Autoclaved lightweight aerated concrete plate

Abstract

The utility model belongs to the technical field of ALC (autoclaved lightweight concrete) boards, and discloses an autoclaved lightweight aerated concrete board which comprises an ALC sandwich board, a fabric reinforced high-ductility concrete surface layer and a high-ductility concrete surface layer, the ALC sandwich panel is formed by pouring autoclaved lightweight aerated concrete, the fabric reinforced high-ductility concrete surface layer is arranged on one side of the ALC sandwich panel, and the high-ductility concrete surface layer is arranged on the other side of the ALC sandwich panel; the fabric reinforced high-ductility concrete surface layer comprises a first high-ductility concrete layer, a fiber fabric grid layer and a second high-ductility concrete layer which are sequentially arranged in a layered mode. The composite plate has the advantages of light self weight, high strength, simple manufacturing process and low manufacturing cost, and can meet the requirements on bending resistance, crack resistance and joint strength of the plate under various use conditions.

Description

Technical Field

[0001] The utility model belongs to the technical field of ALC boards, and particularly relates to an autoclaved lightweight aerated concrete board. Background Art

[0002] Autoclaved Lightweight Aerated Concrete (ALC) board is a porous concrete board made of fly ash (or silica sand), cement and lime as main raw materials, which is cured by high-pressure steam. Traditional ALC board has the advantages of light weight, convenient installation, easy operation and fast construction speed. Due to its loose and porous texture, it is often used as a good thermal insulation and sound insulation material. ALC board can be used as both wall panel and roof panel, and is a new type of building material with superior performance.

[0003] Traditional ALC panels generally have no internal skeleton or are only embedded with treated steel bars for reinforcement. Due to the small thickness of the panels and the low overall strength of the panels, their overall strength and stability are poor, which can easily cause the panels to break or bend during use and transportation, affecting their use. In particular, due to their low strength and poor stress-bearing performance, they can only be used as non-load-bearing components of industrial and civil buildings such as wall panels and roof panels. Therefore, the application of traditional ALC panels in a large number of buildings is greatly restricted.

[0004] At present, some traditional ALC panels are modified by setting reinforced cover plates, reinforcing rib nets, setting connection components or embedded truss structures to improve their structural performance; the specific solutions are as follows:

[0005] (1) When setting a reinforced cover plate, an outer cover plate is set at the top and bottom of the ALC plate body, and a pad is set between the ALC plate body and the outer cover plate, and the outer cover plate is connected to the ALC plate body through the pad; wherein, through the structural setting of the outer cover plate, the pad and the ALC plate body, the influence of external impact force can be effectively reduced, and the pressure resistance and stability of the overall ALC plate can be improved; however, in the scheme of setting a reinforced cover plate, it is necessary to design a groove for the ALC plate body, and it is necessary to make upper and lower pads, outer cover plates and other components, which has a complicated manufacturing process; secondly, it is necessary to reserve positioning holes and then connect and combine the components; in addition, the outer cover plate, upper and lower pads and other components further weaken the advantage of the light weight of the ALC plate; at the same time, the overall cost of the plate is high due to the increase in cost due to the large number of components and the reduction in efficiency due to the complexity of the process; and the reinforced cover plate scheme can only reduce the influence of external impact force and improve the pressure resistance of the plate, but the strength of the overall structure is not improved much, and it can still only be used for frame structure filling and various non-load-bearing walls.

[0006] (2) When setting the reinforcement mesh, the reinforcement mesh is set in the ALC wall panel body. Each layer of the reinforcement mesh includes a plurality of transverse reinforcement bars and a plurality of longitudinal reinforcement bars. The transverse reinforcement bars and the longitudinal reinforcement bars are fixed to form nodes. Two adjacent layers of reinforcement mesh are fixedly connected by connecting bars. The nodes on the two adjacent layers of reinforcement mesh correspond to each other and are fixedly connected by vertical connecting bars. Two adjacent vertical connecting bars are fixedly connected by oblique connecting bars. However, in the scheme of setting the reinforcement mesh, the reinforcement mesh needs to be set in the ALC wall panel body, which has the disadvantages of large amount of steel bars and complicated process, which greatly reduces the efficiency.

