JP2016148149A - Structure and method of manufacturing the same - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a lightweight structure which has high strength and which is excellent in fireproofness and heat insulating properties.SOLUTION: A structure includes a laminate in which a prismatic body having the whole surface of an expanded material coated with a cement layer, a bar arrangement layer, and a prismatic body having the whole surface of an expanded material coated with a cement layer are stacked in this order.SELECTED DRAWING: Figure 1

Description

  The present invention relates to a structure and a manufacturing method thereof.

  In recent years, a wall panel constituting a wall of a building is required to have various characteristics, and one of the characteristics is heat insulation.

  As such a heat-insulating wall panel, there is known an ALC (Autoclaved Lightweight Aerated Concrete) panel made of silica powder, cement, quicklime and aluminum powder of foaming agent.

  In addition, in Patent Document 1, as a wall structure constructed using a wall panel having excellent heat insulation properties, a filler is filled between wall panels made of a resin foam of a specific shape, and a wall material is applied to the outside thereof. A wall structure characterized by being constructed as described above is disclosed.

JP-A-7-238614

  However, the ALC panel needs to be cured in an autoclave (high-temperature high-pressure steam kettle) for about 10 hours under a high temperature of 180 ° C. and high-pressure steam of 10 atm in the production process. Improvements are required from the viewpoint of cost. In addition, since this ALC panel is an inorganic porous board, there are certain restrictions on the weight control, and it has water absorption, and can be used as it is as a building material for structures such as buildings and floating bridges. I can't do it.

  In addition, since the wall structure described in Patent Document 1 requires the use of a resin foam having a specific surface shape, there is room for further improvement in terms of heat insulation and strength, and ease of manufacture. In particular, there was room for further improvement in terms of fire resistance and strength.

  This invention is made | formed in view of the said problem, and makes it a subject to provide the structure which has high intensity | strength, is excellent in fireproof property and heat insulation, and is lightweight.

As a result of intensive studies to solve the above problems, the present inventors have found that the structure can be solved by a structure having a specific structure, and have completed the present invention.
A configuration example of the present invention is as follows.

  [1] It includes a prism body in which the entire surface of the foam is covered with a cement layer, a reinforcing layer, and a laminate in which a prism body whose entire surface of the foam is covered with a cement layer is stacked in this order. A structure

  [2] A structure including a laminate having a cement layer including a lath body, a foam, a reinforcing layer, a foam, and a cement layer including a lath body in this order, and the entire surface of the laminate is a cement layer A structure characterized by being coated.

[3] The method according to [1] or [2], wherein a lath body is present on at least one surface of the foam, and the entire surface of the foam is covered with a cement layer with the lath body. Structure.
[4] Any one of [1] to [3], wherein a lath body exists on the entire surface of the foam, and the entire surface of the foam is covered with a cement layer with the lath body. The structure described in 1.
[5] The structure according to any one of [1] to [4], wherein the entire surface of the foam is covered with a cement layer with at least two lath bodies.

[6] The structure according to any one of [1] to [5], having at least one cement layer formed using a composition containing cement and fly ash.
[7] The structure according to [6], wherein the fly ash content in the composition is 5 to 50 parts by mass with respect to 100 parts by mass of the cement in the composition.

  [8] The structure according to any one of [1] to [7], wherein an expansion ratio of the foam is 10 to 40 times.

  [9] The structure according to any one of [1] to [8], wherein the thickness (length in the stacking direction) of the structure is 50 to 400 mm.

[10] The structure according to any one of [1] to [9], which is a building material.
[11] The structure according to any one of [1] to [10], which is a rod.

[12] The method for producing a structure according to any one of [1] to [11], including the following steps (A) to (B).
Step (A): Step of forming the prismatic body by covering the entire surface of the foam with a cement layer Step (B): Step of laminating the two prismatic bodies obtained in the step (A) via the reinforcement layer

  ADVANTAGE OF THE INVENTION According to this invention, it can provide the structure which has high intensity | strength, is excellent in fireproof property and heat insulation, and is lightweight. Therefore, according to the present invention, it is possible to provide a structure that is suitably used as a building material for a structure such as a building or a floating bridge, particularly as a housing such as a wall, floor, or ceiling.

