Plate-like concrete member and manufacturing method of the same

Abstract

To provide a plate-like concrete member which can prevent deterioration in appearance, and can suppress warpage, and a manufacturing method of the same.SOLUTION: A plate-like concrete member 1 includes: a body plate part 11 obtained by curing, over time, a flowable material containing an aggregate, a curable material, and water; a front face plate part 12 positioned on one surface side of the body plate part 11 and configured to suppress discharge of moisture from the body plate part 11; and a rear face layer part 13 positioned on the other surface side of the body plate part 11 and configured to suppress discharge of moisture from the body plate part 11. The rear face layer part 13 is formed of, for example, a moisture-proof airtight sheet.SELECTED DRAWING: Figure 1

Description

Technical Field

[0001] The present invention relates to a plate-shaped concrete member used as an outer wall material or the like and a method for manufacturing the same.

Background Art

[0002] Patent Document 1 discloses a concrete wall body main body composed of a large number of lightweight aggregates and mortar containing the lightweight aggregates, and a tile adhered to the surface thereof. In the concrete wall body main body, the lightweight aggregates are unevenly distributed on the back surface side, and the mortar is unevenly distributed on the surface side.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] However, in the above concrete wall body main body, in a structure provided with a surface plate portion such as a tile on the surface, there is a difference in the degree of evaporation of moisture in the concrete between the surface side and the back surface side, resulting in a problem that the concrete body warps.

[0005] An object of the present invention is to suppress warping of a plate-shaped concrete member.

Means for Solving the Problems

[0006] In order to solve the above problems, the plate-shaped concrete member of the present invention includes a main body plate portion in which a fluid material containing an aggregate, a hardening material, and water has hardened over time, a surface plate portion located on one surface side of the main body plate portion and suppressing the release of moisture from the one surface side, and a back surface layer portion located on the other surface side of the main body plate portion facing away from the one surface side and suppressing the release of moisture from the other surface side.

[0007] With the above configuration, since the back surface layer portion is provided on the other surface side of the main body plate portion, the difference in the amount of moisture released from one surface of the main body plate portion where the front surface plate portion is located and the amount of moisture released from the other surface of the main body plate portion where the back surface layer portion is located can be reduced, and the warping of the plate-shaped concrete member can be reduced. Further, when the back surface layer portion is located, it is possible to suppress the aggregate from protruding from the concrete surface and prevent poor appearance.

[0008] The back surface layer portion may be formed of a sheet with an anchor inserted into the main body plate portion. According to this, it is possible to suppress the sheet from peeling off from the main body plate portion by the anchor.

[0009] The back surface layer portion may be formed of a sheet with irregularities attached to the main body plate portion. According to this, it is possible to suppress the sheet from peeling off from the main body plate portion by the attachment of the irregularities.

[0010] The back surface layer portion may be formed of a sheet, and a cut portion of a part of the sheet may be bent and embedded in the main body plate portion. According to this, it is possible to suppress the sheet from peeling off from the main body plate portion by the cut portion of the sheet embedded in the main body plate portion.

[0011] The back surface layer portion may be formed of a sheet fixed by a fastening member driven into the main body plate portion. According to this, it is possible to suppress the sheet from peeling off from the main body plate portion by the fastening member.

[0012] The back surface layer portion may be formed of a sheet fixed to the main body plate portion with an adhesive. According to this, it is possible to suppress the sheet from peeling off from the main body plate portion by the adhesive.

[0013] The back surface layer portion may be transparent or translucent. According to this, while confirming the adhesion state of the back surface layer portion to the main body plate portion through the transparent or translucent region, the back surface layer portion can be provided on the main body plate portion.

[0014] The back surface layer portion may be stretchable. According to this, since the back surface layer portion can follow the drying shrinkage of the plate-shaped concrete member, it is possible to suppress the peeling of the back surface layer portion from the main body plate portion.

[0015] The manufacturing method of the plate-shaped concrete member of the present invention is the manufacturing method of the plate-shaped concrete member, wherein a decorative member serving as the surface plate portion is laid on the bottom surface in the formwork, the fluid material is placed in the formwork, and the sheet serving as the back surface layer portion is attached to the other surface side of the main body plate portion before the fluid material hardens.

