AU685800B2 - A method of manufacture for intermediate concrete products preset with external facing material - Google Patents

Description

94. 6.22 (W 81-51 FAX Pg: 0472654888 P, 06 ATJSTRALA BOWtion 3,2 Parents Act 1990

ORIGINAL

COMPLETE SPECIFICATION STANDARD PATENT Invention Title: j A1 IA The following statement Is a full description of this invention, Including the bast method of performing it known to me.- I. n 1 aw Nnss 6 ;Z 69-Z 94, 6. 22 W~ 8:51 71 P,9FAX 0472554889 P. 06 A METHOD~ OF MANUFACTURE PO1R INTERME~DIATE COflCRETB PRODUCTS PRESET WITH EXTERan?~ FACING MATERIAL~ This invention rolates to a m~ethod lor maniufacturing intermiediate concrete procuts preset with tiles, stone or 51 other facing materiel ue4o fox building and public wor'ka construction.

The laying of tiles or stone as a cosmetic facing for the exterior surface of buildings or the laying of tiles And stone an a cosmetic exterior f acing foir civil engineering fO appl~ications such as public parks, roads and so on 1:4 increasing every y'ear.

Similarly, pr oducts w~ihinvolve emedn tiles, stne eta. in concrete products are increasing every year.

recent years, in tzhe buzilding ind~ustry, the production in the factory of products such as~ PC concrete panels arid ouxtaijn walls whi.ch have been preset with tiles, stone or *other facing material and the inclusion of steel reinforcement is becoming widespread in building construction, Also, in t'he case of park~ construction and reside,*tial 9. housing, construction is being carried out which empbasizes aosthetic appearance laying stone and nonslip tiles, etc. In thso public works/civil engineering field, L-Bhaped 2S retaining walls are used for soil stabilization works in residential subdivision and road construction work but tho N 1b) ot:ZL VS-9 -ZZ' 301jdo-gns .iNJ~JVd B W ~nolN 94, ~622 B62 ?'Yf FAX H! 0472564869 P. 07 2 fact that the surface is doricrate creates sesthetic Problems, so it is common to use L-shaped retaining wall s with washed-stone or matrix finishes or, to give an sven more lXtOSettect, to construct walls of bul.1dixzg stone.

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V. V In the Past, as shown in Figures 8 and the method used to embed facing material in theso types of concrete products in the factory was to u~se a lattice.-phaped groove spacing plate 2 thinnor thar. the thickness of the f acing material A in order to set an even spa~cing between the tiles or other facinq material. A. The facing material A is arrangad face down in each of tho spaces formed by~ the lattice shape of the zpaciig plata 2 which lies been placed in the mould I for makin5 concrete products and then the concrete 9 is poured into the mould I. Ase the concr'ete B hardens, it forxs a solid mass with the facing material and after the concret6 B has hardened, it can be removed from the mnould. The result is a concrute product C as shown in P'ig'urs 9.

However, in the case of the above prodatction. method, the Problem is that adhesion between the facing material A and the groove spacing plate 2 is poor and gaps appear between the facing material A and the spacing plate 2 so that it ix not possible to completely preen the seepage of concrete milk throi~gh to the sur1gace of the facing material when the concrete B is pou~red, Consequently, after the concrete product is completed, the surface of the facing material has to be washed with water (or similar). This requiires a' lot of labour tima and so the manufaoturing process canrot be rationalized.

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~k2 A3~ ~j4,4 '44444<444 So, in order to solve the above problems, the inethod set out in the previous patent application, N4o. 63007/94 Ida$ aoijAlo-ans i OZ#!3Nunolgi~aw aA^_,jb7Yj M-16) t'e-9 -ZZ' 94. V6. 22 8.:52 Vf1YFAX P: 0472564889 P. 08 proposed. This method usea parffi n instoad of the Bpaci2W plate 2 as in the past and the groove ispncing ot the facing material Which has boon l.aid ouit in the mould is formed by a Inaterial, for example partffi)< which is transformed by the application of beat fromi solid to 3i~quid or liquid to solid (hereafter refe~rred to simply at ,Paraf fir, and efter the concrete Ls poured, the/ yaraff in, wis malted and removed.