[0007] (3) When setting the connection components, the lightweight sandwich layer is laid flat on the surface of the prefabricated bottom plate, and the lightweight sandwich layer and the prefabricated bottom plate are connected and fixed by multiple groups of spaced connection components; the connection components include multiple tubular bodies and connecting ribs, and the connecting ribs pass through the multiple spaced tubular bodies in sequence, and one end of the tubular body vertically passes through the lightweight sandwich layer and is anchored in the prefabricated bottom plate; due to the large number of connection components, the production is simple but the assembly is time-consuming; among them, the passage of the tubular body will cause defects, resulting in local stress concentration, which makes the overall stress of the lightweight board questionable.

[0008] (4) When setting up an embedded truss structure, a truss is embedded in the main body of the plate; the truss includes main bars and connecting bars, three main bars are arranged in parallel and are distributed in an isosceles triangle, and the connecting bars are connected between two adjacent main bars and are symmetrically arranged at the two sides of the isosceles triangle; the overall performance is improved by using the truss inside the main body of the plate, but the amount of steel used in the truss is large, resulting in a significant increase in the cost of the plate; at the same time, since the material on the surface of the plate has not changed, it is easy to cause the plate to break or bend during use and transportation, affecting its use.

[0009] In summary, the existing technical means for transforming traditional ALC panels have technical problems such as complex structure, low production efficiency and high cost. The present utility model is proposed to solve these problems. Utility Model Content

[0010] In view of the technical problems existing in the prior art, the utility model provides an autoclaved lightweight aerated concrete board to solve the technical problems of the existing technical means for transforming traditional ALC boards, such as complex structure, low production efficiency and high cost.

[0011] In order to achieve the above purpose, the technical solution adopted by the utility model is:

[0012] The utility model provides an autoclaved lightweight aerated concrete board, including an ALC sandwich board, a fabric-reinforced high-ductility concrete surface layer and a high-ductility concrete surface layer;

[0013] The ALC sandwich panel is cast by autoclaved lightweight aerated concrete, the fabric-reinforced high-ductility concrete surface layer is arranged on one side of the ALC sandwich panel, and the high-ductility concrete surface layer is arranged on the other side of the ALC sandwich panel; wherein the fabric-reinforced high-ductility concrete surface layer comprises a first high-ductility concrete layer, a fiber fabric mesh layer and a second high-ductility concrete layer which are arranged in layers in sequence.

[0014] Furthermore, a first embedded steel mesh and a second embedded steel mesh are pre-embedded in the ALC sandwich panel; the first embedded steel mesh and the second embedded steel mesh are arranged in parallel, and are both arranged parallel to the panel surface of the ALC sandwich panel; wherein the first embedded steel mesh is arranged close to the first side surface of the ALC sandwich panel, and the second embedded steel mesh is arranged close to the second side surface of the ALC sandwich panel.

[0015] Furthermore, the distance between the first pre-embedded steel mesh and the first side surface of the ALC sandwich panel is 15-40 mm, and the distance between the second pre-embedded steel mesh and the second side surface of the ALC sandwich panel is 15-40 mm.

[0016] Furthermore, the first embedded steel mesh and the second embedded steel mesh have the same structure, both comprising staggered longitudinal embedded steel bars and transverse embedded steel bars; wherein the longitudinal embedded steel bars are evenly distributed along the longitudinal direction of the ALC sandwich panel, and the transverse embedded steel bars are evenly distributed along the transverse direction of the ALC sandwich panel.

[0017] Furthermore, the diameters of the longitudinal embedded steel bars and the transverse embedded steel bars are 4.5-8 mm; the spacing between two adjacent longitudinal embedded steel bars is 400-800 mm, and the spacing between two adjacent transverse embedded steel bars is 200-300 mm.

[0018] Furthermore, the fiber fabric mesh layer adopts a fiber fabric mesh with a cross mesh structure; wherein the size characteristics of the cross mesh structure are: length×width=(10-30) mm×(10-30) mm.

