KR101216282B1 - Structure and process of manufacturing concrete - Google Patents

Abstract

PURPOSE: A manufacturing method of aerated concrete and a construction method thereof are provided to check mixing amount and installing amount through a monitoring system computer in real time. CONSTITUTION: A manufacturing method of aerated concrete comprises the following steps: checking the fixed quantity of the aerated concrete materials in a metering feeder of an automation casting device; agitating cement which is dry mix, calcium hydroxide and EPS bead (expanded polystyrene bead) in a dry hopper; agitating the dry mixture, water, binder, water reducing agent and foaming agent in a first wet mixing device; and re-mixing the first wet mixed mixture in a secondary wet mixer. The dry mixture comprises powder binder composed of 50-90 wt% of cement and 10-50 wt% of calcium hydroxide and 1-3 times of EPS beads based on the powder binder volume.

Description

Manufacturing method and construction method of foamed concrete mixture which can form floor structure only by foamed concrete layer {structure and process of manufacturing concrete}

The present invention relates to a method of manufacturing a single-layer foamed concrete mixture and a method of construction thereof that meet the floor impact sound insulation performance standards and KS F 4039 foaming concrete performance standards for site casting, and more specifically, it is generated between the floors of multi-story buildings. The present invention relates to a method for manufacturing a foamed concrete mixture which can provide a pleasant living environment by remarkably attenuating light weight and heavy impact sound, and can form a floor structure that is advantageous for saving fossil fuel when heating with excellent heat insulating performance.

The current multi-layer floor structure is provided with an interlayer floor impact sound barrier layer on the upper surface of the interlayer concrete slab. Bubble concrete is placed on it, and after heating for a certain period of time, a hot water pipe for heating is installed on the bubble concrete layer, and after spraying mortar is poured on it, a floor decorative layer such as floor covering, marble, and wood is finally constructed. do.

As described above, it is composed of a double-floor structure partitioned by an interlayer floor impact sound blocking layer installed for light weight and heavy sound blocking and a bubble concrete layer formed for thermal insulation between the layers. The double floor structure thus formed causes a lot of structural problems, and the foamed concrete mixture partitioning the insulating layer also causes many problems. More specifically, the following problems are caused.

first. If the water penetrates into the seam of the interlayer floor impact sound blocker during the construction of aerated concrete and finishing mortar layer, the water is accumulated on the upper surface of the interlayer concrete slab. The layer may partially rise and cause the finishing decorative layer to rise.

second. Pads of organic floor-type elastic materials are installed on the floor impact sound blocking layer between layers. When each layer is not tightly adhered to the floor, a shock overlaps through the vibration space when a shock is applied to the floor decoration layer. It can be cause.

third. Interlayer concrete slab-interlayer floor impact sound barrier layer-foam concrete layers are not tightly adhered to each other, which weakens the compressive strength and permissible tensile force of aerated concrete, causing displacement, cracking, and breakage due to the work load during subsequent processing of aerated concrete. . In addition, work loads are transferred to the entire foam concrete during subsequent processing, which may cause cracking of the foam concrete, and in some cases, even breakage.

fourth. When installing an interlayer bottom impact sound barrier layer using an organic type elastic pad, the removal of foreign substances on the upper surface of the slab to prevent deformation and breakage of the pad may cause an increase in construction date.

fifth. If the foamed concrete layer is constructed below the thickness specified for each part due to the non-uniform height difference of the concrete slab, the compressive strength and the permissible tensile force are attenuated, causing cracking and breakage of the foamed concrete during curing and subsequent process work. It can be cause.

Sixth. As the specific gravity of cement is 3 or more, foaming must be generated as shown in Table 1 below to meet specific gravity specifications of KS F 4039. Therefore, the volume increases in proportion to the foaming ratio. The increase of the volume due to the excessive foaming can cause the fragile physical structure of the foamed concrete mixture to reduce the compressive strength and the allowable tensile force, which can cause cracking and breakage of the foamed concrete. have.

Current bubble concrete foaming ratio (cement specific gravity approximately 3) division KS F 4039 Standard 0.3-0.4 (0.4 items) 0.4-0.5 (0.5 width) 0.5-0.6 (0.6 article) Firing rate About 900% About 700% About 570%

 Seventh. As described above, when a large amount of water is added in consideration of specific gravity, it is left as a surplus water except water for bonding and foaming required for hydration. When surplus water is generated, heavy substances are settled by gravity. It is possible to float light materials, to separate the material of aerated concrete mixture, and to attenuate the compressive strength-tolerable pull-insulation performance of aerated concrete. In addition, laitance is generated by surplus water, and when laitance occurs, settlement occurs due to changes in the bubble concrete cross section, and the size of the settlement becomes larger as the surface becomes larger. Through this process, the water film is generated at the bottom, and the tensile force is weakened on the surface, which may cause settlement and cracking.

