FR2839274A1 - Fabrication of decorative facing involves molding a self-setting fluid material to confer a given texture and/or color to the outer surface of the facing, for masonry or sculptural applications - Google Patents

Abstract

Fabrication of a decorative facing for a panel or a component of concrete or mortar by molding comprises: filling a mould with a fluid material, able to be solidified, to give the final state of texture and/or color to the outer surface of the facing; solidification of the fluid material; and removal of the panel or component from the mold. The fluid material incorporates at least one non-calcareous material chosen from metal oxides, corundum or carbides, such as silicon carbide, chromium oxide, iron oxide, cobalt oxide or titanium oxide.

Description

said rod (30).

  The interior and exterior decorative facings have been used for many years and the techniques used to obtain such facings on pieces of maize, various types of bullshit, linked in particular to the desired effects in terms of colors, textures but also size and level of ornaments or figures made. Of course, we know the sculpting techniques, which consist of chisel or gouge cutting to make ornaments in

teas relief or high relief.

  Techniques for example like poaching, finishing which consists in stamping the surface with a trowel or a pad to create

  wind asperites widely used on lime plasters.

  More recently, techniques allowing surface finishes have been improved thanks to the use in building techniques of various materials making it possible to use coatings.

varied and durable.

  These finishing coatings can be framed or rolled, that is to say worked with a roller to obtain a more or less marked structure relief in a plastic coating, and a frame of surface asperites which will depend on the

  granulometry of the material constitute the coating and the roller used.

  These different types of plasters generally have a thickness

about 2 mm.

  We also know the "granitos", which sells coatings made with a mortar composed of marble granulate and a binder, often colored, which winds after coating and a first hardening pumice and polls

  2s to remove the upper part and make the aggregate, by cutting it, visible.

  These granitos are produced in thick slabs composed of a layer of terrazzo wear on a concrete support (20 to 30 mm thick in total) or

  in thin slabs using binders based on polyester resins.

  However, all of these techniques do not, for example, make it possible to produce surface effects on large pieces presenting very pronounced curves and volumes in relief, and do not make it possible to produce three-dimensional frames under conditions compatible with the production of large-scale works. important. Wiles do not allow you to carry out a decorative work which superimposes two different techniques to create a relief wall decor. In addition, these techniques consist in the application of coatings without there being a real link between the coating and the rest of the part, the latter being reported and this defect of link can cause detachments,

  cracks and other degradations during aging.

  The present invention provides a solution allowing the production of decorative panels but also the production of facing on pieces of large volume. The present invention relates to a method for obtaining decorative facings directly by molding the part intended to present the decorative facing. Wile relates more particularly to a method of manufacturing decorative facing of a panel or piece of concrete or mortar by molding, characterized in that it comprises at least: a step of filling the mold with a fluid material capable of solidifying intended to give the final state of texture and color of the external surface of the facing, a step of solidification and demolding to said panel or

said piece.

  In a variant of the process after unmolding the part,

  performs a step of acidifying the surface of said panel or of said piece.

  The present invention relates to a method of obtaining by molding a part comprising, on an external surface, an external facing layer comprising a mineral decorative material having the properties of a mortar, method according to which a mold having a counter-profile correspond to the external shape of the piece that we want to obtain, we have a mineral decorative material having the properties of a mortar in a fluid state, we complete at least the lower part of the mold with said mineral decoration material in a fluid state, and after a stage of

  solidification said piece is removed from the mold.

  When the process is intended to obtain pieces of large size and volume, the filling of the mold is completed with a conventional mortar. Wile also relates to the fluid material capable of solidifying intended to give the final state of texture and / or color of the external surface of the facing comprising granulate and a hydraulic binder characterized in that it comprises at least granulate in material non-calcareous intended to give the surface state eVou pigments in the form of powder. According to the invention, the granulates made of non-calcareous material intended to give the surface state have a particle size between 50 microns and 2

  mm and wind selected from metal oxides or carbides.

  According to the invention, the pigments in the form of powder have a particle size between 0.1 and 0.8 microns and wind preferably chosen

among the metal oxides.

  According to the invention, the particle size chain is studied so that the rheology of the fluid material capable of solidifying allows that only the granulate in non-calcareous material intended to give the surface state are placed on the walls of the mold either by natural gravity or by vibration. This particular rheology makes it possible to prepare formulations comprising a minimum content of granulate in non-calcareous material intended to give the state

  of surface for an optimized surface result.

