 hours), and then gradually cooled to 20 ° C. at a cooling rate of 15 ° C./h (elapsed time: 7 to 11 hours) ).
After performing the steam curing under the conditions as described above, the block was manufactured by performing the air curing for a while at 20 ° C. and then removing the concrete from the curing room.
And the compressive strength at the time of a predetermined age was measured with respect to this manufactured block (JIS A 1108).
図7は、製造したブロックの材齢と圧縮強度との関係をまとめた表である。
図7に示すように、ブロックは材齢1日では11.3N/mm2の圧縮強度を発現し、その後材齢7日では11.8N/mm2と材齢1日とほぼ同等の圧縮強度を発現する結果となった。
FIG. 7 is a table summarizing the relationship between the age of the manufactured blocks and the compressive strength.
As shown in FIG. 7, block expresses compressive strength of 11.3N / mm 2 at 1 day age of approximately equal compressive strength 11.8 N / mm 2 and
以上、本実施形態に係るセメント含まないコンクリート二次製品の製造方法によれば、材料として、粗骨材と、細骨材と、水と、PFBC灰及び高炉スラグ微粉末を含む結合材とを使用するとともに、材料を、ゼロスランプとなるように配合したことにより、製品の製造過程で、材料を型枠に打ち込み締め固めた後、直ぐに脱型しても、コンクリートは変形することなく、成形された形を留めて自立するので、脱型した状態で養生することができる。すなわち、一つの製品を成形するために必要な型枠の使用時間を短縮することができることから、生産性を向上させることができる。 As described above, according to the method for producing a cement-free concrete secondary product according to the present embodiment, as a material, coarse aggregate, fine aggregate, water, and a binder containing PFBC ash and blast furnace slag fine powder. In addition to using it, the material was blended so that it would become zero slump, so in the manufacturing process of the product, after the material was driven into a mold and compacted, the concrete would not be deformed even if it was removed immediately. Since it is self-supporting with its shape, it can be cured in a demolded state. That is, since the usage time of the mold necessary for molding one product can be shortened, productivity can be improved.
また、本実施形態に係るセメント含まないコンクリート二次製品の製造方法によれば、上記ゼロスランプとなる配合は、具体的に、水結合材比を40質量%以下、及び全骨材量に対する細骨材量の絶対容積比を表す細骨材率を50%以上にすることで実現できる。ここで、水結合材比を40%以下とすることにより、通常よりも水の割合が小さいコンクリートとなるので、固結時における強度の発現が良好になる効果が得られる。また、全骨材量に対する細骨材量の絶対容積比である細骨材率を50%以上とすることにより、通常よりも空隙が多いコンクリートとなるので、保水性及び透水性を備えるポーラスブロックとして適するようになる。 In addition, according to the method for producing a cement-free concrete secondary product according to the present embodiment, the blending that becomes the zero slump specifically has a water binder ratio of 40% by mass or less and a fine amount with respect to the total aggregate amount. This can be realized by setting the fine aggregate ratio representing the absolute volume ratio of the aggregate amount to 50% or more. Here, by setting the water binder ratio to 40% or less, the concrete has a smaller proportion of water than usual, so that the effect of improving the strength during consolidation is obtained. Also, by setting the fine aggregate ratio, which is the absolute volume ratio of the fine aggregate amount to the total aggregate amount, to 50% or more, the concrete has more voids than usual, so a porous block having water retention and water permeability. Will be suitable as.
なお、本実施形態に係るコンクリートの二次製品の製造工程では、コンクリートの養生を蒸気養生としたが、これに限らず、通常の養生(例えば、水中や気中)を行ってもよい。 In the manufacturing process of the concrete secondary product according to the present embodiment, the curing of the concrete is a steam curing. However, the present invention is not limited to this, and a normal curing (for example, in water or in the air) may be performed.
