JPH11268016A - Patterned lightweight cellular concrete plate and manufacture thereof - Google Patents

Abstract

PROBLEM TO BE SOLVED: To improve a bending crack load strength by a method wherein a pattern in given to a concrete plate by placing a designing mold on the surface of the semi-cured lightweight cellular concrete plate so as to vibrate at least either the semi-cured lightweight cellular concrete plate or the designing mold. SOLUTION: Under the state that an uneven patterned designing mold is placed on or beneath a semi-cured lightweight cellular concrete plate and its sides are fixed immovably to the semi-cured lightweight cellular concrete plate, both or either one of the semi-cured lightweight cellular concrete plate and the designing mold are vibrated so as to obtain a patterned semi-cured lightweight cellular concrete plate. The obtained patterned semi-cured lightweight cellular concrete plate is treated by a steam autoclave curing or the like and cured and cooled so as to obtain a patterned lightweight cellular concrete plate. By vibration-molding, a lightweight cellular concrete plate, on the surface of which a pattern in formed by partially flattening the surface part of the concrete plate, can be manufactured.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a lightweight lightweight concrete concrete board and a method for producing the same.

[0002]

2. Description of the Related Art In the field of exterior wall materials for houses, there is an increasing demand for thin exterior wall materials having a thickness of about 12 to 24 mm and having a natural stone-like or brick-like uneven pattern called ceramic siding. In the ceramic siding, since the fiber reinforcing material is mixed into the raw material, the moldability of the uncured material and the shape retention after molding are good, and the uneven pattern can be formed relatively easily by pressing when uncured.

On the other hand, a light-weight cement-based material such as a light-weight aerated concrete plate that has been cured in an autoclave has conventionally been provided with an uneven pattern on the surface by the following method. (1) A method in which the surface of a cured, lightweight cement-based material after curing is cut with a blade to form an uneven pattern. (2) A lightweight cellular mortar is cast into a mold, and a patterned rubber is provided on the upper surface of the cement-based material. A method in which a pattern and a sheet are covered with a roller and the pattern is transferred by rolling with a roller (Japanese Patent Publication No. 3-2)
No. 7368) (3) Cut the semi-cured cellular mortar with a tension wire,
A cut surface with a flatness of 3 mm or less and a mortar of 1
When the hardness is in the range of 0 to 25 pounds, the depth of the concave portion is 2
A method in which a pattern having a concavo-convex pattern of 0 mm or less is pressed against the cut surface to form a pattern (Japanese Patent Publication No. 5-341121). However, a method for imparting a concavo-convex pattern to the lightweight cement-based material is as follows. Problem.

The method (1) is limited to patterns such as stripes and lattices, and it is difficult to reproduce patterns such as natural stones. In addition, since hardened hard material is cut, cutting requires much labor and time, resulting in high cost. Also,
In the method (2), since the mortar is cast into the mold, the mold cannot be removed until the lightweight cellular mortar is hardened. Get high.

Further, the method (3) is excellent in productivity in the prior art, but when the mortar is in a hardness range of 10 to 25 pounds, a mold having an uneven pattern is pressed against the mortar surface. 1m ^{2 with} a large area to form a pattern
In order to manufacture the above-mentioned outer wall material for a house, a press machine of several tens of tons or more is required, which requires large equipment and increases costs. For example, in a semi-cured state having a mortar hardness of 10 to 25 pounds, a pressing pressure higher than a pressure corresponding to the mortar hardness of 1.45 to 3.62 kg / cm ² is required. When a general lightweight 2.86 m long and 0.6 m wide wall made of residential lightweight cellular concrete is made by this method, a press having an area of 1.716 m ² is required, and the pressing pressure is 24. 9 to 62.1 tons are required. Therefore, a large-sized press machine having a large area is required, and the cost increases accordingly.

[0006]

SUMMARY OF THE INVENTION An object of the present invention is to provide a lightweight lightweight cellular concrete plate having a good design and a high-strength heavy part disposed on the surface to provide a high-strength flexural cracking load. DISCLOSURE OF THE INVENTION It is an object of the present invention to provide a plate and a method for manufacturing the plate.

