JP5984140B2 - Method for producing lightweight cellular concrete - Google Patents
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本発明は、軽量気泡コンクリートの製造方法に関し、特に発泡剤として乾式粉砕により得られる金属アルミニウム粉末を使用する軽量気泡コンクリートの製造方法に関する。 The present invention relates to a method for producing lightweight cellular concrete, and more particularly, to a method for producing lightweight cellular concrete using metal aluminum powder obtained by dry pulverization as a foaming agent.
軽量気泡コンクリート（以下、ＡＬＣとも称する）は、無数の細かい気泡を含んだ多孔質体で形成されているため、軽量性、耐火性、断熱性などにおいて優れた諸性能を有しており、建築物の外壁、床材、屋根などの部位に広く使用されている。ＡＬＣの主原料は珪酸質原料と石灰質原料であり、珪酸質原料としては珪石または珪砂が、石灰質原料としては生石灰とセメントが使用されている。また、発泡剤として金属アルミニウム粉末が一般的に使用されている。 Lightweight cellular concrete (hereinafter also referred to as ALC) is made of a porous material containing countless fine bubbles, and therefore has excellent performance in terms of lightness, fire resistance, heat insulation, etc. Widely used on parts such as outer walls, flooring, and roofs. The main raw materials of ALC are siliceous raw materials and calcareous raw materials. Silica stones or quartz sand are used as siliceous raw materials, and quick lime and cement are used as calcareous raw materials. Further, metal aluminum powder is generally used as a foaming agent.
これら原料を用いて一般的に次のような製造工程を経てＡＬＣの製造が行われている。すなわち、まず珪酸質原料及び石灰質原料からなる主原料に発泡剤と水を加えてミキサーで混練し、得られたスラリーを予め補強材を配した型枠に流し込む。型枠内では、発泡剤による化学反応で発泡し、同時に硬化が進行する。そして、半硬化状態になった時点で当該半硬化体を脱型し、ピアノ線などで所定の寸法に切断した後、オートクレーブにより高温高圧蒸気養生を行う。これによりＡＬＣが得られる。 In general, ALC is produced through the following production steps using these raw materials. That is, first, a foaming agent and water are added to a main raw material composed of a siliceous raw material and a calcareous raw material, kneaded by a mixer, and the resulting slurry is poured into a formwork provided with a reinforcing material in advance. In the mold, foaming is caused by a chemical reaction with a foaming agent, and curing proceeds at the same time. And when it will be in a semi-hardened state, after removing the said semi-hardened body and cut | disconnecting to a predetermined dimension with a piano wire etc., high temperature high pressure steam curing is performed with an autoclave. This gives ALC.
発泡剤として使用する金属アルミニウム粉末は、予め数ｍｍ程度の大きさに荒粉砕したアルミニウム箔の原料に粉砕助剤として脂肪酸を添加し、１グラム当たりの水面被覆面積が４５００ｃｍ２以上２００００ｃｍ２になるまで乾式粉砕した後、脂肪酸を０.３質量％以下まで除去してから使用していた。このように、脂肪酸を除去した金属アルミニウム粉末を用いることで、水に溶解してからミキサーで混練する際に金属アルミニウム粉末を均等にスラリー内に分散させることができ、均等に発泡させることが可能になる。 Metallic aluminum powder used as blowing agents, the addition of fatty acid as a raw material in the grinding aid of the aluminum foil was rough ground to a size of the pre-order of a few mm, the water covering area per gram is 4500Cm 2 or more 20000 cm 2 After dry pulverization until the fatty acid was removed to 0.3% by mass or less, it was used. Thus, by using the metal aluminum powder from which fatty acids have been removed, the metal aluminum powder can be evenly dispersed in the slurry when kneaded with a mixer after being dissolved in water, and foamed evenly. become.