Eighth. The vegetable foaming agent mainly used in the current foam concrete mixture has a weak surface tension, which can cause bubbles to be blown out due to the pouring pressure.In addition, if the phase equilibrium is not maintained between the bubbles, the bubbles may rise. It can cause the segregation and cohesion, which can lead to material separation of cement, which can reduce the compressive strength, permissible tensile strength, and thermal insulation performance of aerated concrete.

Ninth. Existing bubble concrete construction is made by combining the skill and experience of the builder, so that it is difficult to uniformize the quality of the bubble concrete, and the construction period is increased due to reconstruction due to the defect.

In order to solve the above-mentioned problems, there has been provided a technology for manufacturing light-weight foamed concrete mixtures having their own interlayer floor impact sound shielding performance by recycling waste lime, Patent No. 10-0943746, but the sharp price increase of perlite used as lightweight aggregate There are problems such as economic deterioration. Thus, there is an urgent need for an alternative to solve the above problems.

An object of the present invention is to provide a bubble concrete mixture manufacturing technology that can form a floor structure with only a single layer of bubble concrete layer. Still another object of the present invention is to provide an installation method that does not cause defects by establishing an automatic pouring system for securing the performance of aerated concrete mixture, standard mixing, and uniform mixing, and is also installed in an automated pouring system. It is possible to precise quantitative blending by checking the compounding amount and pouring amount in real time through a computer, and provides a construction method that is easy to control quality and process in the field.

Foamed concrete mixture manufacturing method that can form a floor structure only by the foamed concrete layer of the present invention, 50 to 90% by weight of cement, 10 to 50% by weight of slaked lime and EPS bead 1-3 times compared to the volume of the powder binder ; 40 to 80% by weight of water relative to the powder binder content; 1 to 5% by weight of the binder relative to the powder binder content; 1 to 5% by weight of the water reducing material relative to the powder binder content; Checking the quantity of each material consisting of 0.05 ~ 0.5% by weight of the foam binder relative to the content of the powder binder in the metering feeder installed in the automated placing equipment; Stirring the dry mixture of cement, slaked lime and EPS bead in a dry hopper; Simultaneously stirring the stirred dry mixture and water, a binder, a water reducing agent, and a blowing agent into a first wet mixer; It relates to a method for producing a bubble concrete mixture, consisting of the step of agitating the first wet stirred mixture again in a second wet mixer.

The present invention improves the problems caused in the conventional double-floor structure of the single-layer bubble concrete layer significantly reduced the light and heavy impact sound, and the automatic pouring system that was made by the conventional builder's skill and experience Construction standard formulation design is possible, and precise quantitative formulation is possible by real-time formulation amount and pour quantity confirmation through Monitoring System Computer installed in automatic pouring system, so that quality control and process control in the field is easy. In addition, the present invention omits the interlayer floor impact sound blocking layer, when the construction of 82.5㎡ APT 500 households with only a bubble concrete layer, the construction date is reduced by about 8 days and the thermal conductivity test according to KS L 9016 "Thermal Conductivity Test by Flat Plate Flow Meter Method" The result is 0.076 ~ 0.086 W / mK, which is about 2 times better than existing foam concrete 0.16 W / mK.

1 to 2 is a photograph showing the specimen of a single layer foam concrete.
3 to 5 are photographs showing a single layer bubble concrete cross section.
6 is a flow chart of an A type automated pouring system process.
7 is a flow chart of a B type automated pouring system process.
8 is a schematic view of an automated type pouring system of type A;
9 is a schematic view of a B type automated pouring system.
10 is a cross-sectional view showing a cross section of a conventional double bottom structure.
11 is a cross-sectional view showing a single layer bubble concrete floor structure of the present invention.

