JPH0657989B2 - Method for producing interior / exterior concrete material - Google Patents

Description

TECHNICAL FIELD The present invention relates to a method for producing a concrete material for interior and exterior of a building.

[Prior Art and Background of the Invention]

Buildings using the ALC method are widespread, but ALC
There are limits to the use of products as interior and exterior materials. ALC
Although the product is produced in a factory by autoclaving the aerated concrete, its quality is improving, but its water resistance and weather resistance are insufficient, and AL
The reason for this is that C products generally have poor design and therefore there is a problem in exposing them as an interior / exterior material as they are.
However, the AL, which has excellent workability, is lightweight and inexpensive
The characteristic of the C product is that there is no other advantage for the construction of buildings such as buildings and general buildings, and there is an advantage that cannot be achieved if this product can be used as it is as an interior / exterior material.

The present invention has been made for the purpose of providing a concrete material that can be used as an interior / exterior material while maintaining the characteristics of ALC products.

[Summary of Invention]

The present invention provides a concrete material for interior and exterior, which is obtained by laminating a thin layer of fiber reinforced concrete using low alkali low shrinkage cement on the surface of a cured concrete of cellular concrete.

Examples of low-alkali, low-shrinkage cement that can be preferably used in the present invention include JP-B-60-58183, JP-A-59-57934, JP-A-60-127252 and JP-A-61-286256. There is a cement that does not substantially produce Ca (OH) ₂ during the hardening reaction proposed by et al. Such cement is available on the market as "Chichibu GRC cement" manufactured by Chichibu Cement Co., Ltd. This cement is a high-alumina low-lime mixture of portland cement composition compound calcium silicate and hain, gypsum, and blast-furnace slag so that substantially all Ca (OH) ₂ that should be produced by hydration can be consumed. This type of cement is characterized by low OH ^- ion concentration because Ca (OH) ₂ is not generated during the curing reaction, and low drying shrinkage because ettringite is generated.

The fiber reinforced concrete which is hardened as a thin layer on the surface of the cellular concrete according to the present invention includes any of the above low alkali low shrinkage cement, carbon fiber, aramid fiber, vinylon fiber, acrylic fiber, glass fiber or stainless steel fiber. It is fiber reinforced concrete in which one kind is dispersed.

In the present invention, a fiber-reinforced concrete in which the fibers are dispersed in a mix using a low-alkali, low-shrinkage cement, which is not yet solidified, is formed into a thin layer on the surface of a cured cellular concrete, and then cured, or separately. The product is made by molding it into a thin layer and then adhering it to the cured cellular concrete. Not performed.

[Detailed Description of the Invention]

The interior / exterior concrete material of the present invention has almost no thickness covered with cellular concrete, and has a thin plate of fiber reinforced concrete (hereinafter, referred to as FRC) attached to the outer surface as an interior / exterior material. When this is used as an interior / exterior material for a building, the thin FRC layer on the outer surface ensures water resistance and durability, while maintaining excellent surface strength. And the surface of the thin plate of FRC can be made a patterned surface, and it is finished beautifully. In addition, tile finishing and stone finishing can be freely performed with high adhesion strength, and even when painting, it is beautifully finished that conventional ALC products can not be obtained. A concrete material for interior / exterior, which has such excellent characteristics, is lightweight, and is inexpensive, has never been found in the prior art.

The concrete interior / exterior material according to the present invention is a method of curing a thin layer of FRC which is not yet solidified on the surface of a cured cellular concrete block or panel (normal ALC product) and curing the integrated product (method (1) and Or as a prefabricated product by a method of bonding a cured fiber-reinforced concrete thin plate to the surface of a cured aerated concrete block or panel (normal ALC product) using an adhesive material (referred to as method (2)). In each case, a concrete clad material with high joint strength can be obtained.

Whichever method is adopted, in the present invention, as the cement that forms the thin layer of FRC, the low alkali low shrinkage cement is used as described above, which prevents the deterioration of the fiber. At the same time, the FRC can be cured without autoclave curing, and an interior / exterior material with excellent adhesive strength and durability can be obtained. This clad material product can be made with a wide range of product thickness of 50 to 250 mm, and the in-plane area can be any size and can be a standard product or a custom product in a panel shape or a block shape. . At that time, most of the thickness is covered by ALC. The layer of fiber reinforced concrete is
Although it depends on the thickness of the ALC, it is 1/3 or less of the total thickness, preferably 1/4 or less, and more preferably 1/5 or less as thin as possible.

In the case of the method (1), FRC is applied on the surface of the ALC cured product.
Will cure a thin layer of. In this case, the FRC that is not yet solidified on the surface of the ALC cured product may be formed into a thin layer and cured. To form a thin layer on the surface of this ALC product, cast molding, extrusion molding, papermaking, roll molding,
Press molding can be applied. Further, these processing methods can be combined and molded.

