GB2255116A - Sound-insulating concrete wall. - Google Patents
Sound-insulating concrete wall. Download PDFInfo
- Publication number
- GB2255116A GB2255116A GB9208628A GB9208628A GB2255116A GB 2255116 A GB2255116 A GB 2255116A GB 9208628 A GB9208628 A GB 9208628A GB 9208628 A GB9208628 A GB 9208628A GB 2255116 A GB2255116 A GB 2255116A
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- United Kingdom
- Prior art keywords
- concrete
- concrete panel
- formed body
- ribs
- concrete material
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
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- 239000004567 concrete Substances 0.000 title claims abstract description 192
- 239000000463 material Substances 0.000 claims abstract description 67
- 238000003825 pressing Methods 0.000 claims abstract description 38
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims abstract description 36
- 239000003818 cinder Substances 0.000 claims abstract description 27
- 239000002270 dispersing agent Substances 0.000 claims abstract description 22
- 239000004568 cement Substances 0.000 claims abstract description 14
- 239000010881 fly ash Substances 0.000 claims abstract description 8
- 239000012783 reinforcing fiber Substances 0.000 claims abstract description 6
- 238000004519 manufacturing process Methods 0.000 claims description 42
- 230000003014 reinforcing effect Effects 0.000 claims description 16
- 238000009413 insulation Methods 0.000 claims description 14
- 239000000835 fiber Substances 0.000 claims description 12
- 229910001294 Reinforcing steel Inorganic materials 0.000 claims description 7
- 230000018044 dehydration Effects 0.000 claims description 7
- 238000006297 dehydration reaction Methods 0.000 claims description 7
- 230000035699 permeability Effects 0.000 abstract 1
- 239000004576 sand Substances 0.000 description 23
- 238000001723 curing Methods 0.000 description 17
- 230000000694 effects Effects 0.000 description 11
- 229920002978 Vinylon Polymers 0.000 description 7
- 238000000034 method Methods 0.000 description 7
- 238000010521 absorption reaction Methods 0.000 description 6
- 239000002184 metal Substances 0.000 description 6
- 238000010276 construction Methods 0.000 description 4
- 239000011398 Portland cement Substances 0.000 description 3
- 238000004140 cleaning Methods 0.000 description 3
- 239000000203 mixture Substances 0.000 description 3
- 229910000831 Steel Inorganic materials 0.000 description 2
- 238000005452 bending Methods 0.000 description 2
- 230000005540 biological transmission Effects 0.000 description 2
- 238000004080 punching Methods 0.000 description 2
- 239000010959 steel Substances 0.000 description 2
- UFWIBTONFRDIAS-UHFFFAOYSA-N Naphthalene Chemical compound C1=CC=CC2=CC=CC=C21 UFWIBTONFRDIAS-UHFFFAOYSA-N 0.000 description 1
- 239000004743 Polypropylene Substances 0.000 description 1
- 230000015572 biosynthetic process Effects 0.000 description 1
- 239000011400 blast furnace cement Substances 0.000 description 1
- 239000000919 ceramic Substances 0.000 description 1
- 230000003247 decreasing effect Effects 0.000 description 1
- 239000003365 glass fiber Substances 0.000 description 1
- 239000008187 granular material Substances 0.000 description 1
- 239000004570 mortar (masonry) Substances 0.000 description 1
- 238000005192 partition Methods 0.000 description 1
- -1 polypropylene Polymers 0.000 description 1
- 229920001155 polypropylene Polymers 0.000 description 1
- 239000011150 reinforced concrete Substances 0.000 description 1
- 238000003860 storage Methods 0.000 description 1
- 229920003002 synthetic resin Polymers 0.000 description 1
- 239000000057 synthetic resin Substances 0.000 description 1
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B28—WORKING CEMENT, CLAY, OR STONE
- B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
- B28B7/00—Moulds; Cores; Mandrels
- B28B7/36—Linings or coatings, e.g. removable, absorbent linings, permanent anti-stick coatings; Linings becoming a non-permanent layer of the moulded article
- B28B7/368—Absorbent linings
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B28—WORKING CEMENT, CLAY, OR STONE
- B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
- B28B13/00—Feeding the unshaped material to moulds or apparatus for producing shaped articles; Discharging shaped articles from such moulds or apparatus
- B28B13/04—Discharging the shaped articles
- B28B13/06—Removing the shaped articles from moulds
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B28—WORKING CEMENT, CLAY, OR STONE
- B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
- B28B3/00—Producing shaped articles from the material by using presses; Presses specially adapted therefor
- B28B3/02—Producing shaped articles from the material by using presses; Presses specially adapted therefor wherein a ram exerts pressure on the material in a moulding space; Ram heads of special form
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B28—WORKING CEMENT, CLAY, OR STONE
- B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
- B28B7/00—Moulds; Cores; Mandrels
- B28B7/0064—Moulds characterised by special surfaces for producing a desired surface of a moulded article, e.g. profiled or polished moulding surfaces
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B28—WORKING CEMENT, CLAY, OR STONE
- B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
- B28B7/00—Moulds; Cores; Mandrels
- B28B7/40—Moulds; Cores; Mandrels characterised by means for modifying the properties of the moulding material