[0016] According to the above method, since the sheet is attached to the other surface side of the fluid material (the main body plate portion) without waiting for the hardening of the fluid material placed in the formwork, the time required for manufacturing the plate-shaped concrete member can be shortened.

[0017] In the manufacturing method of the plate-shaped concrete member in which the back surface layer portion is a sheet fixed by a fastening member driven into the main body plate portion, a decorative member serving as the surface plate portion is laid on the bottom surface in the formwork, the fluid material is placed in the formwork, and after the fluid material is hardened to a predetermined degree, before or after demolding, on the other surface side of the main body plate portion, the sheet serving as the back surface layer portion is fixed by a fastening member driven into the surface.

[0018] In the manufacturing method of the plate-shaped concrete member in which the back surface layer portion is a sheet fixed to the main body plate portion by an adhesive, a decorative member serving as the surface plate portion is laid on the bottom surface in the formwork, the fluid material is placed in the formwork, and after the fluid material is hardened to a predetermined degree, before or after demolding, on the other surface side of the main body plate portion, the sheet serving as the back surface layer portion is adhered by an adhesive.

Effect of the Invention

[0019] According to the present invention, it is possible to suppress warping of the plate-shaped concrete member and prevent the appearance on the back surface side of the plate-shaped concrete member from deteriorating.

Brief Description of the Drawings

[0020]

Figure 1

Figure 2

Figure 3

Figure 4

Figure 5

Figure 6

Modes for Carrying Out the Invention

[0021] Hereinafter, embodiments of the present invention will be described based on the accompanying drawings. As shown in FIG. 1, the plate-shaped concrete member 1 includes a main body plate portion 11, a surface plate portion 12 located on one surface side of the main body plate portion 11 and suppressing the release of moisture from the one surface side of the main body plate portion 11, and a back surface layer portion 13 located on the other surface side of the main body plate portion 11 facing away from the one surface side and suppressing the release of moisture from the other surface side of the main body plate portion 11.

[0022] In this embodiment, the plate-shaped concrete member 1 is a precast curtain wall, and the surface plate portion 12 is made of tiles, stones, etc. The plate thickness of the main body plate portion 11 is about 100 mm. Further, in the main body plate portion 11, reinforcing bars 11a are arranged in a mesh shape. The reinforcing bars 11a are single and are arranged on the central side in the plate thickness direction of the main body plate portion 11.

[0023] The main body plate portion 11 is formed by hardening a fluid material containing aggregate (coarse aggregate, fine aggregate), a hardening material, and water over time. For example, it contains artificial or natural lightweight coarse aggregate as the coarse aggregate and artificial or natural lightweight fine aggregate as the fine aggregate, and contains cement as the above hardening material at a predetermined density (as an example, 300 - 450 kg / m 3 ).) and is made of standard-mixed concrete (general lightweight concrete: drying shrinkage rate of about 500 - 600×10 -6 ). Further, in this embodiment, the main body plate portion 11 contains fibers (fiber-like reinforcing materials) such as resin mixed therein.

[0024] The back surface layer portion 13 is made of, for example, a moisture-proof and airtight sheet such as a polyethylene sheet (hereinafter, may be referred to as sheet 13). It is desirable that the moisture release suppression performance of sheet 13 is about the same as that of the surface plate portion 12. For example, if the moisture release suppression force is low due to the joint portion of the surface plate portion 12, as sheet 13, it is also possible to use a fiber knitted sheet, a paper sheet, etc. with a lower moisture release suppression force than the moisture-proof and airtight sheet. Further, when a plurality of sheets 13 are attached to the other surface side of the main body plate portion 11, a slight gap may be formed between these sheets 13.

[0025] In addition, in this embodiment, the sheet 13 is provided with an anchor 13a that is inserted into the main body plate portion 11 before curing. The anchor 13a may be integrated with the sheet 13 by adhesion (adhesive, silicone paste, etc.), insertion, etc., and may be made of a metal object such as a shear connector, a bolt (with the head located far from the sheet side), a screw, a stud, a dibel, etc. (a rust-proof type is desirable), or a resin object or a wooden object having a similar outer shape. The arrangement pitch of the anchors 13a is, for example, 300 mm or more and 500 mm or less. Note that it is desirable to position the anchor 13a at least on the edge side of the main body plate portion 11.