FIG. 1 is a partially cutaway perspective view showing an embodiment of the structure of the present invention. FIG. 2 is a partially cutaway perspective view showing an embodiment of a prismatic body constituting the structure of the present invention.

≪Structure≫
Hereinafter, the structure according to the present invention will be described with reference to FIGS.
In the first aspect of the structure 2 according to the present invention, the prism 10 having the entire surface of the foam 10 covered with the cement layer 14, the reinforcing layer 20, and the entire surface of the foam 10 are covered with the cement layer 14. The prism body 1 includes a laminate in which the prisms 1 are laminated in this order.
The at least two prisms 1 included in this structure may be the same layer having the same layer configuration, shape, or the like, or may be layers having different layer configurations, shapes, or the like.

Such a structure is well-balanced in high strength, fireproofing and heat insulation, lightweight and inexpensive, and therefore suitable as a building material for structures such as buildings and floating bridges, especially as a housing for walls, floors, ceilings, etc. Used for.
In particular, the structure of the present invention is lightweight and excellent in handleability. Therefore, by using such a structure, buildings that cannot be built without using heavy machinery face the road. It can be constructed even in environments where heavy machinery cannot be used, such as no equipment, and is excellent in workability. Therefore, the structure of the present invention is particularly preferably used when a building is constructed in such an environment with poor workability.

The structure of the present invention is not particularly limited as long as it has the above-described structure. For example, another layer is provided between the prism body and the reinforcing bar layer or on the side opposite to the side of the prism body that is in contact with the reinforcing bar layer. Although it may exist, it is preferable that another layer does not exist between the prismatic body and the reinforcing layer from the viewpoint that the effect of the present invention is more exhibited.
The laminate may include three or more prisms and two or more reinforcing layers.

  The thickness (length in the stacking direction) of the structure of the present invention may be appropriately selected according to the desired application, and is not particularly limited, but is preferably 50 to 400 mm, more preferably 70 to 300 mm.

<Square body>
The prism 1 is not particularly limited as long as the entire surface of the foam 10 is covered with the cement layer 14. Such a prismatic body is a concrete plate, but the core material is a foam, so it is considerably lighter than the weight expected from the appearance, and is excellent in balance between high strength, fire resistance and heat insulation.
Moreover, by using the foam 10 as the core material of the prismatic body, the prismatic body itself can have high heat insulating performance and sound absorption effect, can be reduced in weight, and can be prevented from corrosion and cost reduction.

In the prism 1, not only the widest surface of the foam 10 but also the side surface 16 in the length direction and the side surface 18 in the width direction are covered with the cement layer 14.
Since such a prismatic body 1 is included, the structure 2 of the present invention is excellent in fire resistance, strength, durability, and handleability, has little water absorption, and the cement layer 14 hardly peels off. In particular, even if one surface of the structure 2 of the present invention is exposed to a flame, the surface does not burn, and the flame does not reach the back surface. Is a structure having high fire resistance. In addition, even if a resin foam that is easily eroded by termites is used as the foam 10, the foam 10 inside thereof is not eroded by termites due to the cement layer 14. For this reason, although it is lightweight and cheap, the building material and housing which are excellent in durability can be obtained.

  Although it does not restrict | limit especially as the said foam 10, It is preferable that it is a resin foam, and it is more preferable that it is a resin foam which can shape | mold a continuous foam. Specifically, such a resin is preferably a synthetic resin such as polystyrene, polyurethane, polyvinyl chloride, or polyolefin. Among these, polystyrene foam is preferable from the viewpoints of light weight, excellent heat insulation, low cost, elasticity, and excellent shock absorption.

  For example, a polystyrene foam can be manufactured by foaming polystyrene after mixing a foaming agent therewith while applying high shear stress under heating. As the foaming agent used here, an organic foaming agent having a boiling point that vaporizes at the melting temperature of polystyrene is preferably used, and a hydrocarbon foaming agent having a low environmental load is preferably used.

The expansion ratio of the foam 10 is preferably 10 to 40 times, more preferably 15 to 35 times, and still more preferably about 15 to 30 times.
When the expansion ratio is in the above range, the structure of the present invention having excellent strength can be easily produced, which is preferable. Moreover, when providing a lath body on a foam, it has the effect that it becomes easy to latch this lath body to a foam.
The expansion ratio can be adjusted by adjusting the temperature and pressure during foaming.