また、本実施形態に係るコンクリート二次製品の製造方法では、練り混ぜ後2〜3時間以上前養生期間を置くとしたが、これに限らず、前養生期間を24時間以上置いてもよい。養生条件の違いによるコンクリート二次製品の強度発現効果を検討する試験を行ったので、以下にその詳細について説明する。 Moreover, in the manufacturing method of the concrete secondary product which concerns on this embodiment, although the pre-curing period was put for 2 to 3 hours or more after mixing, it is not restricted to this, You may leave the pre-curing period for 24 hours or more. Since the test which examines the strength expression effect of the concrete secondary product by the difference in curing conditions was done, the details are explained below.
図8は、養生条件に係る試験で用いたコンクリート二次製品の試験体の構成材料及びその配合を示す表である。 FIG. 8 is a table showing the constituent materials of the test body of the concrete secondary product used in the test relating to the curing conditions and the blending thereof.
図8に示すように、養生条件に係る試験では、コンクリート二次製品の試験体の構成材料として、PFBC灰、高炉スラグ微粉末、細骨材、粗骨材、及び混和剤を使用し、これらの材料を、水結合材比(W/B)を30%、全骨材量に対する細骨材量の絶対容積比を表す細骨材率(s/a)を57%、結合材(B)に占める高炉スラグ微粉末(BF)の含有率(BF/B)を30%、コンクリート1m3を作るときに用いる水の使用量を表す単位水量(W)を90kg/m3で配合した。 As shown in FIG. 8, PFBC ash, blast furnace slag fine powder, fine aggregate, coarse aggregate, and an admixture are used as constituent materials for concrete secondary product specimens in tests related to curing conditions. The water binder ratio (W / B) is 30%, the fine aggregate ratio (s / a) representing the absolute volume ratio of the fine aggregate amount to the total aggregate amount is 57%, and the binder (B) The content (BF / B) of blast furnace slag fine powder (BF) occupying 30% was mixed at 30 kg, and the unit water amount (W) representing the amount of water used when making 1 m 3 of concrete was blended at 90 kg / m 3 .
なお、結合材(B)には、PFBC灰(P)及び高炉スラグ微粉末(BF)のみを使用し、そのPFBC灰と高炉スラグ微粉末との質量比は70:30とした。また、スランプ値(JIS A 1101)が実質的にゼロになるように調整するために、混和剤として高性能減水剤を使用し、結合材(B)に対して1.5重量%添加した。 In addition, only PFBC ash (P) and blast furnace slag fine powder (BF) were used for the binder (B), and the mass ratio of the PFBC ash to the blast furnace slag fine powder was 70:30. In order to adjust the slump value (JIS A 1101) to be substantially zero, a high-performance water reducing agent was used as an admixture, and 1.5% by weight was added to the binder (B).
そして、試験体のコンクリートを作製するにあたり、構成材料のうち骨材及び結合材を30秒間空練りしたものに、予め高性能減水剤を加えた水を投入してさらに4分間練り混ぜを行ってフレッシュコンクリートを作製し、その後そのフレッシュコンクリートをモールド(φ100mm×200mm)に打ち込み、棒形振動機で締め固めを行い、その後直ぐに型枠を取り外し、さらにその後養生を行うことにより複数の試験体を作製した。 Then, in preparing the concrete of the test body, the water in which the high-performance water reducing agent was added in advance was added to the one in which the aggregate and the binder were kneaded for 30 seconds, and the mixture was further mixed for 4 minutes. Produce fresh concrete, then cast the fresh concrete into a mold (φ100mm × 200mm), compact with a rod-shaped vibrator, then immediately remove the formwork, and then perform curing to produce multiple specimens did.
図9は、各試験体の蒸気養生の温度履歴を示すグラフである。
図9に示すように、本試験では各試験体に対し、養生条件No.1〜3の養生を行った。
FIG. 9 is a graph showing the temperature history of steam curing of each specimen.
As shown in FIG. 9, in this test, the curing condition No. The curing of 1-3 was performed.
