CN106396735B - 耐火隔温减噪复合墙板的制作方法 - Google Patents

耐火隔温减噪复合墙板的制作方法 Download PDF

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CN106396735B
CN106396735B CN201610793257.6A CN201610793257A CN106396735B CN 106396735 B CN106396735 B CN 106396735B CN 201610793257 A CN201610793257 A CN 201610793257A CN 106396735 B CN106396735 B CN 106396735B
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凌庭生
凌俊儒
徐玲芳
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Abstract

本发明揭示了一种耐火隔温减噪复合墙板的制作方法:步骤1、水泥基材迎火面涂覆防火覆着层;步骤2、发泡硬化;步骤3、在防火覆着层外进行耐碱处理;所述防火覆着层的浆料由高铝水泥、耐火骨料、水/液体外加剂、起泡剂混合构成。本发明耐火隔温墙板制作工艺所生产的耐火保温性远高于目前常用的产品,能够满足更高防火要求的建筑需要。

Description

耐火隔温减噪复合墙板的制作方法
技术领域
本发明涉及建材领域,尤其涉及防火板。
背景技术
耐火墙板为常用的建筑材料,在发生火灾时,能有效的抑制火情扩散,目前的耐火墙板大都是原纸(钛粉纸、牛皮纸)经过三聚氰胺与酚醛树脂的浸渍工艺,高温高压成制备。三聚氰胺树脂热固成型后表面硬度高、耐磨、耐高温、耐撞击,表面毛孔细小不易被污染,耐溶剂性、耐水性、耐药品性、耐焰性等机械强度。这类耐火板只是具有一定的耐火性能,难以满足高防火要求的建筑需要。
发明内容
本发明所要解决的技术问题是开发一种耐火性能更好的耐火板制作工艺。
为了实现上述目的,本发明采用的技术方案为:耐火隔温减噪复合墙板的制作方法:
步骤1、水泥基材迎火面涂覆防火覆盖层;
步骤2、发泡硬化;
步骤3、在发泡的防火覆盖层硬化后,再其表面涂覆耐碱涂层;
所述防火覆盖层的浆料由高铝水泥、耐火骨料、水/液体外加剂、起泡剂混合构成。
所述高铝水泥、耐火骨料、起泡剂、水/液体外加剂的质量比:1:(2.5~3):0.1:(0.2~0.3)。
所述防火覆盖层的浆料的制备方法:
1)将高铝水泥和耐火骨料称重混合并开始第一次搅拌;
2)将1)混合物内加入水/液体外加剂并开始第二次搅拌;
3)将2)混合物内加入起泡剂并开始第三次搅拌。
所述步骤2将水泥基材置于5-35℃的无风环境中硬化,硬化时间以板材强度不低于成品强度的70%为最低限,硬化过程中定期在防火覆盖层外水雾湿养。
发泡的防火覆盖层硬化后将其表面采用中低浓度的硫酸溶液表面处理,或用耐碱涂料涂覆,同时封闭表面孔隙。
水泥基材上防火的覆着层掺入发泡剂后形成含有大量细小均匀的气泡。
所述步骤3涂覆耐碱涂层喷涂厚度3-5mm,所述耐碱涂料为环氧基涂料或硫酸溶液。
一种耐火隔热复合墙板,所述耐火隔热复合墙板包括水泥基材,所述水泥基材的迎火面按照权利要求1-6所述的制作方法处理。
所述水泥基材的两面均按照权利要求1-6所述的制作方法处理。
所述水泥基材为烘干的纤维水泥板或无机材料的骨架结构。
本发明耐火墙板制作工艺所生产的耐火保温性远高于目前常用的产品,能够满足更高防火要求的建筑需要。
附图说明
下面对本发明说明书中每幅附图表达的内容作简要说明:
图1为耐火隔热复合墙板制造方法的工艺流程图。
具体实施方式
本发明以水泥基材作为耐火板基础,水泥基材为烘干的纤维水泥板或无机材料的骨架结构;板材厚度选择5mm已可满足需要,但要求基板表面为粗糙毋抛光。
外形规格:1200/2400×300/600×(10/20/50120)mm;骨架外边框以内的结构可采用“田”、“丰”、“井”等均衡型结构。
湿涨率:≤0.23%;
含水率:≤10%,通常5%
烘干温度:50±5℃
偏差限值:长度±5mm
宽度±3mm
厚度±2mm
混凝土空心墙板:普通板、门框板和过梁板;
板长宽厚符合建筑模数,板长3000mm以内,板宽300/600mm;
隔墙板厚60mm,80mm,100mm;