[0007]

That is, the present invention is as follows. (1) A design mold is placed on the surface of a semi-cured lightweight cellular concrete plate, and a pattern is provided by applying vibration to at least one of the semi-cured lightweight cellular concrete plate or the design mold. A lightweight lightweight cellular concrete board characterized by the following. (2) A method of providing a design by placing a design mold on the surface of a semi-cured lightweight cellular concrete plate, and applying vibration to at least one of the semi-cured lightweight cellular concrete plate or the design mold. A method for producing a lightweight lightweight cellular concrete board, comprising:

The lightweight cellular concrete board in the present invention refers to a lightweight cement-based material containing cells. The lightweight cellular concrete used in the present invention is, for example, lightweight cellular concrete, lightweight mortar, lightweight concrete, etc. cured by autoclave, and is not particularly limited as long as it is a lightweight cement-based material containing cells. Also,
Embed lath nets and reinforcing bars in this lightweight cellular concrete,
Includes reinforcements.

The lightweight cellular concrete used in the present invention is made from a concrete slurry containing, for example, silica stone, cement, quick lime, water as a main raw material, gypsum, crushed debris, etc., if necessary, and further containing air bubbles. be able to. As a method of mixing air bubbles into concrete, a method of foaming by mixing a foaming agent such as aluminum powder into concrete slurry may be used, or a method of mixing air bubbles previously foamed into concrete slurry may be used. .

When the foamed concrete slurry obtained as described above has a hardness suitable for injecting, curing and cutting into a mold in which reinforcing bars such as a lath net and a reinforcing bar are previously arranged, the mold is formed. And a semi-hardened concrete block can be obtained. The semi-cured concrete block can be cut into an appropriate size to obtain a semi-cured lightweight cellular concrete plate.

The semi-cured lightweight cellular concrete board of the present invention has a curing time of the concrete block or the semi-cured lightweight cellular concrete board after cutting so that the compressive strength is 0.2 to 4 kgf / cm ^2. It is preferable to use it after adjusting it, and further, 0.5 to 2 kgf /
It is preferable that the curing time is adjusted so that the curing time becomes ² cm ² . When it is smaller than 0.2 kgf / cm ² , concrete sticks to the design mold and is likely to be broken. Also,
If it is larger than 4 kgf / cm ² , cracks are likely to occur when the design surface having irregularities is vibrated. The design mold in the present invention refers to a mold for imparting an uneven pattern to a semi-cured lightweight cellular concrete plate.

In the method for producing a lightweight lightweight cellular concrete board with a pattern according to the present invention, a design die having a pattern is brought into contact with a semi-hardened lightweight cellular concrete board, and at least one of the design mold and the semi-hardened lightweight cellular concrete board is provided. Vibration is applied to one or both of them to impart an uneven pattern to the semi-cured lightweight cellular concrete plate. FIGS. 1 and 2 show side views of an example of an apparatus for imparting an uneven pattern to a semi-cured lightweight cellular concrete plate by applying vibration. The method for producing a patterned lightweight cellular concrete board of the present invention may be any vibration as long as the design mold bites into the surface of the semi-cured lightweight cellular concrete board due to vibration, and the amplitude and cycle of the vibration are not particularly limited, The amplitude is preferably 0.001 to 5 mm, more preferably 0.1 to 2 mm.

The cycle of vibration is preferably 10 to 40,000 cycles / minute, more preferably 100 to 100 cycles / minute.
00 cycles / minute. When the amplitude is smaller than 0.001 mm and when the cycle of vibration is smaller than 10 cycles / minute, it takes time to provide the concavo-convex pattern. If the amplitude is larger than 5 mm, cracks may occur. Furthermore, the cycle of vibration is 20,000 cycles /
If it is larger than minute, it is out of the audible range and there is no noise. However, if the amplitude is not less than 0.01 mm, cracks are liable to occur.
If greater than 00 cycles / min, the amplitude is 0.01
mm or less. Using a design type in which the convex area of the uneven pattern is arranged in a rib shape, adjusting the vibration time so that the displacement becomes about the maximum depth, and applying the uneven pattern to the semi-cured lightweight cellular concrete board, It is possible to manufacture a lightweight cellular concrete plate in which a heavy portion is arranged in a rib shape on the surface portion of the uneven pattern.