With this method, there is good adhesion between the fcingmatrialandthe.jaratfin.,and it is possible to prevent concrete milk seepinxg through to the surface of the facing material. However, in tho case of mnaterials which are highly water absorptive such ais ceramic tiles and qrnits, if they aro soaked in or brought into contact is with,,Vraffirz they absorb the pitraftin, Not only does the arafinjaum* sti±nirg of the surface and problem~s of' change of olour in 'the finished product but etlso the absorbed paraf fin,,weake~as the adhesion with the concrete resulting in the danger of the facing material pealing or from the conarete. IFurthor, if the paraffin happens to adhere to the back of the faci.ng naterial when 0:0. it is poured, it will inevitably lower the adhesive strangth of the facing material and make quality control difficult.

so? in oases where materials whioh have high water absorp~tive properties are used for facing waterials, the.

manufacture of concrete products by the method using paraffinjis not possible and total control of quality is problemiatic, Tbi~z invention provides a method for manufacturing' concrete products preset with facing m~aterial which -~ad4regses these problems, One, it is possible~ to Prevent C L M Nuflo81iM AbII' (Kf1b) LL:?A VS-9 odi-fl NLZ,! O 6,22 81153 ?iW 1 W FAX 0~ 472664869 0 completel~y the seepagie of concrete mnilk through to the surface of the facing m~aterial and so eliminate the need for the extra work of washing the surfaice of the faoi±bg mnateri.al# etc, Two, even if the faciug material is aL mater.ial with high water absorptive p'roperties# there are no obstacles to using this method and i.t i~s possible to g'iarantee absolute adhesive strengtb.

ITn order to solve the above problemis, the first part of this invention provides a method for making units of facing material. This method involves arranging the tiles, intons or othaor fac~ing material face -4p witb the back or base facing down in the zpecified positions in~ a mould forA making units of facing muaterial. Thon the material is allowed to soak in water or hot water which has been poured in to a specified level relative to the height of' the facing Raterial. Then the liquid fovm of a material which is transformed by hest from volid to liquid or liquid to solid and which alao separates out from the 0. 0 above liquid already in the mould, is pou~red in. When the second liquid has turned to solid by means of either natural or artificial cooling, that part of the facing material above the liquid (ie, the first liquid) and the, solid form a sinqle mass to make a unit of facing material, with the back or basof the tile, sztone or othor facin~g naterial copetl xpsd C. The second part of the invention provides a method for 0. making concrete prodc~ts preset with facing material using the above units of facing rdaterial.

The tiles, stone or other facing material is arranged in the specified positions in a mould for making Units of facing material with the face up and the back facin1g down and soaked in water or hot water which is poured into the mould to tha specified level relative to tbe height of the Z#!NJfo21~w OK-1b) LL:ZL V6-9 -ZZ- ~I~dO-2flS J.

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facincl Muterial. Then the liquid form of a m~ater~ial which ip transformed by hieat from solid to .lquid or l±qUid to solid1 and wh~ich 81sc0 separates Out fzcom the abovementioned liquid already in tho moul.d is pourad in. When this has been turned from a lquid into a solid by neains ot either natural or artificial Clooling, the upper part of the facing material above the water or hot water and the solid formi a single mass with the back of the facing material completely expos~ed thus forming A unit of facing' matorial. The units of facing materild which have been removed from the mioulds are arranqed with the back facing up in a mould for maing concrete products, then concrete is Poured into the mould. When the concrete hardens, it frsa single -mass with the Eacing material. and then heat can be applied to the muould or the product to turn the solid into its liquid form and remove it.

In the case~ of this 'invention, the faoing material can also be ,;atuxrated with water or hot water before it is placed in the rnould~s for in~king units of tacing mataria1, The facing m~aterial is arranged in the specified pattern depending on the type of concrete product in a mould for making units of f~cing material and then the lower part of the facing material is soaked in wdater or hot water which has beau poured into the nould either in adv*Ace or after the facing material has b~een laid out.

In the case of facing material whic~h has high water absorptive p.-opartias, the facing mterial becomes saturated with the water or hot water.

At this atage, a liquid such as liqufied paralfin, i poured into the mou~ld so that it completely covers the upter par~t of the feoing material.

