EP2382070A2 - Method for making and decorating concrete structures - Google Patents
Method for making and decorating concrete structuresInfo
- Publication number
- EP2382070A2 EP2382070A2 EP09703961A EP09703961A EP2382070A2 EP 2382070 A2 EP2382070 A2 EP 2382070A2 EP 09703961 A EP09703961 A EP 09703961A EP 09703961 A EP09703961 A EP 09703961A EP 2382070 A2 EP2382070 A2 EP 2382070A2
- Authority
- EP
- European Patent Office
- Prior art keywords
- concrete
- mold
- concrete structure
- emulsion
- substrate
- 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.)
- Withdrawn
Links
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B28—WORKING CEMENT, CLAY, OR STONE
- B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
- B28B1/00—Producing shaped prefabricated articles from the material
- B28B1/08—Producing shaped prefabricated articles from the material by vibrating or jolting
- B28B1/087—Producing shaped prefabricated articles from the material by vibrating or jolting by means acting on the mould ; Fixation thereof to the mould
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B28—WORKING CEMENT, CLAY, OR STONE
- B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
- B28B1/00—Producing shaped prefabricated articles from the material
- B28B1/008—Producing shaped prefabricated articles from the material made from two or more materials having different characteristics or properties
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B28—WORKING CEMENT, CLAY, OR STONE
- B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
- B28B11/00—Apparatus or processes for treating or working the shaped or preshaped articles
- B28B11/001—Applying decorations on shaped articles, e.g. by painting
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B28—WORKING CEMENT, CLAY, OR STONE
- B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
- B28B23/00—Arrangements specially adapted for the production of shaped articles with elements wholly or partly embedded in the moulding material; Production of reinforced objects
- B28B23/0075—Arrangements specially adapted for the production of shaped articles with elements wholly or partly embedded in the moulding material; Production of reinforced objects for decorative purposes
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B28—WORKING CEMENT, CLAY, OR STONE
- B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
- B28B7/00—Moulds; Cores; Mandrels
- B28B7/36—Linings or coatings, e.g. removable, absorbent linings, permanent anti-stick coatings; Linings becoming a non-permanent layer of the moulded article
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B28—WORKING CEMENT, CLAY, OR STONE
- B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
- B28B7/00—Moulds; Cores; Mandrels
- B28B7/40—Moulds; Cores; Mandrels characterised by means for modifying the properties of the moulding material
- B28B7/44—Moulds; Cores; Mandrels characterised by means for modifying the properties of the moulding material for treating with gases or degassing, e.g. for de-aerating
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B44—DECORATIVE ARTS
- B44C—PRODUCING DECORATIVE EFFECTS; MOSAICS; TARSIA WORK; PAPERHANGING
- B44C1/00—Processes, not specifically provided for elsewhere, for producing decorative surface effects
- B44C1/22—Removing surface-material, e.g. by engraving, by etching
- B44C1/227—Removing surface-material, e.g. by engraving, by etching by etching
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B44—DECORATIVE ARTS
- B44C—PRODUCING DECORATIVE EFFECTS; MOSAICS; TARSIA WORK; PAPERHANGING
- B44C1/00—Processes, not specifically provided for elsewhere, for producing decorative surface effects
- B44C1/24—Pressing or stamping ornamental designs on surfaces
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B44—DECORATIVE ARTS
- B44C—PRODUCING DECORATIVE EFFECTS; MOSAICS; TARSIA WORK; PAPERHANGING
- B44C5/00—Processes for producing special ornamental bodies
- B44C5/04—Ornamental plaques, e.g. decorative panels, decorative veneers
- B44C5/0453—Ornamental plaques, e.g. decorative panels, decorative veneers produced by processes involving moulding
Definitions
- the present invention relates to various methods of manufacturing and decorating concrete structures.
- crete refers to a material made from aggregates, for example sand and / or chippings, agglomerated with a binder.
- the binder can for example be "cement”, that is to say, taken by hydration, thereby obtaining a concrete cement.
- the mechanical compressive strength of concrete varies depending on the nature of the concrete itself, for example depending on the amount of water contained in the concrete.
- Ultra High Performance type concretes (BUHP) and Ultra High Performance Fiber (BFUHP) type concretes are preferred for implementing the present invention.
- the concrete structure may be a structure, a partition, a post, a constituent part of a residential building or office building, a piece of furniture, a floor covering, a cladding, Wall,...
- the subject of the invention is a method for manufacturing a concrete structure, comprising the following steps:
- BUHP ultra-high performance type concrete
- BFUHP Ultra High Performance Fiber
- the evacuation of the air bubbles is for example counteracted by a solid part, for example a plate, for example glass or wood, which can be attached to the mold, for example, and which has for example a horizontal surface in contact with concrete.
