JPH07324483A - Concrete placement rapping material, manufacture thereof and concrete placement method - Google Patents

Abstract

PURPOSE:To facilitate attachment and separation work by installing a non- expandable surface layer to a concrete side surface of a raping material constituted with a closed cell foam made of olefin resin cross linked with a specific gel percentage. CONSTITUTION:A concrete placement rapping material G is constituted with a closed cell foam made of an olefin resin cross linked with 25 to 85% gel percentage, thereby forming a non-expandable surface layer X on the surface to be placed in contact with concrete H. The foam is specified so that it may be expanded 5 to 33 times and its apparent density is specified to be in the range of 0.2 to 0.3g/cm<3>. This rapping material G is placed in contact with a concrete placement sheathing board E, F and the surface layer X is directed so as to be fixed with the side of the board which is in contact with the concrete H. The concrete H is cast at the rapping material G and the sheathing boards E and F. Then, after the concrete H is cured, the rapping material G is stripped from the concrete H together with the sheathing boards E and F.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a die-cutting material for pouring concrete, and more particularly to a die-cutting material used for forming a recess or a cavity in a part of concrete when pouring concrete. is there. It also relates to a method for producing such a die-cut material and a method for placing concrete using such a die-cut material.

[0002]

2. Description of the Related Art Die-cutting materials for placing concrete are known. This stamped material has been made of wood or plastic so far. As the plastic, various resins such as vinyl chloride resin, styrene resin, ethylene resin and propylene resin have been used. Further, as the plastic, a foamed product obtained by foaming this was also used.

Die-cutting materials for concrete pouring have been used by fastening them to concrete dam plates. When the die-cut material made of plastic foam is used by fixing it to the weir plate in this way, if the weir plate is peeled from the concrete after hardening of the concrete, the die-cut material will firmly adhere to the concrete. However, it was difficult to remove the die-cut material together with the barrier plate. When I tried to peel it off forcibly, the die-cutting material was torn and fragments of the die-cutting material remained on the concrete. Attempting to further remove the remaining pieces of die-cutting material would damage the concrete.

In order to solve the above-mentioned problems, Japanese Patent Laid-Open No.
Japanese Patent No. 118462 proposes to attach a release material to the surface of the die-cutting material. In that proposal, the die-cutting material is
It is said that any material such as wood other than foamed plastic can be used. For the release material, apply paraffin,
A polyethylene foam sheet is to be provided by adhering or winding.

However, it is troublesome to provide a release material on the die-cutting material, and it is not easy to implement it. This is because the die-cutting material has the property that it must be cut to the required size and installed at the concrete pouring site. It will be necessary to attach. For that purpose, it is necessary to separately prepare a release material, and it is necessary to apply, dry, or wind the release material.

[0006]

SUMMARY OF THE INVENTION The present invention has been made in order to solve the above problems. That is, the present invention is to provide a die-cutting material that can be easily peeled from concrete by simply cutting a material prepared in advance as a die-cutting material to a required size at a concrete pouring site. .

[0007]

The inventors of the present invention have noticed that what kind of material is particularly suitable for making a die-cut material has not been sufficiently studied so far. That is, foamed plastic was recommended as a die-cutting material, but in addition to those made of styrene resin as foamed plastic, urethane resin, vinyl chloride resin, ethylene resin, vinyl acetal resin, polyester resin, etc. There is a foam made of. this house,
It was not well considered which were suitable for making die-cuts.

The inventor has noticed that, among the above-mentioned various resins, a foam of ethylene resin and propylene resin is suitable for use as a die-cutting material. Ethylene-based resins and propylene-based resins are collectively called olefin-based resins. However, among the olefin-based resins, the non-crosslinked olefin-based resin foam is too rich in flexibility and easily dents due to the pressure of the concrete, and thus it is not suitable as a die-cutting material. Thus, the present inventor has found that the olefin resin foam having a degree of crosslinking within a certain range has few dents due to the pressure of concrete, can be easily released from concrete, is strong against tearing, is lightweight, and is suitable. It has been found that it is suitable as a die-cutting material because it exhibits flexibility and rigidity.