- B28B7/46—Moulds; Cores; Mandrels characterised by means for modifying the properties of the moulding material for humidifying or dehumidifying
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B28/00—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements
- C04B28/02—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements containing hydraulic cements other than calcium sulfates
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B28/00—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements
- C04B28/02—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements containing hydraulic cements other than calcium sulfates
- C04B28/04—Portland cements
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
- E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
- E04B1/62—Insulation or other protection; Elements or use of specified material therefor
- E04B1/74—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls
- E04B1/82—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls specifically with respect to sound only
- E04B1/84—Sound-absorbing elements
- E04B1/86—Sound-absorbing elements slab-shaped
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
- C04B2111/52—Sound-insulating materials
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
- E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
- E04B1/62—Insulation or other protection; Elements or use of specified material therefor
- E04B1/74—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls
- E04B1/82—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls specifically with respect to sound only
- E04B1/84—Sound-absorbing elements
- E04B2001/8423—Tray or frame type panels or blocks, with or without acoustical filling
- E04B2001/8442—Tray type elements
- E04B2001/8447—Tray type elements with two facing trays
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02W—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO WASTEWATER TREATMENT OR WASTE MANAGEMENT
- Y02W30/00—Technologies for solid waste management
- Y02W30/50—Reuse, recycling or recovery technologies
- Y02W30/91—Use of waste materials as fillers for mortars or concrete
Landscapes
- Engineering & Computer Science (AREA)
- Chemical & Material Sciences (AREA)
- Ceramic Engineering (AREA)
- Mechanical Engineering (AREA)
- Manufacturing & Machinery (AREA)
- Physics & Mathematics (AREA)
- Acoustics & Sound (AREA)
- Structural Engineering (AREA)
- Inorganic Chemistry (AREA)
- Chemical Kinetics & Catalysis (AREA)
- Architecture (AREA)
- Materials Engineering (AREA)
- Organic Chemistry (AREA)
- Civil Engineering (AREA)
- Electromagnetism (AREA)
- Press-Shaping Or Shaping Using Conveyers (AREA)
- Manufacturing Of Tubular Articles Or Embedded Moulded Articles (AREA)
Abstract
A concrete panel (605) according to the present invention is obtained by removing a concrete material into a form, pressing the concrete material to form a formed body having an uneven surface, and putting the formed body out of the form. The concrete material for the concrete panel comprises a cement, a fine aggregate, a dispersing agent, reinforcing fibers, and water. The amount of water included in the mixing concrete material is previously reduced by the dispersing agent. The fine aggregate comprises a component consisting of cinder or fly-ash, each of which have a high water permeability ratio and enables the formed body to be compacted so that the formed body can retain its shape even if the formed body is removed from the form quickly after the pressure step. <IMAGE>
Description
CONCRETE PANEL AND METHOD OF MANUFACTURE THEREFOR
BACKGROUND OF THE INVENTION
Field of the Invention
The present invention relates to a concrete panel used as a partition wall in a construction made of concrete, an external wall of building, or an ordinary fence or wall.
In particular, the present invention relates to a concrete panel which is effective for use as a sound insulation wall. Furthermore, the present invention relates to a method of manufacturing a concrete panel, which is effective to manufacture a concrete panel having a thin, uneven and complicated shape.
Related Art
Generally, a cast-in-place concrete wall, or a sound insulation wall comprising two sets of comparatively thin concrete panels provided with a hollowness of some width therebetween, is known for a wall body for a construction made of concrete.
When the thickness of the wall body is increased so as to increase the transmission loss (TL) thereof, a trough portion, which has a TL value less than the theoretical value shown in the massive side, may occur. It is believed that the occurrence of the trough portion is caused by a resonance phenomenon in which the wavelength of a sound obliquely incident upon the wall surface is coincident with the wavelength of a bending vibration of the plate caused by the sound. Such a phenomenon is called the coincidence effect.
The applicant has proposed a sound insulation concrete panel and a sound insulation wall, as described in Japanese
Application No. (Tokugan-Hei) 1-50356 for the purpose of providing a concrete panel which can lower such a coincidence effect in principle and has a light weight and a high strength.
The concrete panel 100 is reinforced by a plurality of reinforcing ribs 101 ..., as shown in FIGS. 1 and 2. A plurality of parallel vibration suppressing ribs 102 are formed on one surface of the concrete panel 100 and are spaced apart from each other at a predetermined distance.
