JP2000006118A - Production of concrete product on surface of which natural stone is embedded, and bottom case of form used in the method - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a method for producing concrete product on the surface of which natural stones are embedded wherein even though amt. of filling of a sealing material is not accurately controlled, height of filling of the sealing material can be made const. and uniform over the whole area. SOLUTION: Natural stones 18 and a sealing material 17 are placed on a bottom case 11 of a form through which water passes but the sealing material does not pass and which is a different body from a form main body 12 and in this case, the natural stones 18 are placed in such a way that they are projected upward from the bottom case 11 of the form. In addition, this bottom case 11 of the form is placed in a water tank and the bottom case 11 of the form and water are moved relatively to fill the sealing material 17 among the natural stones 18 and the excess sealing material is overflowed from the top edge of the bottom case 11 of the form. After the bottom case 11 of the form is taken out, the bottom case 11 of the form and the form main body 12 are assembled and concrete 20 is filled and cured and after the product is taken out of the mold, the sealing agent is removed.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

The present invention relates to a method for producing a concrete product having natural stone embedded in a surface thereof, and a mold bottom case used in the method.

[0002]

2. Description of the Related Art A method for producing a concrete product having natural stone embedded in its surface is known from Japanese Patent Application Laid-Open No. 52-103804. In the case of this method, natural stone is spread on the bottom of the formwork, sand is filled between the natural stones in an appropriate amount,
Concrete is poured, and after the concrete is solidified, the formwork is disassembled and demolded.

[0003] In this method, the sand is usually filled evenly using a sieve, and the joints of natural stones are adjusted to be larger at a wide area and smaller at a narrow area. However, it is extremely difficult to keep the height of sand filling, and thus the height of natural stone protruding from the surface of the finished concrete product, constant by this sand filling method. This is because the total volume of the natural stones arranged in the form is different each time, and it is difficult to adjust the filling amount of sand according to this volume. Furthermore, when filling sand with a sieve, it is troublesome to adjust the filling amount itself, and it takes a very long time to adjust the natural stone joints so that the joints are wider and narrower. And it is difficult to make the filling height of the sand accurate and uniform throughout. This sand filling method is a method performed manually and is not suitable for mechanization.

[0004]

SUMMARY OF THE INVENTION In view of the above-mentioned drawbacks of the prior art, an object of the present invention is to provide a filling height of a filling material, and hence concrete, without accurately adjusting the filling amount of the filling material. Method for producing a concrete product having natural stone embedded in the surface, suitable for mechanization, capable of making the height of natural stone protruding from the surface of the product constant and uniform throughout, and used in the method To provide a mold bottom case.

[0005]

In order to solve this problem, a method according to the present invention is directed to a method in which a natural stone is placed in a form bottom case separate from a form body, which allows water to pass through but does not pass a filler material. By inserting a natural stone so as to protrude upward from the mold bottom case, put the mold bottom case in the water tank, and move the mold bottom case and water relatively, Fill the filling material between the natural stones, let the excess filling material overflow from the upper edge of the formwork bottom case, pull up the formwork bottom case from the water tank, and then remove the formwork bottom case and the formwork body. It is characterized by assembling, casting concrete, curing, removing the product, and then removing the filling material. In this case, preferably, the wings are rotated to generate a water flow in the water tank in order to pack the filler material between the natural stones and overflow the excess filler material.

Another method according to the present invention is to provide a form bottom case separate from the form body, which allows water to pass through but does not pass the filler material.
Put natural stones and sealing material, and then put natural stones so that they protrude upward from the bottom case of the formwork. Spray the natural stones and filling materials in the bottom case of the formwork from above with a shower. By filling the filling material between the natural stones, the excess filling material overflows from the upper edge of the formwork bottom case, assembles the formwork bottom case and the formwork body, casts concrete, cures After the product is removed from the mold, the sealing material is removed.

In this case, it is desirable that after the natural stone is put in the bottom case, the filling material is put into the bottom case. After removing the product, at least the surface portion of the product is immersed in the water in the water tank, so that the filler material can be easily removed. The form bottom case according to the present invention, which is separate from the form body and allows water to pass through but does not pass through the filling material, is characterized in that the depth of the form bottom case is smaller than the height of natural stone.
In this case, it is desirable that the depth of the form bottom case be adjustable. In this case, the bottom case of the formwork is provided with a bottom member such as a wire mesh, a perforated plate, a side wall, and a replaceable spacer that allows water to pass through but does not pass through the filler material, and the bottom member is attached to the side wall via the spacer. Desirably, the depth of the form bottom case is adjustable by replacing the supported spacer with another spacer of a different height. To adjust the depth of the bottom case, the entire bottom case with a different depth may be replaced.

[0008]

In the method of manufacturing a concrete product according to the present invention, after the natural stone and the sealing material are placed in the form bottom case lower than the height of the natural stone, water and the form bottom case are placed in the water tank. By relatively moving or by spraying water like a shower, the filler material enters between the natural stones and fills the natural stones. In addition, excess filler material overflows from the upper edge of the form bottom case.

