Production method of rock wool mixed material, rock wool mixed material, fire resistive covering method, spray construction system of fire resistive covering material

Abstract

To provide a spray construction system of fire resistive covering material allowing cost and manpower of spray rock wall fire resistive covering work in a dry work system to be reduced.SOLUTION: A production method of rock wool mixed material of fire resistive covering material produced through mixture with water at a tip of a spray nozzle includes: a process of acquiring rock wool pieces by cutting a rock wool block; a process of adding powder cement into the rock wool pieces; and a process of mixing the powder cement with the rock wool pieces while disengaging the rock wool pieces.SELECTED DRAWING: Figure 1

Description

Technical Field

[0001] The present invention relates to a method for manufacturing a rock wool mixture used when performing a refractory coating work by a dry method, a rock wool mixture, a refractory coating method, and a spraying construction system for a refractory coating material.

Background Art

[0002] In a building with a steel frame structure, a refractory coating work is performed to coat the surface of the structure with a refractory coating material to form a fire-resistant structure. Among the refractory coating works, when spraying the refractory coating material, a dry method and a semi-dry method are known as the methods. For example, Patent Document 1 discloses a spraying device for semi-dry and dry refractory coating materials.

[0003] The semi-dry method is a method in which rock wool and cement slurry constituting the refractory coating material are pumped through separate routes, and then these are mixed at the tip of a spraying nozzle to form a refractory coating material, which is sprayed onto the surface to be constructed. On the other hand, the dry method is a method in which a mixture of "rock wool and powdered cement", which is a premix product manufactured in a factory and packed in bags, is pumped by an air blower and mixed with water sent through a separate route at the tip of a spraying nozzle to form a refractory coating material, which is sprayed onto the surface to be constructed.

Prior Art Documents

Patent Documents

[0004]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0005] In the dry method, since the rock wool contained in the premix product is densely defibered at the factory, it is widely known that, compared with the semi-dry method, the unevenness of the fireproof coating sprayed on the steel frame surface is suppressed, and the coated shape can be finished neatly. However, the premix product of "rock wool and powdered cement" is expensive and disadvantageous in terms of cost compared with the semi-dry method. For this reason, the dry method is only adopted in limited parts such as repair spraying and is not fully utilized.

[0006] In addition, for fireproof coating work by spraying construction, regardless of whether it is semi-dry or dry, it is necessary to suppress the unevenness of the sprayed fireproof coating material to make it smooth and level it with a trowel or the like so that there is no fuzz on the coated surface, that is, so-called trowel pressing. Such trowel pressing work is carried out by a dedicated skilled worker. In recent years, however, the shortage of skilled workers has become a problem, and problems have arisen from the perspective of labor saving.

[0007] The present invention has been made in view of such problems, and its main object is to reduce the cost and labor of the sprayed rock wool fireproof coating work by the dry method.

Means for Solving the Problems

[0008] The method for manufacturing a rock wool mixture of the present invention for achieving such an object is a method for manufacturing a rock wool mixture that is mixed with water at the tip of a spray nozzle to form a fireproof coating material, comprising a step of cutting a rock wool block to obtain rock wool pieces, a step of adding powdered cement to the rock wool pieces, and a step of mixing with the powdered cement while defibering the rock wool pieces.

[0009] The method for manufacturing a rock wool mixture of the present invention is characterized in that the powdered cement is made in a wet state and added to the rock wool pieces.

[0010] The rock wool mixture of the present invention is characterized by being manufactured by the method for manufacturing a rock wool mixture of the present invention.

[0011] The fireproof coating method of the present invention is a fireproof coating method for spraying a fireproof coating material onto a surface to be coated. The method includes a step of pumping a rock wool mixture of the present invention towards a spraying nozzle while manufacturing it at the construction site, and a step of mixing the rock wool mixture and water at the tip of the spraying nozzle to obtain a fireproof coating material and spraying the fireproof coating material onto the surface to be coated.

[0012] The fireproof coating method of the present invention is characterized in that the fireproof coating material is sprayed onto the surface to be coated while being surrounded by water sprayed from the tip of the spraying nozzle.

[0013] The spraying construction system for a fireproof coating material of the present invention is a spraying construction system for a fireproof coating material for spraying a fireproof coating material onto a surface to be coated. The system includes a manufacturing plant for manufacturing a rock wool mixture, and a spraying nozzle for mixing the rock wool mixture manufactured by the manufacturing plant and water to obtain the fireproof coating material and spraying the fireproof coating material onto the surface to be coated. The manufacturing plant includes a feeder for cutting a rock wool block into a plurality of rock wool pieces, and a defibrator including an air blower for defibrating the rock wool pieces while mixing them with powder cement to form a rock wool mixture and quantitatively pumping the rock wool mixture towards the spraying nozzle. The system further includes a powder supply device for quantitatively supplying the powder cement to the mixture manufacturing device.

