JPH0740320A - Manufacture of decorative sheet prior-set mortar coated lightweight foamed concrete precast panel - Google Patents

Abstract

PURPOSE:To give water resisting performance to a side part of the panel concerned so as to contrive to improve its durability such as freeze-thaw performance and the like by a method wherein high strength dense mortar is poured between forms under the condition that the inner form is installed after decorative sheet blocks are arranged on the bottom face of the form in order to form its side face part and, after the removal of the inner form, pour lightweight foamed concrete slurry and finally cure. CONSTITUTION:After decorative sheet blocks 12 are arranged on the bottom face of a panel molding form 10, an inner form 11 for forming the mortar side face part 17 is arranged. Next, high strength dense mortar is poured between the form 10 and the inner form 11. After the solidification of the mortar, the inner form 11 is removed. In the resultant formed panel core part, lightweight foamed concrete slurry is poured. By being cured in an autoclave after the foaming and hardening of the slurry, both the lightweight foamed concrete and the dense mortar are simultaneously hydrated and hardened. Further, the decorative sheet block 12 is produced by arranging the surfaces of a plurality of decorative sheet so as to come into contact with the surface of a flat-surfaced sheet under the condition that metal gauze is bonded to the rear surface of the decorative sheet in order to preferably protect the surface of the decorative sheet from being polluted or the like.

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 precast mortar-coated lightweight cellular concrete precast panel with a decorative board. More specifically, the present invention has a surface veneer tip portion made of a veneer such as a tile board, a natural stone board, or an artificial stone board, a dense mortar side surface portion, and a lightweight cellular concrete precast core portion, and these are The present invention relates to a method of manufacturing a veneer pre-attached panel that is firmly composited and combined.

[0002]

2. Description of the Related Art In general, the conventional method for finishing decorative panels (tiling, natural stone, etc.) on the surface of lightweight cellular concrete panels has been the retrofitting method by plastering. Such a post-installation method requires a lot of manpower and a long construction period, which starts with the surface treatment of the panel surface, requires uneven repair, tile plastering work, curing, and cleaning processes. These plastering works largely depend on the experience of craftsmen, quality control of cement composition (mortar) which is a plastering material (ratio of water to cement, kneading property, curing temperature, humidity, etc.) is difficult, variation in strength, There is a problem of cracking, peeling, and dropping due to drying shrinkage,
In addition, the arrangement of the decorative plates and the joints are largely due to the quality of plastering work, and it is difficult to obtain highly accurate and uniform products.

On the other hand, the prefabricated method found in the production of PC (precast) plates is that a decorative plate such as a tile is laid out on a paper or plastic sheet, these are placed on the lower surface of the formwork, and then concrete is poured, and the decorative plate is also placed on this. It is a product that is cured together and is a product. Compared to the retrofitting method that involves plastering, a product with superior quality can be obtained.
The tile array method in this pre-attachment method uses an organic adhesive to fix the tile surface to the paper or plastic sheet with an organic adhesive, and an organic joint material is used in the joint portion to prevent concrete curling. There is.

[0004] There is no example in which the pre-plating technique for the PC plate is directly applied to the finishing of a decorative sheet in lightweight cellular concrete, and when a high-temperature curing method such as autoclave curing, which is indispensable for the production of lightweight cellular concrete, is used, curing is performed. After the completion, there is a problem that the paper and the plastic used as the sheet material are burned, which causes serious contamination on the surface of the decorative board such as tiles and natural stones. At present, in order to remove these contaminants, the surface of the decorative material is washed for a long time, and such a method is not preferable in terms of production efficiency and is not practical.

[0005]

In the surface finishing method for the surface of a concrete panel with a decorative plate, when the prioritizing method found in the production of a PC plate in the above-mentioned prior art is applied to the decorative plate prioritizing method for lightweight cellular concrete, The sheet material for pre-positioning developed for PC plate manufacturing requires high curing temperature. In autoclave curing etc., the paper used for tile arrangement, the plastic sheet or the organic adhesive used for bonding these to the tile is Due to the problem of heat resistance, contamination is caused on the surface of the decorative board, which becomes a problem.