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a 4 Bcause the,,,Paraffin, p other SUCh liquid separates competely from the water or hot water which has a4z'eaoy baen Poured inlto the maould, it doces not adhere to that part of the faOin9g material which i.z soaking in the liquid and ;Curtharmore, even in the case ot.ma 0 terial which has high water absorptive properties, the prafin.,oes not soak into the material b~ecause it bas already been saturated with another liquid.

Given time, the liquid such Js,'prafia solidifies naturally.

Alternatively, in order to solidif~y it SIickly, it can be cooled ag ificial1y so that the upper part of the facing mnaterial1 and the,paraffin ~or a single mass to mhake a.

unit of facing material.

Next the units of fa&Lng material are removed from the mouldIs and arranged with the parafin side facing down In a movld for making conrarte products anda the doncrete It poured on top of them.

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4 p4 to44 0 The cOflcretO encases thaw ack of the tacing Mtdria. which Is exposed abova the /%paraff in but doas not penetrate thbrOtgh to the surf ace of the laoing material which is encased inyparaf fin w4o%K* H~aving waited for the Poured concrete to harden while holding it at a temperatura below thi mating point of sot;oA paraffin, steam is applied to cure the ha8rdened concrete.

0athe cu~ring temperature excbedp tthe melting point of Aar a f fin' the paraffin malts and becom"e liquid and can-~be run out 09 tho mould by removing the stopperg trai the drain holes provided in the bottom of the mould, Whatreiliains in the mould is a concrete produ.ct consisting of '94, 6,32 W 8.64 rymf WH FAX P: 0472564869 P.12 7' the facing 'material and the concrete which have been formed into a single mass. once this has been removed from il the mould, a concrete product which has external facing material preset into the surface is complete. i; alternatively, depending on the circumstances, the product :B can be removed from the mould while the paraffin is still solid and then it can be raised to a high temperature by the application of steam (or similar) and the paraffin removed from the product. An exampI4 of the application of this invention isiil explained below with reference to the attached figures I 1 7.

Figure I is a cross-section showinff tiles set into a mould for making units of facing material, 'i Figure 1(B) is a plarimietric a&p of the same.

i g Figure 2 is a cross-section of a mould for units of facing .I j i ~T~material into which liquid has been poured. Figure 3 is a cross-section showing steel mesh reinforcement set into a mould for making units of facing material.

e S Figure 4 is the same cross-section as above ea.e.b=.e with the paraffin-a added. 1 :,Figure 5 is a cross-section which shows the unit of facing material as it is removed from the mould.

Figure 6 is a cross-section of the making of the concrete 1 product.

#;3Nn nO73W -Jbrl 6 SL:ZL VB-9- -0 0 N lA 94, 8166 717' W FAX P! 0472664889P 1 3 P. 13 Figure 7 i- a cross-staction of the finished concrete product.

Figure 8 is a cross-section showing the 'prior art' of the mnufacture of concrete products and Figure 8(B) is a Planin~etric mnap of the sqaln M~ould aS abDO,~ Figure 9 is a Cross-zec Lion of the previous generation of concrete product, I0

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Explanation of symubols 11 mould for mnaki~ng tile units 12 ti1e spacing gauge 13 groove spacing plate 14 liq~uid 15 steel mssh reinforcement 16 paraffin Lxkx. k4cvt.O OC SOI;cl 17 tile unit 21 MOuld fOZr M~aking concrete produ.cts 22 concrete 23 concrete product a tile

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The figurss illustrate the method of manufa concrete product,$ using ties a for the exterr material, As shown in Figures 1 and 4B), t~ are arranged flat using an appropriate size to f; 11 for making til.e units and a tile spacing gaug4 can be freely inserted and removed is plaeced i mould.

The 9grOOVe spacing pl.ate 13 which has a height halt. the thickness of the tilea a, is construct shape of a lattice and the tile Spaoing gauge 12 nture for ial facing istiles a r it a mould e 12hic~h .nsJide the of about :ed in the is ahaped 16 #1 N-16) VL:ZL VS-9 -ZZ,' 0.22 8:-58

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*000 0* S. S *5*5 so that the' tiles a fit exactly into each of the space-v enclosed by tb& groove spacing plate 1Z.