分户板厚100mm,120mm,140mm;
外墙板厚120mm,150mm,200mm;
基板厚度基准单位参照10/20/50mm倍数,并符合建筑模数要求。
如图1所示,耐火隔热复合墙板制造方法包括以下几步:
步骤1、水泥基材迎火面涂覆防火覆盖层;
步骤2、发泡硬化;
步骤3、在防火覆盖层外涂覆耐碱涂层;
其中防火覆盖层的浆料由高铝水泥、耐火骨料、水/液体外加剂、起泡剂混合构成。
水灰比:0.4-0.5;
耐火骨料掺比:耐火骨料磨机粉磨,平均粒径≤1mm,最大粒径5mm,具有良好颗粒级配;
质量比:高铝水泥:耐火骨料:起泡剂:水/液体外加剂
=1:(2.5~3):0.1:(0.2~0.3)
高铝水泥:代号CA,以铝酸钙为主的铝酸盐水泥熟料磨细制成的水硬性胶凝材料。根据需要可在磨制Al2O3含量大于68%的水泥时掺加适量的α-Al2O3粉。
高铝水泥根据Al2O3含量百分数分为四类:CA-50,CA-60,CA-70,CA-80。
高铝(铝酸盐)水泥的细度要求比表面积不小于300m2/kg;
CA-60初凝不得早于60min,CA-60终凝不得迟于18h,其它三类水泥初凝不得早于30min,终凝不得迟于6h。
铝酸盐水泥早强高,凝结硬化快,快硬、早强,水化热高,放热快且热量集中;具有很强的抗硫酸盐腐蚀作用和较高的耐热性,抗碱性差。与耐火粗细集料(如铬铁矿等)可制成耐高温的耐火混凝土,用于抗硫酸盐腐蚀的工程和冬季施工工程。
不适宜大体积混凝土;不能用于与碱溶液接触的工程;不得与未硬化的硅酸盐水泥混凝土接触使用;不得与硅酸盐水泥或石灰混合使用;不能蒸汽养护、不宜在高温季节施工。
耐火骨料品种:
高铝质刚玉、尖晶石、莫来石;
硅线石、红柱石、蓝晶石;
硅石/砂(SiO2≥95%)
粒径:磨机磨细,Max≤5mm,平均粒径≤1mm
配比:高铝水泥:耐火骨料=1:(2.5~3);
3)水/液体外加剂
PH≤7的生活自来水及掺加水溶性起泡剂的生活自来水
4)起泡剂
品种:松香树脂,烷基苯磺酸盐,脂肪醇磺酸盐等非含氧酸性或中性种类;
用量:水泥用量的万分之0.5-1.5;含气量≤5%混凝土体积。
高铝水泥:比表面积≮225m2/kg,最大颗粒3mm;型号CA-50
防火覆盖层的浆料的制备方法如下:
1)将高铝水泥和耐火骨料称重混合并开始第一次搅拌;
2)将1)混合物内加入水/液体外加剂并开始第二次搅拌;
3)将2)混合物内加入起泡剂并开始第三次搅拌。
每次搅拌参数:
搅拌方式:强制搅拌;
搅拌温度:大气温度,常温;极限大气低温5℃,极限大气高温35℃;
搅拌时间:投料加水开始到出料间隔时间15+5 -0min
投料加水开始成型/定型完成≤60min;
每次混合物参数
混合物以坍落度控制:混合物坍落度>40mm且<100mm,采用分次投料强制搅拌,搅拌最短时间120s。
防火覆盖层喷浆附着时,环境参数:温度为大气温度,常温;极限低温5℃,极限高温35℃;喷浆厚度随基材及板材类型在5-100mm,喷涂压力高压(气动):0.3-0.6MPa(可调)。
防火覆盖层喷涂后的发泡硬化在自然养护条件下进行,采用适当材料覆盖并水雾湿养,防风防干、保温防冻(避免气温低于5℃)防高温(避免气温超过35℃),硬化时间以板材强度不低于成品强度的70%为最低限。水泥基材上防火的覆着层掺入发泡剂后形成含有大量细小均匀的气泡,因此具有良好的隔温和隔音减噪性能。
发泡硬化后的防火覆盖层优选进行精加工处理,采用高铝水泥净浆将硬化后的防火覆盖层表面抛光,同时封闭表面孔隙。喷涂厚度3-5mm,喷射风压=0.11×输料管长度(m)MPa。
抛光后的防火覆盖层表面采用耐碱涂料处理,耐碱涂料为环氧基涂料或中低浓度度硫酸溶液。通常外墙喷两面层;内墙、隔断墙喷一面层。每层厚度为40μm,即一面层厚度40μm,两面厚度80μm;,喷涂压力高压(气动):0.3-0.6MPa(可调)。
基于上述生产方法制作的耐火隔热复合墙板包括水泥基材,水泥基材的迎火面按照上述制作方法处理。
本发明耐火隔热复合墙板的耐火隔温减噪指标:
1)外表面温度1000℃(建筑物火灾温度通常为900-1000℃)喷烧2h时耐火层底面≤200℃。结构用钢温度≤200℃时强度基本不变,250℃左右结构钢发生蓝脆现象,强度开始降低。
2)耐火层导热系数≤0.5W/m.K
纤维水泥多孔板导热系数:0.5;水泥刨花板导热系数:0.13(国外产品)~0.18(国内产品)。
3)隔声指数25(dB)
水泥刨花板隔声指数:25~34(dB)。

