JPH05200718A - Concrete form and concrete casting method - Google Patents

Abstract

PURPOSE:To provide a concrete form improved in strength, bending strength and heat insulating properties and excellent in the adhesiveness to concrete and a concrete casting method. CONSTITUTION:At least one surface of a foamed object composed of a synthetic resin is reinforced by cloth composed of a composite fiber and/or composite yarn constituted of an adhesive component and a reinforcing component holding high strength. The cloth and at least one surface of the foamed object are integrally bonded through the adhesive component of the composite fiber and/or composite yarn and a resin having properties bonded to concrete is held to the interior and surface of the cloth to constitute a concrete form. Concrete is cast using this form.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a concrete formwork, a concrete heat insulating composite, and a concrete placing method.

More specifically, the present invention relates to a concrete formwork having strength and flexure resistance capable of withstanding lateral pressure at the time of placing concrete, and capable of adhering well to concrete, and a concrete placing method using the formwork. It is a thing. Further, the present invention relates to a concrete formwork which has particularly good heat insulating properties and can be used as a concrete composite heat insulating material after being placed as a heat insulating material as it is even after placing concrete.

[0003]

2. Description of the Related Art In recent years, with the improvement of people's living standards, an era has been strongly demanded for comfort of a living space by heating and cooling.
However, the energy consumption for that has increased sharply,
Global pollution such as air pollution due to the use of fossil fuel as an energy source and global warming due to an increase in carbon dioxide has become a big problem. In Japan, where most of the energy raw materials depend on foreign countries, the cost burden for energy is large.

Therefore, the establishment of a technique for effectively using energy without waste has become a problem to be solved with priority given to human wisdom. As one of them, it is a national benefit if excellent heat insulating materials can be created, air conditioning with less energy loss can be achieved and energy conservation can be achieved, and in addition, it will contribute to the prevention of deterioration of the global environment and eventually to the happiness of humankind. It is thought that it can contribute.

By the way, as a measure for energy saving in recent buildings, heat insulation of concrete wall surfaces has been widely used. For this purpose, a foam made of synthetic resin is used as a heat insulating material in terms of heat insulating properties and hygroscopic properties.

[0006] At that time, a mold which doubles as a concrete mold and a heat insulating material is used. That is, it is used as a heat insulating material as an integrated body compounded with concrete after the completion of pouring the concrete.

As the conventional concrete formwork used in such a manner, a heat insulating board with double-sided paper, a synthetic resin foam board, a spray foam of polyurethane or phenol resin, etc. are used.

However, the heat-insulating board with double-sided paper is low in strength and is undesirably broken or deformed (deflected) due to lateral pressure during concrete pouring. As a countermeasure against such a problem, there is a means for disposing a supporting material such as a flap material at a high density, but it is not preferable because the work becomes complicated and the construction cost is increased because a large amount of the material is used. Further, since the paper is weak against moisture, the strength is apt to decrease, and there is a problem that the moisture contained in the paper causes mold and the like. Also, for synthetic resin foam boards,
Similar to the above, there is a problem in strength, and at the same time, there is a problem in that the adhesion to the concrete surface is generally poor and peeling easily occurs between the concrete and the foam. Further, the blowing foam of polyurethane or phenol resin has a problem in working environment, and since CFC is mainly used as a blowing agent, it cannot be said to be a preferable method in view of global environment due to ozone destruction. Further, polyurethane has a problem that toxic gas is generated by incineration treatment, and phenol resin is extremely brittle and easily powdered or chipped, which causes a problem in workability.

[0009]

In view of the above-mentioned problems, an object of the present invention is to provide a concrete formwork having good strength, bending resistance, and heat insulation properties, and having excellent adhesiveness to concrete, It is to provide a concrete composite heat insulator and a method for placing concrete.

[0010]

In order to achieve the above object, the present invention has the following constitution.