The present invention is a method for producing a foamed concrete mixture that can form a floor structure with only a single layer of aerated concrete layer, the bottom structure is dualized between the interlayer floor impact sound barrier layer and aerated concrete layer 50 ~ 90% by weight of cement, 10 ~ slaked lime Powdered binder made of 50% by weight and EPS bead (Expanded polystyrene bead) 1-3 times the volume of the powder binder; 40 to 80% by weight of water relative to the powder binder content; 1 to 5% by weight of the binder relative to the powder binder content; 1 to 5% by weight of the water reducing material relative to the powder binder content; Consists of 0.05 ~ 0.5% by weight of the foam material relative to the powder binder content, the EPS bead is made of any one selected from waste EPS bead, general EPS bead and EPS bead containing graphite, each material is installed in the automatic pouring equipment Checking the quantity in the metered feeder; Stirring the dry mixture of cement, slaked lime and EPS bead in a dry hopper; Simultaneously stirring the stirred dry mixture, water, a binder, a water reducing agent, and a blowing agent into a first wet mixer; And it relates to a method for producing a foamed concrete mixture that can form the bottom structure only by the foamed concrete layer consisting of the step of stirring the primary wet stirred mixture again in the secondary wet mixer.

The present invention is the first, second, in the construction method of the foamed concrete mixture used in the construction of the floor structure to make the floor structure which is dualized between the interlayer floor impact sound barrier layer and the foamed concrete layer only a single layer of foamed concrete layer Storing 50 to 90% by weight of cement, 10 to 50% by weight of slaked lime, and 1 to 3 times of EPS bead compared to a powder binder composed of cement and slaked lime in the third silo; Quantitatively checking each material with a quantitative feeder installed in a silo and transporting the dry hopper to a dry hopper using a screw conveyor; The dry mixed mixture is transferred to a primary wet mixer using a powder conveying screw conveyor, and 40 to 80 wt% of water relative to the powder binder content, 1 to 5 wt% of the binder relative to the powder binder content, and reduced by the powder binder content. 1 to 5% by weight of the ash, 0.05 to 0.5% by weight of the foam compared to the content of the binder binder in the quantitative feeder check the quantitatively mixed with the dry mixture at the same time the first wet mixer, the first wet stirring step by the standard blending ratio; And the standard blended wet mixture is transferred to a second wet mixer in a hydraulic pouring machine using a screw conveyor, followed by secondary wet agitation, and then pouring. In this case, each process is automatically controlled by a controller and pouring It relates to the construction method of aerated concrete mixture, characterized in that the compounding amount and the amount of pouring is confirmed in real time through a monitoring system computer installed in the automatic pouring system during construction.

The present invention is 50 ~ 90% by weight of cement, slaked lime in the construction method of the foamed concrete mixture used in the construction of the flooring structure consisting of a single layer of aerated concrete layer of the floor structure, which is dualized between the interlayer floor impact sound barrier layer and the foamed concrete layer 10 to 50% by weight of the powder binder and the mixture consisting of 1 to 3 times the EPS bead compared to the powder binder and the land-packaging the mixture directly into the dry hopper installed in the automatic pour equipment dry mixing step; The dry mixed powder binder is transferred to a primary wet mixer using a powder conveying screw conveyor, and then 40 to 80% by weight of water relative to the powder binder content, 1 to 5% by weight of binder relative to the powder binder content, and compared to the powder binder content. 1 to 5% by weight of the water-reducing material, 0.05 to 0.5% by weight of the foam compared to the content of the powder binder in the quantitative feeder check the quantitatively mixed with the dry mixture at the same time the first wet mixer step by the standard blending ratio; And the standard blended wet mixture is transferred to a second wet mixer in a hydraulic pouring machine using a screw conveyor, followed by secondary wet agitation, and then pouring. In this case, each process is automatically controlled by a controller and pouring It relates to the construction method of aerated concrete mixture, characterized in that the compounding amount and the amount of pouring is confirmed in real time through a monitoring system computer installed in the automatic pouring system during construction.

Foamed concrete mixture of the present invention the ion on the alkaline earth metal and other colloids contained in the binder composed mainly of calcium hydroxide of (Ca ^{2 +)} and the reaction facilitate hydration and other substitution reaction of the cement, and pozzolanic reaction and geo-polymer reaction Efficiently progressed allowable tensile strength and compressive strength.

Slaked lime component analysis table division CaO Ca (OH) ₂ SiO ₂ MgO Fe ₂ O ₃ Al ₂ O ₃ S 1g-Loss % 71.32 - 1.40 2.15 0.25 0.26 - -

 In addition, the remaining water is left in excess of the water required for the hydration and the water required for foaming. When excess water is generated, the heavy material is settled due to the specific gravity difference, and the light material is floated to raise the material of the foamed concrete mixture. It causes separation, increases unit volume weight and attenuates compressive strength-durability-watertight-insulation performance. In the present invention, derivation of the stoichiometric optimal compounding ratio between cement, calcined lime, binder, foaming material does not generate excess water, unit volume weight-compressive strength-durability-watertightness-insulation performance is improved.

