Lightweight cellular concrete panel

Abstract

To provide a lightweight cellular concrete panel hardly causing chipping, cracking or the like caused by an impact, a load or the like during transportation or construction by improving edge opening strength in an edge part outside a reinforcing bar mat of the lightweight cellular concrete panel.SOLUTION: A lightweight cellular concrete panel includes a panel body made of lightweight cellular concrete, and a reinforcing-bar mat having at least two or more main reinforcements arranged along a first direction of the panel body and at least one or more accessory muscle parts arranged along a second direction orthogonal to the first direction of the panel body, the reinforcing-bar mat being embedded substantially parallel to a main surface of the panel body, wherein, in the reinforcing-bar mat, an end portion of at least one or more accessory muscle parts protrudes toward a panel end face side relative to the main reinforcements.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] The present invention relates to a lightweight aerated concrete panel in which a reinforcing member, a reinforcing bar mat consisting of main reinforcement and secondary reinforcement, is embedded. [Background technology]

[0002] Conventionally, a lightweight aerated concrete panel (hereinafter referred to as "ALC panel") has been proposed in which a reinforcing mat consisting of main and secondary reinforcement bars and a mesh-like reinforcing member such as metal lath are embedded within the panel (for example, Patent Document 1). [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Japanese Patent Application Laid-Open No. 2010-077624 Summary of the Invention [Problem to be solved by the invention]

[0004] However, the ALC panel described in Patent Document 1 is configured so that the metal lath protrudes from the outer periphery of the reinforcing bar mat, which consists of main and secondary bars, toward the edge of the ALC panel, which creates the problem that it is not possible to prevent chipping or cracking on the edge of the ALC panel outside the reinforcing bar mat due to impacts or loads during transportation or installation.

[0005] The present invention solves the above-mentioned problems, and its object is to provide a lightweight aerated concrete panel that improves the edge gap strength at the edge of the panel outside the reinforcing mat, making it less susceptible to chipping or cracking caused by impacts or loads during transportation or construction. [Means for solving the problem]

[0006] [1] A panel body made of lightweight aerated concrete; A lightweight aerated concrete panel comprising: a reinforcing bar mat having at least two or more main reinforcements arranged along a first direction of the panel body and at least one or more sub-reinforcements arranged along a second direction perpendicular to the first direction of the panel body, the reinforcing bar mat being embedded approximately parallel to the main surface of the panel body; A lightweight aerated concrete panel characterized in that, in the reinforcing bar mat, the ends of at least one of the secondary reinforcements protrude further toward the end face of the panel than the main reinforcement. [2] A lightweight aerated concrete panel as described in [1], in which the secondary reinforcement of the reinforcing mat protrudes so that the dimension of the unreinforced section from the tip of the secondary reinforcement to the end face of the panel is 40 mm or less. [3] A lightweight aerated concrete panel as described in [1] or [2], in which two or more of the reinforcing mats are embedded at a predetermined interval and approximately parallel to the main surface of the panel body. [4] A lightweight aerated concrete panel as described in [3], wherein the two or more reinforcing bar mats are joined together by connecting bars to form a cage-shaped reinforcing bar mat. [Effects of the Invention]

[0007] According to the present invention, it is possible to provide a lightweight aerated concrete panel that has improved edge strength at the edge portion outside the reinforcing mat of the lightweight aerated concrete panel, making it less susceptible to chipping or cracking caused by impacts or loads during transportation or construction. [Brief explanation of the drawings]

[0008] [Figure 1] 1 is a perspective view showing one example of the configuration of a lightweight aerated concrete panel according to the present invention. [Figure 2] 1A and 1B are a plan view and a cross-sectional view showing an example of the configuration of a lightweight aerated concrete panel according to the present invention. [Figure 3] 1 is a cross-sectional view showing another example of the configuration of the lightweight aerated concrete panel according to the present invention. [Figure 4]10 is a plan view showing yet another example of the configuration of the lightweight aerated concrete panel according to the present invention. [Figure 5] 1 is a plan view and a cross-sectional view showing the configuration of a lightweight aerated concrete panel according to an embodiment of the present invention. [Figure 6] 1 is a plan view and a cross-sectional view showing the configuration of a lightweight aerated concrete panel of a comparative example. [Figure 7] FIG. 2 is a perspective view showing the position where an ALC test piece was taken in the examples. [Figure 8] FIG. 1 is a perspective view showing the position where an ALC test piece was taken in a comparative example. [Figure 9] FIG. 1 is a side view illustrating a measurement method for edge clearance strength testing of lightweight aerated concrete panels. [Figure 10] FIG. 1 is a perspective view illustrating a measurement method for edge clearance strength testing of lightweight aerated concrete panels. DETAILED DESCRIPTION OF THE INVENTION