In the present invention, the heavy portion refers to a portion of the semi-hardened lightweight cellular concrete plate which has been crushed by vibration to have a high specific gravity and becomes a heavy portion after curing.
A specific gravity of 1 cm @ 2 in an arbitrary portion of a lightweight cellular concrete board dried at 40 DEG C. and a humidity of 40% for 24 hours. The specific gravity is preferably 1.2 to 3 times, more preferably 1.6 to 2.5 times the specific gravity of the entire lightweight cellular concrete plate. The portion where the bubble portion remains without being crushed remains as a bubble even after curing. The displacement amount referred to in the present invention means that when a semi-cured lightweight cellular concrete plate is fixed and a design mold having an uneven pattern is brought into contact with the semi-cured lightweight cellular concrete plate to form a pattern by vibration, It refers to the penetration distance of the design die into the hardened lightweight cellular concrete plate.

A lightweight cellular concrete plate having a rib-shaped heavy portion on the surface can be obtained by arranging a design-type convex portion having irregularities in a rib shape. The rib shape here refers to a heavy portion having a continuous length in a lattice shape, a linear shape, and a curved shape.
The length of the heavy portion is not particularly limited, but the longer the longer, the greater the bending crack load. Therefore, the length of the rib-shaped heavy portion is preferably from 10 cm to the entire length of the lightweight cellular concrete plate. Further, the depth of the heavy portion is preferably 1 mm to half the plate thickness. If it is less than 1 mm, the effect of increasing the bending crack load is small, and if it is more than half of the sheet thickness, cracks tend to occur during molding.

The design type used in the present invention is not particularly limited as long as the material has a strength capable of transferring a pattern to a lightweight semi-cured cellular concrete plate. Examples thereof include urethane resin, epoxy resin, styrene resin plastic, and the like.
Steel, stainless steel, aluminum, titanium, or the like can be used. Hard urethane resin, epoxy resin, and metal are particularly preferable in terms of pattern accuracy and durability. The design type uneven pattern is not particularly limited, and for example, stone-like, brick-like, tile-like or the like is used.

In the production method of the present invention, first, a design mold having an uneven pattern is placed on or below a semi-cured lightweight cellular concrete plate, and the side surface is brought into close contact with the semi-cured lightweight cellular concrete plate and does not move. In this method, a semi-cured lightweight cellular concrete board or a design mold is vibrated, and a semi-cured lightweight cellular concrete board with a pattern is formed. Next, the obtained semi-cured lightweight cellular concrete board with the pattern is subjected to treatment such as autoclave steam curing, cured, and cooled to obtain a patterned lightweight cellular concrete board.

The depth of the pattern of the semi-cured lightweight cellular concrete plate is determined by the depth of the design pattern, for example, the depth of the uneven pattern. The depth of the uneven pattern is not particularly limited, but is preferably equal to or less than half the thickness of the lightweight cellular concrete plate. If the depth of the uneven pattern is larger than half of the board thickness,
Cracks may occur. The patterned lightweight cellular concrete board of the present invention can be used as a building material such as an outer wall material, a wall material, an interior wall material, or a ceiling material. The cement-based building material referred to in the present invention means a material containing 5% by weight or more of cement as a raw material. Since the manufacturing method of the present invention is a vibration molding in which vibration is applied to at least one of a semi-cured lightweight cellular concrete plate or the design mold by a vibrator, it is also possible to partially apply vibration, Large equipment such as a machine is not required, so that equipment costs can be reduced and manufacturing costs can be reduced.

In the manufacturing method of the present invention, the part of the semi-cured lightweight cellular concrete plate containing the bubbles deforms due to the vibration and the bubbles are crushed, and the crushed parts become heavy parts, and the crushed parts become heavy parts. By adjusting the shape, vibration amplitude, vibration frequency, or vibration time, a light-weight cellular concrete board with a pattern in which this heavy portion is disposed on the surface can be manufactured. The shape of the heavy portion is not particularly limited and may be partial or full, but a rib-shaped uneven pattern is preferable. With the rib-shaped uneven pattern, the bending crack load strength can be increased.