[0019] Furthermore, the high-ductility concrete surface layer, the first high-ductility concrete layer and the second high-ductility concrete layer are all cast by high-ductility concrete; wherein the raw materials of the high-ductility concrete include: cement, fly ash, silica fume, sand, PE fiber, steel fiber and water.

[0020] Furthermore, the thickness of the ALC sandwich panel is 50-300 mm.

[0021] Furthermore, the fabric-reinforced high-ductility concrete surface layer and the high-ductility concrete surface layer are both 20-200 mm.

[0022] Compared with the prior art, the beneficial effects of the utility model are:

[0023] The utility model provides an autoclaved lightweight aerated concrete board, which effectively improves the crack resistance and ultimate bearing capacity of the ALC board by arranging a fabric-reinforced high-ductility concrete surface layer on one side of an ALC sandwich board and arranging a high-ductility concrete surface layer on the other side of the ALC sandwich board, utilizing the high tensile strength, high compressive strength, high crack resistance and high durability characteristics of the fabric-reinforced high-ductility concrete and the high-ductility concrete; wherein, a fiber fabric grid layer is arranged in the fabric-reinforced high-ductility concrete surface layer, effectively improving the self-crack resistance and ultimate bearing capacity of the fabric-reinforced high-ductility concrete surface layer; at the same time, since the fabric-reinforced high-ductility concrete and the high-ductility concrete have the advantages of light weight and high load-bearing capacity, the autoclaved lightweight aerated concrete board has the advantages of light weight, high strength, simple manufacturing process and low cost, and can meet the requirements for the board's bending resistance, crack resistance and node strength under various use conditions.

[0024] Furthermore, by pre-embedding the first pre-embedded steel mesh and the second pre-embedded steel mesh in the ALC sandwich panel, the ultimate bearing capacity of the panel is effectively improved. BRIEF DESCRIPTION OF THE DRAWINGS

[0025] Figure 1 This is a schematic diagram of the overall structure of the autoclaved lightweight aerated concrete board described in the utility model;

[0026] Figure 2 It is a cross-sectional view of the autoclaved lightweight aerated concrete board described in the utility model;

[0027] Figure 3 It is a schematic structural diagram of the fiber fabric mesh layer in the utility model.

[0028] Among them, 1 is ALC sandwich panel, 2 is fabric-reinforced high-ductility concrete surface layer, 3 is high-ductility concrete surface layer; 101 is the first embedded steel mesh, 102 is the second embedded steel mesh; 201 is the fiber fabric mesh layer. DETAILED DESCRIPTION

[0029] In order to make the technical problems, technical solutions and beneficial effects solved by the present invention more clearly understood, the present invention is further described in detail in the following specific embodiments. It should be understood that the specific embodiments described herein are only used to explain the present invention and are not used to limit the present invention.

[0030] As attached Figure 1-3As shown, the utility model provides an autoclaved lightweight aerated concrete panel, comprising an ALC sandwich panel 1, a fabric-reinforced high-ductility concrete surface layer 2 and a high-ductility concrete surface layer 3; the fabric-reinforced high-ductility concrete surface layer 2 is arranged on a first side of the ALC sandwich panel 1, and the high-ductility concrete surface layer 3 is arranged on a second side of the ALC sandwich panel 1; preferably, the ALC sandwich panel 1 has a thickness of 50-300 mm, a width of 600-1800 mm, and a length of 1800-6000 mm; the fabric-reinforced high-ductility concrete surface layer 2 and the high-ductility concrete surface layer 3 are both 20-200 mm.

[0031] In the utility model, the ALC sandwich panel 1 is cast by autoclaved lightweight aerated concrete, and the raw materials of the autoclaved lightweight aerated concrete include sand, fly ash, cement, silica fume and water; preferably, the raw materials include, by weight: 1 part of sand, 0.1-0.2 parts of fly ash, 0.6-0.8 parts of cement, 0.1-0.2 parts of silica fume and 0.16-0.22 parts of water.

