JP2020084508A - Manufacturing method of panel foe wall - Google Patents

Abstract

To provide a technique capable of forming a relatively thin plate-like panel with mortar.SOLUTION: The present invention relates to a method of manufacturing a wall panel used for a wall of a building, comprising: a first step of placing uncured mortar in a mold forming an outer shape of a wall panel and spreading it over the whole area of the bottom surface of the form with a trowel; a second step of placing a reinforcing material for reinforcing the wall panel in the mold; and a third step of further adding uncured mortar into the mold on which the reinforcing material is placed by the second step, and spreading the mortar by a trowel so that at least the reinforcing material is buried.SELECTED DRAWING: Figure 1

Description

The present application discloses a method for manufacturing a wall panel using mortar.

2. Description of the Related Art In recent years, wall materials preliminarily formed into a plate shape in factories have been used for walls of various buildings such as houses and commercial facilities (see, for example, Patent Documents 1-3).

JP-A-58-185845 JP, 7-300965, A JP, 2016-94792, A

For the inner wall of a building such as a wooden structure, a steel frame structure, an SRC structure (Steel Reinforced Concrete), an RC structure (RC: Reinforced Concrete), for example, a gypsum board that is lightweight and excellent in workability is used. Further, for example, ceramic siding having excellent weather resistance is used for the outer wall of these buildings. However, the gypsum board is inferior in fire resistance to the wall body made of mortar or reinforced concrete, and thus may be burned when a fire occurs inside the building. Also, while ceramic siding is excellent in fire resistance and weather resistance, it does not have the heat insulation required to prevent external cold and warm air from affecting the thermal environment inside the building. , It is necessary to install a heat insulating material on the back side of the ceramic siding.

Therefore, in order to meet these requirements, it is conceivable to form a board for an inner wall or an outer wall by using mortar having excellent fire resistance. However, in order to make a building material that can replace the gypsum board that has been conventionally used as the wall of the inner wall, the size determined by the standard of the gypsum board, that is, the length and width of 910 mm×1820 mm, etc. On the other hand, it is necessary to form the board with mortar so as to have a relatively extremely thin thickness of 9.5 mm or 12.5 mm. In addition, in order to make a building material that can replace the ceramic siding that has been conventionally used as the wall of the outer wall and also has heat insulating properties, a thickness of 10 mm to 50 mm, which is the standard thickness for ceramic siding, can be used. First, it is necessary to form a heat insulating layer composed of a heat insulating material and a mortar layer sandwiching the heat insulating layer from both sides. That is, in order to form a mortar having excellent fire resistance as a board for an inner wall or an outer wall, it is necessary to form the mortar in a plate shape with an extremely thin thickness of, for example, several mm to ten and several mm. Therefore, it was possible to form mortar by pouring it into a mold as long as it is a relatively thick wall used as the outer wall of a high-rise building, but with this method, mortar is formed into a plate with a thickness of several mm to ten and several mm Cannot be formed with.

Then, this application makes it a subject to provide the technique which can form a comparatively thin plate-shaped panel with mortar.

In order to solve the above problems, in the present invention, the panel is formed while spreading the mortar over the entire bottom surface of the mold with a trowel.

More specifically, the present invention is a method for manufacturing a wall panel used for a wall of a building, in which uncured mortar is placed in a mold forming the outer shape of the wall panel, and the entire bottom surface of the mold is A first step of spreading with a trowel, a second step of placing a reinforcing material for reinforcing the wall panel in the formwork, and an uncured inside of the formwork on which the reinforcing material is placed by the second step A third step of further adding mortar and spreading with a trowel so that at least the reinforcing material is filled.

In the case of the above manufacturing method, since the panel is manufactured while spreading the mortar on the bottom surface of the mold with a trowel, for example, a panel having an extremely thin thickness of several mm to ten and several mm is manufactured. Even if it is desired, the panel can be manufactured by spreading the mortar evenly in every corner of the mold. Therefore, according to the above manufacturing method, even a panel having an extremely small thickness relative to the length and width can be formed with mortar. Since the panel manufactured by the above manufacturing method is reinforced with the reinforcing material, it can exhibit the strength required as a wall panel even if it is formed into a relatively thin plate shape.

