JPH02308049A - Composite material for concrete panel - Google Patents

Abstract

PURPOSE:To promote drainage efficiency after concrete is placed by sticking firm lining layers on woven fabrics of synthetic resin monofilament of single surface of the heat treated sheet together as one unit, and accompanying it to the internal surface of a pane. CONSTITUTION:Composite materials A for panels are constituted of lining layers 2 to be stuck on single surface of woven fabrics 1 by using the woven fabrics 1 of monofilament having about 80 - 400 denier texitile diameter such as polyester, etc. and a synthetic sheet such as vinyl chloride, etc. Then, the composite materials A is accompanied to a panel frame (f), and ready mixed concrete C is placed. Cement lime wash is filtered by the woven fabrics 1 of monofilament, and water and cellular are filtered to discharge to the outside of a frame from small holes 5 of the lower part of the panel frame (f). Accord ing to the constitution, the generation of pin holes, pits and the like on the surface of concrete can be prevented, and drainage efficiency can be promoted.

Description

DETAILED DESCRIPTION OF THE INVENTION (Field of Industrial Application) The present invention relates to a novel composite material for concrete panels that is used for the inner surface of concrete panels during concrete pouring.

(Prior Art) Concrete structures for architecture, civil engineering, etc. are constructed by framing wooden or metal concrete panels, pouring cement concrete into the frame, and curing and hardening the concrete. In recent years, buildings have become increasingly high-rise, and from the perspective of streamlining and promoting work, the ratio of water to cement has been increased to give fluidity to cement concrete and increase slump), and the above-mentioned improvements have been made by pumping up, pipe transportation, etc. Cement concrete was poured.

(Problems to be Solved by the Invention) However, although workability is improved when cement concrete with a high water ratio is used as described above, excess moisture and air bubbles remain at the interface with the panel after concrete is poured, causing concrete to deteriorate. The shrinkage of the concrete becomes large and cracks occur, and the strength of the concrete cannot be fully exerted, and many jumpers, bottle threads, and joints are exposed. Furthermore,
Many voids will be formed in the concrete structure, allowing water and air to pass through the voids, neutralizing the concrete and rusting the reinforcing bars, resulting in a significant decrease in the strength of the concrete structure. It happens. Moreover, even if water reducers and fluidizers are added to fresh concrete, vibrations and knocks from the outside of the panel are applied during pouring, which causes air and moisture to concentrate at the interface between the panel and the poured concrete. It is not possible to suppress the occurrence of pinholes, junkers, etc.

In recent years, in view of the above problems, various types of woven fabrics and water-permeable mats have been attached to the inner surface of concrete panels, so that excess moisture and air bubbles in poured concrete can be quickly discharged through the pores in the woven fabrics or water-permeable mats. A construction method was devised and adopted in various fields. In this construction method, when attaching the above-mentioned woven fabric etc. to a panel, the end of the woven fabric etc. is wrapped around the edge of the panel board and stitched at important points, or the entire surface is stitched without wrapping the end of the woven fabric etc. Stop it, or even stick it on the entire surface with adhesive. methods were used.

However, when constructing concrete using panels attached with woven fabric, etc. as described above, the woven fabric is used by cutting a long roll as appropriate, so the woven yarn frays from the cut end, and this frayed yarn can cause damage. This often causes problems such as getting entangled in the concrete and making it difficult to remove it, or leaving frayed threads in the concrete, degrading the appearance.

In addition, since woven fabric has a unique drape property, it tends to wrinkle or loosen when stitching the panel board, and if ready-mixed concrete is poured as is, these wrinkles or loose parts will sink into the concrete layer. This makes peeling extremely difficult and the finished appearance deteriorates significantly. Furthermore, when it is peeled off, it bulges, and when it is used again, the bulged part gets caught up in the concrete, making it almost impossible to peel it off. In addition, when drilling separate holes in a wooden panel, there is a problem in that wood chips may enter between the panel and the woven fabric. In this sense, it is desirable to bond the entire surface, but it is extremely difficult to do on-site work, and furthermore, once the fabric is bonded, it cannot be replaced if the fabric is damaged, making the panel itself unusable. . Furthermore, when the end of the woven fabric is wrapped around the edge of the panel board.