[0014] The spraying construction system for a fireproof coating material of the present invention is characterized by including a spraying device equipped with a robot arm carrying the spraying nozzle.

[0015] According to the manufacturing method of the rock wool mixture, the rock wool mixture, the fireproof coating method, and the spraying construction system for a fireproof coating material of the present invention, a rock wool mixture in which the rock wool is densely defibrated can be obtained by mixing the rock wool pieces obtained by cutting the rock wool block with powder cement while defibrating the rock wool pieces. Also, the rock wool mixture can be manufactured at the construction site.

[0016] As a result, instead of using premixed products manufactured in a factory for the fireproof coating work by the dry method, a rock wool mixture manufactured at the construction site can be used, so that the labor cost can be significantly reduced, and the fireproof coating material formed on the construction target surface can be made into a good-looking coated shape with less unevenness compared to the semi-dry method. In addition, since the rock wool mixture can be pumped toward the spraying nozzle while being manufactured at the construction site, the rock wool mixture can be stably supplied, and the workability of the fireproof coating work by the dry method can be improved.

[0017] Also, when pumping the rock wool mixture toward the spraying nozzle, if the output of the air blower is adjusted to be increased, the entire fireproof coating material formed on the construction target surface can be pressed with air having an increased air volume, and the coating surface can be made smoother and more even. As a result, it is possible to omit the troweling work by skilled workers that has been required conventionally and achieve labor saving.

[0018] Furthermore, when the fireproof coating material is surrounded by water sprayed from the tip of the spraying nozzle, since the misty water adheres to the surface of the fireproof coating material, it is possible to significantly eliminate the fluffiness that easily occurs on the coating surface. In addition, the misty water sprayed from the tip of the spraying nozzle, combined with the use of powdered cement in a wet state, can also prevent the scattering of dust that easily occurs when injecting the rock wool mixture from the spraying nozzle.

[0019] If a spraying construction system for the fireproof coating material including a spraying device equipped with a robot arm is adopted for the above-mentioned fireproof coating work, it is not only possible to contribute to the labor saving of a series of on-site operations related to the fireproof coating work, but also to stably maintain a constant separation distance between the spraying nozzle and the construction target surface even when the output of the air blower that pumps the rock wool mixture toward the spraying nozzle is high and the air volume of the air is large, and it is possible to finish the surface of the fireproof coating material with higher accuracy.

Effect of the Invention

[0020] According to the present invention, by using a rock wool mixture obtained by mixing powdered cement while loosening rock wool, it becomes possible to reduce the cost of refractory coating work by a dry method and to reduce the man-hours required for the entire refractory coating work.

Brief Description of the Drawings

[0021]

Figure 1

Figure 2

Figure 3

Figure 4

Figure 5

Figure 6

Embodiments for Carrying Out the Invention

[0022] The refractory coating method of the present invention, the method for manufacturing a rock wool mixture, the rock wool mixture, the refractory coating method, and the spraying construction system of the refractory coating material can all be adopted for dry spraying rock wool refractory coating work. Hereinafter, taking the case of dry spraying the refractory coating material on the surface of a steel beam as the construction target surface as an example, with reference to FIGS. 1 to 6, the details will be described.

[0023] ≪≪Spraying Construction System of Refractory Coating Material≫≫ As shown in FIG. 1, the spraying construction system 100 of the refractory coating material includes a manufacturing plant 10 for manufacturing a rock wool mixture RC, and a mixing water W 1 and the rock wool mixture RC are mixed to form a refractory coating material M, and a spraying nozzle 70 for spraying this onto the construction target surface F of the steel beam 200, and a spraying apparatus 60 including the spraying nozzle 70.

[0024] <<Manufacturing Plant>> The manufacturing plant 10 is a device for manufacturing a rock wool mixture RC and pumping it to a spraying nozzle 70, and includes a powder supply device 20 and a mixture manufacturing device 30.

[0025] <<Powder Supply Device>> The powder supply device 20 is a device for continuously and quantitatively supplying powdered cement C to the mixture manufacturing device 30. As shown in FIG. 2, it includes a storage tank 21, a stirring blade 22, a rotary valve 23, a powder pumping hose 24, an air supply hose 25, an air blower 26, and a trolley 27.

[0026] The storage tank 21 is a container into which powdered cement C is dropped, and is formed, for example, in a cylindrical shape having a bottom. Inside it, a stirring blade 22 for powdered cement C that rotates around the central axis of the storage tank 21 is provided. Also, an outlet through which powdered cement flows out is provided at the bottom of the storage tank 21, and a rotary valve 23 is provided at this outlet.

[0027] One end of each of the powder pumping hose 24 and the air supply hose 25 is connected to the rotary valve 23. The other end of the air supply hose 25 is connected to the air blower 26, and the other end of the powder pumping hose 24 is connected to the mixture manufacturing device 30 described later. And by installing the storage tank 21 and the air blower 26 on the trolley 27, the powder supply device 20 can be moved within the construction site.