  In a variant, the process according to the invention is characterized in that the mold filling step is carried out in two passes, a filling pass of the lower part of the mold with the fluid material capable of solidifying intended to give the final state of texture and color of the surface of the facing and a pass for filling the upper part of the mold with a fluid material capable of solidifying different intended to produce the non-visible part of the facing or the core of

the room.

  In this variant of the process, the fluid material capable of solidifying with filling used in the second pass differs from that used in the first pass essentially in that it does not include any

  pigment or aggregate intended to give the surface state.

  In the process according to the invention, the mold comprises in counter

  profile a three-dimensional frame allowing to create a volume effect on the facing. In the process according to the invention, the filling of the mold is carried out with fluid materials having characteristics of

  different colors and / or sizes.

  In a variant of the method according to the invention, filling is carried out selectively, by distribution as a function of the counter-profiles of the

  molds used and / or using stencils.

  In the process according to the invention, the fluid material capable of solidifying intended to give the final state of texture and / or color of the external surface of the facing comprises at least one product chosen from

  metal oxides, corundums or carbides.

  When the metal oxides are used as pigments, their particle size is between 0.1 and 0.8 microns; preferably iron oxides, chromium oxides, oxides of

cobalt and titanium oxides.

  When the metal oxides, corundums or carbides are used as granulate intended to give a final state of texture, their particle size is between 3 microns and 3 mm. Due to their particle size, they also play a role in the structure of the mortar obtained, from their coloring, they also bring a color to the facing obtained. In a variant of the method according to the invention, the fluid material capable of solidifying intended to give the final state of texture and color of the external surface of the facing comprises a product chosen from mineral binders in powder based on limestone and d hydraulic clay, like cements and an organic binder like resins A facing is the visible face of any element, that is to say the visible face for example of a decorative panel, or a piece

in volume like a sculpture.

  By decorative panel is meant all prefabricated panels presenting at least on one face a facing whose ['aspect is [' object of a particular aesthetic research, they wind used for the covering of walls or partitions and in presentation like a table . The aspect can be for example a 2s surface finish worked to give a play of colors, texture and even volume by the creation of three-dimensional frames in counter-profile

in the molds.

  The term mold is understood to mean a counter-profile in which a fluid material capable of solidifying is poured which, solidifies, will marry its

form.

  The term “decorative mineral material” having the properties of a mortar, that is to say capable of being implemented in the fluid state and of solidifying, a mixture composed of a binder and of granulate evou pigments used to obtain the final state of texture and color of the surface

exterior of the facing.

  The term “fluid material capable of solidifying” is understood to mean a material whose fluidity, at the time of implementation in the molds, is sufficient to allow the filling of a motile, but whose viscosity allows the use of stencils or the juxtaposition of filling zones without there being a mixture of two materials intended to fill two adjacent zones. The solidification phase of the fluid material is called setting. The setting is defined as a thickening and firming phase leading to solidification, which is a function of the binders used due to the formation of crystals if hydraulic binders or evaporation are used.

  solvents or cross-linking if organic binders are used.

  Among the fluid materials capable of solidifying, mention will be made of mortars and concretes and generally any mixture comprising fillers and a binder, the fillers being able to consist of granulates, powders and

granulate or various aggregates.

  By mortar is meant a mixture composed of a binder, of granulate, inert fillers constitute the skeleton or the framework of the mortar (sands, granulate of different materials, aggregates), and possibly of

eVou pigments of various adjuvants.

  By concrete, we mean an artificial rock composed of granulate and sands agglomerated by a binder, concrete differs from mortars by the fact

  that there are g ra n u late of your it important.

  The term “binder” is understood to mean a material having the property (possibly after hydration) of passing from the liquid or plastic state to 2s the solid state, in order to bond, that is to say to assemble inert materials such as granulate or aggregates. These binders can be chosen from hydraulic binders, which set in an irreversible manner when they are brought into contact with water, this wind with cements and lime, or from organic binders, which sells hydro-carbon binders including solidification or hardening, possibly reversible depending on the temperature and the evaporation of

  their solvents and cross-linking reactions.

  Among the binders used are PORTLAND cements, Aluminous cements and Artificial cements such as, for example, CPA Portland Cement Artificiel, CPJ Portland Cement compound (with adjuvants), BUHP Beton Ultra High Performance, BPR Beton from

Reactive powders.