Blocking decorative boards such as tiles and natural stone boards is indispensable for the manufacturing process of building materials using the pre-positioning method, but when autoclave curing is applied, the conventional arraying method is used for the above reasons. Therefore, it is desired to develop a method for arranging pre-tiled tiles that can be used even in high temperature curing.

In addition, lightweight cellular concrete contains a large number of bubbles in the hardened body structure, is extremely lightweight as compared with ordinary concrete, and has excellent properties such as heat insulation and sound insulation. There is. In the lightweight cellular concrete that has these excellent performances, the presence of the bubbles causes the autoclave curing lightweight cellular concrete material (ALC) to have inferior water absorption resistance, and problems such as freeze-thaw resistance have been pointed out. . At present, the water absorption resistance is improved by internally adding or painting a water repellent into lightweight cellular concrete, but it cannot be said that the maintenance of long-term performance and reliability is sufficient, and It is hoped that the water absorption resistance will be improved.

The present invention is to solve the above-mentioned problems in the prior art, and a method of arranging tiles arranged on the lower surface of the formwork as a front end by a material having poor heat resistance such as a conventional plastic sheet. Without using the tile, array fixing from the back side of the tile with wire mesh, or paper and natural polymer adhesive, protecting the surface of the decorative plate with paper and gypsum, by using the arranging method, the tile can be cured by high temperature such as autoclave, It is an object of the present invention to provide a method of arranging a decorative plate without any fear of contamination on the surface of natural stone. Further, the present invention improves the water absorption resistance, which has been a problem in ALC in the past, and improves durability such as freeze-thaw performance and imparts water stopping performance to the side surface of the panel. It is intended to provide a method for manufacturing a concrete precast panel.

[0009]

A method for producing a decorative mortar-coated lightweight cellular concrete precast panel according to the present invention comprises a decorative board block arranged on the bottom surface of a panel molding mold, and the mortar in the mold. An inner formwork for forming a side face part is arranged, the bottom face part, and a side face part space formed by the formwork and the inner formwork are poured with high-strength dense mortar to solidify it, and Remove the inner mold, inject the lightweight cellular concrete slurry into the panel core formed by the bottom surface and side surfaces, foam and harden it, and cure the precursor molded body formed in the above step in an autoclave. Then, the dense mortar and the lightweight cellular concrete are simultaneously hydrated and hardened.

In the method of the present invention, it is preferable that the decorative plate block is produced by adhering the back surfaces of a plurality of the decorative plates to a wire net with an adhesive material to form an integral block.

In the method of the present invention, when producing the decorative plate block, a plurality of decorative plates are placed on a sheet material having a flat surface, and the surface of the decorative plate is brought into contact with the flat surface of the sheet material. It is preferable that the rear surface of the decorative plate is adhered to the wire mesh via an adhesive material, thereby protecting the surface of the decorative plate from deterioration or contamination.

In the method of the present invention, the adhesive material may be selected from an organic polymer adhesive and an inorganic mortar.

In the method of the present invention, the high-strength dense mortar comprises an inorganic cement material, a crystalline siliceous material,
The crystalline siliceous material contains a quicklime material and a water reducing agent, and the crystalline siliceous material is a fine powder having a specific surface area of 10,000 cm ² / g or more, and the inorganic cement material and the crystalline siliceous material. It is preferable that the blending weight ratio thereof with is 100: 45 to 85.

In the high-strength dense mortar of the present invention, the CaO / SiO ₂ weight ratio is preferably 1 or less.

Further, in the method of the present invention, it is preferable that the high-strength dense mortar further contains a cement hydration accelerator, thereby shortening the required solidification time of the high-strength dense mortar.

The cement hydration accelerator is calcium chloride, nitrate, nitrite, thiosulfate, thiocyanate,
It may be composed of at least one selected from diethanolamine, triethanolamine, calcium formate, calcium acetate, and calcium acrylate.

