Lightweight cement panel

A lightweight cement panel for concrete formwork, comprising:

• a panel proper formed comprising a porous compact produced by filling, curing, and solidifying a mixture prepared by kneading cement, water, reinforcing fibers, and foam obtained by prefoaming a foaming agent in a hermetically sealed cement form block, containing the reinforcing fibers and foam in a dispersion state in the compact, and providing the specific gravity within the range between 0.5 and 1.0;
• a side foam layer comprising expandable synthetic resin that integrally covers the side end face of the panel proper;
• a side face reinforcing sheet comprising woven cloth or unwoven cloth installed to be embedded between the side end face of the panel proper and the side foam layer;
• a surface resin layer comprising synthetic resin that integrally covers the surface of the panel proper;
• a surface reinforcing sheet comprising woven cloth or unwoven cloth that is disposed to be embedded in the surface resin layer.

A method for manufacturing a lightweight cement panel, comprising steps of:

• disposing a panel proper comprising lightweight cement in a product form block with a film, sheet, or board which serves as a surface protection layer disposed on the inner surface of the hermetically-sealable product form block;
• filling a clearance between the inner surface of the surface protection layer and the surface of the panel proper with expandable synthetic resin so that the surface reinforcing sheet comprising woven cloth or unwoven cloth is disposed to be embedded;
• integrally covering the surface of the panel proper with the surface resin layer with the surface reinforcing sheet embedded by closing the product form block under this condition and foaming and hardening the expandable synthetic resin;
• and
• simultaneously bonding film, sheet, or board which serves as the surface protection layer to the panel proper by the surface foam layer.

A method for manufacturing a lightweight cement panel, comprising steps of

• manufacturing a porous compact by filling, curing, and solidifying a mixture prepared by kneading cement, water, reinforcing fibers, and foam obtained by prefoaming a foaming agent in a hermetically sealed cement form block;
• filling expandable synthetic resin between the outer-circumferential side surface of the porous compact and a foam-molding form block to foam and harden in the hermetically sealed foam-molding form block, and integrally covering the outer-circumferential side surface of the porous compact by the expandable synthetic resin layer;
• slicing the porous compact covered by the expandable synthetic resin layer and fabricating a panel proper of a predetermined thickness with the side end face covered by a side foam layer comprising the expandable synthetic resin;
• and
• integrally covering the surface of the panel proper with a surface reinforcing sheet.

A method for manufacturing a lightweight cement panel, comprising steps of:

• manufacturing a porous compact by filling, curing, and solidifying a mixture prepared by kneading cement, water, reinforcing fibers, and foam obtained by prefoaming a foaming agent in a hermetically sealed cement form block;
• temporarily fixing a reinforcing sheet comprising woven cloth or unwoven cloth to the outer-circumferential side of the porous compact;
• filling a clearance between the outer-circumferential side surface of the porous compact to which the reinforcing sheet is temporarily fixed and a foam-forming form block in the hermetically sealed foam-forming form block to allow it to foam and solidify;
• integrally covering the reinforcing sheet and expandable synthetic resin layer on the outer circumferential side surface of the porous compact;
• fabricating a panel proper of a predetermined thickness with the side end face covered with a side face reinforcing sheet comprising the reinforcing sheet and a side part foam layer comprising the expandable synthetic resin by slicing the porous compact with the reinforcing sheet and expandable synthetic resin layer, and
• integrally covering the surface of the panel proper by a surface reinforcing sheet.