- a solid part for example a plate, for example glass or wood, which can be attached to the mold, for example, and which has for example a horizontal surface in contact with concrete.
- the area of the solid part may be greater than or equal to 1 cm 2 , more preferably 1 dm 2 , even better 10 dm 2 , or even 50 dm 2 , or even more.
- Craters have, for example, for at least some, a diameter greater than or equal to 1 mm, or even 2 mm, or even 5 mm or 10 mm and a depth greater than or equal to 0.5 mm, or even 2 mm or 5 mm or 10 mm , see more.
- the number of craters having such dimensions is for example greater than or equal to 1 by dm 2 , better still or equal to 2.5, or even 10, 20 or 50.
- the solid part can only partially cover the upper surface of the concrete, which can create a contrast effect between two regions of the upper surface of the concrete, one smooth and the other with asperities created.
- the solid part is in direct contact with the concrete, so that the evacuation of air bubbles is the most upset possible.
- the vibration of the mold can for example be done through a vibrating support on which the mold is placed.
- the craters obtained can optionally be filled, at least partially, with a resin, for example a colorless or colored transparent resin, or with a concrete of another color for example, in order to provide an additional aesthetic effect.
- a resin for example a colorless or colored transparent resin, or with a concrete of another color for example, in order to provide an additional aesthetic effect.
- the method may also include the step of injecting air into the concrete, before and / or after casting of the concrete, to enhance the formation of air bubbles and increase the likelihood of crater formation under the solid part and / or increase the density or size of the craters.
- the injected air is, for example, compressed air.
- the injection of air is preferably carried out before fixing the solid part which hinders the evacuation of the bubbles and before the vibration is started at all.
- the method may further include the step of placing a material in contact with the concrete prior to setting.
- This material may be placed, in an exemplary implementation of the invention, randomly on one or more areas of the bottom of the mold, or the solid part, or on the surface of the concrete before the introduction of the solid part.
- It is for example a mineral or vegetable material, for example salt, sugar, algae, sand, among others, in order to obtain particular effects related to the nature of the material used, or to an adhesive, a fabric or a sheet of paper, among others.
- At least a portion of the surface of the crater-forming structure is intended to be exposed to the view, at least partially, during the use of the structure, after demolding and possibly assembly with other elements.
- Optical fibers can be deposited in the mold before pouring the concrete.
- the manufacturing process can be used for the manufacture of concrete structures, partitions, buildings, including homes or offices, furniture, for example a tabletop or countertop.
- the structure can be in particular a piece of furniture, including a table or a chair, a floor covering, a building element.
- FIGS. 1A-1C of the attached drawing illustrate steps of an exemplary method according to this first aspect of the invention, allowing the creation of asperities in the form of "craters" on at least a portion of the surface of the invention.
- a concrete structure In order to obtain the finest possible surface condition, concrete of the BFUHP (Ultra High Performance Fiber Concrete) type having a particle size preferably of less than 500 microns can be used.
- BFUHP Ultra High Performance Fiber Concrete
- the various components of the concrete are firstly mixed in a first stage, namely for example: "premix” (mixture of cement, sand, silica and fired silica, that is to say crushed limestone), water, fluidizer, accelerator, fibers and possibly pigments. It is possible to inject air into this mixture, for example with an air gun, to enhance the formation of air bubbles in the concrete. As a result, the probability of forming the asperities is increased.
- the concrete 20 in the fluid state is then cast, as illustrated in FIG. 1A, in a mold 21 (also called formwork), this mold 21 being of any shape and comprising for example a frame 22 and a bottom 23, the filling is preferably performed up to the edge of the frame 22.
- a mold 21 also called formwork
- a plate 24 for example a wooden board, on which a release agent or oil has optionally been sprayed, is affixed to the upper surface of the concrete 20 where it is desired to make appear asperities.
- This plate 24 is preferably fixed to the frame 22 so that the concrete 20 is in perfect contact with the plate 24.
- the plate 24 can be fastened with nails 25 to the frame 22, as illustrated in FIG. .
- the assembly consisting of the mold 21, the concrete 20 and the plate 24 is then vibrated on a vibrating table 27 for a period of between for example 1 and 15 minutes. As a result, the air contained in the concrete 20 rises to its surface.
- the assembly formed by the mold 21, the concrete 20 and the plate 24 is allowed to rest for the time necessary for setting the concrete, then the plate 24 is removed.