In the foam used in the present invention, the surface tension of the foam was improved by maintaining the interface between the binder and the foaming agent by using a foaming agent having a different interface from the binder, and the survival rate of the foam was maintained until curing.

In addition, as the binder reacts with the carbon compound (Co ₂ ) in the air, a pressure difference occurs in the foamed concrete mixture, and the phase equilibrium difference between the water and the carbon compound causes the foam to maintain the phase equilibrium. Foam surrounding the slaked lime-EPS bead prevents sedimentation of cement and slaked lime and prevents the rise of EPS bead Cement, slaked lime and EPS bead have a uniform distribution of upper, middle and lower Strength-durability-watertightness-insulation performance was improved.

  In the present invention, the floor structure is formed only by the single-layer bubble concrete layer, and problems such as the partial swelling of the interlayer bottom layer due to water deformation and crack-crack-breakage, which occurred in the conventional double bottom structure described above, do not occur. Turned out to be.

And in the construction method thereof, it is possible to build an automated pouring system to ensure the performance of the standard mixing, and to mix the foam concrete mixture composed of the primary dry mixer and the primary and secondary wet mixer uniformly, due to the lack of mixing No defects are generated due to the aggregation of bubble groups, and precise quantitative formulation is possible through real-time confirmation of compounding amount and pouring amount through Monitoring System Computer installed in automated pouring system, which makes quality control and process control easy in the field. In addition, the omission of the interlayer floor impact sound barrier layer has been shown to simplify the construction process and shorten the construction date.

EXAMPLES A blending example of a single layer foam concrete mixture is as follows.

Example 1 (waste EPS bead mix formulation ratio) division Powder binder Lung EPS bead
2.2 times the volume of the powder binder water Mixed material cement Lime lime bookbinder Supervision Foam weight (%) 63% 37% 53% 2.1% 2.2% 0.155% Example 519 305 1928 ml 437 17.3 18 1.28

Example 2 (General EPS bead Mixing Ratio) division Powder binder General EPS bead
2 times the volume of powder binder water Mixed material cement Lime lime bookbinder Supervision Foam weight (%) 63% 37% 50% 1.9% 2% 0.15% Example 519 305 1,752 ml 412 15.7 16 1.24

Example 3 (graphite-containing EPS bead mixing ratio) division Powder binder Graphite containing EPS bead
2 times the volume of powder binder water Mixed material cement Lime lime bookbinder Supervision Foam weight (%) 63% 37% 50% 2.2% 2.3% 0.16% Example 519 305 1,752 ml 412 18.1 19 1.32

Insulation Performance of Single Layer Foamed Concrete Mixtures division Based on KS F 4039 Test result Apparent specific gravity Thermal conductivity (W / mK) Apparent specific gravity Thermal conductivity (W / mK) Example 1 0.4-0.5 0.160 or less 0.38 0.086 Example 2 0.35 0.081 Example 3 0.36 0.076

Performance of Single Layer Bubble Concrete Mixtures division Test result Slurry specific gravity Flow value (mm) Settling depth (mm) Apparent weight Compressive Strength (7/28 MPs) Length change rate Example 1 0.47 183 One 0.38 6.9 / 1.35 0.02 Example 2 0.42 185 One 0.35 8.1 / 1.59 0.01 Example 3 0.45 182 One 0.36 7.5 / 1.51 0.01

Single layer bubble concrete mixture floor impact sound performance division Experiment result Structural Accreditation and Management Standard for Floor Shock Sound in Apartment House Lightweight sound (dB) Heavy weight (dB) Rating Lightweight Heavy sound Example 1 44 42 1st grade L ' _nAW 43 L'i, Fmax, _AW 40 Example 2 43 40 2nd class 43 <L ' _nAW 48 40 <L'i, Fmax, _AW 43 Example 3 41 39 Level 3 48 <L ' _nAW 53 43 <L'i, Fmax, _AW 47

As described above, in the multi-layered floor structure, only the single-layer bubble concrete layer has been improved, and problems occurring in the conventional double-floor structure have been improved, and it has been shown to significantly reduce the light weight and the heavy impact sound.

In addition, in the construction method, the formulation was made according to the proficiency and experience of the prior art, in the present invention, it is possible to build a standard formulation design of the automatic pouring system, and in real time through a monitoring system computer installed in the automatic pouring system Precise quantitative formulation was possible by checking the amount of compounding and pouring, and it was shown that quality control and process control in the field were easy.