  Vibration is understood to mean the action which consists in fluidizing in order to compact it a fluid material such as a mortar, for example in molds by subjecting it before its setting to the action of vibrations communicated by

  suitable devices such as vibrating needles or vibrating supports.

  Vibration fluidizes the binder by the phenomenon of thIxotropy, facilitating the

lining against the walls.

  Unmolding is understood to mean; The mold release operation

  the part obtained after solidification.

  Acidification is understood to mean the acidification of the surface of a part obtained by molding, in order to eliminate the milt and to reveal the colors and / or gan ulometries previously provided for by the selective filling in of the mold counter profiles. by materials presenting

  different colors and / or particle sizes.

  Corundum is understood to mean powders of varying particle size comprised for example of 3 microns to 3 mm of crystallized natural aluminum oxide (containing up to 99.8% of alumina Al2O3) of which there are various transparent varieties including precious stones. (ruby, eastern topaz, sapphire, eastern amethyst) and opaque varieties conventionally used in abrasives because of their hardness but which can nevertheless be used for their color. The different shades are due to the presence in the aluminum oxide of chromium (shades of red), of iron (shades of yellow) or

  titanium (shades of blue), the white corundum being pure alumina.

  The carbides used in the form of granulate with a particle size between 3 microns and 3 mm, mainly wind silicon carbides, allowing in addition to their effect of texture, color, luminosity and shine

  to get shades of green and black.

  Other oxides used as pigments in the form of powder with a particle size of between 0.1 and 0.8 microns can be used as

  oxides of chromium, iron, cobalt or titanium.

  According to a preferred embodiment, the implementation technique

  this work is carried out according to the following protocol.

  The wind molds constructed by an impression taking technique by the realization of a membrane for example in silicone from a model of any material or by the direct realization of a negative mold with

  from flexible membrane such as rubber or PVC mats.

  We obtain molds with illustrious counter-profiles in

Figures 1 to 7.

The mussels are presented flat.

  The filling is carried out in a sequential manner, if necessary, that is to say if fluid materials for filling different wind are used. The filling can also be carried out according to zones which wind defined by the placement on the mold of fa, sequential and

temporary stencils.

  The stencils used wind plates in which wind cut out the areas intended to be filled in order to obtain a design, these stencils are in the form of plates of various nature in

  depending on their size, sheet metal, tarpaulin, aluminum foil for example.

  Figures 1 to 7 show counter profiles of the molds that can be used. Figures 1 to 5 illustrate different types of molds, in sectional view showing grooves, used to create reliefs which will

  selectively filled with the fluid material previously defined.

  FIG. 6 illustrates a mold in cross-section view presenting a particular counter-profile which makes it possible to obtain a facing with shapes of

  pellets, said pellets being illustrated in top view in FIG. 7.

  Figures 8 to 10 illustrate results obtained by juxtaposition of the different molds in counter-profile according to particular arrangements by selectively filling the different parts of the mold with materials

  different texture and / or color fluids.

  Figure 8 represents the result obtained by the juxtaposition and recomposition of different frames in the molds to create patterns, the execution of a scraping phase to reveal the material used to fill the other volumes of the mold and the filling. selective of the different zones. Figure 9 shows the result obtained by covering

stencils when filling.

  FIG. 10 represents the result obtained by the implementation of molds comprising ruptures and juxtapositions of parts of molds having different counter profiles or having the same counterprofiles

  but oriented in different directions.

  When the piece is a piece in volume after filling with the aid of the fluid material intended to give the final state of texture and color of the surface of the facing, the complete filling of the mold is carried out with a mortar conventionally used in construction. and not containing material such as corundums, metal oxides or marbles. Depending on the final use of the facing, a consolidation layer can then be spread over the entire surface of the facing to give the relief the desired thickness, for example, a large thickness of conventional concrete, reinforced or unarmed, or of auto concrete can be poured. -placing, for prefabricated walls of structural elements or a low thickness of BUHP concrete

  for a very thin mobile facing, less than 1 cm.

  Depending on the final use of the facing, the fluid materials used to fill the molds may be reinforced by adding

  a mixture of fibers or other reinforcements conventionally used in construction.

