JPH04226302A - Manufacture of large-scaled alc panel - Google Patents

Abstract

PURPOSE:To manufacture an ALC panel of superior installation strength even when a fitment for installing the panel is molded in and without generating localized damage by using mortar slurry for ALC containing aluminum powder as a foaming agent. CONSTITUTION:A molded-in fitment 4 and reinforcing bars 3 are set in a frame consisting of a frame base plate 1 and a side frame component 2, and mortar slurry for ALC composed of a powdery silicic raw material and a lime raw material as main components containing aluminum powder as a foaming agent is injected. The side frame component 2 and a spacer 6 are removed at the stage when the mortar slurry reaches the given strength after primary curing, and its surface is cut by a piano wire and arranged in the given panel thickness, and high temperature and high pressure steam curing is applied.

Description

[Detailed description of the invention]

0001

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for manufacturing a large-sized ALC panel that is integrally molded with metal fittings for mounting the panel embedded therein.

0002

[Prior art] The conventional large ALC panel is 600 mm.
There were large panels made by assembling multiple small panels. In addition, there is also known a large panel that uses quick-setting cement and has air bubbles formed with a foaming agent, which is characterized by a short demolding time.

0003

[Problems to be Solved by the Invention] The former type of large panel made by assembling a plurality of small panels lacks integrity as a panel, and is not particularly preferred in terms of design. Large panels using the latter type of quick-setting cement and having air bubbles formed with a foaming agent have the disadvantage that the panels themselves are fragile, necessitating the use of special reinforcing materials.

[0004] The present invention is an AL using aluminum powder as a foaming agent.
An invention aimed at providing a method for manufacturing a large-sized ALC panel using C mortar slurry, which is characterized in that there is no problem in the strength of attaching the panel to a building even if metal fittings for panel attachment are embedded. It is.

[0005]

[Means for Solving the Problems] The present invention provides a method for installing powdered siliceous raw material after installing metal fittings for mounting and reinforcing reinforcing bars in advance in a formwork with a side frame member height of 100 mm or more and approximately 250 mm. A mortar slurry for ALC, which is mainly composed of and calcareous raw materials and aluminum powder as a foaming agent, is injected to a height corresponding to the height of the panel to be manufactured. After pre-curing, when the specified strength is reached, the side A method for producing large ALC panels, which involves removing the frame, cutting the front side with a wire rod such as piano wire, cutting off the excess foam on the surface, curing the panel with high temperature and high pressure steam to obtain the desired panel thickness. be.

[0006] The large ALC panel in the present invention is a panel larger than a conventional panel with a width of 600 mm,
For example, the panel width is 900 mm or more, preferably 150 mm
0 mm or more, the panel length is 2400 mm or more, preferably 3000 mm or more, the panel thickness is 100 mm or more, preferably 120 mm or more, and the width is 90 mm or more.
0mm to 2400mm, maximum length 8000mm, thickness 7
The large ALC of the present invention can also be applied to panels of about 5 mm to 250 mm.
included in the panel.

[0007] The mortar raw material used in the manufacturing method of the large-sized ALC panel of the present invention is a mortar raw material for ALC which is mainly composed of powdered silicic acid raw material and calcareous raw material used in ordinary ALC, and has aluminum powder as a foaming agent. Mortar that is not used in systems that use ordinary aluminum as a foaming agent should not be used because foaming due to aluminum cannot be expected when using rapid-setting cement that produces hydrogarnet through high-temperature, high-pressure steam curing. It goes without saying that it is possible.

[0008] Furthermore, the C/S of the raw material is preferably 0.8 or more, and the high temperature and high pressure steam curing is performed at a gauge pressure of 8 to 12 kg/c.
Typical conditions with m2 of saturated steam are used. Further, the average bulk specific gravity of the matrix portion (the portion excluding reinforcing bars and the like) of the obtained product is preferably 0.04 to 1.00, particularly preferably 0.40 to 0.60. Also, in order to produce panels with openings, several sizes of opening spacers can be used, depending on the size of the openings, from 300 mm to 2100 mm in width.