Since the thickness of this wrapped portion is added to the width dimension of the panel board, the dimensional error as a whole cannot be ignored in the case of large-scale construction with a large number of panel boards connected.

The present inventors, in Japanese Patent Application No. 63-187665,
We proposed a new composite material for attaching concrete panels that could eliminate the above-mentioned problems, and it became well received in various fields, but as a result of repeated research, we found that woven fabrics of synthetic resin monofilament or their heat treatment We have discovered that by combining a sheet and a backing layer, the drainage efficiency and peelability after concrete placement can be further improved, and the number of diversions can be dramatically increased, and we hereby propose to provide the present invention. be.

(Means for Solving the Problems) The structure of the present invention for achieving the above object will be explained in detail with reference to the attached embodiment drawings. FIG. 1 is a perspective view showing an example of the composite material of the present invention, FIG. 2 is an enlarged sectional view taken along the line ■-■ in FIG. 1, FIG. 3 is a perspective view showing another example of the composite material of the present invention, and FIG. The figure is an enlarged sectional view taken along the line IV-IV of Fig. 3, Fig. 5 is a partial enlarged view and sectional view of the monofilament woven fabric used in the composite material of the present invention, and Fig. 6 is concrete placement using the composite material of the present invention. FIG. 3 is a longitudinal sectional front view of a panel frame showing an example of the method.

That is, the composite material A for concrete panels of the present invention consists of a woven fabric 1 woven from synthetic resin monofilaments 11.
and a backing layer 2 attached to one side of the woven fabric 1, and is attached to the inner surface of the concrete panel P so that the woven fabric 1 is on the inside on the concrete pouring side as shown in FIG. It is something that will be done.

The above-mentioned woven fabric I is woven by plain weaving, twill weaving, or satin weaving [No. 5
See Figure (a)].

In addition, the woven fabric 1 is pressurized and heat treated with a calendar roll at a temperature below the melting point of the filament resin, and the shape of each monofilament 11 is compressed in the thickness direction of the woven fabric to form a sheet [No. See Figure (B)] is preferably adopted. Furthermore, when the general synthetic resin single-component monofilament is heated to the melting point of the resin, it loses its filament performance and shape, making thermal bonding difficult. Sheath part 11 whose surface is made of low melting point synthetic resin
It is made by weaving the monofilaments 11 coated with b, and is heated to form monofilaments 11.11.
It is also desirable to adopt a sheet-like structure in which the sheath parts 11b and llb are fused together so that the intersection of the sheath parts 11b and llb is integrally formed into a sheet shape (see FIG. 5(c)). The above heat treatment is carried out using a heat calender roll at a temperature of 90 to 250°C for 5 minutes.
20"C x 5 minutes is sufficient to achieve fusion and integration.

The above woven fabric (or sheet-like woven fabric subjected to the above heat treatment)
It is essential that No. 1 itself has air permeability (water permeability), and the amount of air permeability is preferably 0.1 to 20 dial/sec as measured by a Frazier type tester. In order to obtain this amount of ventilation, the mesh size of the woven fabric 1 is 40 to 3.
00 mesh is required. That is, if the mesh is coarser than 40 mesh, cement slag in the poured concrete will easily leach out, and if the mesh is finer than 300 mesh, sufficient air permeability will not be obtained.

In the case of heat-treated woven fabrics as shown in Figures 5 (B) and 5 (C), there is little gap between the overlapping parts of the filaments 11 and 11, especially in the case of Figure 5 (C), which can be understood from the cross-sectional view. As described above, such a gap is eliminated by the mutual fusion of the low-melting point resin sheath parts 11b and 11b, so that concrete slag does not get caught and is preferably adopted from the viewpoint of releasability. Sheet-like monofilament woven fabric 1 after this heat treatment
The appropriate thickness is about 0.2 to 0.8110.