- a first alternative embodiment of the method consists in depositing a selected material on a surface of the mold 21 before pouring the concrete 20, on the plate 24 or on the concrete before placing the plate 24, this material being able for example to be salt to create crystals, sugar that can crystallize, seaweed that can expand on contact with fresh concrete to generate marine odors or silt, sand, adhesive, fabric or leaf, to obtain a surface appearance specific to this material.
- the plate 24 may be rigid or flexible, and may possibly not be reported on the mold but be present from the start on it.
- the plate 24 may be flat or not, depending on the shape to be given to the structure.
- the surface covered by the plate can take any vertical orientation, horizontal or other, depending on the use that is made of the concrete structure.
- the structure of the concrete may be devoid of reinforcement such as irons.
- the invention relates to a method of decorating a concrete structure, comprising the following steps: a. coating a permeable substrate with a photosensitive emulsion, b. exposing the substrate thus coated with the emulsion to a radiation source so as to form an image on the substrate, c. developing the emulsion so as to have a local permeability of the substrate related to the image, d. affixing the substrate after developing the emulsion on at least one face of the concrete structure, e.
- a mixture comprising a varnish and / or a coloring agent, including luminescent or phosphorescent, so as to reveal an image-related pattern on the concrete structure, f . allow to dry, for example from a few hours to several days, or, a. coat the concrete structure with a photosensitive emulsion, b. exposing the structure thus coated with the emulsion to a source of light radiation so as to form an image on the structure, c. developing the emulsion so as to have local permeability of the image-related structure, and d.
- a mixture comprising a varnish and / or a coloring agent, including luminescent or phosphorescent, so as to reveal an image-related pattern on the concrete structure, e. let dry, for example from a few hours to several days, f. possibly place the concrete structure on which the mixture has been deposited in hydrochloric acid.
- the substrate may for example comprise a frame fabric, which is coated with photosensitive emulsion, during the first step a.
- the face of the structure on which the substrate is affixed may for example correspond to the "smooth side" of a concrete slab, that is to say the side located against a wall of the mold during setting concrete.
- FIG. 2 illustrates steps of an exemplary method according to the invention, enabling the creation of a pattern on the surface of a concrete structure, according to a principle similar to that of screen printing.
- the concrete used is for example a type of concrete BFUP (Ultra Fiber Concrete
- High Performance having a particle size preferably of less than 500 microns.
- a first step I degreasing a face of the concrete structure 1 on which the printing will be performed, for example using a cloth 3 soaked in a solvent such as acetone.
- a screenprint 4 is produced on which a frame fabric 5 is shown.
- the preparation of the artwork 4 consists of coating the canvas on frame 5 with photosensitive emulsion while working in a space of reduced brightness, for example in a dark room. Then, the photosensitive emulsion is allowed to dry. At the end of this period, the desired pattern is insolated on the artwork and once the sunstroke is over, the artwork is rinsed with water and allowed to dry.
- This mixture M may for example comprise an ink, or pigments mixed with a binder, for example a glossy varnish.
- Luminescent photo-pigments may optionally be incorporated into the mixture M.
- the screen-printing type 4 is preferably chosen so as to have a large mesh and these pigments are present in a mass content preferably greater than or equal to 20%, more preferably 30%, in the mixture M.
- the presence of the varnish within the mixture M may be useful if it is desired subsequently to deposit an acid on the concrete structure, in order to etch the surface thereof and to remove the skin from the concrete on the regions not covered by the mixture M, that is to say the outer layer of the structure having a very thin structure, a few microns thick.
- step III the artwork 4 is affixed to the concrete structure 1, possibly placing shims 6 around the concrete structure 1, on which the frame of the artwork 4 is placed, so as not to perforate the fabric 5 with the angles of the concrete slab 1.
- the mixture M is then deposited by spreading through the fabric 5, for example using a squeegee, making one or more passes and allowed to dry.
- the fabric 5 has a permeability function of the image, so that the mixture M is deposited selectively on the concrete structure and forms the image that is sought to reproduce.
- the concrete slab 7 is allowed to dry for a sufficient period.
- the concrete structure can also be engraved by placing it on the serigraphed side of the mixture in hydrochloric acid.
- the subject of the invention is also a method of manufacturing a concrete structure, comprising the following steps: casting a thin thickness, in particular between 0.5 mm and 5 mm, concrete A in the bottom of a mold and then pour over a concrete B, these concrete A and B being of different colors, one of concrete A and B being intended to form the outer skin of the concrete structure and having a water content sufficiently low to crack on drying with preferably no fibers or low fiber content, and reveal, in the bottom of the cracks, the other concrete, thus creating a contrast effect between the colors of concrete A and B.