養生条件No.1では、前養生期間をとることなしに、温度上昇速度を22.5℃/hで65℃まで室温を上昇させ(経過時間:0〜2時間)、その後65℃の等温養生期間を19時間とり(経過時間:2〜21時間)、その後自然放冷させた。すなわち、養生条件No.1では、前養生を0時間、蒸気養生を21時間行っている。 Curing conditions No. In 1, without increasing the pre-curing period, the room temperature is increased to 65 ° C. at a temperature increase rate of 22.5 ° C./h (elapsed time: 0 to 2 hours), and then the isothermal curing period of 65 ° C. is 19 hours. Taken (elapsed time: 2 to 21 hours), and then allowed to cool naturally. That is, curing condition No. In 1, the pre-curing is performed for 0 hours and the steam curing is performed for 21 hours.
また、条件No.2では、20℃で前養生期間を4時間とり(経過時間:0〜4時間)、その後温度上昇速度を15℃/hで50℃まで室温を上昇させ(経過時間:4〜6時間)、その後その室温で4時間保持させ(経過時間:6〜10時間)、その後さらに15℃/hとして65℃まで室温を上昇させた(経過時間:10〜11時間)。そして、65℃の等温養生期間を17時間とり(経過時間:11〜28時間)、その後自然放冷させた。すなわち、養生条件No.2では、前養生を4時間、蒸気養生を24時間行っている。 In addition, Condition No. 2, the pre-curing period was taken at 20 ° C. for 4 hours (elapsed time: 0 to 4 hours), and then the temperature was increased to 50 ° C. at a rate of 15 ° C./h (elapsed time: 4 to 6 hours). Thereafter, the temperature was maintained at room temperature for 4 hours (elapsed time: 6 to 10 hours), and then further increased to 65 ° C. at 15 ° C./h (elapsed time: 10 to 11 hours). Then, an isothermal curing period of 65 ° C. was taken for 17 hours (elapsed time: 11 to 28 hours), and then allowed to cool naturally. That is, curing condition No. In 2, the pre-curing is performed for 4 hours and the steam curing is performed for 24 hours.
また、養生条件No.3では、20℃で前養生期間を24時間とり(経過時間:0〜24時間)、その後温度上昇速度を15℃/hで50℃まで室温を上昇させ(経過時間:24〜26時間)、その後その室温で4時間保持し(経過時間:26〜30時間)、その後さらに15℃/hとして65℃まで室温を上昇させた(経過時間:30〜31時間)。そして、65℃の等温養生期間を17時間とり(経過時間:31〜48時間)、その後自然放冷させた。すなわち、養生条件No.3では、前養生を24時間、蒸気養生を24時間行っている。 In addition, curing conditions No. 3, the pre-curing period is taken at 20 ° C. for 24 hours (elapsed time: 0 to 24 hours), and then the room temperature is increased to 50 ° C. at a temperature increase rate of 15 ° C./h (elapsed time: 24 to 26 hours). Thereafter, the temperature was kept at room temperature for 4 hours (elapsed time: 26 to 30 hours), and then further increased to 65 ° C. at 15 ° C./h (elapsed time: 30 to 31 hours). And the isothermal curing period of 65 degreeC was taken for 17 hours (elapsed time: 31-48 hours), and it was allowed to cool naturally after that. That is, curing condition No. In No. 3, pre-curing is performed for 24 hours, and steam curing is performed for 24 hours.
そして、このような養生条件で養生を行った後、各試験体について、気中暴露状態での所定材齢時における圧縮強度(JIS A 1108)を測定した。 Then, after curing under such curing conditions, the compressive strength (JIS A 1108) at a predetermined age in the air exposure state was measured for each specimen.
図10は、各試験体の所定材齢時における圧縮強度の結果を示し、同図(a)はその結果をまとめた表、同図(b)はグラフである。なお、各試験体の圧縮強度は、養生終了直後、材齢7日、及び材齢28日の時点で測定した。 FIG. 10 shows the result of the compressive strength at the time of the predetermined age of each test body, FIG. 10 (a) is a table summarizing the results, and FIG. 10 (b) is a graph. In addition, the compressive strength of each test body was measured immediately after completion of curing, at the age of 7 days and at the age of 28 days.