[0009] With reference to the drawings, a preferred embodiment of the lightweight cellular concrete panel according to the present invention will be specifically described. Fig. 1 is a perspective view showing one example of the configuration of a lightweight aerated concrete panel according to the present invention. Fig. 2 is a plan view and a cross-sectional view showing one example of the configuration of a lightweight aerated concrete panel according to the present invention. Figs. 3(a) to 3(d) are cross-sectional views showing other examples of the configuration of a lightweight aerated concrete panel according to the present invention. Fig. 4 is a view showing an example in which some of the secondary reinforcements of the reinforcing mat protrude to the outer peripheral edge of the ALC panel. In the following description, the terms "upper direction" and "lower direction" refer to the "upper direction" and "lower direction" in the respective drawings.

[0010] The lightweight aerated concrete panel (hereinafter referred to as "ALC panel") 1 of the present invention comprises a panel body 1a made of lightweight aerated concrete, and a reinforcing bar mat 4 embedded approximately parallel to the main surface of the panel body 1a, the reinforcing bar mat having at least two main bars 2 arranged along a first direction of the panel body 1a and at least one secondary bar 3 arranged along a second direction perpendicular to the first direction of the panel body 1a. The ALC panel 1 of the present invention is characterized in that the end of at least one or more secondary reinforcement 3 in the reinforcing bar mat 4 protrudes further toward the end face of the panel than the main reinforcement 2.

[0011] Here, in the example shown in Figures 1 to 4, the panel main body 1a has a rectangular plate shape, the first direction is the longitudinal direction (length direction) of the panel main body 1a, and the second direction is the lateral direction (short side direction) of the panel main body 1a. The planar shape of the panel body 1a is not limited, and may be a substantially rectangular shape, a substantially square shape, or any other shape. For example, the panel body 1a may have a short side cut obliquely to the long side. In addition, the numerical values ​​for panel dimensions, etc. shown below include a generally acceptable range of error (for example, approximately ±5 mm for a panel width of 600 mm).

[0012] In this specification, "main surfaces" refers to the widest pair of surfaces among the six surfaces that make up a plate-like panel. "Edge surfaces" refers to surfaces other than the main surfaces, "long edge surfaces" refers to a pair of edge surfaces along the longitudinal direction, and "short edge surfaces" refers to a pair of edge surfaces along the lateral direction.

[0013] In the ALC panel 1 according to the present invention, at least one secondary reinforcement 3 of the reinforcing bar mat 4 embedded in the panel body 1a has its end protruding further toward the panel edge than the main reinforcement 2. In other words, the outer shape of the reinforcing bar mat 4 has its end protruding toward the outer periphery, toward the edge of the panel body 1a. This makes it possible to reinforce the edge of the panel body 1a outside the outer periphery of the reinforcing bar mat 4. As a result, chipping and cracking caused by impacts or loads applied to the edge of the ALC panel 1 outside the reinforcing bar mat 4 during transportation and installation can be prevented.

[0014] Furthermore, by having the ends of the secondary reinforcement 3 of the reinforcing mat 4 protrude further toward the end face of the panel than the main reinforcement 2, the anchoring action of the protruding parts has the effect of making it less likely for the chipped part to fall off even if it is chipped due to a physical impact applied to the edge of the panel body 1a outside the reinforcing mat 4 during transportation or installation.

[0015] Furthermore, by having the ends of the secondary reinforcement 3 of the reinforcing bar mat 4 protrude further toward the end face of the panel than the main reinforcement 2, it becomes less likely that faults will occur due to large gas accumulations that occur near the ends of the secondary reinforcement, preventing a deterioration in the appearance performance of the panel.