That is, the concrete formwork of the present invention is
At least one surface of a foam made of a synthetic resin is a concrete formwork made of a foam which is reinforced by a fabric made of a composite fiber and / or a composite yarn composed of an adhesive component and a strong component retaining high strength. And having a resin that adheres and integrates the fabric and at least one surface of the foam through the adhesive component of the fiber and / or the composite yarn, and that adheres to concrete in the fabric and on the surface of the fabric. It is a concrete formwork characterized by:

Further, the concrete composite heat insulating body of the present invention is a composite structure in which a foam made of a synthetic resin, a fabric for strengthening the foam and a composite structure made of a resin adhering to concrete are combined and integrated. It is a concrete composite heat insulator characterized by being.

Further, the concrete pouring method of the present invention is a composite fiber comprising at least one surface of a foam made of a synthetic resin composed of an adhesive component for adhering to the foam and a strong component having high strength. And / or a foam reinforced with a fabric made of a composite yarn, wherein the fabric and the surface of the foam are bonded and integrated via an adhesive component of the fiber, and concrete is provided in and on the surface of the fabric. A concrete pouring method, which comprises pouring concrete using a concrete form having a resin to be adhered.

[0014]

The present invention will be described in detail below. In the concrete formwork of the present invention, at least one surface of a foam made of synthetic resin is reinforced with a reinforcing cloth to form a concrete formwork. The reinforcing fabric is composed of a composite fiber and / or a composite yarn composed of an adhesive component and a high-strength component that retains high strength.
Alternatively, the cloth and at least one surface of the foam are bonded and integrated via an adhesive component of the composite yarn. Further, a resin that adheres to concrete is retained in the cloth and on the surface of the cloth.

As described in the prior art, it is of course advantageous to use the synthetic resin foam for the concrete formwork and further for the heat insulating plate in terms of the heat insulating property. Due to the lack of concrete, it may be broken or flexed due to the lateral pressure of concrete when concrete is poured,
Conventional foams cannot be used as they are because of problems such as peeling due to poor adhesion between foam and concrete.

In view of such problems, the inventors of the present invention have conducted extensive studies in order to improve the strength, flex resistance, etc. of foams, and have developed both an adhesive component that adheres to the foam and a strong component that contributes to strengthening. A fabric composed of a composite fiber and / or a composite yarn having a component is adhered to a foam, and the foam and the fabric are firmly adhered to each other to form an integrated structure of the foam and the fabric to strengthen the foam, and , In the structure in which the foam and the cloth are integrated, the resin that adheres to the concrete is present in the cloth and on the surface of the cloth,
The cloth and the adhesive resin are firmly integrated.

By the combination of the above, a composite structure in which the foamed body / fabric / resin is firmly integrated.

The present invention is characterized in that a resin that adheres to concrete is used and the resin is present in the cloth and on the surface of the cloth.

When such a composite structure is used as a formwork for concrete pouring, the resin exhibits adhesiveness with the concrete formwork, so that as the concrete hardens, the resin and the concrete are strongly adhered to each other, and eventually foaming occurs. It can be a concrete composite heat insulator in which body / cloth / resin / concrete is firmly integrated. Due to such action and effect, the concrete formwork according to the present invention can be used as a formwork having a strength capable of withstanding the lateral pressure of concrete at the time of placing concrete, and a flexing resistance. It can be used as a board.

The foam used in the present invention is, for example, polystyrene, a styrene / ethylene copolymer, an acrylonitrile / styrene copolymer, a bead molding made of a polystyrene resin such as an ABS resin, and foaming by extrusion molding. A molded product or its raw material can be preferably used. In addition, other various resins such as polyethylene, polypropylene, phenol, polyurethane, polyester, urea, polyvinyl chloride, silicone, epoxy, polyimide and melamine can also be used. Among these, in terms of shape retention and flexing resistance required for concrete formwork, and in order to effectively enhance the reinforcing efficiency by the fabric composed of the above-mentioned composite fiber and / or composite yarn, high rigidity is obtained. It is preferred to use the polymers of

Here, the high-rigidity polymer in the present invention means
The flexural modulus of the resin alone in the non-foam body measured by the ASTM-D790 method is at least 150 kg / mm.
A polymer showing ² or more, especially 200 kg / mm
^Two or more polymers are preferably used. For example, polystyrene, styrene / ethylene copolymers, acrylonitrile / styrene copolymers, foamed molded products made of polystyrene resin such as ABS resin by bead molding or extrusion molding, or raw materials thereof can be preferably used.