In the second step, the reinforcing material may be placed in a mold whose bottom surface is spread with mortar in the first step. With such a manufacturing method, it is possible to manufacture a panel in which the reinforcing material is embedded in the mortar.

Moreover, you may further have the 4th process of mounting the heat insulating material which gives a heat insulating property to a wall panel in a formwork. With such a manufacturing method, it is possible to manufacture a panel in which the heat insulating material is embedded in the mortar.

According to the above method for manufacturing a wall panel, it is possible to form a relatively thin plate-shaped panel with mortar.

FIG. 1 is a first diagram showing an outline of a method for manufacturing a wall panel according to the first embodiment. FIG. 2 is a second diagram showing the outline of the method for manufacturing the wall panel according to the first embodiment. FIG. 3 is a structural diagram of an inner wall panel manufactured by the manufacturing method of the first embodiment. FIG. 4 is a first diagram showing the outline of the method for manufacturing the wall panel according to the second embodiment. FIG. 5 is a second diagram showing the outline of the method for manufacturing the wall panel according to the second embodiment. FIG. 6 is a structural diagram of an outer wall panel manufactured by the manufacturing method of the second embodiment. FIG. 7: is the figure which showed an example of the attachment method at the time of attaching the panel for outer walls to a building. FIG. 8 is a diagram showing an example of the attachment position of the anchor. FIG. 9 is a view showing the internal structure of the outer wall panel at the location where the anchor is attached.

Hereinafter, embodiments of the present invention will be described. The embodiment described below is one mode of the present invention, and the technical scope of the present invention is not limited to the following embodiment.

<First Embodiment>
FIG. 1 is a first diagram showing an outline of a method for manufacturing a wall panel according to the first embodiment. Further, FIG. 2 is a second diagram showing the outline of the method for manufacturing the wall panel according to the first embodiment.
In the first embodiment, a case of manufacturing a panel for an inner wall will be described as an example.

In the first embodiment, as shown in FIG. 1A, a mold K that forms the outer shape of the panel for the inner wall is prepared. And in this 1st Embodiment, the uncured mortar M is put in the mold K (step S11: It is an example of the "1st process" in this application). The uncured mortar M contained in the mold K is spread over the entire bottom surface of the mold K with a trowel.

The mold K is made by fixing bar-shaped square members on four sides of a plywood coated with a release agent on the surface, and forms a mold surface having a size corresponding to the size of the inner wall panel to be prepared as a product. To do. The form K is not limited to a wooden plywood to which bar-shaped square members are fixed, and may be formed using a steel plate, for example, or may be formed using various other materials. It may be one that has been created.

After the mortar M has been spread over the entire bottom surface of the mold K, as shown in FIG. 1B, a metal lath L that reinforces the panel is placed in the mold K (step S12: the present application). It is an example of the "second step". The metal lath L is a reinforcing material having a size corresponding to the size of the panel to be prepared as a product, and is a metal net. Note that, in FIG. 1B, a net in the form of forming a rhombus lattice is illustrated as the metal lath L, but the metal lath L is not limited to such a form. The metal lath L may be, for example, a net in the form of forming a square lattice, may be a net made of a metal having another shape, or may be made of a material other than metal such as carbon fiber. It may be a closed net.

After the metal lath L is placed in the mold K, as shown in FIG. 1C, an uncured mortar M is further put in the mold K (step S13: "3rd" in the present application). Process)). Then, the uncured mortar M placed in the mold K is spread with a trowel so that the metal lath L is filled.

After the mortar is spread so as to fill the metal lath L and the mortar M in the mold K is completely hardened, the mortar in the mold K is hardened as shown in FIG. 2(A). The formed intermediate product C is removed from the mold K. Then, as shown in FIG. 2(B), when the final product is used as an inner wall, the plaster S is thinly spread with a trowel as a finish on the surface facing the indoor side. When the plaster S thinly spread on the surface of the intermediate product C is completely hardened, the inner wall panel 1 which is the final product is completed as shown in FIG. 2(C).

In addition, at the stage in the middle of hardening of the mortar, the form K containing the mortar may be stored in a state of being suspended from the ceiling of the factory by a wire or the like. In this case, the space in the factory can be effectively used. In order to suspend the form K containing the mortar from the ceiling with a wire or the like, it is necessary to form the form K with a steel plate or the like, and firmly fasten the cover of the steel plate covering the form K together with the form K with a band. Will be needed. Further, since the mold K containing mortar is a heavy object, it is desirable to use an apparatus for inclining the mold K together.