  The thickness of the foam 10 can be appropriately set according to the thickness of the prismatic body 1 or the structure 2 to be obtained, but from the viewpoint of having good heat insulation and self-form supportability. , Preferably about 20-100 mm, more preferably about 30-70 mm.

  Although it does not restrict | limit especially as the said cement layer 14, It is preferable that it is a layer which can improve the fireproof property of the said foam 10, durability, and intensity | strength. As a material for forming such a layer, a composition containing water such as various commercially available Portland cements and water can be used, but it is balanced in strength, thermal insulation, fire resistance and surface smoothness. From the viewpoint that a good structure and a prismatic body can be obtained at low cost, it is preferable to use a composition in which fly ash is blended with cement. As the fly ash, fly ash type II is preferable. The fly ash blended in the composition may be one kind or two or more kinds having different specific surface areas.

  By using such a composition containing fly ash, the cement layer 14 has excellent adhesion to the foam 10, particularly a polystyrene foam having a lath body on at least one surface, and is stable over a long period of time. The knowledge that 14 can be formed is also acquired.

  Moreover, by using the composition containing the fly ash, the long-term strength is improved, the durability is excellent, the alkali silica reaction is suppressed, the heat of hydration and the shrinkage of curing are reduced, the water-insoluble, hard It is possible to obtain a cement layer 14 which is solid and dense and hardly causes a cracking phenomenon. Furthermore, since the amount of cement used can be reduced, the prismatic body 1 can be obtained at a lower cost, and since the composition containing fly ash is excellent in fluidity, the formation of the cement layer 14 is excellent and the finished surface is excellent. A smooth and beautiful cement layer 14 can be obtained.

In the composition containing fly ash, the blending amount of fly ash is not particularly limited. However, from the viewpoint of obtaining a composition, a cement layer, a prismatic body, and the like in which the effect is more prominent, Preferably it is 5-50 mass parts with respect to 100 mass parts of cement, More preferably, it is 10-35 mass parts, More preferably, it is 10-30 mass parts.
However, when fly ash cement is used as the cement, it is preferable to determine the amount of fly ash to be added in consideration of the amount of fly ash already blended.

  In the composition forming the cement layer 14, other components such as coarse aggregate, fine aggregate, resin component, surfactant and antifoaming agent are not impaired according to the desired application. You may mix | blend in the range.

  The composition forming the cement layer 14 is preferably further blended with coarse aggregate and / or fine aggregate from the viewpoint of obtaining a structure superior in strength. The coarse aggregate and the fine aggregate can be arbitrarily selected from those usually used in concrete molding. Examples of such coarse aggregate include river gravel, mountain gravel, and sea gravel, and examples of fine aggregate include river sand, mountain sand, and sea sand. Among these, fine aggregates are preferable from the viewpoint of surface smoothness and designability of the resulting structure.

  The fine aggregate is preferably used in an amount in the range of 50 to 300 parts by mass with respect to 100 parts by mass of cement.

  The composition for forming the cement layer 14 may further contain a resin component, and the resin component may be an adhesive property to the foam 10, particularly a polystyrene foam having a lath body on at least one surface. It is preferable to use a re-emulsified powder resin because it can form a cement layer 14 that is excellent in stability and stable over a long period of time.

  Examples of the re-emulsifying powder resin include powdered resins mainly composed of polyacrylic acid ester, styrene butadiene, ethylene vinyl acetate, vinyl acetate / versaic acid vinyl ester, vinyl acetate / versaic acid vinyl ester / acrylic acid ester, and the like. Is mentioned. The resin component can be used alone or in combination of two or more.

  The re-emulsifying powder resin is preferably used in an amount in the range of 1 to 20 parts by mass with respect to 100 parts by mass of cement.