[0032] Specifically, the ALC sandwich panel 1 includes an ALC panel body and a first embedded steel mesh 101 and a second embedded steel mesh 102 embedded in the ALC panel body; the ALC panel body is cast by autoclaved aerated concrete; the first embedded steel mesh 101 and the second embedded steel mesh 102 are arranged in parallel in the ALC panel body, and are both arranged parallel to the panel surface of the ALC sandwich panel 1; wherein the first embedded steel mesh 101 is arranged close to the first side surface of the ALC sandwich panel 1, and the second embedded steel mesh 102 is arranged close to the second side surface of the ALC sandwich panel 1; wherein the spacing between the first embedded steel mesh 101 and the first side surface of the ALC sandwich panel 1 is 15-40mm, and the spacing between the second embedded steel mesh 102 and the second side surface of the ALC sandwich panel 1 is 15-40mm.

[0033] The first embedded steel mesh 101 and the second embedded steel mesh 102 have the same structure, and both the first embedded steel mesh 101 and the second embedded steel mesh 102 include staggered longitudinal embedded steel bars and transverse embedded steel bars; wherein the longitudinal embedded steel bars are evenly distributed along the longitudinal direction of the ALC sandwich panel 1, and the transverse embedded steel bars are evenly distributed along the transverse direction of the ALC sandwich panel 1; wherein the diameters of the longitudinal embedded steel bars and the transverse embedded steel bars are both 4.5-8mm, the spacing between two adjacent longitudinal embedded steel bars is 400-800mm, and the spacing between two adjacent transverse embedded steel bars is 200-300mm.

[0034] In the utility model, the fabric-reinforced high-ductility concrete surface layer 2 comprises a first high-ductility concrete layer, a fiber fabric grid layer 201 and a second high-ductility concrete layer which are sequentially arranged in layers; specifically, one side of the first high-ductility concrete layer contacts the first side surface of the ALC sandwich panel 1, and the other side of the first high-ductility concrete layer contacts the second high-ductility concrete layer; the fiber fabric grid layer 201 is arranged between the first high-ductility concrete layer and the second high-ductility concrete layer; wherein the fiber fabric grid layer 201 adopts a fiber fabric grid with a cross grid structure; preferably, the size feature of the cross grid structure is: length × width = (10-30) mm × (10-30) mm.

[0035] In the utility model, the high-ductility concrete surface layer 3, the first high-ductility concrete layer and the second high-ductility concrete layer are all cast by high-ductility concrete; wherein the raw materials of the high-ductility concrete include: cement, fly ash, silica fume, sand, chopped PE fibers and water.

[0036] Preparation method:

[0037] The utility model discloses a method for manufacturing an autoclaved lightweight aerated concrete board, comprising the following steps:

[0038] Step 1, using steam lightweight aerated concrete to make an ALC sandwich panel 1; specifically, first make and install a template for forming the ALC sandwich panel 1, then install the first embedded steel mesh 101 and the second embedded steel mesh 102 to the preset position of the template, then autoclave the lightweight aerated concrete, and perform curing to obtain the ALC sandwich panel 1.

[0039] Step 2, constructing a fabric-reinforced high-ductility concrete surface layer 2 on one side surface of the ALC sandwich panel 1; wherein the construction process of the fabric-reinforced high-ductility concrete surface layer 2 is specifically as follows: first, constructing a first high-ductility concrete layer on one side surface of the ALC sandwich panel 1, then laying a fiber fabric mesh layer 201 on the surface of the first high-ductility concrete layer, and then constructing a second high-ductility concrete layer on the surface of the fiber fabric mesh layer 201.

[0040] Step 3: constructing a high-ductility concrete surface layer 3 on the other side surface of the ALC sandwich panel 1.

[0041] The autoclaved lightweight aerated concrete board and the ALC sandwich board 1 of the utility model can be mass-produced in a prefabrication plant, and have the advantages of high production efficiency and good product quality; secondly, they can be directly hoisted and assembled for use in on-site construction, which greatly saves scaffolding and formwork, effectively reduces the manpower and work tools for floor construction, reduces labor intensity, and has the advantages of fast construction speed and low project cost; compared with the existing ALC lightweight boards on the market, it has the advantages of low cost, light weight, high strength and simple and convenient production steps; at the same time, it also has good fire retardant, thermal insulation, anti-seepage and waterproof and sound insulation properties.