[0017]

In the method of the present invention, the decorative boards such as tiles and natural stones are accurately arranged in the form using the following pre-attachment method. Temporarily put a decorative plate such as a tile on the back of the tile so that the required joint width and joint type are the same, and place a wire net or a lath wire net on the back of the tile. Pour special cement mortar or synthetic polymer adhesive, natural polymer adhesive (potato starch, corn starch, wheat starch) into the tiles and wire mesh to immobilize them, then block the decorative board. Place the decorative block in the formwork. Make sure that the decorative board has the desired joint width and joint type, and the natural polymer or gypsum slurry is adhered and fixed as an adhesive on the flat surface of the sheet material such as kraft paper or felt yarn to fix the makeup. Block the surface of the board while protecting it, and install it in the formwork.

As a method for holding the tile arrangement, since the wire net is firmly held and fixed to the back foot of the tile by a special mortar, and the wire net is placed near the concrete surface layer portion which receives the flame, the strength at the time of fire resistance is improved. It is possible to increase the number of concrete and to suppress the explosion phenomenon of concrete to the minimum, and it becomes possible to solve the problems such as serious peeling and falling of decorative materials.

Further, the surface of the tile or the natural stone board is closely fixed to the paper or the like by using a natural polymer adhesive or gypsum slurry to prevent the sand of the concrete from entering the surface of the decorative board. Prevents contact with alkaline components that cause deterioration of siliceous materials such as tiles and natural stones,
It is possible to solve the problem of deterioration and contamination of the surface of the decorative plate. In this pre-attachment method, after installing tiles and natural stone boards in the formwork, by arranging a wire net and a lath wire net on the back surface, the problem of peeling and falling off of the decorative plate during fireproofing can be solved in the same manner as the above-mentioned pre-attachment method. You can

After arranging the tiles and the natural stone boards accurately on the bottom surface of the form using the above-mentioned tile and natural stone board pre-attachment method,
Pour a special mix of mortar into the bottom and side of the form, then inject lightweight aerated concrete slurry,
After foaming and semi-curing, the precursor molded body is subjected to autoclave curing to firmly combine the decorative plate such as tiles and natural stone plates on the ALC surface, and manufacture a panel with a high-strength dense mortar layer formed on the ALC side surface. can do.

In this method for producing a precast panel of mortar-coated lightweight mortar coated with tiles and natural stoneboard, the method of forming a dense mortar layer on the side surface of the panel is as follows. After pouring the dense mortar into the gap between the molds and leaving it for a predetermined time, the inner mold is pulled up, and then the lightweight cellular concrete slurry is poured in and foamed and hardened, and then autoclave curing is applied to this precursor molding to obtain AL.
It is possible to manufacture a panel having a dense mortar layer on the C side.

When a dense mortar layer is formed on the ALC side surface, the side surface of the ALC panel is made of a high-strength dense mortar layer by placing a desired shape on the side surface of the mold in advance, and the desired shape is obtained. It is possible to use any joint method and water stop method by selecting these side surface shapes.

In the method of the present invention, by coating the ALC surface with a high-strength dense mortar layer, the low surface strength of the ALC is improved, the water absorption resistance is greatly improved, and the wind pressure resistance and panel strength are improved. Due to the increase, it is possible to manufacture a decorative material preliminarily-prepared ALC panel which has hitherto been unavailable.

[0024]

EXAMPLES The present invention will now be described in detail based on examples. Fabrication of Pre-tiled Tile Arrangement Method of Arranging Decorative Material Blocking from the back surface of the decorative material with a wire mesh will be described with reference to a configuration example shown in FIG.

FIG. 1 shows a sectional view of the pre-tiled tile arrangement method. Here, 1 is a tile for pre-positioning, 2 is a wire net or lath wire net, 3 is a special cement mortar or a synthetic polymer adhesive for holding the tile and the wire net. The pre-positioning tiles 1 are arranged in advance in the required joint width and joint type so that the backs of the tiles face up. A wire net or a lath wire net 2 is placed on it so as to contact the back foot. At this time, it is important that the wire nets and lath wire nets 2 are flat, and the use of non-flat wire nets hinders the flatness of tiles and the arrangement of tiles on the panel surface after being commercialized. In the product of the present invention, a flat metal net is arranged on the back foot of the tile and fixed to improve the flatness of the panel surface after the product is manufactured.