  The thickness of the cement layer 14 is not particularly limited, but is preferably a thickness such that the obtained prismatic body 1 has the following thickness. In particular, the cement layer 14 does not peel off from the obtained structure 2. It is preferable that the thickness is such that the fireproof property and strength of the foam 10 can be improved, and the lightweight structure 2 can be obtained. Examples of such thickness include 1 to 60 mm, preferably 3 to 50 mm, and more preferably 5 to 40 mm. The thickness of the cement layer 14 here refers to the total thickness of the layer containing cement formed on one surface of the foam 10. For example, as described in the method for producing a structure, two cement layers are provided. When formed on a foam, the total thickness of this layer is referred to. When the cement layer is accompanied by (including) a lath body, the total thickness of the cement layer accompanied by the lath body is referred to. When the laminate is further covered with a cement layer after the laminate is laminated through the reinforcing layer, the cement layer included in the prismatic body that exists on one surface of the foam And the total layer thickness of the cement layer covering the laminate.

  The prismatic body 1 has a lath body on at least one surface of the foam from the viewpoint of improving the adhesion between the foam 10 and the cement layer 14 and obtaining a high-strength structure. It is preferable that the entire surface is a prismatic body covered with a cement layer with the lath body, the lath body is present on the entire surface of the foam, and preferably the entire periphery of the foam is surrounded by the lath body, More preferably, the entire surface of the foam is a prismatic body covered with a cement layer with the lath body, and there are at least two lath bodies 11 and 12 on the entire surface of the foam. It is particularly preferable that the prism body is entirely covered with a cement layer with the lath bodies 11 and 12.

When at least two layers of lath bodies are present on the entire surface of the foam, the lath bodies may be in contact with each other, and one lath body is included in the cement layer, so that two layers of lath bodies are included. May not substantially touch.
As a preferable example using a two-layer lath body, in FIGS. 1 and 2, a lath body 11 is directly formed on the foam body 10, and the lath body 12 included in the cement layer 14 is formed on the lath body 11. The aspect which exists is mentioned.

In the prismatic body including such a lath body, the cement layer 14 is more securely and securely held by the foam 10, so that the cement layer hardly peels off and a structure having excellent strength and durability can be obtained.
In addition, by using a lath body, cracks and unevenness that may occur in the cement layer are unlikely to occur, and a structure having a cement layer that is excellent in foam retention and surface smoothness without using expensive resin mortar Can be obtained.

  The lath body is not particularly limited, and a conventionally known lath body can be used. Examples of such lath bodies include metal, glass, carbon fiber, natural resin, and synthetic resin nets, and are not particularly limited. In particular, metal and synthetic resin nets have characteristics. Therefore, it is preferable to use these nets as the lath body.

  In the present invention, when at least two layers of lath bodies are used, the two layers of lath bodies may be the same layer or different layers. For example, when the entire periphery of the foam is surrounded by a lath body, it is preferable to use a metal lath body from the viewpoint of ease of surroundings, etc., and an object is to obtain a structure having more excellent fire resistance. In this case, it is preferable to use a metal lath as the outermost layer of the structure according to the present invention. When the lath is provided on the foam at the same time as forming the cement layer 14, it is easy to manufacture. In view of this, it is preferable to use a synthetic resin lath body.

Examples of the synthetic resin include various resins such as polyolefin, polyamide, polyimide, polystyrene, polyether, polyester, polyamideimide, vinylon, and nylon, such as linear low density polyethylene (LLDPE) and low density polyethylene (LDPE). Polyolefins such as polyethylene and polypropylene are preferred.
The lath body may be a twisted yarn, an aggregate of single filaments, or a woven or non-woven fabric (including a flat string network).

The opening of the lath body is preferably 1 to 50 mm, more preferably 4 to 40 mm. When the mesh opening is in the above range, the cement layer 14 can be more securely and securely held in the foam 10.
In addition, although the shape of the opening of the lath body is arbitrary such as 3 to 6 corners, it is usually 4 corners.

  The wire diameter of the lath body is, for example, 0.1 to 5 mm from the viewpoint of ease of formation on the foam, in particular, ease of production of the foam surrounded by the lath body. Is 0.1 to 2 mm.

  The shape of the prism 1 is not particularly limited, but is usually a quadrangular prism and preferably a rectangular parallelepiped.

The thickness of the prismatic body 1 (the length in the stacking direction of the structure of the present invention) may be appropriately selected according to the desired application. When the structure of the present invention is used as a casing, for example, about It is 20-200 mm, Preferably it is about 30-100 mm.
In addition, the length and width of the prismatic body 1 may be appropriately selected according to a desired application. Usually, the length is about 600 to 6000 mm, and the width is about 150 to 1000 mm. The length is preferably about 1500 to 3000 mm, and the width is about 200 to 700 mm, from the viewpoint of excellent balance in the structure of the structure.

