JPH05228918A - Lightweight aerated concrete panel with double-side pattern and manufacture thereof - Google Patents

Abstract

PURPOSE:To obtain a lightweight aerated concrete panel with double-side patterns, which has excellent homogeneity and in which double-side patterns are easily attached positively, and manufacture thereof. CONSTITUTION:A concrete panel 1 with double-side patterns is manufactured in such a manner that patterns 12 are attached on each one surface of two panel members 11a, 11b in half thickness, a bar arranging unit 2 for reinforcement is buried and interposed between each other surface and both panel members 11a, 11b are unified. The concrete panel 1 is produced in such a manner that concrete slurry is placed into one of flatly positioned forms, to bottoms of which pattern molds are notched, the bar arranging unit 2 for reinforcement is buried in half thickness and half-hardened, concrete slurry is placed into the other forms, semirigid concrete in one forms is superposed instantaneously, the projecting section of the bar arranging unit 2 for reinforcement is buried and unified and concrete slurry is cured and hardened.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a lightweight cellular concrete panel suitable for use as walls in various parts of a building, walls, staircase walls, balcony walls and the like.

[0002]

2. Description of the Related Art Concrete panels are often used for outer walls and partition walls of buildings, or for walls near site boundaries. As the concrete panel, an ordinary mixture or a lightweight cellular concrete panel, a so-called ALC panel or the like is used. In many cases, it is desired that both sides of the concrete panel used in each of the above-mentioned areas be patterned, and methods for obtaining the double-faced concrete panel are roughly classified into a vertical placing method and a flat placing method. The vertical pouring method uses a flat box-shaped formwork consisting of two panels for the formwork in which each pattern is engraved on both sides of the concrete panel and the peripheral members in a vertical position, and pouring concrete slurry from the upper opening. Thus, a double-sided patterned concrete panel corresponding to the engraved pattern can be obtained. The flat-casting method is one in which a bat-shaped mold made up of one panel for a formwork in which a pattern on one side of a concrete panel is engraved and peripheral members is placed flat, and concrete slurry is placed on it, A concrete panel with a single-sided pattern corresponding to the engraved pattern on one surface of the panel is obtained, and a pattern is engraved on the other surface without the pattern by a separately prepared machining process or the like to obtain a double-sided patterned concrete panel.

[0003]

However, each of the methods for obtaining a double-sided patterned concrete panel from lightweight cellular concrete has many drawbacks. That is, it is difficult to obtain a lightweight cellular concrete panel having a uniform density and composition by the vertical casting method. This is because in the case of a lightweight cellular concrete panel, since the casting height is high, the air bubbles below are crushed and the concrete density is different depending on the site, so that the heterogeneity of the concrete slurry is likely to occur. On the other hand, the flat-placing method requires pattern engraving on one side without a pattern by post-processing, which is extremely disadvantageous in terms of processing equipment, labor, time, etc., and is accompanied by processing of cutting chips, etc. ..
It is an object of the present invention to provide a lightweight cellular concrete panel with a double-sided pattern and a method for producing the same, which has no problem in homogeneity and can be easily and surely applied with a double-sided pattern.
Hereinafter, the lightweight cellular concrete panel is simply referred to as "concrete panel" in the present specification.

[0004]

A concrete panel with a double-sided pattern according to the present invention is provided with one of the two panel members for each of the two panel members each having a pattern formed on one surface thereof. A reinforcing bar arrangement unit having an area covering almost the entire area of the surface and straddling both thickness directions of the two panel members is embedded and interposed between the two panel members. Two panel members are brought into close contact with each other and the panel members are integrated. Then, the manufacturing method is to perform the concrete slurry casting into one of the flat form frames engraved with the pattern mold on one surface of the double-sided patterned concrete panel and to form a reinforcing bar arrangement unit having a required thickness. Only half the thickness is embedded in the slurry and cured to a semi-hardened state, and the concrete slurry is cast into the other formwork of the flat plate on which the pattern mold is engraved on the other surface of the double-sided patterned concrete panel. Then, the upper surface of the other mold is filled with the concrete that has been cured to the semi-hardened state, and the upper surface of the one mold is inverted and adhered to continue concrete curing, and after the concrete is hardened, both molds are removed. It is what