  After a solidification or setting phase varying from 5 hours to 3 days depending on the size of the casting and the quality of the binders

  hydraulics used, it is demolded.

  The surface treatment is then carried out by acidification with hydrochloric acid solutions, at concentrations of between 6% and 30%. When acidification is carried out selectively on certain areas, for example using stencils, formulations in the form of acid gels

  hydrochloric acid can be used.

  The acidification can also be carried out according to zones

  previously defined either by relief or by stencils.

  2s The contact time between the acid solution and the surface of the raw facing obtained by demolding is also variable depending on the

search result.

  After ravage and rinse, cage with clear water, the facing obtained wind

put in place.

  By way of example, the following formulations have been used to

make different facings.

Example 1:

  Concrete formula allowing to obtain a facing facing

  on the surface a dark or black color and a grain of corundum.

  - Carrara marble or other provenance (4/8 mm) 700 kg - Carrara marble or other provenance (2/4 mm) 300 kg - Cristalba or Rubina corundum or green or black silicon carbide or mixture (0.8 / 1 , 5) 200 kg - Cristalba or Rubina corundum or green or black silicon carbide or mixture (F 30) 450 kg - Cristalba or Rubina corundum or green or black silicon carbide or mixture (F60) 250 kg - white or gray Portland cement 42.5 or 52.5 500 kg - plasticizer 1% of

weight of cement.

-water e / c <aO, 4

Example 2:

  Formula of a mortar allowing to obtain a facing presenting a poured and pink surface or in shades of red, yellow or

black, and a pink and green grain.

  - Pink corundum (F70) 4800 g - green silicon carbide (F120) 1800 g Secar! 3 (LAFARGE) 71 or melted 3600 g - Limestone filler type Durcal 8) (OMYA) 5 or silica type E600 or mixture 1620 g - oxide of chromium or iron or cobalt 80 g - styrene butadiene or acrylic resin 600 g - water 1500 g - organic or mineral fibers 2 to 4% of the weight of cement

Example 3:

  Formula of a mortar allowing to obtain a facing facing

  a surface with a grain of corundum or silicon carbide.

  - Corundum or silicon carbide (F70) 800 g - Corundum or silicon carbide (F120) 300 g - calcium aluminate 20 to 50, um 600 g - Corundum or silica or limestone 5 um 260 g - color or fume silica 0, 2 to 0.5 um 40 g water 250g - styrene butadiene resin 100 g - trisodium citrate 0.6 to 0.8 g - dihydran 1.2 g lithium carbonate 0.12 g

Example 4:

  Formula used for the realization of a monumental cover in

trots dimensions of color pours.

  Formulation for 1 m3 Gravel 5J20 900 kg Carrara marble 2/4 200 kg Carrara marble 0.8 / 1.5 200 kg Green silicon carbide F30 (0.59mm) 400 kg Green silicon carbide (0.25 mm) 200 kg White Portland cement 52.5 R 500 kg Water: e / c 0.35 Plasticizer 1% Before solidification, the fluid material likely to solidify

  is subjected to needle vibration.

  The release is carried out after three days of setting.

  The surface is subjected to acidification with hydrochloric acid at 30%

  very fast (2 minutes of contact) followed by a rinse, water cage.

Example 5:

  Formulas used to make raised panels.

  The surface is obtained by using a matrix mold

  flexible having grooves as illustrated in FIGS. 1 to 5.

  Single color relief Formulation: White corundum 212 microns 800 g White corundum 106 microns 300 g White cement calcium aluminates 20 to 40 mi 600 g Corundum or silica or limestone 5 mi 260 g Titanium oxide or fumed silica 0.2 to 0.5 mi 40 g Water 220 g Styrene butadiene resin 100 g Trisodium citrate O, 6 to 0.8 g Air extractor 1.2 g Lithium carbonate 0.12 g The mold with grooves or any relief

  (pastilles) is filled with the mortar according to the previous formulation.

  The release is carried out after one day of setting.

  The surface is not subject to acidification.

  This can nevertheless be subjected to acidification depending on

  The research effect, that is to say highlighting the effect on the relief or the texture.

  Two-color relief Formulation a: Green silicon carbide F70 800 g Green silicon carbide F120 300 g Calcium aluminates or white portland 600 g Silica or limestone 5 mi 260 g Water: 220 g Styrene butadiene resin 200 g or plasticizer 100 g adjuvant according to cement chosen 1% of the cement weight Formulation b: Pink corundum F70 800 g Pink corundum F120 300 g Calcium aluminates or white portland 600 g Silica or limestone 260 g Water 220 g Resin or plasticizer according to the cement chosen

  The mold used is a mold having grooves.