A plurality of reinforcing ribs 101 ... are formed on the surface of the panel 100 so that each of the reinforcing ribs 101 ... is laid across each of the thin portions 103 provided between the parallel vibration suppressing ribs 102. As shown in FIG. 2, each of the shortest distances B between the top portions of the adjacent reinforcing ribs 101 ... is set to value less than the 1/4 wavelength C of the wavelength corresponding to the critical frequency of the coincidence effect. Each of the longest distances D between the edges of the top portions of the adjacent ribs 101 ... is set to have a value larger than the 1/4 wavelength of the wavelength corresponding to the critical frequency of the coincidence effect. The 1/4 wavelength of the wavelength corresponding to the critical frequency of the coincidence effect may be replaced by 1/8 or 1/12 wavelength thereof.
Furthermore, the sound insulation wall comprises two sets of wall bodies 104 and 104 each of which is constructed by connecting a plurality of the concrete panels A, as shown in FIG. 3. The wall bodies 104 and 104 are provided in parallel apart from each other at a predetermined distance, including a gap portion 105 therebetween. The sound insulation wall is characterized in that a plurality of connecting ribs 106 ..., which project in the same direction as that of the vibration suppressing ribs 102 ..., are provided on both end portions of each concrete panel 100, and concrete panels A are connected to adjacent panels by connections of connecting ribs 106 and 106 on both end portions thereof, when the connection ribs are directed to the gap portion 105.
In such a construction, when a sound wave in the coincidence range is incident upon the concrete panel 100, both the crest and the node of the bending wave travelling inside the concrete panel 100 are simultaneously suppressed by each of the vibration suppressing ribs 102
Consequently, a lowering of the transmission loss due to the coincidence effect is suppressed to improve the second insulation efficiency.
The sound insulation concrete panel has a width of 450 mm and a standard length of 2,700 mm. The concrete panel has the thinnest portions with a thickness of 15 mm, and has ribs in a lattice shape with a height of 25 mm and a width of 30 mm to 50 mm. Generally, such a concrete panel with a thin, long, uneven and complicated shape has been made by a pouring and steam-curing method, so that the manufacturing method thereof is time-consuming.
A form used for formation of a concrete panel or the like is relatively expensive. In particular, manufacturing the concrete panel is time-consuming, since the panel has a complicated shape.
The pouring and steam-curing method requires a form for manufacturing a concrete panel over a long curing period. Therefore, the method has a problem of requiring many forms and high facility costs so as to manufacture many concrete panels in a short time to increase production efficiency.
SUMMARY OF THE INVENTION
In view of the above circumstances, the applicants have invented a method of manufacturing a concrete panel comprising the steps of putting a concrete material into a form, pressing the concrete material to make a formed body, putting the formed body out of the form by reversing the form, pushing the formed body out of the form quickly after pressing, and returning the form to the step of putting concrete material into the form; this is done instead of the conventional pouring and steam-curing method.
Accordingly, it is possible to manufacture the concrete panel in short time, and to reduce the number of forms necessary.
However, in order to reduce the necessary number of forms by the above-mentioned method, it is necessary to prepare a concrete material which is easily compressed in the form compactly through a pressure forming and which becomes hard so that the formed body hardly gets out of shape by pressing in a short time.
The present invention was developed in view of the above circumstances.
An object of the present invention is to provide a concrete panel which can be manufactured by being removed the form quickly after pressing for a short time.
Another object of the present invention is to provide a method of manufacturing a concrete panel which enables manufacturing in a short time without many forms, so that the concrete panels may be manufactured continuously.
In order to achieve the above object of the present invention, there is provided a concrete panel obtained by putting a concrete material into a form, pressing the concrete material to form a formed body having an uneven surface, and putting the formed body out of the form, wherein the concrete material comprises a cement, a fine aggregate, a dispersing agent, reinforcing fibers, and water; and the fine aggregate comprises a component selected from the group consisting of cinder and fly-ash.
Since a dispersing agent is included in the concrete material, it is possible to reduce the amount of water for mixing concrete material. The fine aggregate comprises a component selected the group consisting of cinder and flyash which enables the formed body to be tightened compactly in the form and to have a high water absorption ratio.
Therefore, it is possible to compact the mixed concrete material in the form in a short time.
Furthermore, the concrete panel is characterized in that the concrete material has a rectangular plate shape and connecting ribs, which project to one side, provided on both ends of the concrete panel, the concrete panel being a component of a wall which comprises a plurality of the concrete panels connected to each other through the connecting ribs, in which a reinforcing steel wire is embedded inside each of the connecting ribs in the longitudinal direction thereof.