The embodiments of the backing layer 2 can be roughly divided into two types. FIG. 1 and FIG. 2 relate to the first aspect,
The backing layer 2 in this figure is made of a stiff synthetic resin sheet (thickness, 0.01 to 2 cm) such as polyvinyl chloride, polyethylene, polyacrylic, or polycarbonate, or a thin sheet of the same synthetic resin (thickness, 0 .5-5m), synthetic resin foam sheets such as styrene and urethane (thickness, 0.5-15-)
, foam board (thickness, 5 to 75 ai), wood board such as plywood board (thickness, 2.5 to 24 m), metal board such as iron or stainless steel (thickness, 0.27 to 25 m), etc. . The backing layer 2 and the woven fabric 1 can be bonded together using double-sided adhesive tape, adhesive, stitching, or the like.

Furthermore, when using the heat-treated woven fabric 1 as described above, the unheat-treated woven fabric 1 and the backing material may be superimposed on a heat calender roll and fused by melting the monofilaments 11. Good, this time, woven fabric 1
The intersections of monofilaments 11 and 11 are also fused together.
It is natural that this will happen.

Next, FIGS. 3 and 4 show a composite material A according to the second aspect of the present invention, and the backing layer 2 in these figures is made of any one selected from synthetic resin net, flat yarn fabric, and nonwoven fabric. A release sheet 4 is attached to the back surface of the water-permeable material 2a with an adhesive coating layer 3 interposed therebetween. The adhesive applied to one side of the water-permeable material 2a is as follows:
Rubber-based adhesives such as natural rubber, recycled rubber, polyisoprene, styrene-butadiene, and polyisobutylene, or acrylic-based adhesives are preferably used. Further, as the release sheet 4 to be attached to the water-permeable material 2a via the adhesive, a release agent may be applied, or raft paper, pulp paper, or various resin sheets 1- may be used.

(Function) The composite material A according to the first embodiment having the above configuration is attached to the concrete panel board P so that the backing layer 2 faces the inner surface of the concrete panel board P. This is because the composite material A has a shape retention function due to the backing layer 2.

By simply fixing the panels at appropriate intervals with stitches, nails, double-sided tape, etc., they can be attached completely along the surface of the panel board P without wrinkles or loosening.

When ready-mixed concrete C is poured into a panel frame f with this composite material A added to the inner surface and framed, moisture and air bubbles in the poured concrete C continue in the direction of the surface area of the woven fabric 1. It is quickly discharged out of the panel frame f through a small hole 5 formed in the lower part of the panel frame f through the hole. Since the woven fabric 1 is woven from the monofilaments 11 as described above, cement slag can be effectively filtered, and water and air bubbles can quickly pass through the mesh between the monofilaments 11. It moves in the area direction and is sequentially discharged.

In this way, the surface of the concrete body C after curing and hardening becomes delicate, and there is no shrinkage or cracking due to drying of excess water, and no rusting of the reinforcing bars due to permeation of carbon dioxide gas.

In addition, there are no pinholes or cavities due to residual air bubbles, making the overall structure extremely robust (20-50% compressive strength compared to conventional models).
) 4IJ structure.

In addition, since the above-mentioned surplus water and air are quickly discharged after pouring as described above, the surplus water and air that have naturally flowed from inside the concrete body C are naturally discharged, and the dry-out phenomenon of cement is prevented. Therefore, the movement of water and air inside the concrete does not stop, and the concrete surface after peeling is finished in an extremely beautiful manner.

Furthermore, since the woven fabric l is woven from synthetic resin monofilaments, it has a smooth surface without minute irregularities or fluff due to fibers unlike multifilament, so it has a substantial contact area with the poured concrete. is small, and there are no fine fibers entangled in the concrete. Therefore, it has excellent peelability from concrete after curing and hardening, and the peeled surface has a glossy appearance and can be used as a finished surface even as it is. . This kind of good removability is due to
The number of times the composite material A is reused (the number of times it is repeatedly used) is dramatically increased, which greatly contributes to cost savings.