[0016] The term "fault" used here refers to a defect caused by a break in the semi-hardened block due to a large gas accumulation during the manufacturing process.

[0017] As shown in Figures 1 and 2, the ALC panel 1 of this embodiment comprises a panel body 1a made of lightweight aerated concrete, and at least two main reinforcements 2 arranged approximately parallel to the longitudinal direction (vertical direction in Figure 2), which is the first direction of the panel body 1a, and a reinforcing bar mat 4 having at least one secondary reinforcement 3 arranged so as to intersect (be perpendicular to) the main reinforcements 2 and to be approximately parallel to the lateral direction (vertical direction in Figure 2), which is the second direction of the ALC panel 1, which is embedded in the ALC panel 1 parallel to the main panel surface of the ALC panel 1.

[0018] The shape, width, thickness, and rebar diameter of the panel body 1a are not particularly limited, but the width is preferably in the range of 200 mm to 700 mm, more preferably in the range of 300 mm to 610 mm, and the thickness is preferably in the range of 50 mm to 175 mm, more preferably in the range of 75 mm to 150 mm. The diameter of the reinforcing bars that make up the main reinforcements 2 and the secondary reinforcements 3 is not particularly limited, but is preferably in the range of 3 mm to 9 mm, and more preferably in the range of 4.5 mm to 7 mm.

[0019] The main reinforcements 2 are arranged at intervals of 40 mm or more in the short direction of the panel body 1a, for example, and the secondary reinforcements 3 are arranged at intervals of 60 mm to 700 mm in the long direction of the panel, for example.

[0020] The number of main reinforcements 2 is not limited to two, but is preferably three or more, and more preferably four or more. The more the number, the better in order to provide panel strength. Furthermore, the number of secondary reinforcements 3 is not limited to one, but can be any number. Preferably, it is two or more, and more preferably, it is three or more. As with the main reinforcements 2, the more the number, the better in order to provide panel strength. The number tends to increase according to the length of the panel body 1a.

[0021] When three or more secondary reinforcements 3 are arranged in the reinforcing bar mat 4, it is preferable to arrange two of them near both longitudinal ends of the panel body 1a. By arranging two secondary reinforcements 3 at the longitudinal ends of the panel body 1a, the main reinforcements 2 can be firmly fixed to the lightweight aerated concrete.

[0022] Furthermore, it is preferable to arrange the remaining secondary reinforcements 3 approximately symmetrically when viewed from the center of the panel body 1a in the longitudinal direction. This allows for a wider openable range, and by arranging the reinforcing bars approximately symmetrically in the longitudinal and lateral directions of the panel body 1a, it is possible to eliminate usability in the longitudinal and lateral directions with respect to the openable range and prevent the reinforcing bars from being cut due to incorrect use. However, the arrangement of the secondary reinforcements 3 is not limited to this, and it does not have to be approximately symmetrical.

[0023] In the example shown in Figures 1 and 2, the reinforcing bar mat 4 has two main reinforcements 2 arranged in the longitudinal direction of the panel body 1a, and five secondary reinforcements 3 arranged in the lateral direction of the panel body 1a, intersecting (orthogonal to) the main reinforcements 2. Of the five secondary reinforcements 3, two are arranged near both longitudinal ends of the panel body 1a, and one is arranged near the longitudinal center of the panel body 1a. The remaining two are arranged approximately symmetrically on the longitudinal end sides of the panel body 1a. In order to increase the panel strength, it is preferable to form a mat shape by joining the intersections of the main reinforcements 2 and secondary reinforcements 3 of the reinforcing bar mat 4 by welding or the like.

[0024] In the ALC panel 1 shown in Figures 1 and 2, two or more reinforcing mats 4 are embedded at predetermined intervals in a manner that is generally parallel to the main surface of the panel body 1a, thereby improving the panel strength and edge clearance strength. In this specification, "edge strength" refers to the strength of the ALC panel 1 outside the reinforcing bar mat 4, i.e., the strength of the area (unreinforced area) at the edge of the ALC panel 1 where no reinforcing bars are arranged.