[0028] The powder supply device 20 having the above configuration can continuously send out the powdered cement C in the storage tank 21 toward the outlet at the bottom by stirring the powdered cement C dropped into the storage tank 21 with the stirring blade 22. Also, when the powdered cement C is to be in a wet state, by supplying water W 3 while stirring with the stirring blade 22, a homogeneous wet powdered cement C can be sent out to the outlet.

[0029] Furthermore, by rotating the rotary valve 23 and operating the air blower 26, the powdered cement C delivered to the outlet of the storage tank 21 can be pneumatically conveyed through the powder conveying hose 24 toward the mixture manufacturing apparatus 30 by using the air supplied from the air supply hose 25. At this time, by adjusting the rotation speed of the rotary valve 23 and the output of the air blower 26, a desired amount of powdered cement C can be continuously and quantitatively supplied toward the mixture manufacturing apparatus 30.

[0030] ≪Mixture Manufacturing Apparatus≫ The mixture manufacturing apparatus 30 is an apparatus that cuts the rock wool block RB into rock wool pieces RP, defibrates them while mixing with the powdered cement C, and obtains the rock wool mixture RC. As shown in FIGS. 3(a) and 3(b), it includes a feeder 40 and a defibrator 50 disposed below the feeder 40. These are mounted on the trolley 31 and can be moved within the construction site.

[0031] ≪Feeder 40≫ The feeder 40 includes an apparatus main body 41, a mounting table 42, and a plurality of roll pins 43 and a rotary cutter 44 provided within the apparatus main body 41.

[0032] As shown in FIG. 3(b), the apparatus main body 41 has a side opening 411 formed on the upper side, and the mounting table 42 is provided so as to be continuous with the side opening 411. Further, as shown in FIG. 3(a), the other end of the powder conveying hose 24 provided in the powder supply apparatus 20 is connected to the apparatus main body 41.

[0033] A plurality of roll pins 43 are radially provided around a pin rotation shaft 431 disposed parallel to the side opening 411 of the apparatus main body 41. The pin rotation shafts 431 are provided in pairs above and below the side opening 411. Thus, when the rock wool block RB placed on the mounting table 42 is inserted into the side opening 411, the plurality of roll pins 33 that rotate together with the pin rotation shaft 431 draw the rock wool block RB into the apparatus main body 41.

[0034] The rotary cutter 44 has a plurality of cutters arranged in parallel on a cutter rotation shaft 441 that is disposed on the side opposite to the side opening 411 across the region provided with the roll pin 43 and is parallel to the pin rotation shaft 431. As a result, the rock wool block RB drawn into the apparatus main body 41 by the roll pin 43 is cut by the plurality of rotary cutters 44 to become rock wool pieces RP, and is dropped into the fluffer 50 positioned below.

[0035] In addition, the powder feed hose 24 connected to the apparatus main body 41 is provided at a height position where the powder cement C can be supplied toward the rock wool piece RP.

[0036] ≪Fluffer 50≫ The fluffer 50 includes a hopper 51 connected to the apparatus main body 41 of the feeder 40, and a plurality of fluffing rakes 52 provided in the hopper 51. Further, it includes a screw feeder 53, a high-speed cutter 54, a rotary valve 55, a mixture feed hose 56, an air supply hose 57, and an air blower 58.

[0037] The fluffing rakes 52 are provided radially in a plurality around a rake rotation shaft 521 that is disposed parallel to the pin rotation shaft 431 and the cutter rotation shaft 441 of the feeder 40. By rotating the fluffing rakes 52 together with the rake rotation shaft 521, the rock wool pieces RP dropped from the feeder 40 can be mixed with the powder cement C while being fluffed. The rock wool mixture RC thus obtained falls into the screw feeder 53 positioned below.

[0038] The screw feeder 53 is installed below the hopper 51 in a posture parallel to the rake rotation shaft 521. Further, a high-speed cutter 54 is provided at one end of the screw feeder 53, and the rock wool mixture RC conveyed to the screw feeder 53 is pulverized again by the high-speed cutter 54. A discharge port for the rock wool mixture RC is provided at the bottom of the hopper 51 positioned below the high-speed cutter 54. A rotary valve 55 is provided at this discharge port.

[0039] One end of each of the mixture feed hose 56 and the air supply hose 57 is connected to the rotary valve 55. The other end of the air supply hose 57 is connected to the air blower 58. Also, the other end of the mixture feed hose 56 is connected to a spray nozzle 70 described later.

[0040] By rotating the rotary valve 55 and operating the air blower 58, the rock wool mixture RC that has passed through the screw feeder 53 and the high-speed cutter 54 is supplied with air A supplied from the air supply hose 57 1 and is pumped through the mixture feed hose 56 toward the spray nozzle 70.

[0041] At this time, by adjusting the rotation speed of the rotary valve 55 and the output of the air blower 58, a desired amount of the rock wool mixture RC can be continuously and quantitatively supplied toward the spray nozzle 70.