Claims (6)

1.耐火隔温减噪复合墙板的制作方法,其特征在于:
步骤1、水泥基材迎火面涂覆防火覆盖层;
步骤2、发泡硬化;
步骤3、在发泡的防火覆盖层硬化后,在其表面涂覆耐碱涂层;
所述防火覆盖层的浆料由高铝水泥、耐火骨料、水/液体外加剂、起泡剂混合构成;
所述高铝水泥、耐火骨料、起泡剂、水/液体外加剂的质量比:1:(2.5~3):0.1:(0.2~0.3);
所述步骤2将水泥基材置于5-35℃的无风环境中硬化,硬化时间以板材强度不低于成品强度的70%为最低限,硬化过程中定期在防火覆盖层外水雾湿养;
发泡的防火覆盖层硬化后将其表面采用中耐碱涂料涂覆,同时封闭表面孔隙;
所述步骤3涂覆耐碱涂层喷涂厚度3-5mm,所述耐碱涂料为环氧基涂料或硫酸溶液。
2.根据权利要求1所述的耐火隔温减噪复合墙板的制作方法,其特征在于,所述防火覆盖层的浆料的制备方法:
1)将高铝水泥和耐火骨料称重混合并开始第一次搅拌;
2)将1)混合物内加入水/液体外加剂并开始第二次搅拌;
3)将2)混合物内加入起泡剂并开始第三次搅拌。
3.根据权利要求2所述的耐火隔温减噪复合墙板的制作方法,其特征在于:水泥基材上防火的覆盖层掺入发泡剂后形成含有大量细小均匀的气泡。
4.一种耐火隔热复合墙板,其特征在于:所述耐火隔热复合墙板包括水泥基材,所述水泥基材的迎火面按照权利要求1-3任一所述的制作方法处理。
5.根据权利要求4所述耐火隔热复合墙板,其特征在于:所述水泥基材的两面均按照权利要求1-3任一所述的制作方法处理。
6.根据权利要求5所述耐火隔热复合墙板,其特征在于:所述水泥基材为烘干的纤维水泥板或无机材料的骨架结构。
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