Furthermore, the color of the surface layer and the inner layer of the concrete layer is the same cement color (dark gray), no chalking is observed, and the whole has uniform properties. This is because when the concrete body C hardens, excess moisture and air inside the concrete body C are discharged at a moderate speed compared to the woven fabric 1, so that alkali is not unevenly distributed on the surface (referred to as the eflo phenomenon).

When using the woven fabric 1 that has been subjected to pressure and heat treatment as shown in FIG. A monofilament 11 which can be used more frequently and has good shape retention, and which has a core material 11a made of high melting point synthetic resin and whose surface is covered with a sheath part 11b made of low melting point synthetic resin, is woven and heat treated. In the case of the woven fabric 1, as described above, there is no concrete entrapment and its releasability is outstanding, so the number of times it can be used increases dramatically. Since only the sheath portion 11b can be melted and the intersection portions can be fused in a short time, excessive heating is avoided, there is no concern that the mesh will be filled with molten resin, and the desired air permeability is reliably maintained. .

In addition, in order to attach the composite material A of the present invention to the concrete panel board P, in addition to the above-mentioned methods of stitching, nails, and double-sided tape, there is also a method of pressing from the woven fabric side with a wooden or metal support (not shown). It is possible. In this case, an uneven pattern is created by the wood part after the panel is released from the mold, and combined with the good releasability of the woven fabric 1 and the concrete body C, this uneven pattern becomes more beautiful than ever before. Become. In addition, when using rigid plywood or metal plate as the backing layer 2, it is also possible to frame the panel frame with appropriate end angles and the composite material of the present invention.
In this case, the material will function as a concrete panel.

The composite material A of the second embodiment is attached to a concrete panel by peeling off the release sheet 4 and applying the adhesive coating layer 3 described above. Since the composite material A is coated with the adhesive coating layer 3, it can be easily attached without using stitches, nails, or the like. In addition, since a water-permeable material 2a as a backing layer 2 is interposed between the adhesive coating layer 3 and the woven fabric 1, excess water and air in the poured concrete that has passed through the woven fabric 1 will be absorbed. It is quickly discharged to the outside of the panel through the gaps in the water-permeable material 2a. Furthermore, since the woven fabric 1 and the water-permeable material 2a serving as the backing layer 2 are integrated into a composite body and are coated with an adhesive coating layer 3, the overall shape retention is good, in conjunction with the properties of the woven fabric 1. , is attached uniformly along the surface of the panel board P without wrinkles or slack.

So, what is the concrete casting method using this composite material A? The advantages are the same as those of the first embodiment, and the detailed explanation thereof will be omitted here, except that the water and air discharge performance is further improved as described above.

(Example) Next, the present invention will be explained in more detail with reference to specific examples.

(a) Preparation of monofilament woven fabric; The following six types of monofilament woven fabrics were prepared.

■ Plain woven polypropylene monofilament with wire diameter of 200 denier, air permeability 5 ad/aA/sea
, thickness Q, 32 mm, 145 strands/inch x 46 strands/inch woven fabric.

■, twill weave of polypropylene monofilament with a wire diameter of 200 denier, air flow rate 1.5 d/al/sea
, 0.31aa thick, 145 threads/inch x 54 threads/inch woven fabric.

■, Polypropylene monofilament with a wire diameter of 200 denier is woven with satin, and the air permeability is 1 ad/aif/
s e c, thickness 0.29m, 145 pieces/inch x 62
Book/inch of woven fabric.

■、I! Made of twill weave polypropylene monofilament with a diameter of 200 denier and air permeability of 0. 'lal/al/
se, thickness Q, 53 m woven fabric.

(2) A sheet-like woven fabric obtained by pressurizing and heating the woven fabric of (1) above using a heat calendar roll at 160 to 165°C.