[0026] Next, a method for manufacturing the plate-shaped concrete member 1 will be exemplified. As shown in FIG. 2, a decorative member that will become the surface plate portion 12 is disposed at the bottom inside a formwork 5 having an inner surface shape that matches the outer shape of a curtain wall or the like, and further, the reinforcing bars 11a are disposed in a manner of floating with respect to the surface plate portion 12.

[0027] Then, fresh concrete (flowable material) containing coarse aggregate and fine aggregate that will become the main body plate portion 11 is placed in the formwork 5. After placement, the surface of the fresh concrete may be leveled with a trowel, and then the sheet 13 may be laid. However, to simplify the leveling operation, the sheet 13 may be laid on the surface of the fresh concrete in such a manner that the anchors 13a are embedded in the fresh concrete. Further, after that, a damper device (not shown) may be placed on the sheet 13 and operated to improve the adhesion between the anchors 13a and the fresh concrete while leveling the surface of the fresh concrete. Note that before laying the sheet 13, a vibrator (not shown) may be inserted into the fresh concrete to vibrate the fresh concrete, thereby improving the adhesion between the reinforcing bars 11a and the fresh concrete.

[0028] With such a manufacturing method, without waiting for the fresh concrete placed in the formwork 5 to cure, the back surface layer portion 13 (sheet 13) is provided on the other surface side of the fresh concrete (main body plate portion 11), so that the time and processes required for manufacturing the plate-shaped concrete member 1 can be shortened.

[0029] In the above example, the sheet 13 had the anchor 13a. However, it is not limited to this. As shown in FIG. 3, the sheet 13 may be a sheet having irregularities 13b that can increase the area of attachment to the main body plate portion 11 before curing, for example, a bubble cushioning material sheet, a sheet applied with pearl paint, or a sheet embossed.

[0030] Alternatively, as shown in FIG. 4, the sheet 13 may be fixed to the main body plate portion 11 by folding a part of the cut portions 13c positioned at a predetermined pitch in the sheet 13 and embedding them in the main body plate portion 11 before curing. The part of the cut portion 13c is, for example, a quadrangular portion in which three sides of a square with each side of 100 mm are cut and the remaining one side is a bending portion. Of course, the part of the cut portion 13c is not limited to such a quadrangular portion.

[0031] Also, as shown in FIG. 5, a sheet 13 without an anchor or irregularities may be fixed to the main body plate portion 11 after being cured to a certain extent by a fastening member 13d. The fastening member 13d is a screw, a push pin, a tacker, etc. The above-mentioned certain extent of curing is a state in which the fluid material has solidified to such an extent that the fastening member 13d driven into the fluid material has its position and posture maintained by the fluid material.

[0032] The production of such a plate-shaped concrete member 1 is the same as that shown in FIG. 4. A decorative member that will become the surface plate portion 12 is laid on the bottom surface in the mold 5, the fluid material is placed in the mold 5, and after the fluid material has cured to the above-mentioned certain extent, before or after demolding, on the other surface side of the main body plate portion 11, the sheet 13 is fixed by a fastening member 13d driven into the surface. For example, several hours after the fluid material is placed in the mold 5, etc., the fastening member 13d can be driven into the main body plate portion 11 to fix the sheet 13.

[0033] Further, as shown in FIG. 6, a sheet 13 without anchors or irregularities may be attached to the other surface of the main body plate portion 11 after the adhesive 13e has hardened to a certain extent. The above-mentioned certain extent of hardening is a state in which the fluid material has solidified to such an extent that the adhesive 13e can be applied. Note that mortar can also be used as the adhesive 13e.

[0034] The production of such a plate-shaped concrete member 1 is the same as that shown in FIG. 4. A decorative member that will become the surface plate portion 12 is laid on the bottom surface in the formwork 5, the fluid material is placed in the formwork 5, and after the fluid material has hardened to the above-mentioned certain extent, before or after demolding, an adhesive 13e is applied to the other surface side of the main body plate portion 11, and the sheet 13 is adhered to the main body plate portion 11 with the adhesive 13e. For example, the above-mentioned sheet 13 is attached about 24 hours after the fluid material is placed in the formwork 5. Since the release of moisture from the main body plate portion 11 continues for about 30 days after placement, even if the sheet 13 is attached 24 hours after placement, for several tens of days thereafter, the release of moisture on the other surface side of the main body plate portion 11 can be suppressed by the sheet 13, and the warping of the plate-shaped concrete member 1 can be reduced.