[0009]

Next, an embodiment of the present invention will be described in detail with reference to the drawings. FIG. 1 shows a first embodiment of the method according to the invention for producing a concrete product having natural stone embedded in its surface. In FIG.
S1 to S10 represent the first to tenth steps of the method. In this case, the upper view of the first step S1 to the fifth step S5 is a plan view, the lower view is a front view, the sixth step S6 to the ninth step S9 are shown only in the front view, In step S10, the upper side is a front view, and the lower side is a bottom view.

Before describing the above steps of the method according to the invention, the form bottom case 11 used in the method according to the invention will be described with reference to FIG. FIG. 2 is a sectional view of the form bottom case 11. The mold bottom case 11 is formed separately from the mold body 12 shown by a two-dot chain line, and is later combined with the mold body to form a mold. The mold bottom case 11 includes a bottom member 13 that forms the bottom, a support member 14 that supports the bottom member, a replaceable spacer 15, and a side wall 16. The bottom member 13 is a wire mesh, a perforated plate or the like that allows water to pass through but does not allow the sealing material 17 to pass therethrough, and the dimension H between the bottom member 13 and the upper edge 16a of the side wall 16 is determined by the form bottom case 1
1 depth. The depth H of the form bottom case 11 is smaller than the height of the natural stone 18. The bottom member 13 is supported by the flange 16b of the side wall 16 via the support member 14 and the spacer 15. The support member 14 is the bottom member 1
3 is a strength member having a hole for supporting the hole 3, and the hole is larger than the mesh of the bottom member 13.
If the bottom member 13 itself has sufficient strength and can be self-supported, the support member 14 is unnecessary. The spacer 15 is formed in a ring shape or a segment shape, and rests on the flange portion 16 b of the side wall 16. The spacer 15 is replaceable, and the depth H of the form bottom case 11 can be adjusted by replacing the spacer 15 with another spacer having a different height h.

In a first step S1 of the method according to the invention shown in FIG. 1, the mold bottom case 11 is cleaned by a suitable method in order to remove the filler material adhered in the preceding manufacturing process. At this time, it is not necessary to completely remove the filling material, for example, it may be removed to such an extent that it does not hinder the arrangement of natural stones in the form bottom case 11 performed in the next manufacturing process. .

In the second step S2, the natural stone 18 is put in the bottom case 11 of the formwork. In this case, it is advantageous to arrange the natural stones 18 automatically by a machine. Natural stone 18
Has a height such that it protrudes from the upper edge 16a of the side wall 16 of the mold bottom case 11. In the third step S3, the filling material 17 is covered with the natural stone 18. The filling material 17 is sized so as not to pass through the bottom member 13 of the form bottom case 11, and is, for example, sand or gravel. In this case, it is not necessary to accurately measure the amount of the filling material 17, but it is sufficient to supply the filling material 17 more roughly than the necessary amount, as described later.

[0013] The natural stone 18 is not stopped just by covering the filling material 17 with the natural stone 18. Therefore, in the fourth step S4, the mold bottom case 11 containing the natural stone 18 and the sealing material 17 is immersed in the water tank 19, and the water (water flow or (Water pressure) is applied to the filling material 17. The effect of water pressure and natural stone 18
The sealing material 17 enters between the natural stones 18 by the action of the water flow passing through the gap and the bottom member 13, and stops the natural stone 18. Furthermore, when strong water flow or pressure acts,
Excess filling material 17 overflows from the upper edge 16a of the side wall 16 of the form bottom case 11 (see steps S4 and S5).
As a result, the filling height of the filling material 17 and, consequently, the protruding height of the natural stone from the surface of the concrete product become equal to the depth H of the form bottom case 11, and become constant.
The filling height of the filling material 17 in the entire form bottom case 11 becomes uniform. As described above, since the surplus sealing material 17 can be easily removed, the supply of the sealing material 17 in the third step S3 may be roughly.

There are various methods for moving the mold bottom case 11 and water relative to each other. For example, a water flow is applied to the sealing material 17 by the rotor 8 (propeller),
The water flow may be applied to the filling material 17 using a submersible pump and a wide nozzle connected to the pump. Furthermore, moving the form bottom case 11 up and down or left and right in the water,
It may be rotated or tilted. At the same time as the movement of the form bottom case 11, a water flow may be generated by a rotating blade or the like. The water flow shown in the lower view of the fourth step S4 is generated by rotating the rotor blades above the form bottom case 11 and swinging the form bottom case 11.

Form bottom case 11 pulled up from water tank 19
Is combined with the formwork body 12 in the sixth step S6, and the ready-mixed concrete 20 is charged and cured in the seventh step S7. Then, the concrete product 21 is released from the mold in an eighth step S8, and in a ninth step S9, at least a surface portion of the product is immersed in water in a water tank 19 in order to remove the attached filler material 17. The finished concrete product 21 is in the tenth step S1
It is shown at 0.

