CA2037473A1 - Method for the manufacture of molded reconstituted granite slabs - Google Patents
Method for the manufacture of molded reconstituted granite slabsInfo
- Publication number
- CA2037473A1 CA2037473A1 CA 2037473 CA2037473A CA2037473A1 CA 2037473 A1 CA2037473 A1 CA 2037473A1 CA 2037473 CA2037473 CA 2037473 CA 2037473 A CA2037473 A CA 2037473A CA 2037473 A1 CA2037473 A1 CA 2037473A1
- Authority
- CA
- Canada
- Prior art keywords
- mixture
- mold
- slab
- particulates
- applying
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Abandoned
Links
Landscapes
- Press-Shaping Or Shaping Using Conveyers (AREA)
Abstract
METHOD FOR THE MANUFACTURE OF MOLDED RECONSTITUTED GRANITE
SLABS
ABSTRACT OF THE DISCLOSURE
An improved method for the production of reconstituted granite slabs is disclosed. Crushed granite, or other suitable particulate, is combined with hydraulic cement, such as Portland cement, and water. The resultant mixture is placed in a mold and vibrated prior to the application of hydraulic pressure. The vibration of the product within the mold results in the larger granite particles moving to the top of the mixture. After the application of pressure, the slab is removed from the mold, cured, ground and polished.
The surface of the slab is high in granite concentration and provides a strong impermeable product.
SLABS
ABSTRACT OF THE DISCLOSURE
An improved method for the production of reconstituted granite slabs is disclosed. Crushed granite, or other suitable particulate, is combined with hydraulic cement, such as Portland cement, and water. The resultant mixture is placed in a mold and vibrated prior to the application of hydraulic pressure. The vibration of the product within the mold results in the larger granite particles moving to the top of the mixture. After the application of pressure, the slab is removed from the mold, cured, ground and polished.
The surface of the slab is high in granite concentration and provides a strong impermeable product.
Description
- 1 2037~73 MEI~IOD FOR THE MANUFACTURE OF MOLDED RECONSTITUTED GRANITE
FIELD OF THE INVENTION
The present invention relates to the field of simulated gMnite and its manufacture, more particularly to a method for the manufacture of molded reconstituted granite slabs.
BACKQRQUND OF THE INVENTIO~
Polished slabs of natural granite have been used for many years as a standard long-lasting construction material. In this polished form it is not only very ,^ 10functional, but has highly decorative properties as well. However, the price of polished natural granite is quite high and this prevents its use in many situations.
There have been many affempts over the years to provide synthetic stone slabs by mixing particulate filler such as stone chips or sand with different types of binder, for example cement or resin. Pigment may also be added. Resulting products are lighter than pure granite and do not have the same functional characteristics as pure granite.
Granite, particularly in a highly polished state, has very low water absorption properties.
It is also quite resistant to the elements, particularly, variations in temperature.
Burger descAbes in his Canadian patents 642,540 and 755,000, methods for ~ .
the p~r~hon of an artificial granite in which hard rock, possibly granite, is mixed with 20 ~ hydraulic cement and molded under pressure. The resultant product is used for slabs, floorinl or~sidewalWp;ldouse.
3 ~ ; ~ the methods disclosed by Burger, the process involves a dry mLl~ of eemenl~and particulate materia L ~In his patents, his water addition is bghtly controlled at S~ and 8~% and not more than 15%, with excess water addition to be carefully avoided. This is done so ~at the water does not squ~ out of the mold during the 90~7059A~
,,: : -. . , .: . . ` :
~;. . - - . ...
2037~3 pressing procedure. In examples used in his process, the maximum size particle is 1/8th of an inch, with at least 50% of the volume of the particles being less than a 200 mesh. The size of the particles ranges from dust to a maximum of 1/8th of an inch. The finer particles of the total amount less than l/8th of an inch diameter consists of 60% dust size particles.
The present invèntion is concerned with an improved process and product of this type. The present invention does not require a close control over the wat~r concentra-tion, as a filter system is used with the molds du~ng the pressing procedure to keep the cement, particles and pigments if any, within the mold. The filter allows the expression of o up to 95% of water in the mixture. The present invention also uses a larger maximum particle size of 12 millimetres and a larger average particle size in which less than 20% of the particles pass 200 mesh.
The present process may also include a vibration step prior to the pressing procedure, in which the larger particles move to the sur~ace of the mixture in the mold as a result of the vibration. This vibration step results in the surface being composed almost entirely of granite.
S~,?~RY OF THE INVENTION
The present invention is concerned with an improved method for the manufacture of a reconstituted stone block or slab.