The degree of crosslinking of the olefinic resin is indicated by the amount of insoluble matter (gel content) when the resin is dissolved in a solvent. Specifically, the olefin resin is immersed in xylene at 120 ° C. for 24 hours, the insoluble matter is taken out and dried in a vacuum for 24 hours, and then the weight of the insoluble matter is measured to express the degree of crosslinking as gel fraction. ing. The gel fraction of the olefin resin suitable for use in the present invention is 25 to 85.
% Range. Among them, the particularly preferable gel fraction depends on the method for producing the foam, and for example, the foam obtained by press-foaming with a chemical crosslinking agent is 65 to 85%.
It is preferable to have a gel fraction of 30% to 50% in a foam obtained by irradiating radiation to cause crosslinking to foam.
A gel having a gel fraction of is preferable.

In the crosslinked olefin resin foam,
The as-foamed surface may have small irregularities, but the surface is covered with a relatively smooth non-foamed skin layer. However, on the surface obtained by cutting the foam with a knife, the non-foamed skin layer is completely removed,
Fine irregularities of the cut bubbles are exposed on the surface.
For this reason, the cross-linked olefin resin foam die-cut material made by cutting with a blade causes concrete to enter into the fine irregularities of air bubbles when concrete is poured on the cut surface, which is cured as it is. Therefore, it becomes difficult to remove the die-cutting material from the concrete after hardening. However, the foam having the above-mentioned non-foamed skin layer is that if concrete is poured onto this skin layer, the foam can be peeled from the concrete without much difficulty after curing,
This inventor found out.

Therefore, the present inventor uses a non-foamed skin layer while leaving a non-foamed skin layer as much as possible when making a die-cutting material from a foam of an olefinic resin, and the surface obtained by cutting with a knife is not I thought to form a foamed skin layer. Therefore, when a heating iron coated with a fluororesin was applied to the cut surface of the olefin resin foam to melt the surface, it was confirmed that a non-foamed skin layer could be formed on the surface. Further, they have found that when the concrete is cured on the skin layer and the foam is peeled from the concrete, the foam can be peeled from the concrete without much difficulty.

Further, as a method of utilizing the non-foamed skin layer as much as possible, it was considered to use a thin foamed sheet of olefin resin. The foamed sheet of cross-linked olefin resin made by irradiation does not have a thickness that can be used as a die-cutting material, but it has a non-foamed skin layer on the surface, so we decided to use this. . That is, the gel fraction produced by irradiation with radiation is 25 to 85.
%, In particular, 30 to 50% cross-linked olefin resin cross-linked foamed sheet of a plurality of closed cells,
When the heat-bonding between them is made into a laminated sheet, the obtained laminated sheet has non-foamed skin layers on the front and back sides, so it was found that it is suitable to use this as a die-cutting material. It was

Further, since the side surface of the above-mentioned laminated sheet is cut with a knife, it does not have a non-foamed skin layer there. We have found that when this side should contact the concrete, it should be heated to melt and form a non-foamed skin layer there. The present invention has been completed based on such knowledge.

The present invention relates to a die-cutting material for concrete pouring, characterized in that it is composed of a closed-cell foam made of a cross-linked olefin resin having a gel fraction of 25 to 85%. It is what

Further, according to the present invention, in the above die-cutting material, when the surface to be contacted with concrete is a surface cut by a blade, the surface abuts a heating iron to melt only the surface, and the The present invention relates to a method for producing a die-cutting material for concrete pouring, which comprises forming a foamed skin layer.

Further, according to the present invention, the gel fraction is 25 to 85.
% Closed-cell foam sheet made of cross-linked olefin resin is placed on the front and back sides and directly heat-bonded, or a closed-cell foam sheet made of olefin resin is interposed therebetween. The present invention relates to a die-cutting material for concrete pouring, characterized by comprising a laminated sheet integrally bonded by heat bonding.