[0005]

The pattern is provided on both sides of the obtained concrete panel by closely adhering two panel members each having a pattern on one side thereof to the other side having no pattern. At this time, the reinforcing bar arrangement unit is embedded and installed over substantially the entire contact surface between the two panel members, and remarkably reinforces the bonding strength of the two panel members against the contact integration. The method of manufacturing this double-sided concrete panel is
Each of the two panel members is formed by pouring concrete slurry into two flat molds in which the respective pattern molds are engraved, and these are closely adhered to each other. It can be obtained at the same time as the casting operation.

In the close integration, concrete slurry is cast into one of the two frame members forming one of the two panel members, the reinforcing bar arrangement unit is arranged, and the concrete is semi-hardened. By curing up to this point, the concrete does not fall off even if the concrete slurry is poured and the upper surface of the other formwork is reversed. Also, when embedding the projecting portion of the reinforcing bar arrangement unit on the upper surface of the semi-hardened concrete in the concrete slurry of the other form, the concrete slurry is that immediately after placing, for example, in the reinforcing bar arrangement unit. Even if the member locally cuts the concrete slurry, the concrete slurry is immediately restored and integrated, and evenly adheres to the surface of the reinforcing bar unit and hardens.

[0007]

1 is a perspective view showing an embodiment of a concrete panel with double-sided pattern according to the present invention including a partial fracture surface, and FIG. 2 is a vertical cross-sectional view seen from the direction of arrow XX in FIG. 3 is an explanatory view showing a method for manufacturing the double-sided patterned concrete panel of FIG. 1, and FIG. 4 is an explanatory view of a double-sided patterned concrete panel manufacturing line incorporating the manufacturing method of FIG. 1 in the figure
Is a concrete panel with double-sided pattern, 11a and 11b are panel members, 12 is a pattern, 2 is a reinforcing bar unit, 3
Reference numerals a and 3b are molds, and reference numerals 31a and 31b are pattern shapes. As shown in FIGS. 1 and 2, the double-sided patterned concrete panel 1 according to the present embodiment has two panel members 11a and 11b whose thicknesses are approximately halved, which are integrated to form the two panel members 11a and 11b. The reinforcing bar arrangement unit 2 having an area extending over almost the entire area of the integrated surface and extending across the thickness direction of both members is embedded.

The reinforcing reinforcing bar unit 2 has a flat box-like shape by connecting a pair of mesh reinforcing bars 21 in which reinforcing bars are arranged in a matrix in the vertical and horizontal directions with flat steel bars 22 at intervals. By arranging this reinforcing bar arrangement unit 2 in the center of the thickness of the double-sided patterned concrete panel 1, when the two panel members 11a and 11b whose thickness has been halved are closely adhered to each other, both members are strengthened. Reinforce the connection. Double-sided concrete panel 1
As shown in FIG. 3, the manufacture of the two panel members 11
The molds 3a and 3b corresponding to a and 11b are placed flat, and the concrete slurry 13 is placed on each of the molds 3a and 3b.
Is performed, the reinforcing bar arrangement unit 2 is embedded at a timing of a specific condition described later, and the molds 3a and 3b are united. In detail, pattern dies 31a and 31b for predetermined patterns 12 formed on the two panel members 11a and 11b, respectively, are formed in advance on the bottom surfaces of the respective molds 3a and 3b and, if necessary, on the side surfaces. The pattern-shaped engraving may be performed directly on the mold, or as a separate member, a sheet or plate to be laid inside the mold may be prepared and engraved on this sheet or the like. These pattern type 31
a and 31b are completed concrete panels with double-sided pattern 1
They may be the same or different on the front and back depending on the usage situation.