In the manufacturing method of the present invention, when a design mold having a rib-shaped uneven pattern is used, a lightweight cellular concrete with an uneven pattern in which a heavy portion is arranged in a rib shape on the surface of a semi-cured lightweight cellular concrete. You can get a board. One of the features of the present invention is that a heavy portion can be arranged in a rib shape on the surface portion, and that the flexural crack load strength of a lightweight cellular concrete plate with an uneven pattern can be increased. . It is considered that the heavy portion has a higher strength than the bubble portion because there are few bubbles, and the bending load of the patterned lightweight cellular concrete plate increases due to the contribution of the heavy portion. In addition, since the heavy part and the bubble part have almost the same composition, they have the same effect on environmental changes such as thermal expansion and water intrusion, and thus have the feature that cracks due to environmental changes are unlikely to occur. .

[0021]

DESCRIPTION OF THE PREFERRED EMBODIMENTS Hereinafter, the present invention will be described in detail with reference to embodiments. The measurement of physical properties is as follows. (1) Compressive strength Value measured according to JIS A 5416 (2) Bending crack load Value measured according to JIS A 5416

[0022]

Examples 1 to 3 70 parts by weight of water, 100 parts by weight of solids consisting of 53 parts by weight of silica, 7.5 parts by weight of quick lime, 37 parts by weight of cement, and 2.5 parts by weight of dry gypsum were used. The lightweight cellular concrete slurry containing 060 parts by weight was poured into a mold in which reinforcing steel was previously arranged, and after curing, a semi-cured lightweight cellular concrete block was obtained. Reinforcing bars are 5mm in diameter round steel 500mm
× 1750mm rectangular, further provided in the width direction, the length direction in each 5mm diameter round bar also provided at 125mm intervals, two nets formed in a grid-like welded cage-like at 25mm intervals used.

The obtained semi-cured lightweight cellular concrete block was cut with a piano wire to obtain a 75 × 600 × 1800 mm semi-cured lightweight cellular concrete plate in which reinforcing steel was disposed at the center. The obtained semi-cured lightweight cellular concrete board is placed in a constant temperature bath at 40 ° C., and the time for placing the semi-cured lightweight cellular concrete board is adjusted (Examples 1 to 3). I got Next, the side of the obtained semi-cured lightweight cellular concrete plate, which was pressed with a steel side mold so as to have no gap, was placed on a 600 × 1800 mm-size design mold having a concavo-convex pattern, and was semi-cured. A steel upper mold was placed on a lightweight lightweight cellular concrete plate, and all of them were placed on a vibration table of a vibrator as shown in FIG. Adjust so that the shaking table vibrates at an amplitude of 0.8 mm and a vibration cycle of 6000 cycles / minute,
Vibration was performed until the displacement amount became 10 mm. The design pattern with the concavo-convex pattern used was a flat plate having a thickness of 10 mm and a height of 10 m.
It is made of hard urethane, and is provided with five linear convex portions having a width of 10 mm, a width of 10 mm, and a taper of 1/2, and five in the width direction and 17 in the length direction at intervals of 100 mm in a lattice shape.

The semi-cured lightweight cellular concrete plate with irregularities is subjected to autoclaving steam curing at 180 ° C.
After cooling, a patterned lightweight cellular concrete plate was obtained. No defects or cracks were observed in the patterned lightweight cellular concrete plate. In addition, each had a lattice-shaped rib-like heavy portion. Table 1 shows the measurement results of the physical properties.

[0025]

Examples 4 to 6 Semi-hardened lightweight cellular concrete blocks produced by the same method as in Examples 1 to 3 were cut with a piano wire, and the same as Examples 1 to 3 in which a reinforcing steel bar was arranged at the center. 75 × 600 × 1800 mm of a semi-cured lightweight cellular concrete plate was obtained. The obtained semi-cured lightweight cellular concrete board is placed in a constant temperature bath at 40 ° C., and the time for placing the semi-cured lightweight cellular concrete board is adjusted. I got

Next, the vibration table was adjusted so as to vibrate at an amplitude of 0.1 mm and a vibration period of 3000 cycles / minute, and was vibrated until the displacement amount became 10 mm. The same design mold as in Example 1 was used as the design mold with a concavo-convex pattern. 0.8m amplitude
m, vibration was carried out until the displacement amount became 10 mm in the same manner as in Examples 1 to 3, except that the vibration was adjusted at a vibration cycle of 6000 cycles / minute. The semi-cured lightweight cellular concrete plate having irregularities was subjected to autoclaving at 180 ° C. in steam and cooled to obtain a patterned lightweight cellular concrete plate.
No defects or cracks were observed in the patterned lightweight cellular concrete plate, and all had a lattice-shaped rib-like heavy portion. Table 1 shows the measurement results of the physical properties.