- the invention also relates to such a structure, comprising a skin of a concrete having a first color, covering a core of a concrete of a second color, the skin being cracked and the color of the heart appearing in the bottom of cracks.
- Figure 3 very schematically shows such a structure.
- the concrete A forms the skin of the structure, cracked and traversed by cracks 26.
- the concrete B which forms the heart is exposed to the view through these cracks.
- the thickness of the skin is for example between 0.5 mm and 5 mm.
- the cracks 26 may optionally be filled with a resin, in particular a transparent resin.
- B BHUP concrete comprising the maximum of similar elements with A to facilitate cohesion.
- a BFUP concrete used for B will provide greater strength for the A + B assembly.
- a large layer of concrete B is poured into the bottom 23 of a mold 22 to form the core of the structure, then a thin layer of concrete A is poured onto the concrete layer B to form the skin. . After drying and demolding, it is possible to sand the concrete structure obtained.
- the first way advantageously allows to exploit the side of the concrete plate in contact with the bottom 23 of the mold 22, that is to say the side that can be smoother
- the second variant allows to exploit the side free of the concrete plate, that is to say the side opposite the bottom 23 of the mold 22, may have a more random appearance.
- the concrete structure may be used as a structural and / or decorative work within a building or as furniture, eg table, chair, countertop, siding, paving,
- This process can be combined with that of craters to obtain craters of different colors.
- the evacuation of the air bubbles can be thwarted by the presence of a solid part in the upper part of the mold, the concrete adjacent to this solid part having a sufficiently thick weak so that the craters that form during the setting of the concrete let appear the underlying concrete, of different appearance.
- the invention also relates to a concrete module of BHT (High Performance Concrete) or higher quality to achieve a modular structure, this module comprising perforated cells made by molding the concrete of the module, the cells being joined to each other, these cells being at least two different sizes and being arranged in such a way as to allow the modules to be assembled to be brought together sufficiently to obtain an impression of visual continuity between the modules thus assembled.
- Each module may for example have more than three, better four, even better five different cell sizes.
- the openings of the cells can be circular, with for example large circles which have a diameter at least double, better at least triple, that of small circles.
- the modules can be assembled together in different ways, to create structures of varying sizes and shapes, able to adapt to the environment in which they are located.
- the various structures can be affixed against the surface of one or more building walls, so as to easily adapt to the spatial configuration of the walls, especially in the corners or at the intersections between two walls or act as a trellis, separating interior partitions between two spaces.
- the openings of the cells may have different shapes, especially other than circular, for example polygonal, in particular rectangular, square or triangular, oval, star, among others.
- the openings of the cells can be filled at least partially with filling elements in order to create new effects or to reinforce the structure thus obtained.
- These elements can be made for example from a colored resin, transparent or translucent.
- the proportion between the cells in the openings is filled and those left empty can for example be less than 1 open filled for 4 empty openings.
- the filling elements intended to fill the cells can still be opaque or integrate light systems or loudspeakers.
- the height of a module is for example between 0.5 and 3 m, better 0.8 and 1.2 m.
- the thickness of a basic module is for example between 8 and 100 mm, preferably between 12 and 45 mm.
- Figures 5 and 6 show, in front view, two examples of modules 60 and 70 having hollow cells 80 of circular shape, with a variable diameter.
- FIG. 7 represents, in perspective, the module 70 of FIG.
- the construction material used to produce the modules is, for example, BFUP type concrete.
- the modules 60 and 70 have for example a thickness of 35 mm and a height of 1 m.
- FIG. 8 represents, in front view, the module 70 of FIG. 6, in which replacement elements 81 made of green translucent resin have been introduced into some of the units 80 of the same diameter.
- FIG. 9 illustrates different possibilities of assembling the modules 60 and 70 of FIGS. 5 and 6.
- the assembly may depend on the spatial configuration of the place where the modules are placed, or result from a personal choice. In particular, for a given space where there is a choice between two different models of modules, and three different locations to place these modules, it is possible to obtain eight different configurations in the positioning of the modules.
- Figure 9 illustrates three of these eight possible configurations for modules
- the modules are arranged to have a certain visual continuity when close together.
- the contact areas between the two adjacent modules can be defined by cells.
- the perimeter of a module can be defined for example by at least five different cells.
- the concrete structure may incorporate at least one electronic sensor, in particular a proximity sensor, for example of the capacitive type, and / or at least one loudspeaker.