The molds 3a and 3b are constructed so that they can be dismantled at the bottom and the periphery. The vertical and horizontal dimensions are the standard dimensions of the double-sided patterned concrete panel 1 to be manufactured, and the peripheral height is the thickness of the two panel members 11a and 11b. Then, the total height of the peripheries of the molds 3a and 3b is set to the completed thickness of the double-sided patterned concrete panel 1. It should be noted that, on the periphery of one of the molds 3a and the periphery of the reinforcing bar arrangement unit 2, the relative position of the two,
A supporting mechanism for the relative height is regulated, and a positioning mechanism that combines a nut 23 and a bolt 24 is arranged in the periphery so that it can be used also as a construction mounting hardware for the completed double-sided patterned concrete panel 1. One mold 3a prepared as described above is placed horizontally, and the concrete slurry 13 supplied from the slurry supply tank 4a is placed therein,
Immediately, the reinforcing bar arrangement unit 2 is embedded to a half thickness and positioned, and the concrete slurry 13 is cured until it becomes a predetermined semi-hardened concrete 14.

The predetermined semi-hardened state is a time point at which the concrete 14 inside and the reinforcing bar arrangement unit 2 do not fall off under the condition that one of the molds 3a in which the concrete slurry 13 is cast is inverted by 180 °. Although it depends on the geometrical dimensions of the patterned concrete panel 1, the geometrical dimensions of the reinforcing bar arrangement unit 2, the properties of the concrete 14, and the like, the time value can be set experimentally in advance.
For example, a conventionally known lightweight aerated concrete material containing cement and silica sand as a main raw material and a foaming agent and the like is manufactured for a partition, and has a thickness of 80 m / m, a length and a width of 900.
For a mm panel, about 50 minutes after casting was sufficient. Immediately before the concrete 14 becomes the predetermined semi-hardened state, the concrete slurry 13 supplied from the slurry supply tank 4b is placed on the other horizontally placed form 3b, and the one form 3a is immediately inverted by 180 °. Then, they are superposed on and closely attached to the form 3b. With this operation, one mold 3
Half of the reinforcing bar arrangement unit 2 protruding above the concrete 14 a is buried in the concrete slurry 13 of the form 3 b, and the concrete slurry 13 hardens in that state. In the above process, the reinforcing bar arrangement unit 2 is buried in the concrete slurry 13 twice in each half of the height, but in each case, since it is the concrete slurry immediately after being placed, it has high fluidity and is not buried. Even if the concrete slurry 13 is cut by the member of the reinforcing bar arrangement unit 2 without immediately exerting resistance, the member surface of the reinforcing bar arrangement unit 2 is uniformly restored with sufficient integration and leaving no defects. cover.

Further, since the concrete slurry 13 that adheres to the semi-hardened concrete 14 is also fresh immediately after being cast and is clean and excellent in activity, both are integrated and hardened with high joint strength. When the concrete slurry 13 in the mold 3b becomes hardened concrete 14 and can be demolded, the molds 3a and 3b are dismantled and removed, and curing is continued to obtain the double-sided patterned concrete panel 1. FIG. 4 shows an outline of an example of the production line for the concrete panel 1 with double-sided pattern. As the concrete slurry 13 to be cast on the molds 3a, 3b, lightweight cement concrete milk containing air bubbles and additives is supplied from the slurry supply tanks 4a, 4b, and in the same manufacturing process as in FIG. A double-sided patterned concrete panel 1 before curing is obtained.