[0042] ≪≪Spray Nozzle 70≫≫ As shown in FIGS. 4(a) and (b), the spray nozzle 70 includes a nozzle body 71 and a gun head 72 provided in the vicinity of the tip of the nozzle body 71.

[0043] As shown in FIG. 4(a), the nozzle body 71 is formed in a substantially cylindrical shape with both ends open, and a mixture ejection port 71a provided at the tip is arranged to communicate with a central opening from the back side of the gun head 72. Also, one end of the mixture feed hose 56, one end of which is connected to the carding machine 50 of the mixture manufacturing apparatus 30 described with reference to FIG. 3, is connected to the rear end of the nozzle body 71.

[0044] As shown in FIG. 4(b), the gun head 72 is formed by a donut-shaped disk surrounding the nozzle body 71, and a mixing water nozzle 73 is provided in the vicinity of the inner peripheral edge on the front surface thereof, and a water mist nozzle 74 is provided in the vicinity of the outer peripheral edge, and a plurality of each are provided at equal intervals.

[0045] As shown in Fig. 4(a), one end of a water supply pipe 731 for supplying the mixed water W is connected to the mixing water nozzle 73 through the gun head 72. The other end of the water supply pipe 731 is connected to a water supply tank 7012 that also constitutes the water supply device 701 through a pump 7011 that constitutes the water supply device 701. 1 On the other hand, for the water mist nozzle 74, one end of a water supply pipe 741 for supplying the water W to be sprayed in a mist form and one end of an air supply pipe 742 for supplying the air A to spray the water W in a mist form are connected to the gun head 72. The other end of the water supply pipe 741 is connected to a water storage tank 7021 that constitutes the water mist supply device 702. Also, the other end of the air supply pipe 742 is connected to a compressor 7022 that also constitutes the water mist supply device 702.

[0046] At the tip of the spraying nozzle 70 configured as described above, as shown in Fig. 4(a), the rock wool mixture RC pumped to the nozzle body 71 is discharged from the mixture ejection port 71a and mixed with the mixed water W ejected from the mixing water nozzle 73 to form the refractory coating material M. This refractory coating material M is further surrounded by the mist-like water W sprayed from the water mist nozzle 74, and at least a part of it is in a state of being adhered and coated with the mist-like water W. 2 As described above, the spraying nozzle 70 capable of spraying the refractory coating material M coated with the mist-like water W is mounted on a spraying device 60 as shown in Fig. 5. 2 The spraying device 60 includes a robot arm 80 and a traveling unit 90 on which the robot arm 80 is mounted. For details of the robot arm 80 and the traveling unit 90, refer to Japanese Patent Application Laid-Open No. 2020-020206. 2 The spraying device 60 includes a robot arm 80 and a traveling unit 90 on which the robot arm 80 is mounted. For details of the robot arm 80 and the traveling unit 90, refer to Japanese Patent Application Laid-Open No. 2020-020206.

[0047] At the tip of the spraying nozzle 70 configured as described above, as shown in Fig. 4(a), the rock wool mixture RC pumped to the nozzle body 71 is discharged from the mixture ejection port 71a and mixed with the mixed water W ejected from the mixing water nozzle 73 to form the refractory coating material M. This refractory coating material M is further surrounded by the mist-like water W sprayed from the water mist nozzle 74, and at least a part of it is in a state of being adhered and coated with the mist-like water W. 1 At the tip of the spraying nozzle 70 configured as described above, as shown in Fig. 4(a), the rock wool mixture RC pumped to the nozzle body 71 is discharged from the mixture ejection port 71a and mixed with the mixed water W ejected from the mixing water nozzle 73 to form the refractory coating material M. This refractory coating material M is further surrounded by the mist-like water W sprayed from the water mist nozzle 74, and at least a part of it is in a state of being adhered and coated with the mist-like water W. 2 At the tip of the spraying nozzle 70 configured as described above, as shown in Fig. 4(a), the rock wool mixture RC pumped to the nozzle body 71 is discharged from the mixture ejection port 71a and mixed with the mixed water W ejected from the mixing water nozzle 73 to form the refractory coating material M. This refractory coating material M is further surrounded by the mist-like water W sprayed from the water mist nozzle 74, and at least a part of it is in a state of being adhered and coated with the mist-like water W. 2 At the tip of the spraying nozzle 70 configured as described above, as shown in Fig. 4(a), the rock wool mixture RC pumped to the nozzle body 71 is discharged from the mixture ejection port 71a and mixed with the mixed water W ejected from the mixing water nozzle 73 to form the refractory coating material M. This refractory coating material M is further surrounded by the mist-like water W sprayed from the water mist nozzle 74, and at least a part of it is in a state of being adhered and coated with the mist-like water W.