<Reinforcement layer>
The reinforcing bar layer 20 is not particularly limited, and examples thereof include a reinforcing bar, preferably a layer in which a reinforcing bar composed of horizontal bars 22 and vertical bars 24 is embedded with concrete. The reinforcing bar layer 20 may be a layer composed of two cement layers 14, lateral bars 22, and vertical bars 24 existing on the reinforcing bar side of the two prisms, and the reinforcing bar side of the two prisms. It may be a layer in which reinforcing bars are embedded in a concrete layer, which is composed of a concrete layer different from the two cement layers 14 present in FIG.
By disposing such a reinforcing layer 20 between the prisms 1, it is possible to obtain a structure having high strength, particularly high bending strength, while maintaining the physical properties of the prisms such as heat insulation. Moreover, even if this structure 2 of this invention is exposed to a flame, this reinforcement layer 20 becomes a fire wall.

  The bar arrangement in the bar arrangement layer 20 has a length equal to or shorter than the length and width of the prism 1 and does not have to protrude outward from the prism 1 but protrudes outward from the prism 1. It may be. When the reinforcing bar protrudes outward from the prism 1, the reinforcing bar is a connection point between the structures when a structure such as a building is constructed using the structure of the present invention. It can be. For example, in the case of using the structure of the present invention having a predetermined length or width in terms of ease of carrying, workability, etc., a structure such as a building that requires a length longer than the length is constructed. In this case, a plurality of structures 2 may be arranged in the length direction, and these structures may be coupled by reinforcing bars, or a structure such as a building that requires a width greater than the width. When constructing the structure, a plurality of structures 2 may be arranged in the width direction, and these structures may be joined by reinforcing bars.

The reinforcing bar is not particularly limited, but a reinforcing bar and a steel bar are preferable.
The diameter of the reinforcing bar is not particularly limited, and may be the same as the diameter of a conventionally used reinforcing bar, but is preferably about 1.5 to 20 mm, more preferably about 2 to 15 mm, Preferably it is about 2-10 mm.
Since the structure of the present invention has the predetermined structure, even if a bar arrangement having such a short diameter is used, the structure has a high strength.

  Note that the interval between the vertical bars and the horizontal bars of the bar arrangement may be appropriately selected according to the desired application, required strength, etc., and the vertical bars and the horizontal bars may be in contact or separated from each other. Alternatively, they may be bound so as to have a lattice shape or the like.

  The concrete layer separate from the two cement layers 14 existing on the reinforcing bar side of the prismatic body that embeds the reinforcing bar is not particularly limited, but a concrete layer that can bond the prisms 1 to each other is preferable, A composition similar to the composition used for forming the cement layer 14 may be used, but it is preferable to use a composition having a low water / cement ratio in order to impart higher strength to the resulting structure. . It is preferable that the concrete layer obtained by blending fine aggregate or the like with this composition maintains a certain shape.

  The thickness (length in the stacking direction) of the reinforcing bar layer 20 is not particularly limited, but the effect of the prismatic body 1 is more exhibited, and a structure having excellent strength and durability can be obtained. Preferably it is about 0-30 mm, More preferably, it is about 0-20 mm. The thickness of the reinforcing bar layer 20 is 0 mm because the reinforcing bar layer 20 is a layer in which the reinforcing bar is embedded in the two cement layers 14 existing on the reinforcing bar side of the two prisms. That means.

≪Structure≫
In the second aspect of the structure according to the present invention, there is a laminated body in which a cement layer including a lath body, a foam, a reinforcing layer, a foam, and a cement layer including a lath body are present in this order. The whole body is covered with a cement layer.

Such a structure is well-balanced in high strength, fireproofing and heat insulation, lightweight and inexpensive, and therefore suitable as a building material for structures such as buildings and floating bridges, especially as a housing for walls, floors, ceilings, etc. Used for.
In particular, the structure of the present invention is lightweight and excellent in handleability. Therefore, by using such a structure, buildings that cannot be built without using heavy machinery face the road. It can be constructed even in environments where heavy machinery cannot be used, such as no equipment, and is excellent in workability. Therefore, the structure of the present invention is particularly preferably used when a building is constructed in such an environment with poor workability.