The present invention is further concerned with providing a method of manufacture for such a block or slab, using a high slump cement and particle mixture.
According to the present invention there is provided a method for the manufacturer of reconstituted stone slabs comprising mixing particulates with hydraulic ;~
cement and water sufficient to produce a high slump concrete mixture, pouring the mixture ' ' : ~ ' ". "
':
- - - -~~ -- - -- - - . . , - . . .
2037~73 into a mold, applying filter means to the surface of the mixture in the mold, applying pressure to the mixture within the mold so as to express excess water therefrom, and removing a resultant molded slab from the mold.
The resultant slab may be ground and polished to provide an excellent surface.
The advantages of the present invention over prior methods include the use of a high slump concrete mixture as opposed to a relatively dry mixture previously disclosed. This is-a result of the use of the polypropylene filter used in the mold in the pressurization process. The filters permit water to be expressed from the mold during the 0 process, but not the concrete mixture and pigments, if any, within.
The present invention also allows for an increased average particle size as well as a larger maximum particle size. This yields an improved surface appearance with a larger percentage of granite or other stone and less cement binder. This effect can be augmented by vibrating the mold, which causes the larger particles to move to the surface of the mixture. When the slab is cut and polished, the surface of the slab is almost entirely granite.
The present invention also provides an enhanced appea~ance over prior products because the polished surface is almost enbrely granite.
D13TAII~D DESCR~ ON
In a ~prd~i embodiment, crushed granite, slag or roclc are blended in a co~ncrete~ n~L~r at the ~ate of 80% crushed material to 20% hydraulic cement. In the present pmcodure, normal Portland cement, High and Early cement or Ciment Fondue is used.~ Pigment may also be added to achieve~ a desired colour. The crushed granite, slag or rack has~a maximum size~ of 12 miDimetres and is well graded downward to 20%
2037~73 passing a 200 mesh.
The crushed aggregate and cement are mixed thoroughly, then water is added at a volume sufficient to accommodate an approximately 255 millimetre slump. The mixture is then poured into a hydraulic press mold, fitted with a polypropylene filter cloth.
A polypropylene filter cloth is also fitted to the die head. The polypropylene ~llters prevent the loss of cement slurry and pigment during the pressing process described below.
Once the mixture is within the mold, the mold is then vibrated for a minimum of two seconds to segregate the large aggregate particles from the smaller particles. Vibration of the mixture results in the larger particles moving towards the 10 surface of the product within the mold.
A die head is positioned above the mold and hydraulic pressure is applied at the rate of lS MPa (or 1,850 - 2,000 psi). During this pressurization, 95% of the mixing water is forced out of the mixture. The die head is then removed and the mold is moved aside. The molded product is then ejected from the mold and picked up and stacked on edge on a steel pallet for curing at room temperature for about 16 hours. Following ~is mitial curing phase, the slabs are moved from the pallets and stored outdoors for a further 28 days. Following the 28th day, the surface of the slab is ground and polished to a high gloss shine, using conventional methods. The size of the slabs produced using the aboYe -method varies from 400 millimetres by 600 millimetres by 100 millimetres to 500 20 millimetres by 1J200 millimetres by 100 millimetres. The minimum compressive strength is at 65 MPa (8,000 psi). The density is 2,400 kilograms per cubic metre and the water -: .
absorption is less than S%. With the addition of silica fume, strengths in excess of 15,000 psi and densities in excess of 152 pounds per cubic foot have been achieved. These data are not meant to be limiting in any way, but only as an indication of the present method.
i.
~ ~~'~'' ':
' ' ~ . ' ' ' ' . , . ' ' . . . . . . .
2037~73 The main application for the products of the above procedure is the produc-tion of surface grave markers. However, it can be used for other functions as well, such as wall panels, flooring, patio/sidewalk slabs or other structures where strength and water resistance are required.
The surface of the product of the above method of manufacture polishes like real stone. Where a vibration step is used in the manufacturing process, the large particles - of granite or other aggregate move to the surface of the mixture, thereby allowing the polishing of a high concentration of aggregate. With a granite aggregate, the impermeable qualities of natural granite are also carried to the surface of the slab with the granite pieces.
0 The present method provides a reconstituted granite slab or artificial which is highly resistant to water absorption and chemical attack. T~he use of slag, a waste product from copper smelting operations, enhances the impermeability properties of the manufactu~ed slab, u well as provlding a means for the re~ycling of, what is normally, unwanted dross.