[0048] ≪≪Spraying Device≫≫ As described above, the spraying nozzle 70 capable of spraying the refractory coating material M coated with the mist-like water W is mounted on a spraying device 60 as shown in Fig. 5. 2 As described above, the spraying nozzle 70 capable of spraying the refractory coating material M coated with the mist-like water W is mounted on a spraying device 60 as shown in Fig. 5.

[0049] The spraying device 60 includes a robot arm 80 and a traveling unit 90 on which the robot arm 80 is mounted. For details of the robot arm 80 and the traveling unit 90, refer to Japanese Patent Application Laid-Open No. 2020-020206.

[0050] <<Robot Arm>> The robot arm 80 includes a manipulator 81 with a multi-joint structure having the above-described spraying nozzle 70 provided at its tip as an end effector, and a mounting jig 82 for mounting the spraying nozzle 70.

[0051] In the present embodiment, a six-axis multi-joint robot is adopted for the manipulator 81, which operates based on a job file and controls the operation of the spraying nozzle 70 by its operation. The job file describes information including the movement path and posture of the spraying nozzle 70 (such as the ejection direction of the refractory coating material M ejected from the gun head 72) based on the operation of the manipulator 81 in parameters and numerical values.

[0052] <<Traveling Unit>> The traveling unit 90 includes at least a base portion 91 that supports the robot arm 80, a traversing device 92, a traveling carriage 93, and a lifting device 94. The base portion 91 is installed so as to be movable along the longitudinal direction on the traversing device 92 and rotatably supports the robot arm 80 within its upper surface.

[0053] The traversing device 92 includes a long frame 921 and a traveling gantry 922 that is movable along the longitudinal direction of the frame 921, and the above-described base portion 91 is installed on this traveling gantry 922. The traveling carriage 93 has a structure that can travel on the floor surface, and the above-described traversing device 92 is placed thereon. Further, the traveling carriage 93 is internally equipped with a lifting device 94 that can raise the traversing device 92.

[0054] With respect to the traveling carriage 93 having such a configuration, the traversing device 92 is arranged so as to pass through the center of gravity of the traveling carriage 93 in plan view and the longitudinal direction thereof, that is, the moving direction of the base portion 91 that supports the robot arm 80, is parallel to the traveling direction of the traveling carriage 93.

[0055] <<Refractory Coating Method>> Using the spraying construction system 100 of the refractory coating material equipped with the above spraying device 60, as shown in FIG. 1, a procedure for dry spraying the refractory coating material M using the rock wool mixture RC onto the construction target surface F provided on the steel beam 200 will be described below with reference to the schematic of the spraying construction system 100 of the refractory coating material shown in FIG. 1.

[0056] <<Preparations>> <<Preparation of Wet Powder Cement Used in Rock Wool Mixture>> Using the powder supply device 20, water W 3 is added to the powder cement C to make it in a wet state.

[0057] As shown in FIG. 2, after dropping the powder cement C into the storage tank 21 of the powder supply device 20, these operations are carried out by stirring with the stirring blade 12 while supplying water W. 3 The wet state is preferably such that when the rock wool mixture RC is sprayed from the mixture ejection port 71a provided at the tip of the spraying nozzle 70, the powder cement C mixed in the rock wool mixture RC does not scatter as dust.

[0058] <<Adjustment of Atomized Water Surrounding the Refractory Coating Material M>> The pressure and discharge air volume of the air A 2 required for spraying the atomized water W from the water mist nozzle 74 2 are adjusted by the compressor 7022 described with reference to FIG. 5. Also, the atomized water W 2 is adjusted so that the spraying amount does not affect the formulation when it adheres to the refractory coating material M.

[0059] <<Adjustment of Output (Air Volume) of the Air Blower for Pressurizing the Rock Wool Mixture>> The air blower 58 provided in the defibrator 50 of the mixture manufacturing device 30 sets its output so as to ensure an air volume that satisfies the two functions of the discharge spraying function and the pressing function of the refractory coating material M.

[0060] The spraying function is to discharge the rock wool mixture RC from the mixture outlet 71a of the nozzle body 71 provided in the spraying nozzle 70, and the refractory coating material M obtained by mixing the discharged rock wool mixture RC and the mixing water W 1 is sprayed onto the construction target surface F. The pressing function is to press the refractory coating material M that has been sprayed onto the construction target surface F and is covered with atomized water W 2 .