FIG. 3 is a structural diagram of the inner wall panel 1 manufactured by the manufacturing method of the first embodiment. Since the inner wall panel 1 is manufactured by the manufacturing method of the first embodiment, as shown in FIG. 3, a mortar layer 1A in which the mortar M is hardened and a stucco layer 1B in which the stucco S is hardened. Have. In addition, the mortar layer 1A is provided with the metal lath L embedded in the mortar M in step S12 described above. Therefore, it can be said that the inner wall panel 1 manufactured by the manufacturing method of the first embodiment is a mortar panel substantially reinforced with the metal lath L.

And since the manufacturing method of the said 1st Embodiment is a form which manufactures the panel 1 for inner walls, spreading the mortar M on the bottom face of the formwork K with a trowel, for example, thickness is several mm to ten-odd mm. Even when it is desired to manufacture the inner wall panel 1 having an extremely thin thickness, it is possible to manufacture the inner wall panel 1 by spreading the mortar to every corner of the mold K. Therefore, according to the manufacturing method of the first embodiment, for example, 9.5 mm or 12 with respect to the size defined by the standard of the ready-made gypsum board, that is, the vertical and horizontal lengths such as 910 mm×1820 mm. The inner wall panel 1 having a relatively thin thickness of 0.5 mm can be formed of mortar. When the thickness of the inner wall panel 1 is 12.5 mm, the mortar layer 1A has a thickness of about 10 mm and the plaster layer 1B has a thickness of about 2 mm.

<Second Embodiment>
FIG. 4 is a first diagram showing the outline of the method for manufacturing the wall panel according to the second embodiment. Further, FIG. 5 is a second diagram showing the outline of the method for manufacturing the wall panel according to the second embodiment. In the second embodiment, a case of manufacturing a panel for outer wall will be described as an example.

In the second embodiment, as shown in FIG. 4(A), a mold K that forms the outer shape of the panel for the outer wall is prepared. Then, in the second embodiment, the uncured mortar M is put in the mold K (step S21: an example of “first step” in the present application). The uncured mortar M contained in the mold K is spread over the entire bottom surface of the mold K with a trowel.

After the mortar M has been spread over the entire bottom surface of the mold K, as shown in FIG. 4B, a heat insulating board D that imparts heat insulation to the panel is placed in the mold K ( Step S22: This is an example of the "fourth step" in the present application). The heat insulating board D is a plate-shaped heat insulating material having a size corresponding to the size of the panel to be prepared as a product. As the heat insulating board D, for example, Styrofoam (registered trademark) manufactured by Dow Kako Co., Ltd. is suitable.

After the heat insulating board D is placed in the mold K, uncured mortar M is further put in the mold K as shown in FIG. 4(C) (step S23). Then, the uncured mortar M placed in the mold K is spread with a trowel so that the heat insulating board D is filled.

After the mortar is spread so as to fill the heat insulating board D, the wire mesh W that reinforces the panel is placed in the form K as shown in FIG. 5A (step S24: in the present application. It is an example of the so-called "second step"). Like the metal lath L, the wire mesh W is a reinforcing material having a size corresponding to the size of the panel to be prepared as a product, and is a metal net, but a plate-shaped lattice is formed by punching and extending a plate material. Unlike the metal lath L described above, metal wires having a diameter of about 3 to 4 mm are arranged vertically and horizontally at intervals of about 10 cm and joined by welding. The "wire mesh" is also called a "welded wire mesh".

After the wire mesh W is placed in the mold K, as shown in FIG. 5(B), uncured mortar M is further put in the mold K (step S25: “first” in the present application). 3 steps”). Then, the uncured mortar M placed in the mold K is spread with a trowel so that the wire mesh W is buried.

After the mortar is spread so as to fill the wire mesh W and the mortar M in the mold K is completely hardened, the mortar in the mold K is hardened as shown in FIG. 5(C). The outer wall panel 2 of the final product formed by is removed from the mold K.