After installing the wire net 2 on the sole 1a of the tile 1,
A special mortar for holding tiles or a synthetic polymer adhesive 3 is poured on it. It is preferable that these are injected only in a part of the tile foot 1a, that is, in an area sufficient for holding the tile and the wire mesh, and if the injection amount is excessive, the tile foot which effectively works for holding the tile will be damaged. It may reduce the adhesion between concrete and tile.

The area of the injection area of the mortar and the polymer adhesive 3 to the tile back 1a is 20% to 70% of the surface area of the tile.
%, And if the injection area is 20% or less, the adhesive strength between the wire mesh and the tile backing foot becomes insufficient,
On the other hand, if it is 70% or more, the adhesion strength between the wire netting and the tile increases, but the area of the backing of the tile, which is effective in adhering to concrete, becomes insufficient. Most preferably, it is about 30% to 50% within the above-mentioned pouring range, and in this case, the holding power of the tile and the wire mesh, and the holding power of the tile and the concrete are balanced with each other.

The special mortar 3 is hardened at room temperature or normal pressure steam curing (40 to 80 ° C.). As a result, the special mortar 3 has high strength, and the tile and the wire mesh are firmly bonded to each other to realize the pre-mounted tile block. This mortar is autoclave-cured (pressure 10 kg / cm ² , temperature 17 ° C.) for panel production.
The strength is further enhanced by the treatment at 5 ° C. and the treatment time is 10 hours), and it becomes an extremely strong inorganic adhesive between the tile and the wire net.

The mortar after steam curing at room temperature has room for the formation of hydrates. Therefore, the strength of the mortar is further increased by performing autoclave curing, or the mortar at the interface with the concrete poured on the back surface of the pre-tiled tile block. The formation of new hydrates can be expected, and the affinity at the interface between the tile-holding mortar and the concrete is also good, so the stability after compounding is excellent.

It is preferable that the surface of the wire net 2 is treated with a cement-based rust preventive material. By doing so, it is possible to prevent the tile surface from being contaminated due to the rust of the wire net, and further to prevent the concrete from being contaminated. It is possible to improve the affinity with and improve the adhesion strength.

Since this pre-tiled tile arranging method adopts a method of firmly holding the tiles from the back surface of the tiles to form blocks, it is not necessary to fix the tile surface with a conventional plastic sheet, and therefore, the autoclave curing or the like is performed. When high temperature curing such as is performed, there is no fear of contamination of the tile surface due to deterioration of the sheet as seen in the conventional method, and a uniform pre-tiled tile arrangement method in high temperature curing is realized. This is a solution to the worry of peeling and falling of tiles after conversion. The above method can also be used for natural stone plates or artificial stone plates.

Method of Arranging Decorative Material A method of arranging the surfaces of the tile and the natural stone slab onto the kraft paper and felt paper with the natural polymer adhesive and the gypsum slurry so as to be protected, fixed and arranged will be described with reference to FIG. FIG. 2 shows a procedure for producing a decorative panel PC panel. Here, 4 represents a sheet material such as kraft paper or felt paper for tile allocation, 5 is a decorative board for pre-positioning, 6 is an adhesive material used for fixing the sheet material 5 and the decorative board 4, 7 Is a sheet material such as paper or veneer for holding the sheet material 5 in which the decorative plates are arranged and fixed in the mold, and 8 is a joint material (gypsum slurry).

As shown in FIGS. 2 (A) and 2 (B), the decorative sheet 5 used for pre-positioning is placed on the sheet material 4.
Are arranged in the required joint width and joint type so that the surface portion faces the lower surface of the form. At this time, in order to bond the decorative sheet 5 and the sheet material 4, the adhesive material 6 is applied to the surface of the decorative sheet in a necessary and sufficient amount and sufficiently adhered to the sheet material 5 and the decorative sheet 4.
It is hydrated and hardened between.