In this way, a wall body can be constructed by arranging concrete panels made of the above-mentioned concrete material. When connecting ribs for connecting adjacent concrete panels to each other are provided on the concrete panel, embedding reinforcing steel wires inside the connecting ribs can reinforce the concrete panel easily.
The concrete panel is characterized in that the concrete material is formed in a rectangular plate shape, a plurality of parallel vibration suppressing ribs are formed at predetermined intervals on the one side of the concrete panel, and a plurality of parallel reinforcing ribs are formed on the side so that each reinforcing ribs is laid across each of the thin portions between the parallel vibration suppressing ribs.
In this way, forming a vibration suppressing rib and a reinforcing rib on a surface of the concrete panel, which is made of the above-mentioned concrete material, enables easily forming a panel with a high sound insulation characteristic by similar steps to that of the aforementioned concrete panel.
The method of manufacturing a concrete panel comprises the steps of, putting a mixed and kneaded concrete material into a form, pressing the concrete material using a pressing plate through an upper opening of the form to make a formed body, removing the formed body from the form by reversing the form, and curing the formed body; wherein the concrete material includes a dispersing agent; a water permeable portion is provided at a pressing surface of the pressing plate to allow water to drain out from the form, which was produced by dehydration from the formed body, the step of putting the formed body out of the form is carried out soon after the step of pressing; and the step of curing the formed body is carried out after the step of putting the formed body out of the form.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a front view showing the shape of a concrete panel.
FIG. 2 is a sectional view showing a horizontal section of the above-mentioned concrete panel.
FIG. 3 is a sectional view showing a sound insulation wall formed by using the above-mentioned concrete panel.
FIG. 4 is a perspective and fragmentary sectional view showing the sound insulation wall.
FIG. 5 is a flow chart showing the steps of manufacturing the concrete panel.
FIG. 6 is a schematic view showing the steps of manufacturing the concrete panel.
FIG. 7 is a sectional view showing the concrete panel having reinforcing steel wires embedded inside connecting ribs.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
An embodiment of the present invention will be explained according to FIGS. 4-7.
FIGS. 4-7 show a method of manufacturing a sound insulation wall comprising the concrete panels A, or of manufacturing the concrete panel 100. The concrete panel 100 according to the present embodiment is similar to the aforementioned concrete panel 100. Therefore, like reference numerals designate like elements having similar function and the explanations thereof will not be repeated hereunder.
The sound insulation wall is constructed by plural connected concrete panels A, each of which has a rectangular shape, as shown in FIG. 4. On both end portions of the concrete panel 100, connecting ribs 106, which project to one side, are formed. A plurality of parallel vibration suppressing ribs 102 extending to the upper and lower direction and a plurality of parallel reinforcing ribs 101 extending to the right and left directions are provided at predetermined intervals respectively on the one side of the concrete panel 100.
These ribs 101 and 102 cross at right angles to form a lattice.
In the concrete panel 100, the vibration suppressing ribs 102 ... are provided at intervals similar to that defined in the aforementioned prior art. The reinforcing ribs 101 and 101 are provided at intervals similar to that of the vibration suppressing ribs 102 and 102.
Two walls 104 and 104, each of which comprises a plurality of connected concrete panels 100, are provided in parallel at a predetermined interval. The upper and lower ends of each concrete panel 100 are attached to steel liners 402 which are provided on the surface of a ceiling 400 and on the surface of a floor 401 respectively. A heat insulating fiber member 403 is provided in a gap portion 105 between the two walls 104 and 104. The end portions in right and left directions of the adjacent concrete panels 100 are connected by the connecting ribs 106. The ribs 106 on one wall 104 are arranged alternately with the ribs 106 on the other wall 104 facing the one wall 104. Each of these ribs 106 is projected to the gap portion 105.
The concrete material for forming such a concrete panel comprises a cement, a fine aggregate, a dispersing agent, reinforcing fibers, and water, as shown in FIG. 5.
The cement may be a normal Portland cement, a highearly-strength Portland cement, or an A-type of Portland blast furnace cement. In this embodiment, a normal
Portland cement was used.
A granulated cinder sand with a diameter of 0.15 mm to 2.5 mm was used as the fine aggregate.
A high efficiency dispersing agent (e.g., MIGHTY 150 made by Kao Corporation) having a dispersing ratio higher than that of an ordinary dispersing agent was used as the dispersing agent.
Synthetic resin fibers such as vinylon fibers, polypropylene fibers, glass fibers, ceramic fibers or the like can be used as the reinforcing fibers. In the embodiment, vinylon fibers (by Kuraray Co., Ltd.) having a length of 8 mm to 16 mm and a thickness of 300 denier to 400 denier were used.
An admixture for expediting the removal of a formed body out of a form immediately (e.g., BLOCASTER-F made by
Kao Corporation) may be added.