In the case of the method (2), the ALC cured body and the cured body of the FRC thin plate are separately manufactured, and these are bonded using an adhesive. In the production of the FRC thin plate, casting molding, extrusion molding, A thin plate is formed by papermaking, roll forming, press forming, etc., and this is cured by steam curing or normal curing. In the case of mass production, the same papermaking method as that applied to the production of asbestos slate can be applied. That is, a slurry of concrete mix in which fibers are dispersed (slurry containing a large amount of water) is prepared, and while stirring this slurry, a wire mesh of a predetermined mesh is continuously made to make a mix having a predetermined thickness to form a thin plate molded product. To cure.

ALC is applied as the cellular concrete used in the present invention. If necessary, various admixtures can be blended in the FRC. When clad, the FRC thin plate may be clad on only one side of the wide side of the ALC.
A FRC thin plate may be clad on both sides of the wide side of C to form a sandwich-shaped clad product. In the latter case, the material is particularly suitable for interior materials such as corridors and partition walls. In the clad product of the present invention, in addition to the concrete exterior material and interior material of the building, the FRC thin plate on the surface serves to reinforce the strength of the ALC body on the surface, so the FRC surface is used as the tension surface or compression surface (floor surface). It can also be used for flooring.

The contents of the present invention will be specifically described below with reference to the drawings.

FIG. 1 is a partially cutaway view showing a typical shape of a concrete clad material for interior and exterior according to the present invention, wherein 1 is a cellular concrete layer and 2 is a fiber reinforced concrete layer. The cellular concrete layer 1 has a rectangular thick panel shape having a necessary thickness as a structural material, and a thin layer of the fiber reinforced concrete layer 2 is joined so as to cover the entire area of the one wide surface side. FR this fiber reinforced concrete layer 2
The layer C will be referred to as the C layer, and the cellular concrete layer 1 will be referred to as the ALC layer. In the example of FIG. 1, the FRC layer 2 completely covers one wide surface side of the ALC layer 1, and at the same time, the edge portion 3 of the FRC layer extends to a part of the thickness of the ALC layer 1 on the side surface in the thickness direction of the ALC layer 1. Extended, and therefore block-shaped ALC
It is shaped like a thin FRC box covering the layers. Vertical and horizontal linear shallow grooves 4 are formed on the outermost surface of the FRC layer 2.
Is attached as a pattern.

FIG. 2 shows a vertical cross section of the clad material shown in FIG. 1, but the ALC layer 1 and the FRC layer 2 are formed on both the wide surface side and the side surface side.
There is no gap between them and they are completely joined. AL
The edge portion 3 of the FRC layer 2 bent to the side surface side of the C layer 1
When the clad material is formed adjacent to each other to form a wall surface, the edge portions 3 come into contact with each other.
With the clad material of the present invention, the disadvantage that the joint strength is weak, such as in the case of LC products, is completely solved, and the joints at this portion can be reliably sealed. Depending on the mode of use, this edge 3 may not be necessary. However, even in this case, it is preferable that substantially the entire area of at least one wide surface side of the ALC layer 1 is covered with the FRC layer 2. Although not shown in the figure, FRC
If the edge 3 of the layer 2 is embedded in the ALC layer in a wedge shape, the reliability of the bonding strength of both layers can be further improved.

FIG. 3 schematically shows a preferred embodiment of the above method (1). In this method, an ALC product (for example, a commercially available ALC product) is used as a raw material for the ALC layer, and first, as shown in the figure, an FRC6 using a low alkali low shrinkage cement on the wide side of the ALC product 5 is used. Is placed (step (a)). Next, the uncured FRC6 that was placed
Is rolled onto the surface of the ALC product 5 by a roll 7 to form a thin layer (step (b)), or the uncured FRC 6 is pressed onto the surface of the FRC product 5 by a pressing plate 8 (step (b)). (b) ′). In this way, a thin layer of fiber-reinforced concrete that has not yet solidified is pressure-bonded to the surface of the ALC product, and the integrated product 10 is steam-cured (step (c)). Depending on the case, the steam curing in the step (c) can be replaced with normal underwater curing or atmospheric curing.

According to this method, the FRC6, which is not yet solidified, is pressure-bonded to the ALC product by a roll or press machine.
In the process of curing FRC, FRC and ALC are joined together with a strong joint strength, and because low alkali low shrinkage cement is used for FRC cement, fiber deterioration due to alkali is prevented, and autoclave curing is also performed. Even without it, strength reduction due to shrinkage at the joint surface is prevented.
When a patterned roll or a patterned press is used as the roll 7 or the press 8 in the steps (b) and (b) ', a clad material for interior and exterior having a pattern on the outermost surface can be obtained.