A setting retarder is preferably added to the adhesive material 3 (for example, gypsum slurry) in order to adjust the pot life. As the setting retarder, an inorganic material is used.
There are fluorinated fluorides, phosphates, zinc oxide, zinc chloride, lead oxide, boron oxide, borax, etc. Organic types include lignin sulfonate, gluconate, polyol polymer complex, citric acid, glucose , Sucrose, sorbitol, pentaerythritol and the like are used. The joint material is filled with the adhesive material 6 to realize the block formation of the tile sheet having high strength and high watertightness.

As shown in FIG. 2 (C), the decorative plate array protected or blocked by the layers of the sheet material 4 and the adhesive material 6 is placed in advance in the frame 7. A synthetic polymer adhesive 9 is used to hold onto a sheet material 8 such as laid paper or veneer.

In the method of the present invention, an adhesive material is applied to the surface of the decorative board and is adhered and fixed on a sheet material such as kraft paper or felt paper to protect the surface of the decorative board from alkaline components, and further to bond the adhesive material. Used as a joint material, ensuring high water-tightness by filling the joint part, preventing the highly alkaline component generated with hydration of cement or the cement itself from entering the surface of the decorative plate, and degrading the surface of the decorative plate. The pollution problem can be solved completely.

When the calcined gypsum slurry is used as the adhesive material, the cement material injected on the surface side of the decorative plate is hydrated and decomposed by curing and can be easily removed from the surface of the decorative plate.

The decorative sheet protecting sheet 4 is strongly fixed to the sheet material 9 such as paper or veneer in the form 7, or the gypsum slurry as the joint material exhibits high strength by the hydration reaction. By firmly fixing the tiles and natural stone boards, a sufficient effect can be expected for holding the arrangement of the decorative boards 5, and the tiles and natural stone boards that are placed due to vibration during concrete pouring easily move. Can also be solved.

As described above, the hardened plaster of the gypsum can be easily washed and removed since the hardened tissue becomes weak after curing in the autoclave, and the prefabricated PC panel can be efficiently manufactured.

(Mortar Composition) The high-strength dense mortar layer forming composition used for coating a decorative plate on the ALC surface or for coating the side surface of the ALC is an inorganic cement material or a finely ground siliceous material. , Calcareous materials, and water reducing agents. Among them, the finely ground silicic acid material preferably has a specific surface area of 10,000 cm ² / g or more, and the content thereof is preferably 45 to 85 parts by weight with respect to 100 parts by weight of the inorganic cement material. This finely ground siliceous material has the optimum CaO / Si content in the mortar composition.
In the O ₂ ratio, the amount of silicic components capable of reacting from the surface of the finely ground siliceous material and the coarsely ground siliceous material was calculated, and the calculated amount of siliceous component and the reactive alkali component from the cement material and the calcareous material. And the formulation system CaO / Si
It is preferable to control the O ₂ ratio to 1 or less.

Good physical properties are that the amount of fine powder of siliceous material in this mortar composition is 20 to 100 parts by weight, preferably 45 to 85 parts by weight, relative to 100 parts by weight of the inorganic cement material. It is optimum for obtaining the above range, and if the amount is more or less than this range, the strength or the like is deteriorated, which is not desirable. The mortar thus blended is prepared by using the finely ground siliceous material and the CaO / SiO ₂
By controlling the ratio, it is possible to reduce the amount of cement used to about 20% while maintaining high strength, which results in the production of harmful cement hydrates such as hydrogarnet which adversely affects the strength properties or the like. It is possible to suppress the occurrence of efflorescence, etc.

(Polymer Adhesive) Similarly, synthetic polymer adhesives used for holding the decorative plate and the wire mesh include epoxy resin type, chloroprene type, alkylphenol resin type, polyurethane type, and the like. A strong holding power is exhibited by adding the finely divided silicic acid material alone or in an arbitrary ratio. The addition ratio of the siliceous material to the synthetic polymer adhesive is preferably in the range of adhesive / siliceous material (weight ratio) = 0.5 to 2.0, and high strength is exhibited. Natural polymer adhesives include potato starch, corn starch, wheat starch and the like.