The structure of the present invention is not particularly limited as long as it has the above structure. For example, the structure includes a cement layer including a lath body and a foam, a foam and a reinforcing layer, or a cement including a lath body. There may be another layer on the side of the layer opposite to the side in contact with the foam, but from the standpoint that the effect of the present invention is more exerted, the gap between the cement layer containing the lath body and the foam It is preferable that no other layer is present in.
Further, the laminate may include a cement layer or foam including three or more lath bodies, and two or more reinforcing layers.

  The laminated portion in the first aspect and the second aspect of the structure according to the present invention has substantially the same structure. That is, in the laminated body in the second aspect, when the layers constituting the laminated body are labeled for convenience, the cement layer 14A including the lath body, the foam 10A, the reinforcing layer 20, the foam 10B, and the lath It can be expressed that the cement layer 14B including the body is a laminated body existing in this order, and the laminated body according to the first aspect can be obtained by adding a sign to the layers constituting the laminated body for convenience. Can be expressed as a laminated body in which the prismatic body 1A covered with a cement layer, the reinforcing bar layer 20, and the prismatic body 1B covered with a cement layer are laminated in this order. .

Here, the cement layer 14A in the second mode corresponds to the cement layer 14 on the side opposite to the side in contact with the reinforcing bar layer 20 of the prismatic body 1A in the first mode, and the foam in the second mode. 10A corresponds to the foam contained in the prismatic body 1A in the first aspect, the reinforcing bar 20 in the second aspect corresponds to the reinforcing layer 20 in the first aspect, and in the second aspect The foam 10B corresponds to the foam contained in the prismatic body 1B in the first aspect, and the cement layer 14B in the second aspect has a side in contact with the reinforcing bar layer 20 of the prismatic body 1B in the first aspect. Corresponds to the cement layer 14 present on the opposite side.
Therefore, specific examples of the lath body, the cement layers 14A and 14B, the foams 10A and 10B, and the reinforcing layer 20 in the second aspect are the same examples as those described in the first aspect, respectively. The preferred embodiments are also the same.
The cement layers 14A and 14B, the lath bodies included in these layers, and the foams 10A and 10B may be the same or different.

In the second aspect, the entire surface of the laminate is covered with a cement layer. The surfaces of the cement layer that are substantially perpendicular to the stacking direction of the laminate are the cement layers 14A and 14B.
The cement layer covering the entire surface of the laminated body is a cement layer containing a lath body from the viewpoint that adhesion between the cement layer and the layer constituting the laminated body is improved and a high-strength structure is obtained. It is preferable that Specific examples of the cement layer and the lath body are the same as those described in the first aspect, and the preferable aspects are also the same.

<< Production Method of Structure of the Present Invention >>
The structure of the present invention can be produced by a method including the following steps (A) to (B).
Step (A): Step of forming the prismatic body by covering the entire surface of the foam with a cement layer Step (B): Step of laminating the two prismatic bodies obtained in the step (A) via the reinforcement layer

<Process (A)>
In the step (A), preferably, after a lath body is provided on at least one surface of the foam 10, more preferably, the entire surface of the foam 10 is surrounded by the lath body, and then the cement layer 14 is formed on the entire surface of the foam 10. A step of forming the prism 1 by disposing and curing (curing) the forming material is preferable.

The method of providing the lath body on at least one surface of the foam is not particularly limited, but the lath body may be fixed to the surface of the foam by a fixing means such as staples, or the foam is wound around the lath body, The entire periphery of the foam may be surrounded by the lath body by joining the ends of the lath body.
In this case, in particular, the adhesion between the foam and the resulting cement layer is improved, and a high-strength structure can be easily obtained. It is preferable to fix to the surface of a foam by fixing means, such as.

  As a method for disposing the cement layer forming material, a method of applying the cement layer forming material by a conventionally known coating method such as spray coating or coating using a trowel may be used. The molded foam) may be dipped in the cement layer forming material. A predetermined mold is prepared in advance, and the cement layer forming material is disposed on the inner peripheral surface of the mold. After the foam (foam coated with a lath body) is placed in the mold, the above-mentioned surface is not applied to the upper surface of the cement layer forming material by a conventionally known coating method such as spray painting or painting using a trowel. The method of apply | coating a cement layer forming material may be sufficient.