[0061] Therefore, the air blower 58 provided in the defibrator 50 should be adjusted to increase the output so that the air volume of the conventionally adopted air A 1 is increased. The air volume of the air A 1 should be set to such an extent that the refractory coating material M discharged from the spraying nozzle 70 does not bounce back without adhering to the construction target surface F

[0062] ≪Setting of the discharge amount of the rock wool mixture and the discharge amount of water≫ The discharge amount of the rock wool mixture RC and the mixing water W 1 should be set so that the refractory coating material M obtained by mixing them satisfies the standard mixture specified in the "Construction Management Guidelines for Sprayed Rock Wool Coated Fire Resistant Structures, Revised in 2012, Rock Wool Industrial Association" (hereinafter referred to as the "Construction Management Guidelines"). 1

[0063] Then, considering the set discharge amount of the rock wool mixture RC and the air volume of the air A 1 required for the air blower 58 of the defibrator 50 described above, the rotational speed of the rotary valve 55 provided at the discharge port of the defibrator 50 is adjusted. Also, based on the set discharge amount of the rock wool mixture RC, the supply amount of the powdered cement C is set, and the rotational speed of the rotary valve 23 provided at the outlet of the powder supply device 20 and the output of the air blower 26 are adjusted

[0064] ≪Manufacturing and pressure feeding process of the rock wool mixture≫ ​When the above-mentioned preparatory work is completed, the manufacturing plant 10 equipped with the powder supply device 20 and the mixture manufacturing device 30 is operated to manufacture the rock wool mixture RC and pump it toward the spraying nozzle.

[0065] As described with reference to FIGS. 2 and 3, the wet powder cement C in the storage tank 21 of the powder supply device 20 is continuously and quantitatively supplied toward the mixture manufacturing device 30 through the rotary valve 23 and the powder pumping hose 24.

[0066] As described with reference to FIG. 3, the rock wool block RB is placed on the mounting table 42 provided in the feeder 40 of the mixture manufacturing device 30 and inserted into the side opening 411 of the device main body 41. Then, the plurality of roll pins 33 pull the rock wool block RB into the device main body 41, and the pulled rock wool block RB is cut by the plurality of rotary cutters 44 to become rock wool pieces RP, which are dropped onto the carding machine 50 located below.

[0067] The dropped rock wool pieces RP are carded by the carding brush 52 of the carding machine 50 and mixed with the powder cement C supplied from the powder supply device 20. The thus obtained rock wool mixture RC is continuously and quantitatively pumped toward the spraying nozzle 70 through the screw feeder 53, the rotary valve 55, and the mixture pumping hose 56 by using the air A 1 supplied from the air supply hose 57.

[0068] ≪Spraying process of refractory coating material≫ The rock wool mixture RC pumped from the carding machine 50 is discharged from the mixture ejection port 71a of the spraying nozzle 70, and the mixing water W 1 is discharged from the mixing water nozzle 73.

[0069] When the mixing ratio of the refractory coating material M in which these are mixed satisfies the above-mentioned construction management guidelines, the atomized water W 2 is sprayed from the water mist nozzle 74, and the atomized water W 2Confirm adhesion. After that, operate the spraying device 60, and while moving the spray nozzle 70 along the movement path, movement speed, and posture based on the job file, spray the refractory coating material M onto the construction target surface F as shown in FIG. 1.

[0070] Then, since the rock wool contained in the refractory coating material M using the rock wool mixture RC has finer and denser particles compared to the semi-dry case, the refractory coating material M sprayed onto the construction target surface F forms a coating surface with reduced unevenness. Also, the refractory coating material M sprayed onto the construction target surface F is pressed in various directions including the spray thickness direction through the coating surface covered with the atomized water W 1 by the air A 2 discharged together with the rock wool mixture RC from the mixture ejection port 71a.

[0071] As a result, the unevenness that has been sufficiently reduced compared to the semi-dry case is further leveled, and a smooth finish surface can be obtained. This makes it possible to omit the troweling work that skilled workers used to perform after spraying.

[0072] Also, by spraying the atomized water W 2 and attaching it to the surface of the refractory coating material M, the fluffing that easily occurs on the surface of the refractory coating material M can be significantly eliminated. The atomized water W 2 can also prevent the scattering of dust that may occur when the rock wool mixture RC is discharged from the spray nozzle 70, in combination with the adoption of the powdered cement C in a wet state.

[0073] Furthermore, if the output of the air blower 58 of the fiberizer 50 is increased as much as possible, the rock wool mixture RC is pumped while being stirred inside the mixture pumping hose 56. As a result, the rock wool contained in the rock wool mixture RC is further fluffed inside the mixture pumping hose 56, and the particles become finer. This further suppresses the unevenness of the refractory coating material M sprayed onto the construction target surface F, and it becomes possible to finish the coating shape beautifully.

[0074] In this way, by using the rock wool mixture RC manufactured at the construction site instead of the premix product manufactured at the factory and spraying the refractory coating material M onto the construction target surface F by the dry method, the labor cost can be significantly reduced, and compared with the semi-dry method, a good-looking coated shape with less unevenness on the surface of the refractory coating material M sprayed on the construction target surface F can be obtained.

[0075] Also, by manufacturing the rock wool mixture RC at the construction site and pumping it toward the spraying nozzle 70, the rock wool mixture RC can be stably supplied to the spraying nozzle 70, and it becomes possible to improve the workability of the refractory coating work by the dry method.