(Method of Forming Side Layer with High Strength Dense Mortar) A method of forming a high strength dense mortar layer on the side surface of the ALC in the method of the present invention will be described with reference to FIG.
10 is a mold for manufacturing ALC panels, 11 is an inner mold for forming a high-strength and dense mortar layer, 12 is a decorative material used in advance, and 13 is a wire mesh or lath wire mesh for preventing explosion of mortar during fireproofing. , The convex portion 1 on the inner wall surface of the formwork 10.
4 may be formed, the mold 10 may be held by the holder 15, and the spacer 16 may be arranged between the mold 10 and the inner mold 11.

Form 10 as shown in FIG.
Is prepared, and the block-shaped makeup 12 used for pre-positioning is accurately placed therein. Tile, without using wire mesh in blocking natural stone, gypsum slurry, wire mesh when fixed to paper with natural polymer adhesive,
The lath wire mesh 4 is arranged on the back surface of the decorative material.

Next, the inner mold 11 is installed in the mold 10 so that a predetermined mortar thickness is obtained. A mortar layer is formed on the side surface of the mold by pouring a specially mixed mortar rich in fluidity into the gap (about 25 to 40 mm) between the mold 10 and the inner mold 11. At this time, a mortar layer is formed and composited on the back surface of the decorative material 12 arranged on the bottom surface of the mold.

After injecting the mortar into the mold 10, the inner mold 11 is pulled up after a certain period of time. If the pulling time is too early, the solidification of the mortar layer on the side surface of the form becomes insufficient and the self-supporting shape cannot be maintained. For this reason, an appropriate amount of a component that promotes hydration of cement is mixed in the mortar component, and this is solidified in a short time so that the inner formwork can be removed and the lightweight cellular concrete slurry can be poured. This special mortar layer reproduces the shape of the inner wall surface of the mold 10 and thus the ALC
The joint portion on the side surface of the panel can be formed of high-strength dense mortar.

After removing the inner mold form, as shown in FIG. 3B, the lightweight foam concrete slurry is poured into the space formed by the dense mortar side surface portion 17 and the decorative material portion 18, This is foamed and cured to form a lightweight foam concrete core. The obtained precursor molded body is shown in FIG.
As shown in FIG. 3, the mold 10 is taken out and subjected to autoclave curing.

(Performance) In the panel example thus constructed, a flat wire mesh is arranged on the back surface of the tile and fixed by a special mortar, so that the tile is very tiled, and the tile surface is excellently preliminarily attached. Blocking of the tile sheet has been realized. Since the mortar used for fixing has CaO / SiO ₂ controlled, it is said that a strong hardened body structure is formed by autoclave curing and the adhesion between the tile and the wire mesh is excellent. In addition, this wire mesh also has the effect of preventing the explosion of concrete that can be seen during a fire, and also improves the fire resistance performance of the outer wall panel.

Further, in the case where the surface of a decorative board such as a tile or a natural stone board is protected and fixed with a gypsum slurry, a natural polymer adhesive and paper, the cause of the deterioration of the siliceous component and the high alkalinity of cement water or the like. Prevent the invasion of ingredients,
By solving the problems of deterioration and contamination of the surface of the decorative board, we have achieved an accurate arrangement of the decorative boards.

The dense mortar layer strongly composites a decorative material on the ALC surface and further coats the panel side surface with the dense mortar layer to solve the problem of water absorption resistance, which has been a problem in conventional ALC. Further, since the side surface shape can be freely attached to the mortar layer portion depending on the shape of the side plate to be prepared, any panel joint method can be adopted and a water blocking mechanism can be added.

Coating the ALC surface with a high-strength mortar is not only an improvement of the conventional ALC but also a new one with excellent functionality while maintaining the excellent performance of the ALC such as lightness, heat insulation and sound insulation. Providing concrete panels.