The present invention also relates to a method for placing concrete using the die-cutting material.
The method comprises a closed-cell foam made of a cross-linked olefinic resin having a gel fraction of 25 to 85%, and a mold having a non-foamed skin layer on at least a part of its surface. Abut the cut material on the concrete pouring dam,
The skin layer is fixed toward the side in contact with the concrete, and the concrete is cast toward the die-cutting material and the dam plate,
The feature is that the die-cut material is peeled off from the concrete together with the dam plate after the concrete is hardened.

In the present invention, as the olefin resin,
In addition to homopolymers such as ethylene, propylene, butene, isoprene, pentene and methylpentene, copolymers thereof can be used. Among them, as the homopolymer of ethylene, any of high density polyethylene, medium density polyethylene and low density polyethylene can be used. Further, as the copolymer, ethylene / vinyl acetate copolymer, ethylene / acrylic copolymer, ethylene / styrene copolymer, ethylene / propylene copolymer, ionomer, ethylene / propylene / diene terpolymer, etc. Can be used.

The above olefin resin is crosslinked to form a closed cell foam. By being cross-linked,
The elasticity is increased, the mechanical strength is increased, the heat resistance is also improved, and foaming is easy. The crosslinking may be caused by an organic peroxide or may be caused by irradiation with ionizing radiation. The olefin resin is preferably cross-linked at the same time when the olefin resin is extruded and foamed to form a large foam. Closed-cell property means that the cells in the foam are separated from each other and the foam does not have air permeability.

In order to extrude and foam the olefinic resin, a blowing agent may be mixed with the olefinic resin, and the resulting mixture may be put into an extruder and extruded into a desired cross-sectional shape. As the foaming agent, both a thermal decomposition type solid compound and a vaporization type foaming agent can be used. As the thermal decomposition type foaming agent, an inorganic compound such as ammonium carbonate or an organic compound such as azodicarbonamide can be used. As the vaporizing type foaming agent, carbon dioxide gas, propane, butane or the like can be used.

The apparent density of the foam is 0.03 to 0.2.
It is preferably in the range of g / cm ³ . Among them, the range of 0.05 to 0.1 g / cm ³ is more preferable. If the apparent density is lower than 0.03 g / cm ³ , the foam will be too soft and will be easily deformed at the time of placing concrete. Conversely, if it is higher than 0.2 g / cm ³ , the elasticity will be insufficient. This is because it becomes difficult to attach the die to the die.

Further, the above-mentioned foamed material corresponds to foamed material in a foaming ratio of 5 to 33.3 times. This range is a preferable range in terms of workability, cushioning property, compressive strength, tear strength, etc. of the foam.

The die-cut material according to the present invention is characterized by having a non-foamed skin layer on the surface to be contacted with concrete. A part of the non-foamed skin layer can be applied to the non-foamed skin layer formed on the foam when the foam molding is performed. However, even if it is used as a die-cut material, some work is usually required to form a non-foamed skin layer.

That is, since the shapes of the die-cut materials vary, the die-cut material cannot be extruded and foamed as it is. The die-cut material is often made by mechanically cutting from a large-sized molded body that has been foam-molded. When the die-cutting material is produced by cutting in this way, even if the surface of the original plate-like foam remains on the surface of the die-cutting material, the remaining surface is usually only one surface.
It is unlikely that more than a face will remain. On the other hand, since the die-cut material comes into contact with concrete on at least two sides, a new non-foamed skin layer must be formed on at least one side. Therefore, the die-cut material according to the present invention is
It is necessary to form a non-foamed skin layer on at least one of the surfaces obtained by mechanical cutting.

In order to form a non-foamed surface layer on the surface obtained by mechanical cutting, a trowel heated above the melting temperature of the olefin resin is brought close to or in contact with the cut surface to melt only the surface resin. It is obtained by doing. It is desirable to coat the surface of the iron with a fluororesin. This is because coating with a fluororesin allows the trowel to slide smoothly while pressing it against the foam surface. It is desirable to heat at 300 ° C. or higher.