すなわち、ＡＬＣを製造する場合には、補強材を配置した型枠内に上記した主原料および発泡剤に水を混合して得られるスラリーを流し込んで発泡及び硬化させて半硬化体を形成するが、その際、上記方法で作製された金属アルミニウム粉末が均等に分散した場合には、型枠内に流し込んでから数分で発泡が始まって膨張し、２０分から５０分で型枠内で最大高さまで体積膨張し、ほぼそのままで半硬化状態となる。しかしながら、金属アルミニウム粉末が均等に分散しなかった場合は、不均質な発泡や発泡阻害を生じて、ＡＬＣが不良品となることがあった。 That is, when manufacturing ALC, a slurry obtained by mixing water into the main raw material and the foaming agent described above is poured into a mold having a reinforcing material, and foamed and cured to form a semi-cured body. In this case, when the metal aluminum powder produced by the above method is evenly dispersed, foaming starts and expands within a few minutes after pouring into the mold, and the maximum height is reached within 20 to 50 minutes. The volume expands to a certain level and becomes almost semi-cured as it is. However, when the metal aluminum powder is not evenly dispersed, nonuniform foaming or foaming inhibition may occur, resulting in a defective ALC.
また、乾式粉砕をした金属アルミニウム粉末に付着している脂肪酸を除去せずにそのまま発泡剤として使用した場合には、水と混合する際に溶解しない部分が多く生じ、スラリー内に均等に分散されにくくなる。更に、水と発泡剤との予混合に攪拌槽を用いる場合は、当該攪拌槽の内部や攪拌槽からの抜き出し配管内に金属アルミニウム粉末が残留して、不均質な発泡や発泡不足などの問題を引き起こし、ＡＬＣの外観を著しく損ねて不良品となることがあった。 Also, when the fatty acid adhering to the dry pulverized metal aluminum powder is used as it is as it is without removing the fatty acid, there are many parts that do not dissolve when mixed with water, and it is evenly dispersed in the slurry. It becomes difficult. Furthermore, when a stirring tank is used for premixing water and a foaming agent, metal aluminum powder remains in the stirring tank or in the extraction pipe from the stirring tank, causing problems such as inhomogeneous foaming and insufficient foaming. And the appearance of the ALC was significantly impaired, resulting in a defective product.
このように、脂肪酸を添加して乾式粉砕をした金属アルミニウム粉末に対して脂肪酸の除去を行わない場合は水に溶解しにくくなるため、従来は特許文献１に示すように、乾式粉砕をした金属アルミニウム粉末の中に含まれる脂肪酸を０.３質量％以下まで除去したものを使用し、これにより発泡剤が水に溶解しにくくなることに起因する問題を防いでいた。しかしながら、乾式粉砕後に脂肪酸を０.３質量％以下まで除去する処理のためのコストがかさむため、結果的に高価な金属アルミニウム粉末を使用せざるを得ない状況にあった。 Thus, since it becomes difficult to melt | dissolve in water when the removal of a fatty acid is not performed with respect to the metal aluminum powder which added the fatty acid and carried out the dry grinding | pulverization, as shown in patent document 1, conventionally the metal which carried out the dry grinding | pulverization What removed the fatty acid contained in aluminum powder to 0.3 mass% or less was used, and the problem resulting from it becoming difficult to melt | dissolve a foaming agent in water was prevented. However, since the cost for the treatment for removing the fatty acid to 0.3% by mass or less after the dry pulverization is increased, an expensive metal aluminum powder must be used as a result.
本発明は、上記した従来の問題点に鑑みてなされたものであり、不均質な発泡や発泡不足を生じさせることなく安価且つ簡易にＡＬＣを製造できる方法を提供することを目的としている。 The present invention has been made in view of the above-described conventional problems, and an object of the present invention is to provide a method capable of producing ALC easily and inexpensively without causing inhomogeneous foaming or insufficient foaming.