Production Examples 1 to 3 and Comparative Production Examples 1 to 3 Table 1 shows the composition of the mortar used in the present invention and its performance. In each of Production Examples 1 to 3 and Comparative Production Examples 1 to 2 (when the siliceous material is out of the optimum range) and Comparative Production Example 3 (general plaster mortar), the cement composition shown in Table 1 is used. Was prepared. However, the inorganic cement material is Portland cement, and the siliceous material is a finely ground silica stone with a specific surface area of 12,000 cm ² / g.
(Production Examples 1 to 3, Comparative Production Examples 1 and 2) and Toyoura Standard Sand (Comparative Production Example 3). This mortar composition is shown in Table 1.
A cement slurry was prepared by kneading with the amount of water described in 1 above, and subjected to autoclave curing for 10 hours.

In order to measure the adhesion strength with the tile,
A tile (having a size of 40 mm × 40 mm) was placed in advance in a 70 mm × 70 mm × 10 mm mold, and the above cement slurry was poured into the same in the same manner and subjected to autoclave curing. The compression strength, bending strength, and adhesion strength with the tile of the obtained mortar molded product were measured by the usual methods. The results are shown in Table 1.

[0054]

[Table 1] As can be seen from Table 1, in Production Examples 1 to 3 using the finely ground siliceous material having a specific surface area of 12,000 cm ² / g, about 2 to 2 are compared with the general plaster mortar in Comparative Production Example 3.
A mortar molded product having a bending strength and a compressive strength of 4 times was obtained.

The optimum amount of the fine siliceous material is 20 to 100 parts by weight, preferably 45 to 85 parts by weight, based on 100 parts by weight of the inorganic cement material.
As shown in ~ 2, when the amount of the fine siliceous material added is larger than this, an extreme decrease in strength is recognized, and the strength is similar to plaster mortar. Further, if the compounding amount of the fine siliceous material is smaller than this, similarly a decrease in strength is recognized, which is a problem.

The holding power with the tiles in the mortar molded products of Production Examples 1 to 3 was much larger than that of plastering mortar, and showed an adhesive strength of about 20 Kgf / cm ² or more. In this adhesion test, the strength value obtained here is considered to be the breaking strength of the tile itself because the tile was destroyed before the peeling of the tile and mortar layer occurred, and the tile holding force by the mortar layer was obtained this time. It is presumed that it is even larger than the given value. Clearly, it has a high holding power that has never been seen before.

[0057]

INDUSTRIAL APPLICABILITY The present invention is a method of manufacturing a lightweight cellular concrete panel with a tile and a natural stone pre-fixed, and the method of pre-tiling the tile and the natural stone plate is a PC plate without using a wet method involving plastering work which is conventionally found in the tile finishing method of ALC. The pre-attachment method in (1) is applied and improved to make it suitable for ALC panel production.

The conventional pre-positioning technique for the PC version is as follows:
It cannot be used for those involving high temperature curing such as autoclave curing in ALC production. For this reason, as a method of prefabricating the decorative board, a wire mesh placed on the back side of the tile is fixed with special mortar, synthetic polymer adhesive, natural polymer adhesive, and the prefabricated tile is made into sheets and blocks. Alternatively, the surface of a tile or natural stone is adhered and fixed to gypsum slurry, natural polymer adhesive, kraft paper, felt paper, or the like.

According to the present invention, since it is not necessary to use a plastic material having poor heat resistance, which has been conventionally used for pre-fixing a PC plate, it is possible to manufacture a pre-fixing panel requiring autoclave curing without worrying about contamination on the tile surface. And In addition, the wire mesh used for blocking has an effect of preventing tiles from peeling and falling off, and particularly exerts an effect of increasing strength during fireproofing and peeling tiles due to explosion of concrete.

Further, since the dense mortar layer is formed on the side surface and the surface of the ALC panel, the strength of the panel is improved, the water absorption resistance is improved, and the physical properties are greatly improved as compared with the conventional ALC panel. Can be expected to improve. In addition, since the side plate shape can be freely changed by the dense mortar layer, the panel joint method can be freely selected and a water stop mechanism can be added, thus making it possible to manufacture a lightweight panel that has never been seen before. Will be realized.