(2) Monofilament with a wire diameter of 200 denier, the surface of which is a polypropylene linear core covered with a polyolefin resin sheath, is plain-woven and heat-treated with a heat calender roll at 130°C, with an air permeability of 5 al/al/ s
a c, sheet-like woven fabric with a thickness of 0.38 m.

(b) Preparation of composite material: Two types of backing layers, a synthetic resin thin plate and a synthetic resin net, are prepared for the above woven fabrics ■ to ■, and each woven fabric is coated with solvent-based chloroprene on one side of these backing layers. The adhesive was applied uniformly to bond them together. As for (2) and (2), they were fused and integrated with these backing layers by heating.

(c) Creation of formwork; The above composite material is made of plywood for general formwork (900 x 1800m)
2 panels with stitching attached to one side of the fabric so that the woven fabric is on the surface, and 2 panels of the same plywood without the composite material attached.
A square prism formwork with a cross section of 900 x 900 cm and a height of 1,800 m was made from the sheets. In this case, the frames were constructed so that the parts to which the composite material was added and the parts to which the composite material was not added were adjacent to each other, and the composite material was on the inner surface. Also,
A small hole for water permeation was created at the bottom of each panel.

(d) Placing and curing of fresh concrete; slump 18a
1 (water ratio: 38%) of fresh concrete was poured into the above formwork. Immediately after pouring, nearly transparent water began to flow out from the lower holes of the panels to which the composite material had been added, but cement-colored water began flowing out from the lower holes of the panels to which no composite material had been added after a few minutes. water started flowing out.

(e) Release of mold; After curing for 72 hours, the mold was released. The panel loaded with the composite material can be released from the mold extremely easily, and there is almost no cement adhesion to the surface of the woven fabric.

It was in sufficient condition to be reused. The surface of the concrete structure was dark gray and extremely glossy, with almost no pinholes or junkers observed. -It takes time and effort to demold panels that are not loaded with composite materials, a large amount of cement adheres to the panels, and the surface of the concrete structure becomes chalky, with many pinholes, junkers, etc. Ta.

(f) Measurement of concrete surface strength; The degree of repulsion was measured using the Schmidt hammer method at 9 evenly distributed points on the top, middle, bottom, and left and right center of each surface of the concrete structure. Measurements were made at 25 points at each location. ), the formula by the Architectural Institute of Japan (F (surface strength) = 7.
The surface strength was calculated by 3.Ro (degree of repulsion)+1003. As a result, the panel side to which the composite material of the present invention was added had an average surface strength of 421 kgf/a#, while the panel side to which the same composite material was not added had an average surface strength of 368 kgf/a#. /ad. This is about 14%
This corresponds to an increase in strength.

Although plain weave, twill weave, and satin weave of the woven fabric of the present invention all give good results, there are some differences in characteristics between them. That is, in the case of plain weave, the ability to collect cement slag (filtration ability) is high, but it is slightly prone to clogging, in the case of Ha, the ability to collect cement slag and clogging is moderate, and in the case of satin weave, the ability to collect cement slag and clogging is moderate. Although it has a low ability to collect cement slag, it has excellent peelability.

Therefore, it is desirable to use them appropriately depending on the intended use.

(Effects of the invention) As mentioned above, the composite material for concrete panels of the present invention has the following effects:
A stiff backing layer is attached to one side of the woven fabric made of monofilament synthetic resin fibers, so when it is attached to a concrete panel, it will not wrinkle or loosen, and will fit perfectly along the panel surface. I can do it. Therefore, the woven fabric does not get entangled in the poured concrete layer, and combined with the smooth surface of each woven fabric filament, peeling is extremely easy and there is little damage to the woven fabric, making it unnecessary to repeat the process. It is considered possible to use it. In addition, there is no fear that the threads will fray from the ends, so there is no need to wrap them around the ends of the panel, so even if a large number of panels are connected, there will be no dimensional errors as mentioned above. Even if the holes are drilled, there is no concern that wood chips will get entangled in the woven fabric because they are separated by the lining material.