FIG. 6 is a structural diagram of the outer wall panel 2 manufactured by the manufacturing method of the second embodiment. Since the inner wall panel 1 is manufactured by the manufacturing method of the second embodiment, as shown in FIG. 6, it has the first mortar layer 2A and the second mortar layer 2B in which the mortar M is hardened. Further, between the first mortar layer 2A and the second mortar layer 2B, the heat insulating board D placed in the mold K in the above step S22 is arranged. Therefore, it can be said that the outer wall panel 2 manufactured by the manufacturing method of the second embodiment is a mortar panel that is substantially reinforced by the wire mesh W and has the heat insulating property by the heat insulating board D.

And since the manufacturing method of the said 2nd Embodiment is a form which manufactures the panel 2 for outer walls, spreading the mortar M on the bottom face of the formwork K with a trowel, for example, thickness is several mm to ten-odd mm. Even when it is desired to manufacture the outer wall panel 2 having the extremely thin first mortar layer 2A and the second mortar layer 2B, the outer wall panel 2 is formed by spreading the mortar to every corner of the mold K. It is possible to manufacture Therefore, according to the manufacturing method of the second embodiment, for example, in a thickness of 10 mm to 50 mm, which is a standard thickness in ready-made ceramic siding, a heat insulating layer formed of a heat insulating material, It is possible to form the outer wall panel 2 of mortar having a structure that forms a mortar layer sandwiching the heat insulating layer from both sides.

FIG. 7: is the figure which showed an example of the attachment method at the time of attaching the panel 2 for outer walls to a building. Since the outer wall panel 2 is a member used as an outer wall, it is preferable that the outer wall panel 2 is attached to a building so that a gap is not formed at least between the outer wall panels 2 in order to prevent entry of wind and rain. Therefore, as for the edge of the outer wall panel 2 where the outer wall panels 2 are adjacent to each other, for example, as shown in FIG. 7A, between the end surface of the first mortar layer 2A and the end surface of the second mortar layer 2B. If a step is formed in the outer wall panel 2 as shown in FIG. 7B, the outer wall panel 2 can be attached to the building with the edges of the outer wall panel 2 meshing with each other at the step. It is possible to eliminate the gap between them.

In this case, a gap is formed between the edges of the outer wall panel 2 that are engaged with each other by the step, as shown in a portion indicated by “gap” in FIG. 2B. By applying the caulking material or the like, it is possible to provide a higher airtightness between the outer wall panels 2 by applying the caulking material or the like.

<Confirmation test>
A confirmation test was conducted as to whether or not the wall panel manufactured by the manufacturing method of the first embodiment or the second embodiment satisfies the fire resistance performance required for building materials, and the results are shown below.

The surface of each of the inner wall panel 1 manufactured by the manufacturing method of the first embodiment and the outer wall panel 2 manufactured by the manufacturing method of the second embodiment is formed of a layer in which mortar M is hardened. ing. Therefore, regardless of the total thickness of the inner wall panel 1 and the outer wall panel 2 and the presence or absence of the heat insulating board D, at least a single layer formed by curing the mortar M satisfies the fire resistance performance required for building materials. It is considered that both the inner wall panel 1 and the outer wall panel 2 exhibit the necessary fire resistance performance required for building materials. Therefore, in this confirmation test, a test body corresponding to the inner wall panel 1 manufactured by the manufacturing method of the first embodiment was prepared, and a test was performed to determine whether or not the test body passed the heat generation test. In this test body, only the mortar layer 1A in which the mortar M was hardened was used, and the plaster layer 1B formed by applying the plaster S was omitted.

As a test body, a panel having a thickness of 10.9 mm in which a metal lath was embedded in the central portion in the thickness direction was prepared. The size of the test body is 99.9 mm×100.0 mm. Moreover, the mass of the said test body is 152.3 g. In addition, the test specimen was subjected to an exothermic test based on the non-combustible performance test method in the "Fireproof Performance Test/Evaluation Work Method Manual" established by the Hokkaido Research Institute (a heating time of 20 minutes, setting Radiant heat amount 50 kW/m ² , exhaust gas flow rate 24 L/sec).