The non-foamed skin layer may be in a state where the cut air bubbles are not exposed on the surface. That is, when the foam is formed by mechanical cutting, numerous tiny cavities of the cut cells are exposed on the surface, and there are deep cavities that undercut inside, so that the non-foaming skin layer The formation of the above means to eliminate such a deep hollow. The skin layer is preferably smooth, but may have some irregularities. The thickness of the skin layer is 1 mm
It is particularly preferable that the thickness is as thin as about 10 to several hundreds of μm.

In the die-cutting material according to the present invention, the non-foamed skin layer is brought into contact with the concrete pouring weir plate toward the side in contact with the concrete, and the die-cutting material is fixed to the weir board. Used to provide a recess or cavity in the shape of a stamping material in concrete by casting concrete toward the barrier plate and peeling the stamping material together with the barrier plate after the concrete hardens.

The die-cutting material according to the present invention is effective, for example, in forming a notch for draining water on the upper part of a foundation when a foundation of a building is made by pouring concrete. More specifically, in order to prevent water from entering the inside of the building, the lower end of the outer wall A is located below the lower end of the fixed structure B in order to prevent water from entering the inside of the building. Needed. For this reason, the foundation C must be configured such that a part of the outside is cut out, and the lower end of the cutout D is an inclined surface that lowers toward the outside. In order to make the foundation C in this shape by using concrete, the weir plates E and F are arranged side by side as shown in FIG. 2, and the die-cutting material G for making the notch D is fixed to the weir plate F. Then, it is decided to pour concrete H. Up until now, wood has been used as the die-cutting material G, but since the wooden die-cutting material has various drawbacks as described below, the die-cutting material according to the present invention is intended to improve this. It is useful.

Since the wood die-cutting material is water-absorbing, it easily adheres to the concrete and is therefore difficult to be separated from the concrete. Further, since the wooden die-cutting material is difficult to bend, it is difficult to bring it into close contact with the weir plate. Therefore, a gap is likely to be formed between the die-cutting material and the weir plate, and concrete enters the gap and solidifies. However, it is difficult to separate the barrier plate and the die-cutting material from the concrete. In addition, JP-A-4-118
Providing a release material to the die-cutting material, as recommended by Japanese Patent No. 462, improves the water absorption of the surface, but as long as a wooden material is used as the die-cutting material, a gap is created and concrete enters and solidifies in the gap. It is not possible to eliminate the difficulties caused by doing.

On the other hand, the die-cut material according to the present invention is
Since it is composed of a closed-cell foam made of a cross-linked olefin resin, it has poor adhesion to concrete and is easily peeled off from concrete, and since it has strong elasticity, it does not yield to the pressure of concrete, It is possible to suppress wasteful entry of concrete, and because it is tough, it does not shred when peeling and fragments remain. Therefore, this die-cut material is suitable for concrete pouring.

When the die-cut material according to the present invention is used at the position shown in G of FIG. 2, a non-foamed skin layer X is provided on the surface 1 and the surface 2 as shown in FIG. This is because the die-cutting material shown in FIG. 3 is fixed so that the surface 4 faces upward and the surface 3 faces the dam plate, and as a result, the surface 1 and the surface 2 contact the concrete. Because. As shown in FIG. 3, when a die-cut material provided with a non-foamed skin layer X is used, after the concrete is hardened, the die-cut material is warped in the longitudinal direction and separated from the concrete as shown in FIG. Will be even easier. Then, after the die-cut material is peeled off, the notch D having an accurate inclined surface can be formed in the base C.