図10に示すように、各試験体の圧縮強度は、養生終了直後からその違いが明瞭に現れ、養生条件No.1〜3の順に大きくなっていることがわかる。これは、前養生期間を長くとるほど、結合材の70%を占めるPFBC灰に含まれるCaO及びSO3の水和反応が進行し、Ca(OH)2やエトリンガイト等が生成されることにより自硬性が発揮されるとともに、生成されたCa(OH)2が刺激剤となって高炉スラグの水和反応を促進させ、さらに硬化を助長する(潜在水硬性)ためであると考えられる。 As shown in FIG. 10, the difference in the compressive strength of each specimen clearly appears immediately after the end of curing. It turns out that it becomes large in order of 1-3. This is because the longer the pre-curing period, the more the CaO and SO 3 contained in the PFBC ash, which occupies 70% of the binder, the hydration reaction proceeds, and Ca (OH) 2 and ettringite are generated. This is considered to be due to the fact that the hardness is exhibited and the produced Ca (OH) 2 acts as a stimulant to promote the hydration reaction of the blast furnace slag and further promote hardening (latent hydraulic).
また、各試験体は、材齢日数が経過するに従って徐々に圧縮強度が増加しており、材齢28日においての圧縮強度が、養生条件No.1では14.3N/mm2、養生条件No.2では17.3N/mm2、養生条件No.3では21.7N/mm2となる。 Each specimen gradually increased in compressive strength as the age of the material passed, and the compressive strength at the age of 28 days was determined as the curing condition No. 1 is 14.3 N / mm 2 , and curing condition No. 2 is 17.3 N / mm 2 , and curing condition No. 3 is 21.7 N / mm 2 .
ここで、建築工事標準仕様書・同解説JASS5では、耐久設計で確保すべき所要のコンクリートの強度(耐久設計基準強度)を、供用限界期間が30年の一般的なものを18N/mm2と定めている。これに対し、本試験結果によれば、コンクリート二次製品をNo.3の養生条件で製造した場合に、一般的な耐久設計基準強度を満足する。 Here, in the building construction standard specification and the explanation JASS5, the required concrete strength (durability design standard strength) to be secured in the durability design is 18 N / mm 2 , which is a general one with a service limit period of 30 years. It has established. On the other hand, according to the test results, the concrete secondary product was No. When manufactured under the curing condition 3, the general durability design standard strength is satisfied.
すなわち、本実施形態に係るコンクリート二次製品を製造するにあたり、前養生期間を24時間以上置くことにより、コンクリート二次製品に一般的な設計基準強度を発現させることができる。 That is, in producing the concrete secondary product according to the present embodiment, a general design standard strength can be expressed in the concrete secondary product by setting the pre-curing period for 24 hours or more.
S10 材料の計量工程
S20 練り混ぜ工程
S30 打ち込み工程
S40 締め固め工程
S50 脱型工程
S60 蒸気養生工程
S10 Material measurement process S20 Mixing process S30 Driving process S40 Compaction process S50 Demolding process S60 Steam curing process
Claims (6)
前記結合材は、PFBC灰及び高炉スラグ微粉末からなり、
スランプ値が実質的にゼロとなるように前記コンクリートを配合し、
練り混ぜられた前記コンクリートを、前記コンクリート二次製品の成形用の型枠に打設し、
前記型枠に打設したコンクリートを締め固め、
前記コンクリートを養生することなく、前記締め固められたコンクリートの前記型枠を取り外し、
前記型枠が取り外されたコンクリートに対し、20℃で少なくとも24時間の前養生を行った後、前記コンクリートを蒸気養生することを特徴とするコンクリート二次製品の製造方法。 A method for producing a secondary concrete product from concrete comprising fine aggregate, coarse aggregate, water, and binder,
The binder is made of PFBC ash and blast furnace slag fine powder ,
Mixing the concrete so that the slump value is substantially zero,
Placing the mixed concrete into a mold for molding the concrete secondary product;
Compacting the concrete placed in the formwork,
Without curing the concrete, remove the formwork of the compacted concrete,
A method for producing a secondary concrete product, comprising subjecting the concrete from which the formwork has been removed to precuring at 20 ° C. for at least 24 hours and then steam curing the concrete.
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