As in Figure 1 after the tile spacoing gaugs 12 has been assembled ip the mould 11 for mahing tile units, the ti.les are arranged face up with the back facing down in each of the spaces of the said gauge 12.

The tiles a are arranged flat in the mnould. The exact groove spacing is mintained around themi by the groove zPacing plate 13 and the upper half ot the tiles a (as seen from the face of the tiles) protudes above the tile spacing gauge 12..

N~ext, an shown in Fig'ure 2, a liquid 14 such as water or hot water is pouared into the mould for tile units to the depth of the tile spacing gauge 12 so that the lower half of the til1es are soaking in the liquid 14.

The p~uriing of the liquid 14 into the mould 11 can be done after the til.es a are laid out as above or it can be, poured into the mould~ 11 before the tiles a are arranged.

As shown in Eiqura 3, after the liquid 14 han seon poured, steel mash 15 for rainforcement is goet in~side the tile unit rnotld 11 at an appropriato pesition aibove the tiles a, Net s shown in Figure 4, l*kiquid paraffin 14 is poured into the tile unit mtould I) I o that the upper, half of the tiles a is conpletoly encased in the ~tsfaffin .6 f It p

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The liquid paragfin 16. separatea out comPletelY frOYD thO liquid 14 which was already poured into the mould 11 and floats on top of tho liquid 14.

W ,01I fIIL\ V6- .Id-n 1~V ~A kZ#!3NNnoois 8:59FAX 1j; 0472654880 0 The liquid paraffi.nAcollects at a position above the tile apacing gauge 12 and is poured in so as to~ encase the upper part of the tiles a (as seen from the tae of the tiles) and remains separate from the liquid below the tile spacing gauge 12. Then th Paafn".f oliJdified by natuiral or artificial cooling.

By virtue .q its adhesiveness to the tileos a( the solidifie4,\paragfr1 16 formns a single maass with the tiles a. and the roinfrcing mesh Bo that it forms5 a tile unit IQ 17.

11% this case, the paraffinA 16 Will not adheara to the lower part which is the back of th tiles a ari which has bean As showri in Figure 5, the tile unit 17, which is formed *when the p11araffin '16 solidifies, is rem~oved from the tile 1.rXit mould 11.

Next, as shown in Figure 6, a miould 21 for concrete proftats of the appropriate shape fox the p~articular concrete product is prepared and ax number of the tilie units 17 are arrangied in the vnould 21. this case, the tile units 17 are arned with the paraffin sida 16 down and the ba.ck of the tiles a faciig up and as shown in the figure, the til.e units 17 are alo arranged on the side of the m~ould 21 which stands Concrete 2? is poured into tho mould 21 in~ which the tile units 17 hav been arranged and the surface is finisho6 with a trpwai.

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4 22 Vy W FA P 0472664889 P 1 03 The poure on) f rom surfaoe q by the~ ?NP the tiles

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hen, by omm3itted oul'd 21,t 1, so t; od7 form he muould ni relati lith the 5 is att rtocc .o form~ a ~fter the rescribe .t is rem coOncre i±gure 7) l th res ?emovel oeft to d concrete 22 gradually hardens but pas.t* (and so the concrete 22 flooa not~ soop through to thO f the tiles a which have boon~ completely z~ale.G Araffial 16 so that no staining of the surface of will Oo~ur, :eta 22 .s allowed to.Pavra at a temperature neltincg point of the Aparaffin Alter it has the concrete 22 is cured with stamm (or similar) the curing temperature exceeds the malting point Paratfin 16, the parffi.n begins, to melt Aqd remioving the stoppers and opening the holea from diagram) provided in the botftom of the9 tbeqarfin A can be dr~ained out of the mould .i h~at only the concrete product which is a single ted by the tiles a arid the aoncvoto 22 rejnainx in .21.

on to~ the tiles a, oince the concrete 22 cm o nOW back of the tilea to which absol.utel.y o 4 :ached and f ills in the spacing between the tils ~ncrete 22 ohd the tiles a bind togetber strongly.

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concrete has been strengtheno~d bY curing at theid tempdicature an~d for the presoribed time, when aeved from~ the mould, a finished product which is te product 23 preset with tiler. a (as shown in is obtained.

pect to the above (that is,~ the rnelting an0.