Instead of the die-cut material shown in FIG. 3, a die-cut material as shown in FIG. 5 can be used. The die-cut material shown in FIG. 5 is an olefin resin foam sheet 1
It is made by laminating three sheets of 1, 12, and 13. The foamed sheets 11 and 13 are sheets obtained by irradiating a raw sheet formed by extrusion with radiation to form a foamable sheet, and then heating and foaming the sheet, when the respective sheets are extruded. It has a non-foamed skin layer on both the front and back sides. The foam sheet 12 sandwiched therebetween may be the same sheet as the sheets 11 and 13, but may be a sliced sheet instead. The die-cutting material of FIG.
No. 13 to No. 13 have a non-foamed skin layer X on the front and back because they are integrated by heating and welding the surfaces.
However, since the side surface 14 is originally a surface cut by a blade, there is no non-foaming skin layer, so a heating iron is brought into contact therewith to melt only the surface, and the non-foaming skin layer X
Was set up. The die-cutting material of the present invention may be as shown in FIG.

The die-cut material shown in FIGS. 3 and 5 is cut or heat-deformed to form a joint-like joint at the end in the longitudinal direction, and as shown in FIG. It is easy to connect in the direction or at right angles. Therefore, the die-cutting material according to the present invention is convenient because it can be connected without any gaps in the long corners and the projected corners and the recessed corners.

Since the die-cut material according to the present invention is made of a crosslinked olefin resin foam, it is flexible and tough, and therefore can be fixed to a dam plate or the like by a simple method. . That is, the die-cut material according to the present invention can be easily fixed by the stopper J having a U-shaped cross section in order to fix it to the dam plate F as shown in G of FIG.

As shown in FIGS. 7 and 8, the stopper J is made of an elastic plate made of steel or the like in a U-shape that narrows toward the opening, and a punching hole K is formed on the side in contact with the die-cutting material G. A warp protrusion L formed by punching is provided around the hole K and projects inward. Then, when the opening of the fastener J is opened and the ends of the die-cutting material G and the dam plate F are inserted into the opening and released, the protrusion L bites into the die-cutting material G as shown in FIG. The die-cutting material G can be easily fixed to the barrier plate F. Therefore, the die-cut material according to the present invention is convenient for use.

The die-cutting agent according to the present invention can have a marked line on its surface to determine the height of the concrete to be poured. That is, as shown in FIG. 9, the marked lines 5 and 6 are provided on the vertical surface 1 to be in contact with the concrete, and the upper end of the concrete to be poured can be determined by the marked line. The marking line can be provided by printing. 1
When a plurality of marking lines are provided on one surface, it is preferable that the marking lines have different colors. The marked line can be inserted by abutting a heated nichrome wire. Until now, the height of the concrete was measured from the top of the formwork with a finger to determine the top of the concrete, but if you attach the above-mentioned marking line, you can easily measure the top of the concrete without using a finger. And it can be accurately determined.

Although the case where the die-cutting material according to the present invention is used as the face-piece used when making the building foundation has been described above, the die-cutting material according to the present invention is not limited to the case where it is used as the face-piece. The die-cut material according to the present invention can also be used when a ventilation hole or a ventilation hole is provided in a concrete wall. The die-cutting material used in that case has a rectangular parallelepiped shape as shown in FIG.
The four surfaces of are the surfaces that should come into contact with concrete, so
The non-foamed skin layer X is formed on each of these surfaces.

[0038]

According to the present invention, since the die-cutting material is made of a resin foam, it is lightweight and easy to carry, and since the olefin resin is used as the resin, it has a poor adhesive force to concrete and therefore can be peeled off. Since it is easy to use, a cross-linked olefin resin is used, so the foam is highly elastic and tough, so it is easy to bring it into close contact with the dam plate, etc.
Even if it is pulled strongly at the time of peeling, it does not break even if it is pulled strongly, and since the foam used is a closed-cell foam, concrete does not penetrate into the inside of the die-cutting material, so a cavity with the shape of the die-cutting material is created in the concrete. It can be formed reliably and easily. When the expansion ratio is 5 to 33 times and the apparent density is in the range of 0.2 to 0.03 g / cm ³ , it is particularly easy to process the foam, and the foam has an appropriate density. It has elasticity, compressive strength, and tear strength, and is therefore convenient for use as a die-cut material.

Further, according to the present invention, the die-cut material having a non-foamed skin layer formed on the surface thereof is particularly easy to separate from the concrete after hardening of the concrete, and the cavity having the shape as the die-cut material is more surely formed in the concrete. And can be easily formed.