  When arranging the cement layer forming material, the adhesion between the foam and the resulting cement layer is improved, and a higher strength structure can be easily obtained. It is preferable to dispose the cement layer forming material while providing a lath body made of synthetic resin. As this method, a conventional method such as spray coating or painting using a trowel is applied while a lath body is provided on a foam (a foam coated with a lath body), or a predetermined formwork is created in advance. Then, after arranging the lath body and the cement layer forming material on the inner peripheral surface of the mold, a method of arranging a foam (foam covered with the lath body) in the mold is mentioned.

  In addition, from the point that a higher strength structure can be obtained, a cement layer forming material is disposed on a foam (foam covered with a lath) while providing the lath, and cured for a predetermined period of time. Thereafter, it is preferable that a cement layer forming material is disposed on the obtained laminated body while providing a lath body, and is cured for a predetermined period. That is, it is preferable to form at least two cement layers including a lath body, and it is more preferable to form about 2 to 6 layers.

  When the structure of the present invention is used as a building material or a frame, it is necessary to construct a wall without a gap, and thus a prismatic body excellent in dimensional accuracy such as a smooth surface and a right angle of the structure. In particular, the surface smoothness and dimensional accuracy are improved by forming a prismatic body by spray coating using a composition containing the fly ash, trowel coating, or a method using a formwork. An excellent prismatic body can be obtained.

  In order to improve the familiarity between the foam and the cement layer when the cement layer forming material is disposed, a primer or an adhesive may be applied to the foam surface in advance. It may be sufficiently moistened.

<Process (B)>
In the step (B), preferably, a reinforcing bar is disposed on the prismatic body obtained in the step (A), and a reinforcing layer forming material is further disposed as necessary, and another prism is disposed thereon. The step of arranging the body is mentioned. At this time, the two prisms may be joined using a conventionally known separator.

  In addition, when arranging the concrete layer forming material, a primer or an adhesive may be applied in advance to the surface of the prism body in order to improve the familiarity between the prism body and the reinforcing layer. The surface may be sufficiently moistened.

  Although the structure of the present invention can be obtained by the step (B), a lath is formed on the entire circumference of the laminate obtained in the step (B) from the viewpoint that a higher strength structure can be obtained. After providing the cement layer forming material while providing the body and curing for a predetermined period, it is preferable to further dispose the cement layer forming material while providing the lath body to the obtained laminate and curing for a predetermined period. That is, it is preferable to form at least two cement layers including a lath body on the entire circumference of the laminate obtained in the step (B), and it is more preferable to form about 2 to 6 layers.

<Other manufacturing methods>
In addition to the method including the steps (A) to (B), for example, the structure of the present invention is formed by disposing a cement layer forming material while providing a lath body on at least one surface of a foam. After obtaining a laminate and laminating the two obtained laminates by providing a reinforcing layer on the surface opposite to the surface on which the cement layer forming material is disposed, the entire surface of the obtained laminate is a cement layer. It can also be manufactured by a method of coating with.

<Application>
Since the structure of this invention has the said effect, it can be conveniently used as building materials, such as a wall, a floor, and a ceiling, especially as building materials of structures, such as a building and a floating bridge.
The structure may be a structure constructed from the structure of the present invention alone, but a structure constructed by combining a plurality of the structures of the present invention, for example, connecting them at a reinforcing bar. It may be a thing.

  EXAMPLES Hereinafter, although an Example is given and this invention is demonstrated more concretely, this invention is not limited by these.

[Example 1]
A polystyrene foam having a length of about 2640 mm, a width of about 225 mm, and a thickness of about 50 mm was prepared by a conventionally known method.

  In addition, Hayato Portland Cement (Mitsubishi Cement Co., Ltd.), Type II Fly Ash (Jepec Co., Ltd.) and Dry Silica No. 4 (Tohoku Seizuna Co., Ltd.) are combined with cement and fly ash. Cement layer is formed by mixing well in an amount that makes the mass ratio 7: 3, and in an amount that makes the mass ratio of cement and cinnabar about 1: 1, and then adding water that can be troweled. Made the material.