[0009]

[Function] In the present invention, ALC which has powdered silicate raw material and calcareous raw material as main components and aluminum powder as a foaming agent.
Because it uses a mortar slurry made for use in concrete, it is not as fragile as panels manufactured by using rapid setting cement as the main component and forming air bubbles with a foaming agent, and the height of the side frame members is 100 mm or more. The mortar slurry for ALC is poured to a height corresponding to the height of the panel to be manufactured using a formwork of about 250 mm.In order to manufacture it by a flat casting method that matches the height of a single panel, it is usually buried. Even if you embed a mounting bracket in a panel that has a defect in that the bracket significantly inhibits the foaming of the mortar and as a result, the pull-out strength of the embedded bracket varies widely within the same panel, the resulting panel will not have any When the absolute dry bulk specific gravity of the two parts is ρ1, ρ2 (ρ2 ≧ρ1), ((
By successfully keeping ρ2 - ρ1 )/ρ1 always below 0.02, and by making the maximum width of the void around the reinforcing bars less than half the diameter of the reinforcing bars, the reinforcing bars and ALC They succeeded in integrating it with the matrix. As a result, although the large ALC panel obtained by the manufacturing method of the present invention is a large panel, it is difficult to cause local destruction of the panel, and exhibits the effect that it has excellent mounting strength to a building with embedded metal fittings. Since the metal fittings are built-in, it also has the effect of simplifying the process of installing panels at building construction sites.

[0010] Therefore, there is no need for an extremely uneconomical design such as arranging reinforcing reinforcing bars densely around the embedded metal fittings, which is required when there is a large difference in specific gravity within the panel. others,
According to the present invention, the reinforcing reinforcing bars are hardly pushed up by the foaming expansion of the slurry, so that the positional accuracy of the mounting fittings is extremely improved.

Furthermore, in the present invention, when a predetermined strength is reached after pre-curing, the side frame is removed and the surface side is cut with a wire rod such as piano wire to cut off the excess foamed part on the surface to form the desired shape. Since the panel thickness is adjusted, products with uniform thickness can be manufactured. Finishing materials such as exterior paint adhere extremely well to the surface cut with wire rods such as piano wire. On the other hand, the opposite surface of the panel is in contact with the bottom of the formwork and is a smooth surface.

[0012] Furthermore, the large-sized ALC obtained by the manufacturing method of the present invention
The panel can be cured in an autoclave, and the panel surface can be cut, and the bottom surface impregnated with a release agent and/or the balanced surface made of piano wire or the like can be removed by cutting. Due to the cutting process, the panel surface becomes a smooth surface with exposed air bubbles, and because the difference in specific gravity within the panel is small, the air bubble pores are uniform over the entire surface, so the penetration of finishing agents such as paint is uniform, and uneven application of exterior paint is prevented. There are advantages in that the amount of coating is reduced, the adhesion is improved, and the amount of application is reduced.

[0013]

EXAMPLES The manufacturing method of the present invention will be explained in detail below based on examples. As shown in FIGS. 1 and 2, side frame members 2 are attached to the bottom plate 1 of the formwork according to the dimensions of the ALC panel to be manufactured.
was moved in a parallel direction and then fixed freely. Formwork bottom plate 1
A mold release agent is applied to the side frame member 2 in advance. The size of the formwork bottom plate 1 used in this example was 1800 mm in width.
mm, the length is 60 mm, and the height of the side frame member 2 is 150 mm.
mm, and the side frame member 2 was fixed at the length of the formwork bottom plate 1 of 3700 mm.

Of course, using this formwork, the ALC mortar that has reached a predetermined height is divided into width and length directions of the formwork.
It is also possible to produce multiple large ALC panels at once. Moreover, although the formwork shown in FIG. 2 is a formwork for manufacturing flat normal panels, it is also possible to produce irregularly shaped panels using a formwork with an irregular shape.

[0015] Next, the reinforcing reinforcing bars 3 constructed in advance are installed in the formwork, and are fixed in precise positions by a reinforcing bar fixing jig 5 using the embedded metal fittings 4 fixed to the reinforcing bars. In this embodiment, a spacer 6 for forming an opening is also fixed at a precise position in the center of the form to prevent mortar slurry from entering the opening. The spacer may be made of iron, stainless steel, plastic, rubber, aluminum, or the like. Into the formwork prepared in this manner, mortar slurry is poured to a height corresponding to the thickness of the panel to be obtained, taking into account the increase in height due to foaming.