In the product of the present invention, since the mortar part formed on the side surface and the lightweight cellular concrete part formed on the side surface are simultaneously cured by the autoclave, the hydration hardening progresses at the same time. Manufacture was realized.

[Brief description of drawings]

FIG. 1 is a partial cross-sectional front view showing an example of the configuration of a decorative board pre-attachment block.

2 (A), (B), and (C) are cross-sectional explanatory front views showing an example of a procedure for arranging a decorative plate pre-attached block on a panel molding form.

3 (A), (B) and (C) are cross-sectional explanatory front views showing an example of a procedure for manufacturing a precast panel of the present invention.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 ... Tile board 1a ... Back foot 2 ... Wire mesh 3 ... Adhesive 4 ... Sheet material 5 ... Decorative board 6 ... Adhesive material 7 ... Form 8 ... Sheet material 9 ... Adhesive 10 ... Form 11 ... Inner form 12 … Decorative material block 13… Wire mesh 14… Formwork inner wall surface 15… Formwork holder 16… Spacer 17… Mortar side part 18… Decorative material part 19… Lightweight cellular concrete core part

─────────────────────────────────────────────────── ─── Continuation of the front page (51) Int.Cl. ⁶ Identification number Office reference number FI Technical indication location C04B 38/00 302 E04F 13/08 102 Q 9127-2E (72) Inventor Satoshi Ozawa Funabashi City, Chiba Prefecture 585 Tomimachi, Sumitomo Cement Co., Ltd. Building Materials Division (72) Inventor Masayoshi Konishi 585, Tomimachi, Funabashi, Chiba Sumitomo Cement Co., Ltd. Building Materials Division

Claims (8)

[Claims] 1. A decorative plate block is arranged on the bottom surface of a panel molding mold, and an inner mold for forming a mortar side surface is arranged in the mold, and the bottom surface and the mold are arranged. A high-strength dense mortar is poured into the side surface space formed by the frame and the inner mold to solidify it, the inner mold is removed, and the panel core formed by the bottom surface portion and the side surface portion is lightweight. Injecting aerated concrete slurry, foam and harden it, the precursor molded body formed by the above step is cured in an autoclave, the dense mortar and the lightweight cellular concrete are simultaneously hydrated and hardened. A method for manufacturing a lightweight cellular concrete precast panel with a decorative mortar-coated mortar. 2. The method according to claim 1, wherein the decorative plate block is produced by adhering the back surfaces of a plurality of the decorative plates to a wire mesh with an adhesive material to form an integral block. 3. When manufacturing the decorative board block,
A plurality of decorative plates are arranged on a sheet material having a flat surface so that the surface of the decorative plate contacts the flat surface of the sheet material, and the back surface of the decorative plate is bonded to the wire mesh. The method of claim 2, wherein the material is adhered through, thereby protecting the veneer surface from deterioration or contamination. 4. The method according to claim 2 or 3, wherein the adhesive material is selected from organic polymer adhesives and inorganic mortars. 5. The high-strength dense mortar contains an inorganic cement material, a crystalline siliceous material, a quicklime material, and a water reducing agent, and the crystalline siliceous material is 10,000.
The method according to claim 1, which is a fine powder having a specific surface area of cm ² / g or more, and a compounding weight ratio of the inorganic cement material and the crystalline siliceous material is 100: 45 to 85. . 6. The method according to claim 5, wherein the CaO / SiO ₂ weight ratio of the high-strength dense mortar is 1 or less. 7. The method of claim 5, wherein the high strength dense mortar further comprises a cement hydration accelerator. 8. The cement hydration accelerator is calcium chloride, nitrate, nitrite, thiosulfate, thiocyanate,
The method according to claim 7, comprising at least one selected from diethanolamine, triethanolamine, calcium formate, calcium acetate, and calcium acrylate.