The concrete material comprises 100 weight parts of cement, 80-150 weight parts of cinder sand, 0.5-2.0 weight parts of high efficiency dispersing agent, 30-33 weight parts of water, and 1.7-5.1 weight parts of vinylon fibers.
In the embodiment, a mixed concrete material was used. The concrete material comprises 251 kg/m3 of water, 761 kg/m3 of cement, 913 kg/m3 of cinder sand, 19.5 kg/m3 of vinylon fibers, and 4.6 kg/m3 of high efficiency dispersing agent.
The high efficiency dispersing agent is used for decreasing the mix proportion of water in the concrete material 600 so that the formed body can be removed the form quickly after the pressing step to reduce the pressing time. Accordingly, the necessary minimum amount of water can be added to the concrete material when the material is mixed and kneaded. The amount of water from the dehydration of the concrete material is reduced so that the formed body retains its shape when the formed body is removed from the form quickly after the pressing step.
Therefore, it is possible to reduce the pressing time.
If the mix proportion of the high efficiency dispersing agent is much more than 2.0 weight parts to a 100 weight parts of cement, the components may separate from each other, Less than 0.5 weight parts of dispersing agent is insufficient to be effective. To keep the mix proportion of water between 30 to 33 weight parts to 100 weight parts of cement can decrease the pressing time.
The vinylon fibers are added as reinforcing members for increasing the strength of the concrete panel.
Addition of vinylon fibers of more than 5.1 weight parts is ineffective in producing a greater effect, and the addition of less than 1.7 weight parts is ineffective in increasing the strength of the concrete panel.
Since cinders or the like which are fine aggregates have a high ratio of water absorption, it has not generally been often used as an aggregate for mortar or cement generally. However, it is necessary to remove the formed body out of the form quickly after pressure forming and to use the form for another forming as soon as possible. In the present invention, the cinder sand having a high ratio of water absorption is effective to compact the concrete material to the form and to decrease the amount of excessive water in the cement of the formed body after the pressure step. Addition of the cinder sand of more than 150 weight parts or less than 80 weight parts to 100 weight parts of cement, is not satisfactory.
A method of manufacturing a concrete panel using such a concrete material will be explained as follows.
As shown in FIGS. 5 and 6 schematically, cement, cinder sand, vinylon fibers, water, and a high efficiency dispersing agent, which are components of the concrete material 600, are respectively measured, and are mixed ard kneaded together by a mixer (step 501).
Next, the mixed concrete material 600 is put into a form 601. The form 601 has a bottom with an uneven surface corresponding to the shape of the concrete panel 100, and side walls 602 which are provided at the side edges of a bottom plate 603 so that the side walls can be rotated toward the outside extending around the side edges. The upper side of the form is open. The bottom surface 604 of the form 601 is lined with an oil-paper so as to be able to separate the formed body 605 from the form 601 easily and to prevent the form 601 from being soiled.
Then, the form 601 including the concrete material 600 is vibrated to fill up and compact the concrete material 600 in the form 601 and the upper surface thereof is made even (step 502).
A water permeable sheet 606 is placed on the upper surface of the filled concrete material 600 so as to dehydrate smoothly through the pressed surface when the concrete material is pressed through the upper opening of the form 601 (step 503).
Then, the concrete material 600 in the form 601 is pressed from the upper direction by a pressing plate 607.
A metal net 608 is stuck on the pressure surface 607a of the pressure plate 607. Furthermore, a punching metal plate 609, which is a flat metal plate having numerous through-holes, is stuck on the under surface of the metal net 608. When the concrete material 600 is pressed, water passing through the permeable sheet 606 from the dehydrated concrete material 600 can drain therethrough. By such a construction, dehydration during pressing can be accelerated. Consequently, it is possible to decrease the processing time.
Next, pressing is released. Thereafter, a curing plate 610 is placed on the permeable sheet 606 placed on the formed body 605 (step 505).
The form 601 is reversed so that the curing plate 610 faces downward (step 506). The side plates 602 and 602 forming the side walls of the form 601 are opened outwardly and the formed body 605 is removed from the form so that the curing plate 610 is on the lower side (step 507).
The removed formed body 605 is loaded on a rack (step 510) to be cured (step 511) in the state of being placed on the curing plate 610. The form 601 from which the formed body was removed is reversed again (step 512). The oilpaper 611 lining the inner surface of the form 601 is removed and the form 601 is cleaned (step 513). After the cleaning, the side plates 602 and 602 are closed to construct the form (step 508). The bottom surface 604 of the form 601 is lined with a new oil-paper 611. After a new oil-paper is put in the form, the form is returned to the step of putting concrete material into a form again (step 509).
The cured formed body 605 is removed from the rack and is reversed. The curing plate 610 and the permeable sheet 606 are separated (step 514). In such a way, a concrete panel 100 is completed. Thereafter, the resulting concrete panels 100 are piled (step 515) and stored (step 516).