[0076] Furthermore, by adopting the spraying device 60 equipped with the robot arm A mounted with the spraying nozzle 70, not only can it contribute to the labor saving of a series of on-site operations related to the refractory coating work, but also even when the output of the air blower 58 is high and the air volume of the air A 1 is large, the separation distance between the spraying nozzle 70 and the construction target surface F can be stably maintained at a constant value, and it becomes possible to finish the surface of the refractory coating material M with higher accuracy.

[0077] ≪≪Experimental Results≫≫ An experiment was conducted to spray the refractory coating material M onto the construction target surface F by the dry method using the rock wool mixture RC obtained by defibrating and mixing the above-mentioned powdered cement C and the rock wool block RB. The experimental results are shown below with reference to Fig. 6.

[0078] ≪Experimental Content≫ In the experiment, at the manufacturing plant 10, a rock wool mixture RC with a mixing ratio of 3:2 of the weight ratio of the rock wool material obtained by defibrating the rock wool block RB and the powdered cement C was prepared and supplied to the spraying nozzle 70. At the tip of the spraying nozzle 70, the rock wool mixture RC and the mixing water W 1 were mixed to form the refractory coating material M, and this was sprayed onto the steel skeleton.

[0079] The mixing ratio of the rock wool mixture RC conforms to the standard mixing ratio specified in the above construction management guidelines. Also, when manufacturing the rock wool mixture RC, water W corresponding to 10% of the weight of the cement was added to the powdered cement C to make it in a wet state. 3 and made it in a wet state.

[0080] The powder supply device 20 described with reference to FIG. 2 adjusted the rotational speed of the rotary valve 23 and the output of the air blower 26 so that 7.34 kg (6.67 kg of powdered cement + 0.67 kg of water) of the wet powdered cement C could be supplied toward the feeder 40 within the time from when 10 kg of the rock wool mass RB was put into the feeder 40 of the mixture manufacturing device 30 until it was dropped into the defiberizer 50.

[0081] For the mixture manufacturing device 30 described with reference to FIG. 3, the output of the air blower 58 of the defiberizer 50 was maximized. Moreover, the target of the 30 - second discharge amount of the powdered cement C contained in the rock wool mixture RC discharged from the gun head 72 of the spraying nozzle 70 was set to 2000 g as the intermediate value, and the rotational speed of the rotary valve 55 of the defiberizer 50 was adjusted to satisfy this.

[0082] The water supply device 701 described with reference to FIG. 4 set the 30 - second discharge amount of the mixed water W discharged from the gun head 72 in consideration of the fact that the wet powdered cement C was discharged from the gun head 72 of the spraying nozzle 70 at the above - mentioned target value, and set the inverter frequency of the pump 7011. Similarly, for the water mist supply device 702 described with reference to FIG. 4, the control pressure of the compressor 7022 was set so that the spray water amount would be 0.5 L / min. 1

[0083] FIG. 6(a) shows the state of the refractory coating material M sprayed on the surface of the steel skeleton by the dry method under the above - mentioned conditions. Also, as a comparative example, FIG. 6(b) shows the refractory coating material M sprayed on the surface of the steel skeleton by the conventionally - practiced dry method (factory - manufactured premix product). 1shows the state. Similarly, as a comparative example, Fig. 6(c) shows a refractory coating material M sprayed on the surface of a steel skeleton material by a conventionally practiced semi-dry method (mixing rock wool and cement milk). 2 shows the state.

[0084] In Figs. 6(a) to (c), the trowel pressing after spraying is not carried out. First, looking at Fig. 6(c), the refractory coating material M 2 has unevenness on its entire surface and is in a rough state, and a lot of fluffing is also observed, so it can be seen that the surface needs to be finished by trowel pressing. On the other hand, looking at Fig. 6(a), it can be seen that the refractory coating material M has eliminated unevenness and fluffing on its entire surface, and a smooth surface is formed.

[0085] Such a refractory coating material M shown in Fig. 6(a) is a refractory coating material M sprayed by a dry method using a premix product manufactured in a factory shown in Fig. 6(b) 1 and can be seen to be finished in a coating shape similar to that.

[0086] The method for manufacturing the rock wool mixture, the rock wool mixture, the refractory coating method, and the spraying construction system for the refractory coating material of the present invention are not limited to the above embodiments, and various changes can be made without departing from the spirit of the present invention.

[0087] For example, in the present embodiment, the spraying nozzle 70 as shown in Fig. 4 is adopted, but its structure and shape are not necessarily limited to this. Similarly, the spraying device 60 shown in Fig. 5 is also not limited to this, and any device that contributes to the automation of the spraying construction may be adopted.

[0088] Also, in the present embodiment, the case where the defibrator 50 constituting the mixture manufacturing device 30 is provided with the defibrating comb 52 as shown in Fig. 3 is taken as an example. However, it is not limited to this, and for example, a structure in which return blades are attached to the defibrating comb 52 or the comb rotating shaft 521 may be adopted.