FIG. 4 is an illustrative process diagram for explaining another embodiment of the method (1). In this case, first, the thin plate manufacturing form 11
FRC12 using low alkali low shrinkage cement is placed therein (step (d)). Then, the ALC product 5 is pressure-bonded to the uncured FRC 12 existing in the mold 11 by using the press plate (steps (e) and (f)). Then, after demolding,
Steam curing the clad molded product 13 in which the ALC product 5 and the uncured FRC part are pressure-bonded to each other (process
(g)). In some cases, the steam curing in step (g) can be replaced with normal underwater curing or atmospheric curing.

Even with this method, the uncured FRC12 can be firmly pressed and cured to the ALC product 5, so the strength of the joint surface between the two becomes sufficiently high, and since FRC of low alkali low shrinkage cement is used, autoclave curing is possible. F without
The problem of poor joint strength due to RC shrinkage is avoided.
Then, if the formwork 11 to be used is provided with a pattern, the FRC on the outermost surface can be provided with the pattern.

In addition to the method illustrated above, the FRC thin plate cured as in the method (2) above and the ALC product may be joined using an adhesive. As this adhesive, for example, an epoxy-based, unsaturated polyester-based or urethane-based adhesive can be used, and latex mortar or latex cement can also be used. In order to manufacture a hardened FRC sheet, as mentioned above, cast FRC that has not yet solidified using low alkali low shrinkage cement,
It may be formed into a thin plate by extrusion molding, paper making, roll molding, press molding, etc., and steam curing or ordinary curing is performed to cure it. A patterned ALC clad product can be obtained by applying a pattern to the FRC sheet during the forming.

Thus, according to the present invention, a novel concrete cladding material for interior and exterior can be obtained. In each method, each step is simple and the number of steps is small, so that it can be economically manufactured, a pattern can be freely added, and the bonding strength between both materials is extremely high. The concrete clad material obtained according to the present invention has the characteristics of cellular concrete that are lightweight and inexpensive, but its surface is covered with a thin FRC layer, so that it has durability, water resistance, and weather resistance. In addition, the product has excellent surface strength.
Therefore, it is possible to maintain sufficient quality as a concrete exterior material for a building. In addition, conventional ALC can also be used for tile finishing, which has problems in terms of adhesion strength and water resistance.
It will provide the market with new materials with new characteristics and design as lightweight interior and exterior materials for building structures, such as beautiful finishes that cannot be obtained as they are.

[Brief description of drawings]

FIG. 1 is a partially cutaway perspective view showing a typical shape of a concrete clad material for interior and exterior according to the present invention, FIG. 2 is a longitudinal sectional view of the clad material of FIG. 1, and FIG. FIG. 4 is a schematic process drawing for explaining one manufacturing method of the wearing concrete clad material, and FIG. 4 is a schematic process drawing for explaining another manufacturing method. 1 ... Aerated concrete layer (ALC layer), 2 ... Fiber reinforced concrete layer (FRC layer), 3 ... F
Edge of RC layer 2, 4 ... Groove pattern.

 ─────────────────────────────────────────────────── ─── Continuation of the front page (72) Hiroaki Nakagawa Inventor Hiroaki Nakagawa 2-191-1 Tobita-cho, Chofu-shi, Tokyo Inside Kashima Construction Co., Ltd. (72) Inventor Keiichi Taniguchi 2-1-11-1 Tobita, Chofu-shi, Tokyo (56) Reference JP-A-56-46743 (JP, A) JP-A-60-127252 (JP, A) JP-A-61-1757 (JP, A) JP-A-51 -127527 (JP, A) Actually open 51-5829 (JP, U)

Claims (2)

[Claims] 1. A non-solid fiber-reinforced concrete in which fibers are dispersed in a mix using a low-alkali, low-shrinkage cement that does not substantially produce Ca (OH) ₂ during a hardening reaction, A method for producing an interior / exterior concrete material, characterized in that the surface of a panel is formed into a thin layer by cast molding, extrusion molding, papermaking, roll molding or press molding, and the integrated product is steam cured or cured in water or air. . 2. A non-solid fiber-reinforced concrete in which fibers are dispersed in a mix using a low-alkali low-shrinkage cement that does not substantially produce Ca (OH) ₂ during a curing reaction is cast, extruded, After being formed into a thin plate by papermaking, roll forming or press forming, this is steam cured or cured in water or air to be cured, and then
A method for producing a concrete material for interior and exterior, comprising bonding the cured thin plate to a cured cellular concrete block or panel with an adhesive.