The curing plate 610 separated from the formed body 605 is cleaned to be sent to the step again in which the curing plate 610 after the pressing step is placed on the formed body 605 (step 517).
The concrete panel 100 can be manufactured by repeating the above steps. It is unnecessary to prepare many forms 601, since the pressing step requires only several minutes by using the above concrete material 600.
It is possible to manufacture the concrete panel 100 by sending the form, from which the formed body 605 was removed, back to the pressing step.
The transfer of the form 601, the curing plate 610, and the formed body 605 to each step is carried out by a conveyor.
The concrete panel 100 according to the present embodiment uses the above concrete material 600, in particular, cinder sand may be used as a fine aggregate.
Therefore, it is possible to compact the concrete material in the form when the concrete panel is being manufactured by applying pressure, even if the pressure-application time is short. Since the cinder sand has a high ratio of water absorption, it is possible to decrease the amount of excessive water in the mixed concrete material, so that the formed body retains its shape even if the formed body is removed the form quickly after the pressure step. It is possible to form a formed body by applying only slight pressure because the cinder sand can absorb excessive water in the formed body so that a large applied pressure is not required for dehydration of the formed body.
The dispersing agent was previously added to the concrete material 600 to decrease the amount of water.
Therefore, the dispersing agent enables reduction of the pressing time in combination with the effect of the cinder sand.
Therefore, it is possible to manufacture the concrete panel 100 in a short time. In the method of the present invention, a form 601 is being used in the step of a pressing step for a short time, the previous and subsequent steps of putting the concrete material 600 into the form and the step of cleaning the form 601; after these steps, the form 601 can be used for manufacturing another concrete panel 100 by being sent to the prior step; and therefore, it is possible to manufacture concrete panels A continuously without using numerous expensive forms 601, and the manufacturing costs of the concrete panel are thereby reduced.
A concrete panel P as shown in FIG. 7 has a shape similar to that of the concrete panel 100. The concrete panel P has reinforcing steel wires 700 embedded inside connecting ribs 106 in the longitudinal direction of the connecting ribs 106.
Such a reinforced concrete panel P is manufactured by the following process.
In the above manufacturing process, before the concrete material 600 is put into the form 601, there is provided a step of arranging (step 518) bundles of steel wires 700 in grooves for forming the connecting ribs 106 on both end portions of the form 601, as shown in the flowchart in FIG. 5. Consequently, it is possible to manufacture the concrete panel P having embedded wires as reinforcing steel wires 700 inside the connecting ribs 106, as shown in FIG. 7. Therefore, it is possible to increase the strength of the concrete panel 100 easily and at low cost.
In the concrete panel 100, cinder sand was used as a fine aggregate. However, ordinary sand may be used as a fine aggregate in order to remove the formed body from the form quickly after pressure applied. In this case, it is difficult to compact the formed body and ordinary sand has a low absorption ratio in comparison with cinder sand.
Since ordinary sand requires a long time and a large applied pressure forming, it is preferable to use the cinder sand. It is possible to use a granulated fly-ash with a 0.15 mm to 5.0 mm average granule diameter instead of the cinder sand so as to obtain effects similar to that of using the cinder sand.
In the above embodiment, the method of manufacturing the concrete panel 100 was described. However, various types of concrete panels other than the concrete panel 100 can be manufactured by the method of the present invention.
In the method of manufacturing a concrete panel according to the present invention, a form 601 is occupied for manufacturing a concrete panel 100 only during the pressing step, the previous and subsequent steps of putting the concrete material 600 into the form, and the step of cleaning the form 601. After these steps, the form 601 can be used for manufacturing another concrete panel 100 by being returned to the previous step. Therefore, it is possible to manufacture concrete panels A continuously without using numerous expensive forms 601, and to reduce the manufacturing cost of the concrete panel.
The amount of water is reduced by adding a dispersing agent to the concrete material 600. Furthermore, the water permeable sheet 606 is placed on the concrete material 600.
The metal net 608 and the punching metal 609 are attached on the pressure surface of the pressure plate 607.
Therefore, the amount of water in the concrete material 600 is previously reduced. The dehydration of the formed body during the pressing step is carried out smoothly.
Consequently, it is possible to reduce the time for pressing and to manufacture the concrete panel in a short time.
According to the method of the present invention, a small number of forms are used in rotation, so that a large area for manufacture is not required. The formed body 605 is removed from the form and is loaded on a rack so that the formed body is placed on the curing plate 610 and is cured. Therefore, it is possible to reduce the area for curing. Furthermore, the cured concrete panels are piled and stored after being removed from the curing plate, so that the piled concrete panels does not require a wide area for storage.
The area occupied by the whole manufacturing equipment for the concrete panel may be small in comparison with that of a conventional one. Therefore, it is possible to reduce the cost for equipment or the like.