FIG. 3 shows a second embodiment of the method according to the invention. In this case, since steps other than steps S4 and S5 are the same as those of the first embodiment, they are not shown. In the case of the second embodiment, the form bottom case 1
Instead of immersing 1 in a water tank, water 22 is applied like a shower to natural stone 18 and filling material 17 in form bottom case 11. When the water passes between the natural stones 18 and the bottom member 13, the sealing material 17 enters between the natural stones 18,
The natural stone 18 is stopped. Further, when strong water pressure or water flow is applied, the surplus sealing material 17 is removed from the form bottom case 1.
One of the side walls 16 overflows from the upper edge 16a. This method using shower water is advantageous, for example, when using fine aggregate of 1.5 mm or less as a filler. On the other hand, the method of immersion in a water tank shown in FIG.
This is advantageous when the above coarse aggregate is used as a filler.

[0017]

According to the method for producing a concrete product according to the present invention, after the natural stone and the sealing material are put in the bottom case of the form lower than the height of the natural stone, the water and the form are placed in the water tank. By moving the bottom case relatively, or by spraying water like a shower, the filler material enters between the natural stones, and quickly and reliably fills the natural stone. Furthermore, since the excess filler material overflows from the upper edge of the formwork bottom case and the filling height of the filler material is determined by the depth of the formwork bottom case, adjust the filling amount of the filler material accurately. Even if not, the filling height of the filling material becomes constant and uniform throughout. This filling operation can be mechanized.

[Brief description of the drawings]

FIG. 1 shows a first embodiment of the method according to the invention for producing a concrete product having natural stone embedded in its surface.

FIG. 2 is a longitudinal sectional view of a form bottom case used in the method according to the present invention.

FIG. 3 shows a part of a second embodiment of the method according to the invention for producing a concrete product.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 11 Form bottom case 12 Form main body 13 Bottom member 14 Support member 15 Spacer 16 Side wall 16a Upper edge 16b Flange part 17 Filler material 18 Natural stone 19 Water tank 20 Ready-mixed concrete 21 Concrete product 22 Shower-like water

 ────────────────────────────────────────────────── ─── Continuing on the front page (72) Inventor T. Yonishi 210-1 Yoshida Paper Bag, Mizumaki-cho, Onga-gun, Fukuoka F-term in Kyodo Machinery Co., Ltd. 4G052 AB13 AB27 AB42

Claims (8)

[Claims] 1. A natural stone and a sealing material are placed in a form bottom case separate from the form body, which allows water to pass through but does not allow the filling material to pass therethrough, and projects upward from the form bottom case. Put the natural stone in this way, put this form bottom case into the water tank, and move the form bottom case and water relatively to fill the filling material between the natural stones. After overflowing from the upper edge of the mold bottom case and lifting the mold bottom case from the water tank, assemble the mold bottom case and the mold body, cast concrete, cure, remove the product, A method for producing a concrete product having natural stone embedded in a surface, characterized by removing a filler material. 2. The method according to claim 1, wherein the wings are rotated to generate a water flow in the water tank in order to pack the filler material between the natural stones and to overflow the excess filler material.
A method of manufacturing concrete products with natural stone embedded in the surface. 3. A natural stone and a sealing material are placed in a form bottom case separate from the form body, which allows water to pass through but does not allow the filling material to pass therethrough, and projects upward from the form bottom case. Put the natural stone in the same way as above, fill the natural stone and the sealing material in the mold bottom case with water from above in the form of a shower, and fill the sealing material between the natural stones. A surface characterized by overflowing from the upper edge of the formwork bottom case, assembling the formwork bottom case and the formwork body, casting concrete, curing, removing the product, and removing the sealing material. A method of manufacturing concrete products with natural stone embedded in them. 4. A concrete product having natural stone embedded in the surface thereof according to claim 1 or 3, wherein after filling the natural stone into the form bottom case, the filling material is put into the form bottom case. How to manufacture. 5. The natural stone on the surface according to claim 1, wherein at least a surface portion of the product is immersed in water in a water tank to remove the filling material after removing the product from the mold. How to make concrete products with embedded. 6. Water for use in the method according to any one of claims 1 to 5, but not for a filler.
A mold bottom case, wherein a depth of the mold bottom case is shallower than a height of natural stone in a mold bottom case separate from the mold body. 7. The mold bottom case according to claim 6, wherein the depth of the mold bottom case is adjustable. 8. A mold bottom case includes a bottom member, such as a wire mesh or a perforated plate, through which water passes but does not pass through a filler material, a side wall, and a replaceable spacer. 8. The mold bottom case according to claim 7, wherein the depth of the mold bottom case is adjustable by replacing the spacer with another spacer having a different height supported by the side wall.