[0035] Further, the sheet 13 may be transparent or translucent. According to this, the sheet 13 can be attached to the main body plate portion 11 while confirming the attachment state of the sheet 13 to the main body plate portion 11 through a transparent or translucent region.

[0036] Further, the sheet 13 may be made of a stretchable sheet. According to this, since the sheet 13 can follow the drying shrinkage of the plate-shaped concrete member 1, it is possible to suppress the sheet 13 from peeling off from the main body plate portion 11.

[0037] Further, in the above, an example in which the back surface layer portion 13 is the sheet 13 has been shown, but the back surface layer portion 13 may be a waterproof resin material film applied to the main body plate portion 11.

[0038] In addition, in this embodiment, an example in which the plate-shaped concrete member 1 is a precast curtain wall has been shown. However, the present invention is not limited to this, and the plate-shaped concrete member 1 may be a precast floor slab.

[0039] As described above, the embodiments of the present invention have been described with reference to the drawings. However, the present invention is not limited to the illustrated embodiments. Various modifications and variations can be made to the illustrated embodiments within the same scope or equivalent scope of the present invention.

Explanation of Reference Numerals

[0040] 1: Plate-shaped concrete member 5: Formwork 11: Main body plate portion 11a: Reinforcing bar 12: Surface plate portion 13: Back surface layer portion (sheet) 13a: Anchor 13b: Concavo-convex 13c: Partially cut portion 13d: Fastening member 13e: Adhesive

Claims

1. A plate-shaped concrete member comprising: a main body plate portion in which a fluid material containing aggregate, a hardening material, and water has hardened over time; a surface plate portion located on one surface side of the main body plate portion and suppressing the release of moisture from the one surface side; and a back surface layer portion located on the other surface side of the main body plate portion facing away from the one surface side and suppressing the release of moisture from the other surface side.

2. The plate-shaped concrete member according to Claim 1, wherein the back surface layer portion is formed of a sheet with an anchor inserted into the main body plate portion.

3. The plate-shaped concrete member according to Claim 1, wherein the back surface layer portion is formed of a sheet with unevenness adhering to the main body plate portion.

4. The plate-shaped concrete member according to Claim 1, wherein the back surface layer portion is formed of a sheet, and a cut portion of the sheet is bent and embedded in the main body plate portion.

5. The plate-shaped concrete member according to Claim 1, wherein the back surface layer portion is formed of a sheet fixed by a fastening member driven into the main body plate portion.

6. The plate-shaped concrete member according to Claim 1, wherein the back surface layer portion is formed of a sheet fixed to the main body plate portion by an adhesive.

7. The plate-shaped concrete member according to any one of Claims 1 to 6, wherein the back surface layer portion is stretchable.

8. A manufacturing method for manufacturing the plate-shaped concrete member according to any one of Claims 2 to 4, comprising laying a decorative member to be the surface plate portion on the bottom surface in a formwork, placing the fluid material in the formwork, and attaching the sheet to be the back surface layer portion on the other surface side of the main body plate portion before the fluid material hardens.

9. A manufacturing method for manufacturing the plate-shaped concrete member according to claim 5, comprising laying a decorative member that will become the surface plate portion on the bottom surface within a formwork, placing the fluid material within the formwork, and after the fluid material has hardened to a certain degree, fixing a sheet that will become the back surface layer portion to the other surface side of the main body plate portion by means of the fastening member driven into the surface, either before or after demolding. A manufacturing method for a plate-shaped concrete member, characterized by this.

10. A manufacturing method for manufacturing the plate-shaped concrete member according to claim 6, comprising laying a decorative member that will become the surface plate portion on the bottom surface within a formwork, placing the fluid material within the formwork, and after the fluid material has hardened to a certain degree, adhering a sheet that will become the back surface layer portion to the other surface side of the main body plate portion with an adhesive, either before or after demolding. A manufacturing method for a plate-shaped concrete member, characterized by this.

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