)f the paraffin. 16), a&fter the concrete has bveen kiar.rI:,, the conarete product 23 can be removed ~~PP FAX~ 131 0 s 472663486 R 04 frmthe mo3uld 21 and, after it has been romoved, the paraffin,,an be kioatod, malted and reooverod, F'urther, the tilds a were qiven as atn exmple of tacinq materials but stone can also be used. Also, apart from th flat concrete panel shown in the Zigure, the concrete products 23 which can be made includevig concrete panals, curtain walls, L-sb~psd concrota retaining wiilla, concrete paving blocks and concrete fences4. in order to make theze produicts, it is simply a matter of providing ni mould which is of the appropriate shape and size tor making these concrete produots.

In addition, using th~e above method of pz'ocuction, it tile or stone which hap, h~qhWwater absorptivs properties is used, by soaking the lower half of the t.acingr matarial in the liquid 14 Which is poured into the mould 11 during the procas fo nain th6 tieuis1 that the facingr zaterial abraorbs the liqui4, when thbkpiaraffin,,.s poured in, inprognation of tho tatting material th ae ng can be prevented. In this way, zkt the next stave of the production of the concrete product, the problem of the paraffin Alo ttestg ntepocs twihth ie4nt 17 ar rdcd9i re opeetee oecmltl k0**9kW~ alsorpio at the N inafib the ces awinh mthertil the facing material can be soaked beforehiand so that it will absorb liquid prior to being arranged in tbo mlould 11.

~c~RA(7 /N T V6-9 -Z.4 iN ivd AG'A 8 8~2; r I0 4*44 4 4 4404 44** 4494 4JO4 W' *)900 FAX J i 0472664869 P, As oxplaine4 above, this invention involves arranginq facin~g miaterial in a mould lor miakinq units of facin~g material and soaking it in a liquid whith is added to a specifiad level relative to the height of the facinV material. Then a liquid such as IParaffint'i poured into the 'mould and allowed to solidify so that the facing 7natorial and the solid combine to torm a unit of tacing material. Next the units otfLacin5 material are arranged in~ a. miotd for making concrete products and, after theL concrete haxs brieti poured into the mould and allowed to harden, the abovs-nentioned solid Is maltad to a 1qi and removed.

Consequently, the stfect ot this invention with resPect to the production of concrete products prestt with facing material, is that whaii the concrete in poqred, the seepage of concrete milk through to the surface of the facing natarial can be prevented entirely b~ecause the facing material is encased in a solid zuch as,.paraffirk This means, therefore, that the work of washiing the tinished pro~duct is unnecessary and this, in turni, makes it possible both to achieve cost reductions by rationalizing work proces~ses and to produce a product with a beautifiul surtace at a low price.

Further, because the facin5 material is already soaking in a liLquid when the paraffin ^(or similar) is pourod in, the 14quid and the araftineparata comp)atoly and staining.

due to seapago through to the surface of the faaing material does not occur and so thiere is no nead for a process to remove the paraffinA(or similar) from the Sirface of the facing material..

SU13 further, because the 4ang material is xoaked in liq~uid, even where the facing material is ai material with high water abzorptivs propert3.ez, bocausa it has alre~ady p

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aborbod a 'liquid, there is no danger that when the Paratfin (or .yilar) is pou.radP tbo''h rf i impregnate the mnaterial and cause the adhesion between the facing material end the concrete to b)O weakened and, at the same timae, the 000pi.ng Of.,paraffix1,thxroUgh to ths ~surf ace of the facing material can be prtovented so that a good quality product which 15 not subject to the dainger of poeling/separation of the facing material can be provided.

Finally, b~ecause Paraffin~is easy to shape, it does not require a lot of laibour and, because of the difference in its spocific gravity from that of water, it separates out from the water and can be recovered. So the work of washino the Zinished produict als~o becomes vir~tually unnecassary and the recovered paralfin can be reused rapeatedly thus leading to cost reduction.