[0089] With such a structure provided with return blades, by appropriately adjusting the number thereof, it is possible to ensure a long residence time of the rock wool mixture RC obtained by mixing the powdered cement C while defibrating the rock wool pieces RP. As a result, the rock wool contained in the rock wool mixture RC is defibrated more densely, so that when the refractory coating material M using this is sprayed onto the construction target surface F, it is possible to further suppress unevenness in the coated shape.

[0090] Furthermore, in the present embodiment, in consideration of suppressing the generation of dust from the rock wool mixture RC discharged from the spray nozzle 70, the powdered cement C used in the production of the rock wool mixture RC is made in a wet state, and also, when spraying the refractory coating material M onto the construction target surface F, atomized water W 2 is sprayed. However, if the generation of dust can be suppressed by other means, these means do not necessarily have to be adopted.

Explanation of Reference Numerals

[0091] 100 Spraying Construction System 10 Manufacturing Plant 20 Powder Supply Device 21 Storage Tank 22 Stirring Blade 23 Rotary Valve 24 Powder Pressure Feeding Hose 25 Air Supply Hose 26 Air Blower 27 Cart 30 Mixture Manufacturing Device 31 Cart 40 Feeder 41 Device Body 411 Side Opening 42 Mounting Table 43 Roll Pin 431 Pin Rotation Shaft 44 Rotary Cutter 441 Cutter Rotation Shaft 50 Defibrator 51 Hopper 52 Defibrating Brush 521 Brush Rotation Shaft 53 Screw feeder 54 High-speed cutter 55 Rotary valve 56 Mixture feed hose 57 Air supply hose 58 Air blower 60 Spraying device 61 Manipulator 62 Base part 63 Transverse device 631 Frame 632 Traveling gantry 64 Traveling carriage 65 Lifting device 66 Mounting jig 70 Spraying nozzle 71 Nozzle body 71a Mixture ejection port 72 Gun head 73 Nozzle for mixed water 731 Water supply pipe 74 Water mist nozzle 741 Water supply pipe 742 Air supply pipe 701 Water supply device 7011 Pump 7012 Water supply tank 702 Water mist supply device 7021 Water storage tank 7022 Compressor 80 Robot arm 81 Manipulator 82 Mounting jig 90 Traveling part 91 Base part 92 Transverse device 921 Frame 922 Traveling gantry 93 Traveling carriage 94 Lifting device F Surface to be constructed RB Rock wool block PP Rock wool sheet RC Rock wool mixture C Powder cement M Refractory coating material M1 Fireproof coating material (premix product) M 2 Fireproof coating material (semi-dry method) W 1 Mixing water (water to be mixed into the rock wool mixture) W 2 Water (water to be sprayed in mist form) W 3 Water (water to keep the powdered cement in a wet state) A 1 Air A 2 Air (for mist)

Claims

1. A method for manufacturing a rock wool mixture that forms a refractory coating material by being mixed with water at the tip of a spraying nozzle, comprising: a step of cutting a rock wool block to obtain rock wool pieces; a step of adding powdered cement to the rock wool pieces; a step of mixing with the powdered cement while loosening the rock wool pieces; A method for manufacturing a rock wool mixture, characterized by comprising the above steps.

2. The method for manufacturing a rock wool mixture according to Claim 1, characterized in that the powdered cement is in a wet state and added to the rock wool pieces.

3. A rock wool mixture, characterized by being manufactured by the method for manufacturing a rock wool mixture according to Claim 1.

4. A refractory coating method for spraying a refractory coating material onto a surface to be coated, comprising: a step of pumping the rock wool mixture according to Claim 3 towards a spraying nozzle while manufacturing it at the construction site; a step of mixing the rock wool mixture and water at the tip of the spraying nozzle to obtain a refractory coating material, and spraying the refractory coating material onto the surface to be coated.

5. The refractory coating method according to Claim 4, characterized in that the refractory coating material is sprayed onto the surface to be coated while being surrounded by water sprayed from the tip of the spraying nozzle.

6. A spraying construction system for a refractory coating material for spraying a refractory coating material onto a surface to be coated, comprising: a manufacturing plant for manufacturing a rock wool mixture; a spraying nozzle that mixes the rock wool mixture manufactured by the manufacturing plant and water to obtain the refractory coating material, and sprays the refractory coating material onto the surface to be coated, wherein the manufacturing plant includes: a feeder that cuts a rock wool block into a plurality of rock wool pieces, and a defibrator that includes an air blower that mixes the rock wool pieces with powdered cement while defibrating them to form a rock wool mixture, and quantitatively pumps the rock wool mixture to the spraying nozzle; a powder supply device that quantitatively supplies the powdered cement to the mixture manufacturing device.

7. The spraying construction system for a refractory coating material according to Claim 6, characterized by including a spraying device including a robot arm equipped with the spraying nozzle. ​ ​ ​ ​

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