Then, the concrete panel 1 with double-sided pattern in which the molds 3a, 3b are dismantled and demolded is loaded on a carrier 5 and pre-cured in a pre-curing chamber 6 in a steam atmosphere at normal pressure, and then high temperature by an autoclave 7 Complete curing in high-pressure steam atmosphere and remove. The cured double-sided patterned concrete panels 1 are taken out one by one from the carriage 5, subjected to inspection and finish coating in the coating space 8, transported to the storage space 9 and stored, and shipped as required. Since the double-sided patterned concrete panel 1 according to the present embodiment is constructed and manufactured as described above, even a lightweight cellular concrete panel which is likely to cause a problem in homogeneity can have a very uniform property. Also, the two panel members 11a and 11b
Even if it is divided into two parts and joined later, they can be strongly and surely integrated by the embedded interposition of the reinforcing bar arrangement unit 2 at a good timing. By dividing the two panel members 11a and 11b, it is possible to efficiently form a double-sided pattern.

The method for producing a double-sided patterned concrete panel of the present invention can be modified in various ways other than the above embodiment. For example, the reinforcing bar arrangement unit may be installed in advance before the concrete slurry is poured into one of the molds. In this case, the nut 23, which is a metal when mounting and installing as a panel, is not located in the central portion of the panel thickness, but this does not cause a problem in use. Further, by changing the thickness of one side of the mold, the metal piece can be positioned at the center of the thickness by the above means. The reinforcing bar arrangement unit 2 is a pair of mesh bars 21 in the above-mentioned embodiment, but it may be composed of an extract band metal. Also,
Even in the production line, the slurry supply tank can be shared by one group and can be placed and joined on one line.

[0014]

According to the double-sided patterned concrete panel and the method for producing the same according to the present invention, it is possible to obtain a lightweight cellular concrete panel having excellent homogeneity and capable of easily and reliably applying a double-sided pattern.

[Brief description of drawings]

FIG. 1 is a perspective view including a partially broken surface of a double-sided patterned concrete panel showing an embodiment of the present invention.

FIG. 2 is a vertical cross-sectional view as seen from the direction of arrows along the line XX in FIG.

FIG. 3 is an explanatory diagram of a method for manufacturing the double-sided patterned concrete panel of FIG. 1.

FIG. 4 is an explanatory view of a production line for a concrete panel with a double-sided pattern incorporating the production method of FIG.

[Explanation of symbols]

 1 Double-sided concrete panel 3a, 3b Formwork 11a, 11b Panel member 12 Pattern 13 Concrete slurry 14 Concrete 31a, 31b Pattern type

Claims (3)

[Claims] 1. The two panel members each having an area covering substantially the entire area of one surface of the two panel members with respect to each of the two panel members formed by patterning one surface of each of the two panel members. The reinforcing bar arrangement unit that has a form of straddling both thickness directions is embedded between the two panel members,
A lightweight cellular concrete panel with a double-sided pattern, which is obtained by closely adhering the two panel members and integrating the panel members. 2. A reinforcing bar arrangement unit having a required thickness, in which concrete slurry is cast into one frame of a flat plate in which a pattern mold is engraved on one surface of a lightweight cellular concrete panel with a double-sided pattern. Is buried in the slurry for about half its thickness and cured to a semi-cured state,
The concrete slurry is cast into the other formwork of the flat plate in which the pattern form is engraved on the other side of the double-sided patterned lightweight cellular concrete panel, and the upper surface of the other formwork is cured to the semi-cured state. A method for producing a lightweight cellular concrete panel with double-sided pattern, in which the upper surface of the one mold containing the concrete is inverted and closely adhered to continue concrete curing, and after the concrete is hardened, both molds are removed to form a panel. 3. Arrangement of a reinforcing bar arrangement unit at a predetermined depth and placing of concrete slurry on one of the flat form frames in which a pattern mold is engraved on one side of a double-sided patterned lightweight cellular concrete panel. Carry out the concrete to a semi-hardened state, cast concrete slurry into the other formwork of the flat plate engraved with the pattern mold on the other side of the double-sided patterned lightweight cellular concrete panel, Double-sided to form a panel by continuing the concrete curing by reversing and closely adhering the upper surface of one of the molds containing the concrete that has been cured to the semi-cured state on the upper surface of the mold and after curing the concrete. A method for manufacturing a lightweight cellular concrete panel with a pattern.