[0042] (1) Advantage of low cost: Since the main material of the ALC sandwich panel 1 is autoclaved lightweight aerated concrete, it is economical and practical. Although the fabric-reinforced high-ductility concrete surface layer 2 and the high-ductility concrete surface layer 3 arranged on both sides of the ALC sandwich panel 1 will increase the overall absolute cost of the panel, it is relatively cheaper than panels with equivalent strength on the market. Secondly, in actual use, the surface of the autoclaved lightweight aerated concrete panel does not need to be plastered, which greatly reduces the cost. At the same time, the surface of the autoclaved lightweight aerated concrete panel can be directly puttyed and sprayed with paint, which directly reduces the product price and subsequent maintenance costs. In addition, the panel uses a low amount of steel, which reduces the cost of steel and the cost of the production process in the production project.

[0043] (2) Advantages of light weight: Since the main material of autoclaved lightweight aerated concrete panels is autoclaved lightweight aerated concrete, its bulk density is small, which can effectively reduce the weight of the building and reduce the investment in foundation and structure; at the same time, the panel components are light in weight, which is convenient for production, transportation and installation, reducing the cost of construction measures.

[0044] (3) Advantages of high strength: Since a fabric-reinforced high-ductility concrete surface layer 2 and a high-ductility concrete surface layer 3 are arranged on both sides of the plate, a fiber fabric mesh layer 201 is arranged in the fabric-reinforced high-ductility concrete surface layer 2, and the high strength, high durability, high ductility and crack control ability of the fabric-reinforced high-ductility concrete surface layer are utilized, the plate with improved performance can fully meet the requirements for plate bending resistance, crack resistance and node strength under various use conditions; the autoclaved lightweight aerated concrete plate can be used in scenes where it cannot be used, for example: non-load-bearing components of industrial and civil buildings such as wall panels and roof panels, and due to its greatly improved strength, it can also be used in load-bearing components in buildings including but not limited to floor slabs or interior wall panels.

[0045] (4) Advantages of simple and convenient production steps: The autoclaved lightweight aerated concrete board of the utility model can improve the mechanical properties of the component by applying the fabric-reinforced high-ductility concrete surface layer 2 and the high-ductility concrete surface layer 3 on the two side surfaces of the ALC sandwich panel 1, and avoid the cracking problem of the lightweight board during the production, transportation and installation construction process, without the need to apply prestress. The prestressing process is not used, which avoids the adverse effects caused by the relaxation of prestress and improves the durability of the product.

[0046] (5) Fire-retardant performance: The raw materials and products of the autoclaved lightweight aerated concrete board are inorganic and do not produce toxic gases in the event of a fire.

[0047] (6) Thermal insulation performance: Autoclaved lightweight aerated concrete has not only good thermal insulation performance, but also good thermal insulation performance. When a reasonable thickness is used, it can be used not only in cold areas with high thermal insulation requirements, but also in hot summer and warm winter areas or hot summer and warm winter areas with high thermal insulation requirements, meeting the requirements of energy-saving standards.

[0048] (7) Regarding the performance of anti-seepage and waterproofing: First, the fabric-reinforced high-ductility concrete surface layer 2 and the high-ductility concrete surface layer 3 have good anti-seepage and waterproofing properties; second, the small holes inside the ALC sandwich panel 1 are all independent closed holes with a diameter of about 1 mm, which can effectively prevent moisture diffusion.

[0049] (8) Sound insulation performance: Since autoclaved lightweight aerated concrete is a porous material composed of a large number of uniform, unconnected tiny pores, it has excellent sound insulation performance and meets the multifunctional requirements of the building in terms of livability.