The composition of the mortar slurry used in this example was 50 parts by weight of silica powder, 40 parts by weight of ordinary Portland cement, 10 parts by weight of quicklime, 60 parts by weight of water, and 0.07 parts by weight of aluminum powder, and the viscosity was 2500cp
That's all. The mortar slurry injected in this way is
After pre-curing, when the specified strength is reached, remove all the side frames, remove the spacers for the openings, cut the front side with piano wire to the specified panel thickness of 125 mm, and heat it at high temperature. High-pressure steam curing was performed.

[0017] Since the reinforcing bar fixing jig 5 was supported perpendicularly to the bottom of the form using embedded metal fittings, the mortar had hardened semi-plastically and had not yet been cut with the piano wire. By vertically pulling out the reinforcing bar fixing jig 5, it is possible to easily form an opening with good positional accuracy that continues from the panel surface to the embedded metal fitting 4. Next, after completing the high-temperature, high-pressure steam curing, the panels were machined to make the surfaces in contact with the bottom of the formwork smooth, and panels with the part impregnated with the mold release agent removed were also manufactured. As shown in FIG. 3, the surface condition of this panel is such that the bubble cross section 8 is exposed, and the adhesion of the finishing paint is good, and there is little variation in the adhesion strength of the finishing paint. The finish material adhered very well to the surface cut with piano wire before curing in high-temperature, high-pressure steam.

By the manufacturing method explained above, the width is 180 mm.
Large AL with 0mm, length 3700mm, and thickness 125mm
Panel C was manufactured. The bulk specific gravity of this panel is JIS
It was measured in the matrix part of ALC according to the test method specified in A5416 "Autoclave-cured lightweight cellular concrete products". The measurement of this specific gravity difference used a 10 cm square cube cut out perpendicularly to the panel in the thickness direction of the panel as a sample.

The measurement results show that ((ρ2 - ρ1)/ρ1 is always less than 0.02 when the absolute dry bulk specific gravity of any two parts in the panel is ρ1, ρ2 (ρ2 ≧ρ1), and that around the reinforcing bars The maximum width of the gap existing in the steel bar was less than half the diameter of the reinforcing steel.The accuracy of the mounting position of the embedded metal fittings was also at the planned position.

[0020]

Effects of the Invention According to the manufacturing method of the present invention, a large panel with a width of more than 600 mm and preferably 900 mm or more can be manufactured.
Even if the panel is 500 mm or more and has built-in metal fittings, it has a uniform structure, excellent panel strength, and has the novel effect of not causing local destruction. Even if a large-sized ALC panel is attached to a building using, for example, four embedded metal fittings as shown in the figure, no strength problems will occur.

[0021] As described above, the manufacturing method of the present invention uses inexpensive raw materials to produce a large-sized A
This has the advantage that an LC panel can be manufactured and a large ALC panel with a large opening can be manufactured.

[Brief explanation of the drawing]

FIG. 1 is a perspective view of a formwork used in an embodiment of the present invention.

FIG. 2 is a sectional view of a formwork used in an example of the present invention.

FIG. 3 is an enlarged cross-sectional view of a cut surface of an ALC panel obtained by the present invention.

[Explanation of symbols]

1 Formwork bottom plate 2 Side frame members 3 Reinforcement reinforcing bars 4 Embedded metal fittings 5 Jig for fixing reinforcing bars 6 Spacer for opening 7 ALC panel 8 Bubble cross section

Claims (1)

[Claims] [Claim 1] The height of the side frame member is 100 mm or more25
After installing mounting hardware and reinforcing reinforcing bars in advance in a formwork of about 0 mm, lightweight aerated concrete (hereinafter referred to as ALC), which is mainly composed of powdered silicate raw materials and calcareous raw materials and uses aluminum powder as a foaming agent, is made. Pour the mortar slurry to a height corresponding to the height of the panel to be manufactured, and when it reaches the specified strength after pre-curing, remove the side frame and cut the front side with wire material such as piano wire. A method for producing a large ALC panel, which comprises cutting off excess foam on the surface, curing the panel with high-temperature and high-pressure steam to obtain a desired panel thickness.