  A metal lath having an opening of about 13 mm was placed on the entire surface of the polystyrene foam, and then fixed with staples.

  Next, a synthetic resin lath having an opening of about 5 mm and the cement layer forming material are disposed (arranged layers) on the inner peripheral surface (five surfaces) of a wooden mold of a predetermined size that has been prepared in advance. And a polystyrene foam surrounded by a metal lath body is placed in the mold, and then the cement layer is provided with a synthetic resin lath body on the upper surface where the cement layer forming material is not disposed. A laminate was obtained by disposing the forming material (the thickness of the disposed layer was about 5 mm) and curing for a predetermined period.

  Next, after placing the synthetic resin lath body having an opening of about 5 mm and the cement layer forming material on the inner peripheral surface of a wooden mold of a predetermined size prepared in advance, in the mold, After the obtained laminate was placed, the cement layer forming material was placed while the synthetic resin lath was placed on the upper surface where the cement layer forming material was not placed, and was cured for a predetermined period. By repeating this process once more, a prismatic body was obtained. Two such prismatic bodies were created.

  A bar arrangement consisting of vertical and horizontal bars having a diameter of about 3 mm was placed on the obtained prismatic body, and the obtained prismatic body was further placed thereon, and this laminate was fixed.

  Next, a synthetic resin lath body having an opening of about 5 mm and the cement layer forming material are disposed on the inner peripheral surface of a predetermined size wooden mold (the thickness of the disposed layer is about 5 mm). Then, after placing the obtained laminate in the mold, the cement layer forming material was disposed (disposed) while providing a synthetic resin lath on the upper surface of the cement layer forming material not disposed. The layer thickness was about 5 mm) and cured for a predetermined period. By repeating this process two more times, a structure was obtained.

A support having a circular cross section was installed at a distance of 1000 mm between the supports, and the obtained structure was placed on the support so that the center in the longitudinal direction was the center between the supports. Next, a load of 25 to 250 kg was applied to the center of the arranged structure from above. Even when a load of 250 kg was applied, the structure was not damaged, and no change in appearance such as cracks in the cement layer could be confirmed.
Even when the same test was performed using the prismatic body instead of the structural body, the prismatic body was not damaged, and no change in appearance such as cracks in the cement layer could be confirmed.
From the above, it was confirmed that the structure of the present invention has sufficient strength to be used as a building material or a casing.

1: prismatic body 2: structure 10: foam 11, 12: lath body 14: cement layer 16: side surface in the length direction 18: side surface in the width direction 20: reinforcement layer 22: transverse muscle 24: longitudinal muscle

Claims (12)

  A structure characterized by comprising a prism body in which the entire surface of the foam is covered with a cement layer, a reinforcing layer, and a laminate in which the prism body whose entire surface of the foam is covered with a cement layer is laminated in this order. body.   A structure including a laminate having a cement layer including a lath body, a foam, a reinforcing layer, a foam and a cement layer including a lath body in this order, and the entire surface of the laminate is covered with the cement layer A structure characterized by being.   The structure according to claim 1 or 2, wherein a lath body exists on at least one surface of the foam, and the entire surface of the foam is covered with a cement layer with the lath body.   The lath body exists on the entire surface of the foam, and the entire surface of the foam is covered with a cement layer with the lath body. Structure.   The structure according to any one of claims 1 to 4, wherein the entire surface of the foam is covered with a cement layer with at least two lath bodies.   The structure according to claim 1, comprising at least one cement layer formed using a composition containing cement and fly ash.   The structure according to claim 6, wherein the fly ash content in the composition is 5 to 50 parts by mass with respect to 100 parts by mass of cement in the composition.   The structure according to any one of claims 1 to 7, wherein an expansion ratio of the foam is 10 to 40 times.   The structure according to any one of claims 1 to 8, wherein the thickness of the structure (the length in the stacking direction) is 50 to 400 mm.   The structure according to any one of claims 1 to 9, which is a building material.   The structure according to any one of claims 1 to 10, which is a casing. The manufacturing method of the structure of any one of Claims 1-11 containing following process (A)-(B).
Step (A): Step of forming the prismatic body by covering the entire surface of the foam with a cement layer Step (B): Step of laminating the two prismatic bodies obtained in the step (A) via the reinforcement layer

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