Landscapes
- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Chemical & Material Sciences (AREA)
- Ceramic Engineering (AREA)
- Manufacturing & Machinery (AREA)
- Structural Engineering (AREA)
- Moulds, Cores, Or Mandrels (AREA)
- On-Site Construction Work That Accompanies The Preparation And Application Of Concrete (AREA)
- Finishing Walls (AREA)
Abstract
Description
Claims
Applications Claiming Priority (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
FR0850444A FR2926742B1 (en) | 2008-01-24 | 2008-01-24 | METHODS OF MAKING AND DECORATING CONCRETE STRUCTURES |
Publications (1)
Publication Number | Publication Date |
---|---|
EP2382070A2 true EP2382070A2 (en) | 2011-11-02 |
Family
ID=39830175
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
EP09703961A Withdrawn EP2382070A2 (en) | 2008-01-24 | 2009-01-19 | Method for making and decorating concrete structures |
Country Status (3)
Country | Link |
---|---|
EP (1) | EP2382070A2 (en) |
FR (2) | FR2926742B1 (en) |
WO (1) | WO2009092977A2 (en) |
Families Citing this family (4)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
CN104908148A (en) * | 2015-06-01 | 2015-09-16 | 济南城建集团有限公司 | Cable trough cover plate prefabricated template and construction method thereof |
CN111168834A (en) * | 2018-11-12 | 2020-05-19 | 深圳市高新建混凝土有限公司 | Method for manufacturing light-transmitting concrete member |
CN111823356B (en) * | 2020-07-20 | 2021-07-09 | 山东科技大学 | Automatic formula concrete test block vibrameter |
FR3124427A1 (en) * | 2021-06-24 | 2022-12-30 | Luma/Arles | Concrete panel, method of manufacturing such a panel and mold for implementing the method |
Family Cites Families (12)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US1568070A (en) | 1925-04-03 | 1926-01-05 | William H Jennens | Method of making artificial stone |
US2689381A (en) * | 1953-03-20 | 1954-09-21 | Oscar J Terriere | Method of making tile |
US3269886A (en) | 1964-06-17 | 1966-08-30 | R J Purtell | Artistic masonry item and method of making |
AU5920580A (en) * | 1979-08-14 | 1980-09-11 | Wolftiles Australia Pty. Ltd. | Method of making cement tiles |
FR2577844B1 (en) | 1985-02-26 | 1990-08-24 | Gorget Jacques | PROCESS FOR THE MANUFACTURE OF RECONSTITUTED SIZED STONES HAVING THE APPEARANCE OF RECOVERY STONES AND STONES OBTAINED THEREBY |
FR2661669B1 (en) * | 1990-05-04 | 1992-08-14 | Francais Ciments | ADDITIVE FOR CONCRETE PRODUCTS. |
DE4235333C1 (en) * | 1992-10-20 | 1994-03-03 | Stoll Volker | Forming pictures on floor covering of stone or ceramics - by covering with light sensitive layer, exposing, developing, etc. |
US5393377A (en) * | 1994-02-03 | 1995-02-28 | Pasaran Sayago; Ricardo | Method of etching stone materials |
US6673503B2 (en) * | 1994-11-07 | 2004-01-06 | Barbara Wagner | Energy activated electrographic printing process |
IT1311048B1 (en) | 1999-11-15 | 2002-02-28 | Gruppo Ceramiche Saicis S P A | METHOD FOR MANUFACTURING TILES WITH THE APPEARANCE OF SPLIT QUARRY STONE. |
AU2002356940A1 (en) * | 2001-10-29 | 2003-05-12 | Interface, Inc. | Methods for finishing top surfaces of concrete filled access floor panels |
TW200712032A (en) * | 2005-09-19 | 2007-04-01 | Ruentex Eng & Constr Co Ltd | Light transparent concret construction material and its manufacturing method |
-
2008
- 2008-01-24 FR FR0850444A patent/FR2926742B1/en active Active
-
2009
- 2009-01-19 WO PCT/FR2009/050067 patent/WO2009092977A2/en active Application Filing
- 2009-01-19 EP EP09703961A patent/EP2382070A2/en not_active Withdrawn
-
2012
- 2012-11-13 FR FR1260794A patent/FR2980192B1/en not_active Expired - Fee Related
Non-Patent Citations (1)
Title |
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See references of WO2009092977A2 * |
Also Published As
Publication number | Publication date |
---|---|
FR2926742A1 (en) | 2009-07-31 |
FR2980192A1 (en) | 2013-03-22 |
WO2009092977A2 (en) | 2009-07-30 |
WO2009092977A3 (en) | 2010-03-25 |
FR2926742B1 (en) | 2012-12-28 |
FR2980192B1 (en) | 2014-01-17 |
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