[0025] These two or more reinforcing bar mats 4 are preferably joined together with connecting bars (spacers) or the like to form a basket-shaped reinforcing bar mat, which not only provides greater panel strength but also makes it easier to set the basket-shaped reinforcing bar mats into the formwork when manufacturing the panel.

[0026] In this embodiment, the arrangement of the main reinforcements 2 and secondary reinforcements 3 is substantially the same in two or more reinforcing bar mats 4. In other words, when the panel body 1a is viewed in plan, the main reinforcements 2 and secondary reinforcements 3 may substantially overlap each other in a pair of reinforcing bar mats 4. However, the arrangement of the main reinforcements 2 and secondary reinforcements 3 in two or more reinforcing bar mats 4 is not limited to this, and may be different for each reinforcing bar mat 4.

[0027] In this embodiment, at least one or more secondary reinforcements 3 of the reinforcing bar mat 4 are approximately parallel to the main surface of the panel body 1a, and the ends of the secondary reinforcements 3 protrude further toward the end surface of the long side of the panel than the main reinforcements 2.

[0028] The ends of the secondary reinforcement 3 form protruding extensions 3a that extend beyond the periphery of the reinforcing bar mat 4, i.e., beyond the main reinforcement 2, toward the edge of the ALC panel 1. The protruding length (T1) of the protruding extensions 3a of the secondary reinforcement 3 is extended so that the dimension (T2) of the unreinforced section from the tip of the protruding extensions 3a of the secondary reinforcement 3 to the long side end face of the ALC panel 1 is a specified dimension.

[0029] The predetermined dimension here is not particularly limited, but in order to improve the edge strength of the unreinforced portion where there are no sub-reinforcements 3, the dimension (T2) of the unreinforced portion is preferably 40 mm or less, more preferably 35 mm or less, and particularly preferably 30 mm or less.

[0030] The protruding length (T1) of the secondary reinforcement 3 is not particularly limited, but in order to improve the edge clearance strength, it is preferably 5 mm or more, more preferably 10 mm or more, and particularly preferably 15 mm or more. However, if the protruding length of the secondary reinforcement 3 is extended and the dimensions of the unreinforced portion are made too small, the protruding secondary reinforcement 3 may come into contact with the cutting blade used to process the long edge during processing of the ALC panel, potentially damaging the blade. Therefore, care must be taken when setting this value. The upper limit of T1 is preferably set to, for example, 55 mm or less.

[0031] Furthermore, the ratio (T1 / T3) of the protruding length (T1) of the secondary reinforcement 3 to the dimension from the reinforcing mat 4 toward the edge of the ALC panel 1 (here, the length (T3) from the main reinforcement 2 arranged at the end of the reinforcing mat 4 to the long side edge of the ALC panel 1) is not particularly limited, but to improve edge clearance strength, it is preferably 20% or more, more preferably 25% or more, and particularly preferably 30% or more. Furthermore, the upper limit of T1 / T3 is preferably 75% or less. This allows for sufficient reinforcement of the outer edge of the reinforcing mat 4 while preventing damage due to contact between the secondary reinforcement 3 and a cutting tool during processing of the ALC panel 1.

[0032] According to the above configuration, by having the ends of the secondary reinforcements 3 embedded in the panel body 1a protrude further toward the edge of the panel body 1a than the outer periphery of the reinforcing bar mat 4, it is possible to reinforce the edge portion outside the outer periphery of the reinforcing bar mat 4. As a result, chipping and cracking that can occur on the edge portion of the ALC panel 1 outside the reinforcing bar mat 4 due to impacts and loads during transportation and installation are less likely to occur.

[0033] Although Figures 1 and 2 show a case where all of the secondary reinforcements 3 of a pair of reinforcing bar mats 4 are protruding, the present invention is not limited to this, and it is sufficient that the end of at least one secondary reinforcement 3 of the reinforcing bar mat 4 protrudes toward the end face of the long side of the panel beyond the main reinforcement 2.

[0034] For example, in the example shown in FIG. 3(a), the ends of the secondary reinforcement 3 of one of a pair of reinforcing bar mats 4 are protruded in the vertical direction to form protruding extensions 3a.