The resin used in the present invention for adhering to concrete is not particularly limited as long as it is a resin adhering to concrete, and various resins can be used. In particular, according to the findings of the present inventors. For example, polyacrylic resin, polyurethane resin, epoxy resin, etc. are effective, but especially when using a resin mainly formed from polysulfide-modified epoxy resin and amines or polyaminoamides, adhesion to concrete It is suitable in terms of good properties. Further, among them, a preferable representative one is an epoxy resin having a polysulfide skeleton introduced to an epoxy resin having a bisphenol skeleton, preferably represented by the following general formula (1), and such a resin is concrete. It has excellent properties that it adheres well and is strong against moisture.

[0023]

[Chemical 3] R ₁ and R ₃ in the general formula (1) represent an organic group containing a bisphenol skeleton. Examples of the organic group containing a bisphenol skeleton are similar to or similar to bisphenol A type epoxy resin, bisphenol AD type epoxy resin, halogenated bisphenol A type epoxy resin, bisphenol F type epoxy resin, halogenated bisphenol F type epoxy resin, and the like. The thing containing a molecular structure can be mentioned.

R ₂ in the general formula (1) is a polysulfide skeleton represented by the following general formula (2).

[0025]

[Chemical 4] The following ranges are preferable for m and n in the general formula (2).

1 ≦ m ≦ 3, 1 ≦ n ≦ 50 More preferably, 1.5 ≦ m ≦ 2.5, 2 ≦ n ≦ 30 If the S average content m of the polysulfide skeleton is less than 1, the usual bisphenol It becomes the same as the type epoxy resin, and when m exceeds 50, the viscosity becomes high and it becomes difficult to use.

Examples of such polysulfide-modified epoxy resin include, for example, "FL" manufactured by Toray Thiokol Co., Ltd.
"EP-10", "FLEP-50", "FLEP-6"
0 ”or the like can be used.

It is also preferable to use a bisphenol type epoxy resin mixed with such a polysulfide-modified epoxy resin, if necessary.

Examples of such amines or polyaminoamides include triethylenetetramine, isophoronediamine, 1,3-bis (aminomethyl) cyclohexane, 1,2-diaminocyclohexylamine,
Bis (4-amino-3-methylcyclohexyl) methane, m-phenylenediamine, 4,4′-methylenedialinine, N-benzylethylenediamine, 1- (2-aminoethyl) piperazine, N, N′-dimethylamino-
n-propylamine, N, N, N ', N'-tetramethylhexamethylenediamine, N-methylpiperidine, N,
N'-dimethylpiperidine, dimethylaminomethylphenol, 2,4,6, -tris (dimethylaminomethyl)
Imidazoles such as phenol and 2-ethyl-4-methylimidazole, modified polyamines (for example, "Adeka Hardener EH-220", "Adeka Hardener EH-230", "Adeka Hardner EH" manufactured by Asahi Denka Co., Ltd.)
-531 ", ICI Japan Limited" Ankaramin WCA ", Yuka Shell Epoxy Co., Ltd.
"Epomate N-001", "Epomate RX-"
3 "," Sumikyu-AF "manufactured by Sumitomo Chemical Co., Ltd.," Fujicure # 5420 "manufactured by Fuji Kasei Kogyo Co., Ltd.," React CA-681 "manufactured by Mitsubishi Kasei Kogyo Co., Ltd.), polyamidoamine (for example, ICI Japan Japan
Limited "AnkaMind 501", Fuji Kasei Kogyo Co., Ltd. "Tomade # 245", etc.) can be used.

At this time, the compounding amount of the amines or polyaminos varies depending on the amine value of the amines or polyaminoamides used, and there is a point that cannot be generally stated. -10
It is preferably 0 parts by weight, more preferably 5 to 8
0 parts by weight.

In the present invention, the resin that adheres to concrete or the layer of the resin may be used by adding titanium oxide, a pigment, a filler, a flame retardant or the like to the resin layer, if necessary. It is also preferable to use various additives together.

The resin is a liquid resin stock solution, a solution,
It is applied in various forms such as emulsion, dispersion and latex, and by various methods such as impregnation, spraying and coating. By the application, the resin exists in the fiber structure of the cloth and on the surface of the cloth, and can firmly adhere to the foam and the cloth.