As a result of the test, the total heat generation amount for 20 minutes was 7.6 MJ/m ² , and the maximum heat generation rate was 10.4 kW/m ² . That is, it was confirmed that the good result was below the upper limit specified value of 8 MJ/m ² of the total calorific value for 20 minutes required to satisfy the fire resistance performance of the building material. In addition, even with respect to the criterion of 10 seconds, which is the specified value of the duration time of more than 200 kW/m ² required to satisfy the fire resistance performance of building materials, since it did not exceed 200 kW/m ² , there is no problem. confirmed.

For the convenience of production, this test body was produced by using a mortar containing 98% of lightweight mortar and 2% of Porlandan cement and containing only 0.3% of ethylene vinyl acetate resin. While gross calorific value becomes a value of 7.6MJ / ^{m 2,} by removing ethylene vinyl acetate-based resin, the total calorific value of 20 minutes is expected to become 7.2MJ / ^{m 2} the following values. Therefore, if the inner wall panel 1 manufactured by the manufacturing method of the above-described embodiment is used as a substitute for a gypsum board, the fire resistance performance can be much higher than that of the gypsum board, and thus the fire resistant panel for an inner wall can be used.

A test was also conducted in which a test body corresponding to the inner wall panel 1 of the first embodiment was prepared, and the test body was exposed to a flame and heated at about 1500 degrees for 30 minutes. As a result, it was confirmed that the test body could withstand heating without disintegrating. On the other hand, when a similar test was performed on an off-the-shelf gypsum board having the same thickness as this test body, a through hole was formed about 20 minutes after the start of heating, and about 30 minutes after the start of heating. When it passed, the board collapsed. Therefore, the superiority of the inner wall panel 1 of the first embodiment was confirmed not only by the heat generation test described above but also by the result of this heating test. This superiority is considered to be the same for the outer wall panel 2 of the second embodiment.

FIG. 8 is a diagram showing an example of the attachment position of the anchor. The outer wall panel 2 manufactured by the manufacturing method of the second embodiment may be provided with anchors A at two positions on the upper end, for example, as shown in FIG. 8. The anchor A has a hole for inserting a screw or a hook, and fixes the outer wall panel 2 to the building in a suspended form. When the building to be attached has a steel frame structure, for example, the outer wall panel 2 is screwed to the lightweight steel frame which is the structural material of the building through the anchor A with tapping screws or the like. In addition, for example, when the building to be attached is a wooden structure, the outer wall panel 2 is screwed to the wooden plywood or the beam forming the wall surface of the building through the anchor A with a wooden screw or the like.

FIG. 9 is a view showing the internal structure of the outer wall panel 2 at the location where the anchor A is attached. As shown in FIG. 9, the anchor A is a substantially L-shaped metal fitting, and a part of the anchor A is embedded in the outer wall panel 2. Therefore, if another outer wall panel 2 or the like is overlaid so as to cover the anchor A, the anchor A is not exposed on the outer surface of the outer wall panel 2. Further, the anchor A has a structure in which it is caught by the wire mesh W in the outer wall panel 2, as shown in FIG. 9. Therefore, the hanging force of the anchor A does not concentrate on the upper portion of the outer wall panel 2 but reaches the entire outer wall panel 2 through the wire mesh W. Therefore, even if the weight of the outer wall panel 2 is concentrated on the anchor A, the upper portion of the outer wall panel 2 is not locally damaged.

K・・Form M・・Mortar L・・Metal Lath W・・Wire mesh C・・Intermediate product S・・Stucco D・・Insulation board A・・Anchor 1・・Inner wall panel 1A・・Mortar layer 1B・・Plaster layer 2... Exterior wall panel 2A... First mortar layer 2B... Second mortar layer

Claims (3)

A method for manufacturing a wall panel used for a building wall,
A first step in which uncured mortar is placed in a mold forming the outer shape of the wall panel, and spread over the entire bottom surface of the mold with a trowel;
A second step of placing a reinforcing material for reinforcing the wall panel in the formwork;
A third step of further putting uncured mortar into the mold on which the reinforcing material is placed by the second step, and spreading with a trowel so that at least the reinforcing material is filled.
Wall panel manufacturing method. In the second step, the reinforcing material is placed in the mold whose bottom surface is spread with mortar in the first step.
The method for manufacturing a wall panel according to claim 1. Further comprising a fourth step of placing a heat insulating material that imparts heat insulating property to the wall panel in the formwork,
The method for manufacturing a wall panel according to claim 1 or 2.

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