[0050] The autoclaved lightweight aerated concrete board described in the utility model, by respectively arranging a fabric-reinforced high-ductility concrete surface layer 2 and a high-ductility concrete surface layer 3 on both sides of an ALC sandwich panel 1, utilizes the high strength, high durability, high ductility and excellent crack control ability of the high-ductility concrete and the fiber fabric grid layer arranged therein, and combines the light weight, fire retardant, thermal insulation and anti-seepage and waterproof properties of the ALC sandwich panel 1, thereby changing the limitation that the traditional ALC autoclaved lightweight concrete board can only be used for non-load-bearing components; in the utility model, the autoclaved lightweight aerated concrete board does not need to be prestressed, and does not need to adopt a prestressing process, thereby avoiding the adverse effects caused by prestress relaxation and improving the durability of the product.

[0051] The above embodiment is only one of the implementation methods that can realize the technical solution of the utility model. The scope of protection required by the utility model is not limited only to this embodiment, but also includes within the technical scope disclosed by the utility model, any changes, replacements and other implementation methods that can be easily thought of by any technician familiar with the technical field.

Claims

1. An autoclaved lightweight aerated concrete board, characterized in that: It comprises an ALC sandwich panel (1), a fabric-reinforced high-ductility concrete surface layer (2) and a high-ductility concrete surface layer (3); The ALC sandwich panel (1) is cast using autoclaved lightweight aerated concrete, the fabric-reinforced high-ductility concrete surface layer (2) is arranged on one side of the ALC sandwich panel (1), and the high-ductility concrete surface layer (3) is arranged on the other side of the ALC sandwich panel (1); wherein the fabric-reinforced high-ductility concrete surface layer (2) comprises a first high-ductility concrete layer, a fiber fabric mesh layer (201), and a second high-ductility concrete layer which are sequentially layered.

2. The autoclaved lightweight aerated concrete board according to claim 1, characterized in that: A first embedded steel mesh (101) and a second embedded steel mesh (102) are also embedded in the ALC sandwich panel (1); the first embedded steel mesh (101) and the second embedded steel mesh (102) are arranged in parallel, and are both arranged in parallel with the panel surface of the ALC sandwich panel (1); wherein the first embedded steel mesh (101) is arranged close to the first side surface of the ALC sandwich panel (1), and the second embedded steel mesh (102) is arranged close to the second side surface of the ALC sandwich panel (1).

3. The autoclaved lightweight aerated concrete board according to claim 2, characterized in that: The distance between the first embedded steel mesh (101) and the first side surface of the ALC sandwich panel (1) is 15-40 mm, and the distance between the second embedded steel mesh (102) and the second side surface of the ALC sandwich panel (1) is 15-40 mm.

4. The autoclaved lightweight aerated concrete board according to claim 2, characterized in that: The first embedded steel mesh (101) and the second embedded steel mesh (102) have the same structure, and both include staggered longitudinal embedded steel bars and transverse embedded steel bars; wherein the longitudinal embedded steel bars are evenly distributed along the longitudinal direction of the ALC sandwich panel (1), and the transverse embedded steel bars are evenly distributed along the transverse direction of the ALC sandwich panel (1).

5. The autoclaved lightweight aerated concrete board according to claim 4, characterized in that: The diameters of the longitudinal embedded steel bars and the transverse embedded steel bars are 4.5-8 mm; the spacing between two adjacent longitudinal embedded steel bars is 400-800 mm, and the spacing between two adjacent transverse embedded steel bars is 200-300 mm.

6. The autoclaved lightweight aerated concrete board according to claim 1, characterized in that: The fiber fabric mesh layer (201) adopts a fiber fabric mesh with a cross mesh structure; wherein the dimension feature of the cross mesh structure is: length×width=(10-30) mm×(10-30) mm.

7. The autoclaved lightweight aerated concrete board according to claim 1, characterized in that: The thickness of the ALC sandwich panel (1) is 50-300 mm.

8. The autoclaved lightweight aerated concrete board according to claim 1, characterized in that: The thickness of the fabric-reinforced high-ductility concrete surface layer (2) and the high-ductility concrete surface layer (3) are both 20-200 mm.

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