上記目的を達成するため、本発明が提供する軽量気泡コンクリートの製造方法は、珪酸質原料と石灰質原料からなる主原料に発泡剤と水とを加えてスラリーとし、これを補強材を配置した型枠内に流し込んで半硬化体を形成し、得られた半硬化体を高温高圧蒸気養生してなる軽量気泡コンクリートの製造方法において、前記発泡剤として、脂肪酸を添加して乾式粉砕した金属アルミニウム粉末に脱脂処理を行わずにそのまま水溶性の分散剤である低級アルコールと水とを加えて均一に混合したものを使用することを特徴としている。 In order to achieve the above object, a lightweight cellular concrete manufacturing method provided by the present invention is a mold in which a foaming agent and water are added to a main raw material composed of a siliceous raw material and a calcareous raw material to form a slurry, and this is provided with a reinforcing material. In the manufacturing method of lightweight cellular concrete formed by pouring into a frame to form a semi-cured body, and curing the obtained semi-cured body at high temperature and high pressure steam, as the foaming agent, a metallic aluminum powder dry-ground by adding a fatty acid Further, it is characterized in that a water-soluble dispersant , a lower alcohol , which is a water-soluble dispersant, and water are added and mixed uniformly without performing a degreasing treatment.
本発明によれば、既設プラントの大掛かりな改造を要することなく安価且つ簡易にＡＬＣを製造することが可能になる。 According to the present invention, it is possible to manufacture ALC easily and inexpensively without requiring extensive modification of an existing plant.
以下、本発明のＡＬＣの製造方法の一具体例について説明する。珪酸質原料、石灰質原料、及び必要に応じて使用される石膏を主とする固体粉末状の主原料に発泡剤と水を加えてミキサーで混合撹拌し、これにより得られるスラリーを補強鉄筋を配した型枠に流し込む。型枠内のスラリーは、発泡剤による化学反応で発生する水素ガスが気泡を形成することによって発泡すると共に、主原料の固体粉末が水和反応を起こすことで、その流動性を徐々に失い半硬化体へと移行する。得られたケーキ状の半硬化体をピアノ線で所定の大きさに切断し、オートクレーブで水蒸気養生することによりＡＬＣパネルが得られる。 Hereinafter, a specific example of the ALC production method of the present invention will be described. Add a foaming agent and water to the main raw material in the form of a solid powder mainly composed of siliceous raw material, calcareous raw material, and gypsum used as needed, and mix and stir with a mixer. Pour into the finished formwork. The slurry in the mold foams when hydrogen gas generated by the chemical reaction with the foaming agent forms bubbles, and the solid powder of the main raw material undergoes a hydration reaction. Transition to a cured product. The obtained cake-like semi-cured product is cut into a predetermined size with a piano wire and steam-cured with an autoclave to obtain an ALC panel.
ここで、発泡剤には乾式粉砕した金属アルミニウム粉末に水溶性の分散剤を添加したものを使用する。このうち、金属アルミニウム粉末は、原料として予め数ｍｍ程度の大きさに荒粉砕したアルミニウム箔を用い、この原料に粉砕助剤としてステアリン酸やオレイン酸を代表とする脂肪酸を添加し、常圧で不活性な気体の雰囲気中で水面被覆面積が４５００ｃｍ２以上２００００ｃｍ２以下になるまで粉砕した後、４４μｍふるい残分が２０〜５０質量％となるように分級し、これにより、水面拡散面積が４５００〜１２０００ｃｍ２程度の粉末とするのが好ましい。 Here, as the foaming agent, a dry-ground metal aluminum powder to which a water-soluble dispersant is added is used. Among these, the metal aluminum powder uses an aluminum foil roughly pulverized to a size of about several mm in advance as a raw material, and a fatty acid typified by stearic acid or oleic acid is added to the raw material as a pulverization aid. after water surface area covered in an atmosphere of inert gas was ground to a 4500Cm 2 or more 20000 cm 2 or less, and classified as 44μm sieve residue is 20 to 50 wt%, thereby, the water covering area 4500 It is preferable to use a powder of about ˜12000 cm 2 .