[0027]

Examples 7 to 9 Semi-hardened lightweight cellular concrete blocks produced in the same manner as in Examples 1 to 3 were cut with a piano wire, and reinforcing steel was placed at the center.
A semi-cured lightweight cellular concrete plate of 75 × 600 × 1800 mm similar to that of No. 3 was obtained. The obtained semi-cured lightweight cellular concrete plate is placed in a constant temperature bath at 40 ° C., and the time for placing is adjusted to adjust the compressive strength.
9) Different semi-cured lightweight cellular concrete boards were obtained.

Next, the bottom surface and the side surfaces of the semi-cured lightweight cellular concrete plate are pressed and fixed with a steel mold so that there is no gap, and a 600 × 1800 mm design pattern with a concavo-convex pattern is placed thereon. And two portable vibrators were placed on the steel upper mold as shown in FIG. The design mold was adjusted by a portable vibrator so as to vibrate at an amplitude of 3 mm and a vibration cycle of 100 cycles / minute, and was vibrated until the displacement reached 10 mm. The same design pattern with a concavo-convex pattern as in Example 1 was used. The semi-cured lightweight cellular concrete plate having irregularities was subjected to autoclaving at 180 ° C. in steam and cooled to obtain a patterned lightweight cellular concrete plate. No defects or cracks were observed in the patterned lightweight cellular concrete plate, and all had a lattice-shaped rib-like heavy portion. Table 1 shows the measurement results of the physical properties.

[0029]

Comparative Examples 1 to 3 Semi-hardened lightweight cellular concrete blocks produced by the same method as in Examples 1 to 3 were cut with a piano wire, and reinforcing steel bars were arranged at the center.
A semi-cured lightweight cellular concrete plate of 75 × 600 × 1800 mm similar to that of No. 3 was obtained. The obtained semi-cured lightweight cellular concrete plate is placed in a constant temperature bath at 40 ° C., and the time for placing is adjusted to adjust the target compressive strength, and three types (Comparative Examples 1 to 3) have different compressive strengths. A semi-cured lightweight cellular concrete plate was obtained. .

The semi-cured lightweight cellular concrete board was subjected to autoclaving steam curing as in Examples 1 to 3 without any irregularities, and cooled to obtain an ordinary lightweight cellular concrete board. No defects or cracks were found in this ordinary lightweight cellular concrete plate. Table 1 shows the measurement results of the physical properties. Each of the patterned lightweight cellular concrete boards obtained in the examples had a higher bending crack load than the ordinary lightweight cellular concrete boards without the uneven pattern of Comparative Examples 1 to 3.

[0031]

[Table 1]

[0032]

According to the method for manufacturing a lightweight lightweight concrete board with a pattern of the present invention, a lightweight lightweight concrete board having a pattern formed by partially crushing the surface portion by vibration molding can be manufactured. It is possible to manufacture a lightweight lightweight cellular concrete board in which a heavy portion is arranged. The patterned lightweight cellular concrete board of the present invention has high strength,
Even with a rib-shaped uneven pattern, the resistance to bending cracking is large and the strength is high as compared with the conventional one.

[Brief description of the drawings]

FIG. 1 is a side view illustrating a manufacturing method for giving vibration by a shaking table.

FIG. 2 is a side view illustrating a manufacturing method of vibration molding by a portable vibrator.

[Explanation of Signs] 1 Top formwork 2 Semi-hardened lightweight cellular concrete plate 3 Side formwork 4 Design type 5 Vibration table 6 Vibrator drive unit 7 Portable vibrator 8 Portable vibrator vibrator 9 Bottom formwork

Claims (2)

[Claims] 1. A design mold is placed on a surface of a semi-cured lightweight cellular concrete board, and a pattern is given by applying vibration to at least one of the semi-cured lightweight cellular concrete board or the design mold. Lightweight cellular concrete board with pattern, characterized in that: 2. A method for producing a pattern by placing a design mold on a surface of a semi-cured lightweight cellular concrete plate,
A method for producing a patterned lightweight cellular concrete plate, characterized by applying vibration to at least one of the semi-cured lightweight cellular concrete plate or the design mold.