It is also quite possible to add various pigments, as well as microsilica components, depending ùpon tho type of slab desired. The resultant product is inexpensive when compared to~polished granite. ~ ~ ~
Since ~arious modifications can be made ~m my invention as hereinabove described, and many~ apparently ~widely~ dlfférent emb~diments of same made within the pirit~al~d~s~ of the claims without~dep~ting~;from~such~spint ~d s~, it is intended 0 li~ matt~ ~tatned i n the accom~n~ng specification shall be int~d as illustra-and not in a lin~ng~sense.~
FIELD OF THE INVENTION
The present invention relates to the field of simulated gMnite and its manufacture, more particularly to a method for the manufacture of molded reconstituted granite slabs.
BACKQRQUND OF THE INVENTIO~
Polished slabs of natural granite have been used for many years as a standard long-lasting construction material. In this polished form it is not only very ,^ 10functional, but has highly decorative properties as well. However, the price of polished natural granite is quite high and this prevents its use in many situations.
There have been many affempts over the years to provide synthetic stone slabs by mixing particulate filler such as stone chips or sand with different types of binder, for example cement or resin. Pigment may also be added. Resulting products are lighter than pure granite and do not have the same functional characteristics as pure granite.
Granite, particularly in a highly polished state, has very low water absorption properties.
It is also quite resistant to the elements, particularly, variations in temperature.
Burger descAbes in his Canadian patents 642,540 and 755,000, methods for ~ .
the p~r~hon of an artificial granite in which hard rock, possibly granite, is mixed with 20 ~ hydraulic cement and molded under pressure. The resultant product is used for slabs, floorinl or~sidewalWp;ldouse.
3 ~ ; ~ the methods disclosed by Burger, the process involves a dry mLl~ of eemenl~and particulate materia L ~In his patents, his water addition is bghtly controlled at S~ and 8~% and not more than 15%, with excess water addition to be carefully avoided. This is done so ~at the water does not squ~ out of the mold during the 90~7059A~
,,: : -. . , .: . . ` :
~;. . - - . ...
2037~3 pressing procedure. In examples used in his process, the maximum size particle is 1/8th of an inch, with at least 50% of the volume of the particles being less than a 200 mesh. The size of the particles ranges from dust to a maximum of 1/8th of an inch. The finer particles of the total amount less than l/8th of an inch diameter consists of 60% dust size particles.
The present invèntion is concerned with an improved process and product of this type. The present invention does not require a close control over the wat~r concentra-tion, as a filter system is used with the molds du~ng the pressing procedure to keep the cement, particles and pigments if any, within the mold. The filter allows the expression of o up to 95% of water in the mixture. The present invention also uses a larger maximum particle size of 12 millimetres and a larger average particle size in which less than 20% of the particles pass 200 mesh.
The present process may also include a vibration step prior to the pressing procedure, in which the larger particles move to the sur~ace of the mixture in the mold as a result of the vibration. This vibration step results in the surface being composed almost entirely of granite.
S~,?~RY OF THE INVENTION
The present invention is concerned with an improved method for the manufacture of a reconstituted stone block or slab.
The present invention is further concerned with providing a method of manufacture for such a block or slab, using a high slump cement and particle mixture.
According to the present invention there is provided a method for the manufacturer of reconstituted stone slabs comprising mixing particulates with hydraulic ;~
cement and water sufficient to produce a high slump concrete mixture, pouring the mixture ' ' : ~ ' ". "
':
- - - -~~ -- - -- - - . . , - . . .
2037~73 into a mold, applying filter means to the surface of the mixture in the mold, applying pressure to the mixture within the mold so as to express excess water therefrom, and removing a resultant molded slab from the mold.
The resultant slab may be ground and polished to provide an excellent surface.
The advantages of the present invention over prior methods include the use of a high slump concrete mixture as opposed to a relatively dry mixture previously disclosed. This is-a result of the use of the polypropylene filter used in the mold in the pressurization process. The filters permit water to be expressed from the mold during the 0 process, but not the concrete mixture and pigments, if any, within.
The present invention also allows for an increased average particle size as well as a larger maximum particle size. This yields an improved surface appearance with a larger percentage of granite or other stone and less cement binder. This effect can be augmented by vibrating the mold, which causes the larger particles to move to the surface of the mixture. When the slab is cut and polished, the surface of the slab is almost entirely granite.
The present invention also provides an enhanced appea~ance over prior products because the polished surface is almost enbrely granite.