Further, according to the method for producing a die-cut material according to the present invention, a die-cut material having a non-foamed skin layer on the surface to be contacted with concrete can be easily produced.

Furthermore, according to the concrete pouring method of the present invention, the die-cutting material of the present invention having a non-foamed skin layer on the surface is used, and the skin layer is directed toward the side in contact with the concrete. Fixed to the dam for concrete pouring,
Since the concrete is cast toward the die-cutting material and the weir plate, it becomes easy to peel off the die-cutting material together with the weir plate after the concrete hardens, and it is easy and reliable to form a cavity on the concrete in the shape of the die-cutting material. Can be formed. The present invention provides such benefits.

[Brief description of drawings]

FIG. 1 is a vertical sectional view of a conventional lower part of a building.

FIG. 2 is a vertical cross-sectional view showing an example of using a die-cutting material when the foundation C shown in FIG. 1 is made of concrete.

FIG. 3 is a partially cutaway perspective view of the die-cut material according to the present invention.

FIG. 4 is a perspective view showing a peeled state of the die-cut material according to the present invention.

FIG. 5 is a partially cutaway perspective view of another die-cutting material according to the present invention.

FIG. 6 is a perspective view showing a connection mode of the die-cut material according to the present invention.

FIG. 7 is a partially cutaway perspective view showing a mode in which the die-cut material according to the present invention is fixed to a dam plate.

8 is a partially cutaway perspective view of the stopper used in FIG. 7. FIG.

FIG. 9 is a partially cutaway perspective view of another die-cut material according to the present invention.

FIG. 10 is a perspective view of still another die-cutting material according to the present invention.

[Explanation of symbols]

 1 Surface of die-cut material 2 Surface of die-cut material 3 Surface of die-cut material 4 Surface of die-cut material 5 Mark line 6 Mark line 11 Foamed sheet with non-foamed skin layer 12 Foamed sheet 13 Non-foamed skin layer Foam sheet with side 14 Side A Outer wall B Fixed structure C Foundation D Notch E Weir plate F Weir plate G Die-cut material H Concrete J Stopper X Non-foamed skin layer

Claims (7)

[Claims] 1. A die-cutting material for concrete pouring, comprising a closed-cell foam made of a cross-linked olefinic resin having a gel fraction of 25 to 85%. 2. The foam according to claim 1, wherein the foam is foamed 5 to 33 times and the apparent density is in the range of 0.2 to 0.03 g / cm ³ . Die cutting material for concrete pouring. 3. A closed-cell foam made of a cross-linked olefinic resin having a gel fraction of 25 to 85%, and a non-foamed skin layer is formed on the surface to be contacted with concrete. A die-cutting material for concrete pouring, which is characterized in that 4. A laminated sheet comprising two closed-cell foam sheets made of a cross-linked olefin resin having a gel fraction of 25 to 85% placed on the front and back sides and integrated by heat bonding. The characteristic die-cutting material for concrete pouring. 5. The die-cutting material for concrete placing according to claim 4, wherein a closed-cell foam sheet made of an olefin resin is sandwiched between two foam sheets to form a laminated sheet. 6. A closed-cell foam made of a cross-linked olefin resin having a gel fraction of 25 to 85% is cut into a desired shape with a blade, and the cut surface has a melting temperature of the olefin resin or higher. A method for producing a die-cut material for concrete pouring, which comprises contacting a heated trowel to melt only the surface and forming a non-foamed skin layer on the surface to be contacted with concrete. 7. A closed-cell foam made of a cross-linked olefinic resin having a gel fraction of 25 to 85%, and a non-foamed skin layer provided on at least a part of its surface. The die-cutting material is brought into contact with the weir board for concrete pouring, the skin layer is fixed toward the side in contact with the concrete, concrete is cast toward the die-cutting material and the weir board, and the weir is set after the concrete hardens. A method for placing concrete, characterized in that the die-cut material is peeled off from the concrete together with the plate.