The formed body 605 can be easily removed the form 601 by reversing the form, so that the manufacture of the concrete panel does not require a long time.
As described above, the concrete panel according to the present invention provides the following excellent effects.
First, since the concrete panel according to the present invention uses the above concrete material, in particular, cinder or fly-ash as a fine aggregate, it is possible to compact the concrete material in the form, when the concrete panel is manufactured by applying pressure, even if the pressure applying time is short. Since the cinder sand and the fly-ash have a high ratio of water absorption, it is possible to have the excessive water in the mixed concrete material absorbed into the cinder sand or the like, so that the formed body can retain its shape to cure even if the formed body is removed from the form quickly after a short pressure step.
Second, it is possible to form a formed body by applying a small amount of pressure, because the cinder sand can absorb excessive water in the formed body not to require a large applied pressure for dehydration of the formed body. Therefore, it is possible to manufacture the concrete panel in a short time.
Third, the cinder sand or the like is used as a fine aggregate and a dispersing agent is added to the concrete material; it is therefore possible to decrease the amount of water in the mixed concrete material compared to prior practice. Therefore, it is possible to reduce the pressing time due to the combined the effect of the cinder sand.
Fourth, the form is occupied by the pressing step for only a short time. After the pressing step, the form can be used for manufacturing another concrete panel by being sent to the prior step. Therefore, it is possible to manufacture concrete panels continuously without using numerous expensive forms and to reduce the manufacturing cost of the concrete panel.
A wall body can be constructed by arranging the above concrete panels. When connecting ribs for connecting adjacent concrete panels to each other are provided on the concrete panel, embedding reinforcing steel wires inside the connecting ribs can reinforce the concrete panel easily.
Claims (11)
1. A concrete panel obtained by putting a concrete material into a form, pressing the concrete material to form a formed body having an uneven surface, and removing the formed body from the form,
wherein the concrete material comprises a cement, a fine aggregate, a dispersing agent, reinforcing fibers, and water; and wherein the fine aggregate comprises a component selected from the group consisting of cinder and fly-ash.
2. A concrete panel as claimed in claim 1; wherein the concrete material has a rectangular plate shape and has connecting ribs which project to the one side provided on both ends of the concrete panel, the concrete panel being a component of a wall which comprises a plurality of the concrete panels connected to each other through the connecting ribs; and wherein a reinforcing steel wire is embedded inside each of the connecting ribs in the longitudinal direction thereof.
3. A concrete panel as claimed in claim 1; wherein the concrete material has a rectangular plate shape, a plurality of parallel vibration suppressing ribs are formed at predetermined intervals on the one side of the concrete panel, and a plurality of parallel reinforcing ribs are formed on the side so that each reinforcing rib is laid across each thin portion between the parallel vibration suppressing ribs.
4. A concrete panel as claimed in claim 2; wherein the concrete material has a rectangular plate shape, a plurality of parallel vibration suppressing ribs are formed at predetermined intervals on the one side of the concrete panel, and a plurality of parallel reinforcing ribs are formed on the side so that each reinforcing rib is laid across each thin portion between the parallel vibration suppressing ribs.
5. A method of manufacturing a concrete panel comprising the steps of: putting a mixed and kneaded concrete material into a form, pressing the concrete material using a pressing plate through an upper opening of the form to make a formed body, putting the formed body out of the form by reversing the form, and curing the put out formed body;
wherein the concrete material includes a dispersing agent; a water permeable portion is provided at a pressing surface of the pressing plate for taking water, which was obtained by dehydration from the formed body, outside the form; the step of putting the formed body out of the form is carried out soon after the step of pressing; and the step of curing the formed body is carried out after the step of putting the formed body out of the form.
6. A method of manufacturing a concrete panel as claimed in claim 5; wherein the concrete material comprises a cement, a fine aggregate, a dispersing agent, reinforcing fibers, and water; and the fine aggregate comprises a component selected from the group consisting of a cinder and fly-ash.
7. A wall body structure having a sound insulation function comprising: two walls provided in parallel to face each other with a predetermined gap, each of said two walls comprising a plurality of concrete panels and a means for connecting said concrete panels, each of said concrete panels having a rectangular plate shape, a plurality of parallel vibration suppressing ribs formed at predetermined intervals on the inner side of the concrete panel, and a plurality of parallel reinforcing ribs formed on the side so that each reinforcing ribs is laid across each of thin portions between the parallel vibration suppressing ribs.
8. A wall body structure as claimed in claim 7; wherein the structure further comprising a heat insulating fiber means provided in said gap between the two walls.
9. A concrete panel substantially as hereinbefore particularly described with reference to the accompanying drawings.
10. A method of manufacturing a concrete panel substantially as hereinbefore particularly described with reference to the accompanying drawings.