In this construction method, when the interlayer floor impact sound shielding layer was omitted, and the generation of 82.5m2 APT 500 households with only the bubble concrete layer, the construction date was reduced by about 8 days. In addition, the results of thermal conductivity test according to KS L 9016 "Thermal conductivity test by plate flow meter method" showed 0.076 ~ 0.086 W / mK, which is about 2 times better than existing foam concrete 0.16 W / mK.

10: air bubble concrete layer
100: bottom layer 200: side wall layer
300: sound insulation layer 400: side sound insulation layer
500: upper concrete layer 600: hot water pipe for heating

Claims (3)

In the manufacturing method of the foamed concrete mixture which can form the floor structure with only a single layer of aerated concrete layer, the floor structure which is dualized between the interlayer floor impact sound blocking layer and the bubble concrete layer,
Powder binder composed of 50 to 90% by weight of cement and 10 to 50% by weight of slaked lime,
And 1-3 times the volume of the powder binder material (Expanded polystyrene bead: EPS bead);
40 to 80% by weight of water relative to the powder binder content;
1 to 5% by weight of the binder relative to the powder binder content;
1 to 5% by weight of the water reducing material relative to the powder binder content;
Consists of 0.05 ~ 0.5% by weight of the foam compared to the powder binder content,
The EP bead (EPS bead) is a material consisting of any one selected from lung EPS bead (EPS bead), general EP bead (EPS bead) and graphite containing (EPS bead) to the automatic pouring equipment. Checking the quantity in the metering device installed;
Stirring the cement, the hydrated lime, and the EP bead in a dry hopper;
Simultaneously stirring and stirring the stirred dry mixture, the water, the binder, the water reducing material, and the foaming material into a first wet mixer; And
A method for producing a foamed concrete mixture which can form a floor structure with only a foamed concrete layer consisting of the step of stirring the first wet stirred mixture again in a second wet mixer.
In the construction method of the foamed concrete mixture used for the construction of the floor structure of the floor structure which is dualized between the interlayer floor impact sound barrier layer and the foamed concrete layer with only a single layer of foamed concrete layer, the construction method is
A powder binder composed of 50 to 90% by weight of cement and 10 to 50% by weight of slaked lime in the first, second and third silos,
Storing 1 to 3 times of EP beads (EPS bead) relative to the volume of the powder binder;
Quantitatively checking each material with a quantitative feeder installed in the first, second and third silos, and then dry mixing and conveying them to a dry hopper using a screw conveyor;
The dry mixed mixture is transferred to a primary wet mixer using a powder conveying screw conveyor,
40 to 80% by weight of water compared to the powder binder content,
1 to 5% by weight of the binder relative to the powder binder content,
1 to 5% by weight of the water reducing material relative to the powder binder content,
0.05 ~ 0.5% by weight of the foam compared to the content of the binder binder in the quantitative feeder check the quantitatively mixed with the dry mixture at the same time the first wet mixer, the first wet stirring step by the standard blending ratio; And
The standard blended wet mixture is transferred to a second wet mixer in a hydraulic pourer using a screw conveyor, followed by a second wet agitation, followed by pouring. Each process is automatically controlled by a controller. Method for constructing a foamed concrete mixture, characterized in that the compounding amount and the pouring amount is confirmed in real time through a monitoring system computer installed in the automatic pouring system during construction.
In the construction method of the foamed concrete mixture used for the construction of the floor structure of the floor structure which is dualized between the interlayer floor impact sound barrier layer and the foamed concrete layer with only a single layer of foamed concrete layer, the construction method is
Powder binder composed of 50 to 90% by weight of cement and 10 to 50% by weight of slaked lime,
Packing the mixture consisting of 1 to 3 times the volume of the EPS binder (EPS bead) to the volume of the powder binder, and then mixing the ground packaged mixture directly with a dry hopper installed in an automatic pouring equipment;
The dry mixed mixture is transferred to a primary wet mixer using a powder conveying screw conveyor.
40 to 80% by weight of water compared to the powder binder content,
1 to 5% by weight of the binder relative to the powder binder content,
1 to 5% by weight of the water reducing material relative to the powder binder content,
0.05 ~ 0.5% by weight of the foam compared to the amount of the binder binder in the quantitative feeder by checking the quantitative feeder and the first wet blending step by the standard blending ratio at the same time into the first wet mixer; And
The standard blended wet mixture is transferred to a second wet mixer in a hydraulic pourer using a screw conveyor, followed by a second wet agitation, followed by pouring. Each process is automatically controlled by a controller. Method for constructing a foamed concrete mixture, characterized in that the compounding amount and the pouring amount is confirmed in real time through a monitoring system computer installed in the automatic pouring system during construction.

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