従来は上記と同様に分級した後、加熱乾燥などの脱脂処理を施して脂肪酸の量が金属アルミニウム粉末に対して０.３質量％以下まで除去したものを使用するのが一般的であった。これに対して、本発明においては、発泡剤として、脂肪酸を添加して乾式粉砕した金属アルミニウム粉末にそのまま水溶性の分散剤を添加したものを使用する。これにより、金属アルミニウム粉末に付着した脂肪酸を加熱乾燥等の脱脂処理により取り除くことなく水に溶解することができる。すなわち、脂肪酸の脱脂工程を省略できるので従来の乾式粉砕金属アルミニウム粉末よりも簡易かつ低コストにＡＬＣを製造する事が出来る。 Conventionally, after classifying in the same manner as described above, it has been common to use a product that has been subjected to a degreasing treatment such as heat drying to remove the amount of fatty acid to 0.3% by mass or less with respect to the metal aluminum powder. On the other hand, in this invention, what added the water-soluble dispersing agent as it is to the metal aluminum powder which added the fatty acid and dry-milled is used as a foaming agent. Thereby, the fatty acid adhering to the metal aluminum powder can be dissolved in water without being removed by a degreasing treatment such as heat drying. That is, since the fatty acid degreasing step can be omitted, ALC can be produced more easily and at a lower cost than conventional dry-pulverized metallic aluminum powder.
水溶性の分散剤としては、例えば非イオン系の界面活性剤や低級アルコールを使用することができる。この分散剤を金属アルミニウム粉末１重量部に対して０.００１〜０.３重量部程度添加するのが好ましい。水溶性の分散剤を添加した後は、これら金属アルミニウム粉末と分散剤との合計１重量部に対して、水１０〜６０重量部を加えて予め混合してから発泡剤としてスラリーに添加することが望ましい。これにより、金属アルミニウム粉末に脂肪酸が付着している場合であっても均一に混ざり易くなり、スラリー調製が行われるミキサーに投入した時点でアルミニウム粉末を主原料に均質に混ぜ易くなる。 As the water-soluble dispersant, for example, a nonionic surfactant or a lower alcohol can be used. It is preferable to add about 0.001 to 0.3 parts by weight of this dispersant with respect to 1 part by weight of the metal aluminum powder. After adding the water-soluble dispersant, add 10 to 60 parts by weight of water to the total of 1 part by weight of the metal aluminum powder and the dispersant, and then add them to the slurry as a foaming agent. Is desirable. Thereby, even when the fatty acid adheres to the metal aluminum powder, it becomes easy to mix uniformly, and when it is put into a mixer where slurry preparation is performed, the aluminum powder is easily mixed homogeneously with the main raw material.
上記した予め加える水の量が１０重量部未満では、ミキサーによる攪拌混合の際に、混合度合いのバラツキが大きくなり、型枠内での半硬化体の発泡高さなどの管理が難しくなる。一方、上記した予め加える水の量が６０重量部を超えるとアルミニウム粉末と分散剤と水との予混合のための攪拌槽が大きくなりすぎるなどの点で不経済となる割に効果が上がらない。 If the amount of water added in advance is less than 10 parts by weight, the mixing degree varies greatly during the stirring and mixing by the mixer, and it becomes difficult to manage the foaming height of the semi-cured body in the mold. On the other hand, if the amount of water to be added in advance exceeds 60 parts by weight, the effect is not increased although it becomes uneconomical in that the stirring tank for premixing the aluminum powder, the dispersant and water becomes too large. .
このように、乾式粉砕した金属アルミニウム粉末にその水への溶解性を高めるべく分散剤を添加し、好適には所定量の水を予め加えて混合してからＡＬＣ製造工程において発泡剤として使用することによって、乾式粉砕した金属アルミニウム粉末の脂肪酸を取り除くための従来の脱脂工程を省くことが可能になり、よってＡＬＣ製造の際の原材料の混合攪拌工程を簡素化して、低コストでＡＬＣパネルを製造することができる。なお、本発明においてＡＬＣは、ＪＩＳ Ａ ５４１６に規定しているＡＬＣの範囲のものに限定されず、広義のＡＬＣを意味している。 In this way, a dispersant is added to the dry-pulverized metallic aluminum powder to increase its solubility in water, and preferably a predetermined amount of water is added in advance and mixed before use as a foaming agent in the ALC manufacturing process. As a result, it is possible to omit the conventional degreasing process for removing the fatty acid from the dry pulverized metallic aluminum powder, thus simplifying the mixing and stirring process of raw materials during the production of ALC, and manufacturing an ALC panel at a low cost. can do. In addition, in this invention, ALC is not limited to the thing of the range of ALC prescribed | regulated to JISA5416, The ALC in a broad sense is meant.