The composite fiber constituting the cloth is composed of an adhesive component capable of adhering to the foam and a strong component having high strength and contributing to strengthening. Preferred forms of such composite fibers include core / sheath type fibers, bimetal type fibers, multilayer bonded type fibers, radial multilayer type fibers, and the like. Among these, a structure having many core components in the sheath component. The multifilamentary / sheath type composite fiber which is the fiber of 1) is preferable. That is, for example,
It is represented by polymer array fibers, mixed spun fibers and the like.

The thickness of the composite fiber is not particularly limited as long as it is suitable as a fiber entangled body or a reinforcing material for its specific use. Generally, the range of 0.1 to 1000 denier is preferable for the composite fiber, and the multi-core /
In the sheath-type composite fiber, the thickness of the core fiber is usually preferably about 1/3 to 1/1000 of that of the composite fiber, and the number of cores in the composite fiber is in the range of 3 to 10000. Is preferable, and 10 to 1000 are particularly preferable.

It is important that the adhesive component of the composite fiber or yarn is one that causes thermal deformation or melting by heating to bring about high adhesiveness with the foam, and further the following A or B It is preferable that they are satisfied. That is, A: a polymer containing the same monomer units as the foam, and B: a polymer having good adhesiveness and compatibility with the foam.

Among them, those of A are particularly preferable, but even if they do not contain the same monomer unit as the foam, an anchor effect or the like acts on the foam due to thermal deformation or melting and a preferable adhesion is obtained. As long as it can be achieved, the object of the present invention can be sufficiently achieved. The heat distortion temperature of the adhesive component is at least 10 ° C higher than the heat distortion temperature of the foam.
It is preferably lower than the above. As such a preferable example,
Examples thereof include a polystyrene copolymer obtained by copolymerizing styrene with a higher alcohol ester of acrylic acid or methacrylic acid, a polyester copolymer having an acid component of terephthalic acid / isophthalic acid, and a glycol component of ethylene glycol.

On the other hand, as the strong component, polyesters typified by polyethylene terephthalate, polyamides typified by nylon 6, nylon 66, aramids, other polyarylate, polyacrylonitrile, polyethylene, polypropylene, polyvinyl alcohol,
It is possible to use polymers having various spinnability such as polyurethanes and modified copolymers thereof or mixtures of other components. Depending on the foam type from these polymers, One kind or two or more kinds of polymers may be used depending on the purpose and application of the foam.

Further, in the above description, the case of the composite fiber obtained by the composite spinning has been described, but the present invention is not limited to the case of using such a composite fiber, and the core component or It is also possible to use a composite yarn such as a sheath component, or a mixed yarn (including a twisted yarn) made of fibers made of a polymer described as an adhesive component and a strong component.

That is, in the present invention, a composite yarn using a combination of fibers or yarns made of an adhesive component and fibers or yarns made of a strong component may be used.

The fibers constituting the fabric may be in the form of cotton (short fibers) or long fibers (filaments), and these may be used in whole or in part to form webs or nonwovens. A woven fabric, a knitted fabric, a net sheet, or the like, or a fabric that is made of a composite thereof is used.

[0041]

The present invention will be described in more detail with reference to the following examples.

In the examples, all "percentages" are by weight.

Example 1 As a composite fiber, a polymer array fiber having a sheath component of 80 parts by weight of styrene / 20 parts by weight of 2-ethylhexyl acrylate copolymer and a core component of nylon 6 (fiber length: 51
mm, number of islands: 36, denier of composite fiber: 3d), a nonwoven fabric web was produced through the steps of card and cross wrapper, and then needle punched to produce a nonwoven fabric. A 25 mm thick polystyrene extruded foam (30 times foamed product) and the above non-woven fabric are used to arrange non-woven fabric / foam / non-woven fabric in this order, and heat and pressure are applied with a mirror calender roller (roller temperature 160 ° C., roller speed 2 m / min). ), And the nonwoven fabric was adhere | attached on both the front and back surfaces of the foam, and the nonwoven fabric reinforcement foam was produced. Next, an emulsion of "FLEP-60" manufactured by Toray Thiokol Co., Ltd. was used as a resin, and "Adeka Hardener EH-220" manufactured by Asahi Denka Kogyo Co., Ltd. was used as a curing agent, and the ratio of resin / curing agent was 100 parts by weight / 20. After mixing and stirring as a part by weight, it was applied to one surface of the nonwoven fabric reinforced foam and cured at room temperature.