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Claims (4)

1. A method for manufacturing units of facing material to be used for making concrete products preset with external facing material, involving a sequence of operations performed in the order specified below: tiles, stone or other facing material are placed in the specified positions with the face up and the back facing down in a mould for making a unit of facing material; (ii) the said unit mould is then filled with water or hot water (also referred to as the first liquid) to the specified level relative to the height of the facing material which is thus soaking in the water; (iii) a material which as well as being transformed from solid to liquid or liquid to solid by the application of heat, also separates out from the above liquid already in the said mould, is poured into the said mould in its liquid form (also referred to as the second liquid); (iv) the second liquid is then cooled naturally or artificially to turn the liquid to solid so that the upper part of the facing material above the first liquid and the solid form a ingle mass which constitutes a unit of facing material; the unit of facing material is then r-moved from the mould.

2. A method for manufacturing concrete products preset with external facing material using units of facing material as defined in Claim 1, involving a sequence of operations performed in the order specified below: (ii) the units of facing material as defined in Claim 1 are arranged with the back of the facing material facing up in a mould for making concrete products; (iii) concrete is then poured into the mould and when it hardens, it forms a single mass with the facing material; (iv) heat is then applied to the mould containing the product or to the product after it has been removed from the mould to melt the solid to its liquid form and remove it.

3. A method for manufactur'ing units of facing material as defined in Claim 1 where, in the case of highly absorptive facing materials, an additional operation of soaking the materials before placing them in the mould for making units of facing material is added to the sequence specified in Claim 1, that is, prior to operation in Claim 1.

4. The method defined in Claim 1 for manufacturing units of facing material to be used for making concrete products preset with facing material in which the sequence of operations and (ii) as specified in Claim 1 is reversed, that is, the water or hot water is poured into the mould for units of facing material before the facing material is placed in the said mould. .i. 4 V. 4' 26 06 0009 00000i 00 S 0 *00 *0~ *00 0 0 0

550000. Il-~a~a~ at-un~~arra~ a FA 047266500o PI1 00 7fretelin ah-ve the V0 A-fi e I which constitutes a unit of tacing mater±z~l. Theu it; of0 faoing material which have been removed gr me1 mould are then arranged with the back of the cing material taoing up i.n a mould f or makinsr a rots Products. Concrete is then poured into the d and whati the concre~te hardens, it foriis a sin naa with the facing materil. Then heat can be a ecd to the mould or to the product to maelt the ~ho method for manufacturing c~qe~ pr'oducts preset with external facing material asin ClaiM 2 i' characterizedi by the fact that it prevonts the absorption of the mraterial. which is transfozmed by heat trom soli~d to liquid or liquid to solid by the facng naterial byr first saturating the facing material which 'ids been arranged in a mould for units of facing material with water. PC concrete panels manufactured by the mtothod "TId in Claims 2 and 3 above. 7 ~-.Concreta curtain walls manufactured by the method dvc=h "in Claims 2 and 3 above. L-shappd ~concrete retaining walls manutactured by the method in Claim~s 2 and 3 above, M Fat conarete panels ,concrete pavinq bimk a1S nd concrete fences manufactured by the meth~od dSebd Clains 2 and 3 Above. U Z 7 7- of U0 *S#!SNUnOS12N VA 4 ERXE J. ?CGOWN KAkSUY4 HlOK& 20 juxE, 1994 ~3I~O-gns J.Nai~d A~ Ao~ 814 FAX P; 0472664889 P, D ABISTRACT To provide a method for making Concrete products preset with 9&oi4nv material which overoies tkia problems of staining of the surf ace of the facing materi~al and Pe±n9/separation of the facing material. go that high quality products can be manufactured at low~ cost. A mathod of manufacture for concrete products preset with externaal facing m~aterial is di'ezooed. The facing material i.s arranged in a mould 11 for making units of facing mraterial and water or hot water 14 is poured in. to cover the lower part of the facing material. Then. Aiaffin,"16 is poured into the mould and allowed to solidity so that the f acing material and the val.id /*-combine to fOrm a unit of facing material. These units of facing material are then arranged in a mould for making concrete products. After the qpncrate has booen poured and allowed to harden, and zoliA %AQSA( thaej"Paraf fiu ,4or sinuilar) malted and removed, a concre.te product with facing miaterial set into the surface is obtained. p 9 41 ~j ,i~f *:Go 0* OS 00 0 *0 *05* *5O* S *0 S o S. 0* 0~ 'A ~oI~Q-gflS .LN~L' VWSN8noglaW