脂肪酸が付着した状態の金属アルミニウム粉末１重量部を５０重量部の水の中に加えた試料１〜４のスラリーを作製した。なお、金属アルミニウム粉末としては、ＵＣルーサル社の製品「ＨＡＰ−１」を用いた。これら試料１〜４のスラリーに対して、それぞれ表１に示す処理を施して脂肪酸が付着した状態の金属アルミニウム粉末が水に溶解するか調べた。 Slurries of Samples 1 to 4 were prepared by adding 1 part by weight of metal aluminum powder with fatty acid attached thereto to 50 parts by weight of water. In addition, as a metal aluminum powder, the product “HAP-1” manufactured by UC Rusal was used. The slurries of Samples 1 to 4 were each subjected to the treatment shown in Table 1 to examine whether the metal aluminum powder with the fatty acid attached was dissolved in water.
すなわち、試料１のスラリーには分散剤として非イオン系の界面活性剤溶液を金属アルミニウム粉末１重量部に対して０.０１重量部加えて２０秒間攪拌混合し、試料２のスラリーには分散剤として低級アルコールを金属アルミニウム粉末１重量部に対して０.０１重量部加えて２０秒間攪拌混合した。一方、比較例としての試料３のスラリーには分散剤を加えずに６０秒間攪拌混合し、比較例としての試料４のスラリーには分散剤を加えずに２４０秒間攪拌混合した。これらの結果を表1に示す。 That is, 0.01 part by weight of a nonionic surfactant solution as a dispersant is added to the slurry of sample 1 with respect to 1 part by weight of the metal aluminum powder, and the mixture is stirred and mixed for 20 seconds. As a lower alcohol, 0.01 part by weight with respect to 1 part by weight of metal aluminum powder was added and stirred and mixed for 20 seconds. On the other hand, the slurry of sample 3 as a comparative example was stirred and mixed for 60 seconds without adding a dispersant, and the slurry of sample 4 as a comparative example was stirred and mixed for 240 seconds without adding a dispersant. These results are shown in Table 1.
上記表１に示すように、脂肪酸が付着した状態の金属アルミニウム粉末に分散剤を添加せずに水のみを加えて攪拌した試料３及び４のスラリーにおいては、６０秒及び２４０秒攪拌をしても脂肪酸が付着した状態の金属アルミニウム粉末は水に全量が溶解しないことが認められた。一方、脂肪酸が付着した状態の金属アルミニウム粉末に分散剤として非イオン系界面活性剤または低級アルコールを加えた試料１及び２のスラリーにおいては、水中での攪拌により２０秒以内に溶解することが確認できた。 As shown in Table 1 above, in the slurry of Samples 3 and 4 in which only the water was added to the metal aluminum powder with the fatty acid adhered and the mixture was stirred, the mixture was stirred for 60 seconds and 240 seconds. In addition, it was confirmed that the metal aluminum powder with the fatty acid attached was not completely dissolved in water. On the other hand, it was confirmed that the slurry of Samples 1 and 2 in which a nonionic surfactant or a lower alcohol was added as a dispersant to a metal aluminum powder with fatty acid attached dissolved within 20 seconds by stirring in water. did it.
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| JPS5585449A (en) * | 1978-12-15 | 1980-06-27 | Sumitomo Metal Mining Co | Manufacture of lightweight foamed concrete by steam curing |
| JPS56166309A (en) * | 1980-05-22 | 1981-12-21 | Toyo Alum Kk | Manufacture of flaky metallic powder |
| JPH11292655A (en) * | 1998-04-17 | 1999-10-26 | Asahi Kasei Metals Kk | Aluminium powder for blowing agent for light weight (foamed) concrete, and its aqueous paste composition |
| JP4374112B2 (en) * | 2000-03-24 | 2009-12-02 | クリオン株式会社 | Method for producing lightweight cellular concrete |
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