  The splines are filled with the mixture of formulation a.

  The surface is then scraped so that the intervals between the

  grooves reveal the matrix.

  The rest of the thickness is completed with the mixture of

formulation b.

  After taking for a day, the surface is subjected to a

  acidification with 24% hydrochloric acid solution then rinsed.

Example 6:

  S Two-color relief with cut and recomposed matrix Formulation a: Pink corundum F70 800 g Pink corundum F120 300 g White cement 600 g Limestone 5 mi 260 g Iron oxide jane 40 g Formulation b: Green silicon carbide F70 800 g Green silicon carbide F120 300 g White cement 400 g Gray cement 200 g Limestone 5 mi 260 g Cobalt oxide 40 g We use a mold with grooves, cut and recomposed, we thus obtain drawings by the change of orientation of the grooves. The wind grooves filled with the mixture of formulation a,

  then after scraping, with the mixture of formulation b.

  After a day of setting and demolding the surface is subjected to acidification with a hydrochloric acid solution at 24 or 30% then rinsed, cage

at the water.

Example 7:

  Multicolored relief with the use of stencils.

  The mold has grooves which have been cut and then recomposed. The wind flutes filled with the mixture of the formulation a

from example 6.

  A stencil is then placed on the motile, each part of the stencil is removed to fill the area thus defined. The different zones correspond to the different parts of the wind stencil successively filled with fluid materials of different formulation

depending on the effect sought.

  When the second layer is complete, that is to say that all the parts of the stencil have been replaced by a layer of mortar, a thickness of 0.5 to 0.8 mm is obtained. A consolidation layer is then poured over the entire surface. After solidification for a period of 1 to 2 days, acidification

is done.

  This acidification can also be carried out selectively using hydrochloric acid formulations, in the form of gels and in

using stencils.

Claims (12)

  1. Method for manufacturing decorative facing of a panel or piece of concrete or mortar by molding, characterized in that it comprises at least: a step of filling the mold with a fluid material, capable of solidifying, intended to give l final state of texture and color of the exterior surface of the facing, a step of solidification at said   fluid material, and a demolding step, to said panel or said piece.   2. Method according to claim 1 characterized in that the mold filling step is carried out in two passes, a filling pass of the lower part of the mold with the fluid material capable of solidifying intended to give the final state of texture and color of the external surface of the facing, and a pass for filling the upper part of the mold with a fluid material capable of solidifying differently intended to produce the non-visible part of the facing or the core of. I have it.   3. Method according to any one of the preceding claims   characterized in that after demolding, an acidification step of the   surface of said panel or of said piece.   4. Method according to any one of the preceding claims   characterized in that the mold includes a frame in counter-profile   three-dimensional to create a volume effect on the facing.   5. Method according to any one of the preceding claims   characterized in that the filling of the slurry is carried out with fluid materials having characteristics of coloring and of different particle sizes. 6. Method according to claim 5 characterized in that the filling is carried out fa, con selective, by distribution according to counter profiles of the molds used.   7. Method according to claim 5 characterized in that the   filling is carried out using stencils.   8. Method according to any one of the preceding claims   caracteris.e in that the fluid material capable of being solidified intended to give the final state of texture of the external surface of the facing comprises at least one non-calcareous material chosen from metal oxides, corundums or carbides, such as silicon carbides, oxides of   chromium, iron, cobalt or titanium oxides.   9. Method according to claim 8, characterized in that the non-calcareous material is in the form of an aggregate of particle size included between 3 microns and 3 mm.   10. Method according to any one of claims 1 to 7,   characterized in that the fluid material capable of solidifying intended to give the final state of color of the external surface of the facing comprises   at least one pigment chosen from metal oxides.   11. Method according to claim 10, characterized in that the pigment is in the form of a powder with a particle size of between 0.1 and 0.8 microns.   12. Method according to any one of claims 1 to 7   characterized in that the fluid material capable of solidifying intended to give the final state of texture and color of the external surface of the facing comprises a product chosen from mineral powder binders based on limestone and hydraulic clay, such as cements, eVou a binder