11. A wall body structure substantially as hereinbefore particularly described with reference to the accompany drawings.
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
JP3117982A JPH04321547A (en) | 1991-04-22 | 1991-04-22 | Concrete panel |
JP11812491A JPH04320805A (en) | 1991-04-22 | 1991-04-22 | Manufacture of concrete panel |
Publications (2)
Publication Number | Publication Date |
---|---|
GB9208628D0 GB9208628D0 (en) | 1992-06-03 |
GB2255116A true GB2255116A (en) | 1992-10-28 |
Family
ID=26456002
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
GB9208628A Withdrawn GB2255116A (en) | 1991-04-22 | 1992-04-21 | Sound-insulating concrete wall. |
Country Status (2)
Country | Link |
---|---|
CN (1) | CN1066019A (en) |
GB (1) | GB2255116A (en) |
Cited By (7)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
BE1009315A3 (en) * | 1995-04-13 | 1997-02-04 | Decatron | Sound-insulating wall and a method for constructing this wall |
WO2001087565A1 (en) * | 2000-05-17 | 2001-11-22 | Domostatik Gmbh | Method for fabricating fibre concrete products |
ES2163350A1 (en) * | 1999-01-15 | 2002-01-16 | Gasteiz Desarrollo Ind E Ingen | Automated industrial installation for production of acoustic panels and other similar products for the residential and public sectors. |
ES2163349A1 (en) * | 1999-01-15 | 2002-01-16 | Gasteiz Desarrollo Ind E Ingen | Procedure for manufacturing acoustic protection panels and other similar products for the residential and public sectors. |
WO2003055658A1 (en) * | 2001-12-18 | 2003-07-10 | Monotile S.R.L. | Process for manufacturing tiles or panels in concrete-based conglomerated material, advantageously for floating floorings, as well as tile or panel obtained by means of such process |
WO2004054770A1 (en) * | 2002-12-13 | 2004-07-01 | Monotile S.R.L. | Procedure for obtaining cement tiles or panels, a die for the production of such tiles or panels, and cement tiles or panels |
DE102010020493A1 (en) * | 2010-05-14 | 2011-11-17 | Thomas Friedrich | Method and device for producing semi-open concrete parts |
Citations (2)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US4261754A (en) * | 1977-05-05 | 1981-04-14 | Dansk Eternit-Fabrik A/S | Fiber reinforced building products and method of producing same |
WO1982002195A1 (en) * | 1980-12-22 | 1982-07-08 | Reginald Frank Grace | Cementitious article |
-
1992
- 1992-04-21 GB GB9208628A patent/GB2255116A/en not_active Withdrawn
- 1992-04-22 CN CN92102872A patent/CN1066019A/en active Pending
Patent Citations (2)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US4261754A (en) * | 1977-05-05 | 1981-04-14 | Dansk Eternit-Fabrik A/S | Fiber reinforced building products and method of producing same |
WO1982002195A1 (en) * | 1980-12-22 | 1982-07-08 | Reginald Frank Grace | Cementitious article |
Cited By (8)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
BE1009315A3 (en) * | 1995-04-13 | 1997-02-04 | Decatron | Sound-insulating wall and a method for constructing this wall |
ES2163350A1 (en) * | 1999-01-15 | 2002-01-16 | Gasteiz Desarrollo Ind E Ingen | Automated industrial installation for production of acoustic panels and other similar products for the residential and public sectors. |
ES2163349A1 (en) * | 1999-01-15 | 2002-01-16 | Gasteiz Desarrollo Ind E Ingen | Procedure for manufacturing acoustic protection panels and other similar products for the residential and public sectors. |
WO2001087565A1 (en) * | 2000-05-17 | 2001-11-22 | Domostatik Gmbh | Method for fabricating fibre concrete products |
WO2003055658A1 (en) * | 2001-12-18 | 2003-07-10 | Monotile S.R.L. | Process for manufacturing tiles or panels in concrete-based conglomerated material, advantageously for floating floorings, as well as tile or panel obtained by means of such process |
CN1302903C (en) * | 2001-12-18 | 2007-03-07 | 莫诺迪勒有限公司 | process for mfg. tiles or panels in concrete-based conglomerated material, advantageously for floating floorings, as well as tile or panel obtained by means of such process |
WO2004054770A1 (en) * | 2002-12-13 | 2004-07-01 | Monotile S.R.L. | Procedure for obtaining cement tiles or panels, a die for the production of such tiles or panels, and cement tiles or panels |
DE102010020493A1 (en) * | 2010-05-14 | 2011-11-17 | Thomas Friedrich | Method and device for producing semi-open concrete parts |
Also Published As
Publication number | Publication date |
---|---|
CN1066019A (en) | 1992-11-11 |
GB9208628D0 (en) | 1992-06-03 |
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