[0035] In addition, in the example shown in Figure 3(b), of a pair of reinforcing bar mats 4, in one reinforcing bar mat 4, the end of the secondary bar 3 protrudes upward to form a protruding extension 3a, and in the other reinforcing bar mat 4, the end of the secondary bar 3 protrudes downward to form a protruding extension 3a.

[0036] In the example shown in FIG. 3(c), the ends of the secondary reinforcements 3 of a pair of reinforcing bar mats 4 are protruded upward to form protruding extensions 3a.

[0037] In the example shown in FIG. 3(d), the ends of the secondary bars 3 of a pair of reinforcing bar mats 4 are protruded downward to form protruding extensions 3a.

[0038] In the example shown in Figure 4, seven secondary reinforcements 3 are arranged, and the protruding extensions 3a of some of the secondary reinforcements 3 may be made to protrude toward the outer periphery of the reinforcing bar mat 4, i.e., toward the end face of the long side of the panel, further than the main reinforcements 2. Note that the locations of the secondary reinforcements 3 from which the ends protrude are not particularly limited, but it is preferable to extend the protrusions of all secondary reinforcements 3.

[0039] Furthermore, when the dimension of the unreinforced portion up to the short-side end face of the panel body 1a is large, it is preferable to have the ends of the main reinforcement 2 protrude further toward the short-side end face than the secondary reinforcement 3. Protruding the ends of the main reinforcement 2 also has the effect of improving edge gap strength, and is preferable because it makes it less likely for chipping or cracking to occur on the edges of the panel body 1a outside the reinforcing bar mat 4 due to impacts or loads during transportation or installation.

[0040] Although the embodiment of the present invention has been described above, the present invention is not limited to this and can be modified as appropriate within the scope of the invention. [Example]

[0041] The present invention will be described in more detail below with reference to examples, but the present invention is not limited to these examples.

[0042] (Production of ALC panels) Reinforcing bar mats with the configuration shown in Figure 5 were prepared, and two reinforcing bar mats were placed opposite each other and connected with spacers or the like to form a basket-shaped reinforcing bar mat. The main reinforcement 2 of the two reinforcing bar mats shown in Figure 5 was made of carbon steel with a diameter of 7 mm (JIS A 5416:2016 compliant), and the secondary reinforcement 3 was made of carbon steel with a diameter of 4.5 mm (JIS A 5416:2016 compliant).

[0043] The raw materials for ALC panels, silica stone, quicklime, cement, aluminum powder, additives, and water, were mixed in a specified ratio to form a slurry. A cage-shaped reinforcing bar mat was placed inside the formwork, and the resulting ALC slurry was poured into the formwork. The cage-shaped reinforcing bar mat had been previously treated with anti-corrosion agents.

[0044] The aluminum powder was then foamed by reaction with the alkaline component, and hardened by hydration of the calcareous raw material until it reached the required hardness. The resulting semi-hardened body was demolded and cut to the required dimensions. The semi-hardened body was then cured with high-temperature, high-pressure steam. This resulted in the production of an ALC panel. The dimensions of the ALC panel were 3,000 mm in the longitudinal direction, 600 mm in the transverse direction, and 100 mm thick. As shown in Figure 5, an ALC panel was obtained with two reinforcing bar mats embedded in layers facing each other.

[0045] In the reinforcing bar mat shown in Figure 5, the length of the protruding extensions 3a on the upper side of all secondary reinforcements 3 in the foaming direction is 33 mm, and the dimension of the unreinforced section from the tip of the protruding extensions 3a on the upper side in the foaming direction to the end surface of the long side of the panel is 26 mm. On the other hand, the length of the protruding extensions 3a on the lower side in the foaming direction is 20 mm, and the dimension of the unreinforced section from the tip of the protruding extensions 3a on the lower side in the foaming direction to the end surface of the long side of the panel is 21 mm.

[0046] The ALC panel thus obtained was cut to 100 mm lengthwise at a position where the secondary reinforcement was present, as shown in Figure 7, to obtain ALC test pieces measuring 100 x 600 x 100 mm. As shown in Figure 7(a), ALC test piece 1 was obtained from the end of the panel lengthwise, and was used as the sample piece for Example 1. Furthermore, as shown in Figure 7(b), ALC test piece 2 was obtained from near the center of the panel lengthwise, and was used as the sample piece for Example 2.