Moreover, when ready-mixed concrete is poured into a formwork framed by panels loaded with this composite material, excess water and air bubbles in the poured concrete are quickly discharged from the pores that extend in the direction of the surface area of the woven fabric. Therefore, no pinholes, jitters or pockmarks occur on the concrete surface, and together with the above-mentioned good releasability, an extremely beautiful and glossy finished appearance can be obtained. Furthermore, an extremely strong structure is obtained with no air bubbles forming inside the concrete layer, and the carbonation of the concrete and the occurrence of cracks are suppressed by drastically reducing the number of pinholes, etc., and its durability is dramatically improved. do.

Furthermore, if a heat-treated filament woven fabric is used as the woven fabric, concrete slag will not get stuck in it, and the releasability will further improve, and the number of reuses will further increase, which will greatly contribute to lowering the cost of concrete construction methods. In addition, in the case of a woven fabric woven from monofilaments coated with a low-melting point resin, the filaments do not shift from each other and there is no fraying from the ends, which further improves peelability and allows heat treatment at low temperatures. In addition, since the mesh is not filled with molten resin, the desired amount of ventilation can be maintained. In particular, when a heat-treated woven fabric is used, it is convenient to overlap it with the backing material and heat-treat it so that they can be mutually bonded and integrated at the same time.

Additionally, if you use a water-permeable material as the backing layer, the drainage efficiency from the poured concrete will be even better! A dense and solid concrete structure can be obtained. Furthermore, if a rigid plywood or metal plate is used as the backing layer, this itself can be made into a concrete panel.

It is clear that the present invention, which has many advantages as described above, will be highly valued especially when applied to the construction of architectural structures and the like.

[Brief explanation of the drawing]

FIG. 1 is a perspective view showing an example of the composite material of the present invention, FIG. 2 is an enlarged sectional view taken along the line nn of FIG. The figure is an enlarged cross-sectional view taken along the line IV-fV of Figure 3, Figure 5 is a partial enlarged view and cross-sectional view of the monofilament woven fabric used in the composite material of the present invention, and Figure 6 is concrete placement using the composite material of the present invention. FIG. 3 is a longitudinal sectional front view of a panel frame showing an example of the method. (Explanation of symbols) 1... Woven fabric, 2... Backing layer, 2a... Water permeable material, 3... Adhesive coating layer, 4... Release sheet, A... Present invention Composite material for concrete panels, P
...Concrete panel, C...Concrete body. - Above - Applicant Central Engineering Co., Ltd. (and 2 others) Agent Patent attorney (6235) Hidehiko Matsuno P... Concrete panel, C... Concrete body Figure 3 Figure 4

Claims (1)

[Claims] 1. A composite material for concrete panels comprising a woven fabric woven from synthetic resin monofilaments and a backing layer adhered to one side of the woven fabric. 2. The composite material for concrete panels according to claim 1, wherein the woven fabric is obtained by pressurizing and heating a woven body of synthetic resin monofilaments and compressing the monofilaments. 3. The above woven fabric is a monofilament woven body in which the surface of a core material of a high melting point synthetic resin is covered with a sheath part of a low melting point synthetic resin, and the intersecting parts of the monofilaments are integrated by mutual fusion of the sheath parts. The composite material for concrete panels according to claim 1, which is a composite material for a concrete panel. 4. The composite material for concrete panels according to claim 1, wherein the backing layer is made of any one selected from a wood board, a synthetic resin sheet, a thin synthetic resin board, a foamed synthetic resin sheet, a foamed synthetic resin board, or a metal plate. 5. The composite material for concrete panels according to claim 1, wherein the backing layer is made of a water-permeable material selected from synthetic resin net, flat yarn fabric, and non-woven fabric. 6. The composite material for concrete panels according to claim 5, wherein a release sheet is attached to the back surface of the water-permeable material via an adhesive coating layer.