D13TAII~D DESCR~ ON
In a ~prd~i embodiment, crushed granite, slag or roclc are blended in a co~ncrete~ n~L~r at the ~ate of 80% crushed material to 20% hydraulic cement. In the present pmcodure, normal Portland cement, High and Early cement or Ciment Fondue is used.~ Pigment may also be added to achieve~ a desired colour. The crushed granite, slag or rack has~a maximum size~ of 12 miDimetres and is well graded downward to 20%
2037~73 passing a 200 mesh.
The crushed aggregate and cement are mixed thoroughly, then water is added at a volume sufficient to accommodate an approximately 255 millimetre slump. The mixture is then poured into a hydraulic press mold, fitted with a polypropylene filter cloth.
A polypropylene filter cloth is also fitted to the die head. The polypropylene ~llters prevent the loss of cement slurry and pigment during the pressing process described below.
Once the mixture is within the mold, the mold is then vibrated for a minimum of two seconds to segregate the large aggregate particles from the smaller particles. Vibration of the mixture results in the larger particles moving towards the 10 surface of the product within the mold.
A die head is positioned above the mold and hydraulic pressure is applied at the rate of lS MPa (or 1,850 - 2,000 psi). During this pressurization, 95% of the mixing water is forced out of the mixture. The die head is then removed and the mold is moved aside. The molded product is then ejected from the mold and picked up and stacked on edge on a steel pallet for curing at room temperature for about 16 hours. Following ~is mitial curing phase, the slabs are moved from the pallets and stored outdoors for a further 28 days. Following the 28th day, the surface of the slab is ground and polished to a high gloss shine, using conventional methods. The size of the slabs produced using the aboYe -method varies from 400 millimetres by 600 millimetres by 100 millimetres to 500 20 millimetres by 1J200 millimetres by 100 millimetres. The minimum compressive strength is at 65 MPa (8,000 psi). The density is 2,400 kilograms per cubic metre and the water -: .
absorption is less than S%. With the addition of silica fume, strengths in excess of 15,000 psi and densities in excess of 152 pounds per cubic foot have been achieved. These data are not meant to be limiting in any way, but only as an indication of the present method.
i.
~ ~~'~'' ':
' ' ~ . ' ' ' ' . , . ' ' . . . . . . .
2037~73 The main application for the products of the above procedure is the produc-tion of surface grave markers. However, it can be used for other functions as well, such as wall panels, flooring, patio/sidewalk slabs or other structures where strength and water resistance are required.
The surface of the product of the above method of manufacture polishes like real stone. Where a vibration step is used in the manufacturing process, the large particles - of granite or other aggregate move to the surface of the mixture, thereby allowing the polishing of a high concentration of aggregate. With a granite aggregate, the impermeable qualities of natural granite are also carried to the surface of the slab with the granite pieces.
0 The present method provides a reconstituted granite slab or artificial which is highly resistant to water absorption and chemical attack. T~he use of slag, a waste product from copper smelting operations, enhances the impermeability properties of the manufactu~ed slab, u well as provlding a means for the re~ycling of, what is normally, unwanted dross.
It is also quite possible to add various pigments, as well as microsilica components, depending ùpon tho type of slab desired. The resultant product is inexpensive when compared to~polished granite. ~ ~ ~
Since ~arious modifications can be made ~m my invention as hereinabove described, and many~ apparently ~widely~ dlfférent emb~diments of same made within the pirit~al~d~s~ of the claims without~dep~ting~;from~such~spint ~d s~, it is intended 0 li~ matt~ ~tatned i n the accom~n~ng specification shall be int~d as illustra-and not in a lin~ng~sense.~
Claims
CLAIMS:
(1) A method for the manufacture of reconstituted stone slabs comprising mixing particulates with hydraulic cement and water sufficient to produce a high slump concrete mixture, pouring the mixture into a mold, applying filter means to the surface of the mixture in the mold, applying pressure to the mixture within the mold so as to express water therefrom, and removing a resultant molded slab from the mold.
(2) A method according to Claim i including the further steps of allowing the slab to cure, grinding and polishing a surface of the slab.
(3) A method according to Claim 1 wherein the particulates are selected from the group consisting of crushed granite, slag, and rock.
(4) A method according to Claim 3 wherein the particulates have a maximum particulate size of 12 millimetres and no greater than 20% percent of the particulates have a size less than 200 mesh.
(5) A method according to Claim 4 wherein the hydraulic cement is one selected from the group consisting of Portland cement, High Early cement, Ciment Fondue and microsilica.
(6) A method according to any one of Claims 1 to 5 including mixing silica fume with the particulates, hydraulic cement and water.
(7) A method according to Claim 1 comprising applying a pressure to the said mixture of between 1,850 pounds per square inch and 2,000 pounds per square inch.