[0047] The sample pieces of Example 1 and Example 2 thus obtained were each thoroughly dried indoors, and then subjected to an edge-opening strength test.

[0048] For comparison, a reinforcing bar mat was prepared without protruding ends of the secondary reinforcements, as shown in Figure 6, and an ALC panel was manufactured under the same conditions as above, with two reinforcing bar mats embedded in layers facing each other. As shown in Figure 8(a), ALC test piece 3 was taken from the end in the longitudinal direction of the panel, which was used as the sample piece for Comparative Example 1, and as shown in Figure 8(b), ALC test piece 4 was taken from near the center in the longitudinal direction of the panel, which was used as the sample piece for Comparative Example 2.

[0049] (Method for measuring edge strength) As shown in Figures 9 and 10, each of the ALC test pieces 1 to 4 for the Examples and Comparative Examples was placed horizontally on the test stand of a universal testing machine (TENSILON RTC-2410, manufactured by A&D Co., Ltd.), and the ALC test piece was clamped so that it overhanged 60 mm from the upper end of the ALC test piece in the foaming direction. Next, a load was applied perpendicular to the surface of the ALC test piece, with a loading point 50 mm from the upper end of the ALC test piece in the foaming direction. The maximum load until the test point broke was determined and used as an index of edge clearance strength. For Example 1 and Comparative Example 1, the loading direction was from the short edge of the panel as shown in Figure 9(a), and for Example 2 and Comparative Example 2, the loading direction was from the panel plate surface as shown in Figure 9(b).

[0050] The evaluation criteria were that the maximum load in the edge gap strength test for the comparative example was improved compared to the maximum load in the edge gap strength test for the example and the comparative example, and the maximum load in the edge gap strength test was calculated as the average value of three tests. The test results are shown in Table 1.

[0051] [Table 1]

[0052] As is clear from the results shown in Table 1, it was confirmed that the ALC panels of the examples had improved edge clearance strength compared to the comparative examples. Furthermore, in the examples, even when the test portion of the ALC test piece broke, the broken portion did not fall off, and it was confirmed that the anchoring action of the protruding portion of the extended secondary reinforcement had a fall-preventing effect.

[0053] In the above example, the length of the protruding extension of the secondary reinforcement above the foaming direction is 33 mm, and the dimension of the unreinforced section from the tip of the protruding extension above the foaming direction to the end face of the long side of the panel is 26 mm, but it is expected that similar effects will be obtained with ALC panel shapes and sizes, rebar diameters, and rebar lengths other than those in the above example. [Industrial Applicability]

[0054] According to the present invention, it is possible to improve the edge gap strength at the edge outside the reinforcing mat, thereby making it possible to create a lightweight aerated concrete panel that is less likely to chip or crack due to impacts or loads during transportation or construction, and the panel can be suitably used as a lightweight aerated concrete panel. [Explanation of symbols]

[0055] 1...ALC panel 1a...Panel body 2…Main reinforcement 3…Subplot 3a...Protruding extension 4...Reinforcing bar mat

Claims

1. A panel body made of lightweight aerated concrete; A lightweight aerated concrete panel comprising: a reinforcing bar mat having at least two or more main reinforcements arranged along a first direction of the panel body and at least one or more sub-reinforcements arranged along a second direction perpendicular to the first direction of the panel body, the reinforcing bar mat being embedded approximately parallel to the main surface of the panel body; A lightweight aerated concrete panel characterized in that, in the reinforcing bar mat, the end of at least one of the secondary reinforcements protrudes toward the end face of the panel beyond the main reinforcement.

2. 2. A lightweight aerated concrete panel as described in claim 1, wherein the secondary reinforcements of the reinforcing mat are protruded so that the dimension of the unreinforced portion from the tip of the secondary reinforcement to the end face of the panel is 40 mm or less.

3. 3. A lightweight aerated concrete panel according to claim 1, wherein two or more of the reinforcing mats are embedded at predetermined intervals in a direction substantially parallel to the main surface of the panel body.

4. 4. The lightweight aerated concrete panel according to claim 3, wherein the two or more reinforcing bar mats are joined together by connecting bars to form a cage-shaped reinforcing bar mat.

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