The composite structure of foam / fabric / resin thus obtained was laid so that the resin surface became the concrete pouring surface,
It was used as a formwork at the time of pouring concrete, and after the concrete was hardened, it was left as it was without being removed and used as a heat insulating material for concrete to obtain a concrete heat insulating plate composite. As a result, in concrete pouring, it sufficiently withstands the driving lateral pressure, does not cause breakage or large bending, has good adhesiveness with concrete, and has good inner wall finish such as plaster finish.

[0045]

As described above, the concrete formwork and the concrete heat insulating board composite of the present invention can be used with a formwork without causing breakage or large flexure, which can sufficiently withstand the driving side pressure in concrete placement. Further, since it has good heat insulating properties and has excellent adhesiveness to concrete, it can be used as a heat insulating material for concrete that is left as it is without being removed after curing.

Further, since it is lightweight, easy to handle, and has high strength, it is excellent in workability for formwork construction, can shorten the construction period, and is extremely economically advantageous.

Claims (11)

[Claims] 1. A foam in which at least one surface of a foam made of a synthetic resin is reinforced by a fabric made of a composite fiber and / or a composite yarn composed of an adhesive component and a strong component retaining high strength. A concrete formwork comprising: the fabric and at least one surface of the foam bonded and integrated via the adhesive component of the fiber and / or the composite yarn, and concrete is formed in the fabric and on the surface of the fabric. A concrete formwork that holds a resin to be bonded. 2. The concrete formwork according to claim 1, wherein the synthetic resin is a high-rigidity resin having a flexural modulus of 150 kg / mm ² or more in the resin alone in the non-foamed resin. 3. The resin that adheres to concrete is a resin mainly formed of a polysulfide-modified epoxy resin having epoxy groups at both ends having a bisphenol skeleton and a polysulfide skeleton, and amines or polyaminoamides. Concrete formwork according to 1. 4. The concrete formwork according to claim 1, wherein the foam is a polystyrene resin foam. 5. The concrete formwork according to claim 2, wherein the polysulfide-modified epoxy resin is represented by the following general formula (1). [Chemical 1] Here, R ₁ and R ₃ represent an organic group containing a bisphenol skeleton. R ₂ represents a polysulfide skeleton represented by the following general formula (2). [Chemical 2] However, 1 ≦ m ≦ 3, 1 ≦ n ≦ 50 6. The concrete formwork according to claim 1, wherein the adhesive component has a heat distortion temperature lower than the heat distortion temperature of the foam by 10 ° C. or more. 7. The composite fiber or composite yarn is a core / sheath composite composite fiber or composite yarn.
Described concrete formwork. 8. The concrete formwork according to claim 6, wherein the core / sheath type composite structure is a multi-core / sheath type composite fiber. 9. A concrete composite heat insulation, comprising: a composite structure comprising a foam made of a synthetic resin, a fabric reinforcing the foam and a resin adhering to concrete, and a concrete structure. body. 10. At least one surface of a foam made of a synthetic resin is reinforced by a fabric composed of a composite fiber and / or a composite yarn composed of an adhesive component that adheres to the foam and a strong component that retains high strength. A concrete form having a resin which adheres to the concrete in the cloth and on the surface of the foam, wherein the cloth and the surface of the foam are bonded and integrated via an adhesive component of the fiber. A method for placing concrete, which comprises using the method to place concrete. 11. A foam made of a synthetic resin, at least one surface of which is reinforced by a fabric made of a composite fiber and / or a composite yarn composed of an adhesive component that adheres to the foam and a strong component that maintains high tenacity. A concrete form having a resin which adheres to the concrete in the cloth and on the surface of the foam, wherein the cloth and the surface of the foam are bonded and integrated via an adhesive component of the fiber. A method for placing concrete, which comprises using the same as a heat insulating material for concrete without removing the formwork after placing the concrete.