(8) A method according to Claim 1 wherein applying the filter means therein comprises applying a is a filter cloth to the mold before the mixture is poured.
(9) A method according to Claim 8 wherein applying the filter means further comprises applying a filter cloth to the mixture after it is poured into the mold.
(10) A method according to any one of Claims 1 to 5 and 7 to 9 further comprising vibrating the mixture in the said mold, prior to applying pressure to the mixture.
(11) A method according to anyone of Claims 1 to 5 and 7 to 9 wherein the ratio of particulates to hydraulic cement is 80% crushed particulates and 20% hydraulic cement.
(12) A method according to any one of Claims 1 to 5 and 7 to 9 comprising adding a pigment to the said mixture prior to the application of pressure.
(13) A method according to Claim 2 wherein the slab is allowed to cure in a first stage and a second stage, wherein the first stage comprises curing the molded slab for a minimum of 16 hours at room temperature, and wherein the second stage comprises curing the molded slab for a minimum of 28 days out of doors.
(14) The invention according to any one of Claims 1 to 5 and 7 to 9 wherein the slump is a 255 millimetre slump.
(1) A method for the manufacture of reconstituted stone slabs comprising mixing particulates with hydraulic cement and water sufficient to produce a high slump concrete mixture, pouring the mixture into a mold, applying filter means to the surface of the mixture in the mold, applying pressure to the mixture within the mold so as to express water therefrom, and removing a resultant molded slab from the mold.
(2) A method according to Claim i including the further steps of allowing the slab to cure, grinding and polishing a surface of the slab.
(3) A method according to Claim 1 wherein the particulates are selected from the group consisting of crushed granite, slag, and rock.
(4) A method according to Claim 3 wherein the particulates have a maximum particulate size of 12 millimetres and no greater than 20% percent of the particulates have a size less than 200 mesh.
(5) A method according to Claim 4 wherein the hydraulic cement is one selected from the group consisting of Portland cement, High Early cement, Ciment Fondue and microsilica.
(6) A method according to any one of Claims 1 to 5 including mixing silica fume with the particulates, hydraulic cement and water.
(7) A method according to Claim 1 comprising applying a pressure to the said mixture of between 1,850 pounds per square inch and 2,000 pounds per square inch.
(8) A method according to Claim 1 wherein applying the filter means therein comprises applying a is a filter cloth to the mold before the mixture is poured.
(9) A method according to Claim 8 wherein applying the filter means further comprises applying a filter cloth to the mixture after it is poured into the mold.
(10) A method according to any one of Claims 1 to 5 and 7 to 9 further comprising vibrating the mixture in the said mold, prior to applying pressure to the mixture.
(11) A method according to anyone of Claims 1 to 5 and 7 to 9 wherein the ratio of particulates to hydraulic cement is 80% crushed particulates and 20% hydraulic cement.
(12) A method according to any one of Claims 1 to 5 and 7 to 9 comprising adding a pigment to the said mixture prior to the application of pressure.
(13) A method according to Claim 2 wherein the slab is allowed to cure in a first stage and a second stage, wherein the first stage comprises curing the molded slab for a minimum of 16 hours at room temperature, and wherein the second stage comprises curing the molded slab for a minimum of 28 days out of doors.
(14) The invention according to any one of Claims 1 to 5 and 7 to 9 wherein the slump is a 255 millimetre slump.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CA 2037473 CA2037473A1 (en) | 1991-03-04 | 1991-03-04 | Method for the manufacture of molded reconstituted granite slabs |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CA 2037473 CA2037473A1 (en) | 1991-03-04 | 1991-03-04 | Method for the manufacture of molded reconstituted granite slabs |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA2037473A1 true CA2037473A1 (en) | 1992-09-05 |
Family
ID=4147117
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA 2037473 Abandoned CA2037473A1 (en) | 1991-03-04 | 1991-03-04 | Method for the manufacture of molded reconstituted granite slabs |
Country Status (1)
| Country | Link |
|---|---|
| CA (1) | CA2037473A1 (en) |
Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN114560721A (en) * | 2022-03-09 | 2022-05-31 | 德清诺贝尔陶瓷有限公司 | Natural texture decorative rock plate and manufacturing method thereof |
-
1991
- 1991-03-04 CA CA 2037473 patent/CA2037473A1/en not_active Abandoned
Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN114560721A (en) * | 2022-03-09 | 2022-05-31 | 德清诺贝尔陶瓷有限公司 | Natural texture decorative rock plate and manufacturing method thereof |
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Legal Events
| Date | Code | Title | Description |
|---|---|---|---|
| FZDE | Dead |