JP2003080513A - Method for manufacturing concrete product with patterned surface and exposed aggregate finish design panel to be used for this method - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a method for manufacturing a concrete product with a patterned surface, by which an operation can be efficiently performed and a specified quality can be ensured. SOLUTION: A base paper 4 with a concrete curing retarding agent layer 5 formed on the surface is attached to the surface of a veneer plywood 2 through a pressure-sensitive adhesive layer 3. Then under this state, a desired pattern is cut in the base paper 4 by means of a cutter, then this pattern part or any part other than the pattern is removed to obtain a wash-off and expose design panel, and this design panel is attached to a concrete form. Finally a concrete material is formed to obtain the concrete product.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for producing a surface-exposed concrete product for producing a concrete product by casting a concrete material using the washout design panel, and a washout design panel used therefor.

[0002]

2. Description of the Related Art Conventionally, there is a "washout method" as a surface finishing method for concrete. This "washout method" is a method of forming a washout pattern by performing a washout finish on the surface of a concrete product to express makeup, and the following method is often performed. That is, first, a liquid concrete hardening retarder is applied to the surface of the inner surface of the mold corresponding to the surface to be washed out and then dried. Then, after pouring concrete material and curing and hardening, the mold is demolded. Next,
The uncured portion of the surface of the concrete product thus obtained, which has been penetrated by the concrete retarder, is washed out with water. In this way, a washout pattern is formed on the surface of the concrete product.

Further, in the case of designing in the wash-out finish, a method using a wash-out design sheet capable of controlling the concrete hardening delay property is used. That is, a washout design sheet having a concrete retarder layer formed on the surface of a sheet-shaped film is prepared in advance. Then, among the inner surfaces of the formwork, the washout design sheet is arranged on the surface corresponding to the surface to be washed out so that the concrete hardening retarder layer is the contact surface with the concrete material, and nails or adhesive tape is used. And so on. Then, after pouring concrete material and curing and hardening, the mold is released from the mold and the washout design sheet is peeled off. Next, the uncured portion of the surface of the concrete product thus obtained, which has been penetrated by the concrete hardening retarder, is washed out with water. In this way, a washout pattern is formed on the surface of the concrete product.

[0004]

However, in the method of applying the concrete hardening retarder, it is difficult to make the coating thickness (application amount) uniform, and the concrete hardening retarder sometimes drips. For this reason, at the time of the wash-out finishing, a part with a large wash-out amount and a part with a small wash-out amount are formed, the wash-out surface is not uniform, and the wash-out pattern is not uniform. With this, it is not possible to secure a certain quality of the concrete product. Further, according to this method, a waiting time is required until the applied concrete hardening retarder is dried, resulting in poor work efficiency. On the other hand, in the method using the above-mentioned washout design sheet, since the washout design sheet is thin (1 mm or less) in terms of flexibility, flexibility, etc. (that is, there is no rigidity), it requires manpower to attach to the formwork, and Difficult to install in place. In addition, the washout design sheet may be slack, and wrinkles may be left on the concrete product if the washout design sheet is wrinkled when placing concrete.
With this, it is not possible to secure a certain quality of the concrete product. As described above, even with this method, the work efficiency when setting the mold on the form is poor, and a certain quality cannot be ensured.

The present invention has been made in view of the above circumstances, and provides a method for producing a surface-patterned concrete product which has good work efficiency and can ensure a certain quality, and a washout design panel used therefor. To aim.

[0006]

In order to achieve the above object, the present invention provides a base paper having a concrete hardening retarder layer formed on the surface thereof with a plate-like or film-like rigid base material via an adhesive layer. Cut the desired pattern on the above-mentioned base paper with the cutter attached to the surface of the material, then remove this pattern part or the part other than this pattern part to make a washout design panel. Is attached to a concrete formwork and a concrete material is cast to produce a concrete product, and the first method is to produce a surface-patterned concrete product. The base paper is plate-shaped or film-shaped through an adhesive layer. After being attached to the surface of the rigid base material, the desired pattern is cut on the base paper with a cutter, and then the surface of the base paper is printed. A concrete hardening retarder layer is applied to the above, and the washout design panel is prepared by removing the above-mentioned pattern part or the part other than the above-mentioned pattern part, and this washout design panel is attached to the concrete formwork, and the concrete material is placed. The second gist is the method of manufacturing surface-exposed concrete products that are used to produce concrete products. It is a washout design panel that is used by attaching it to a concrete formwork when casting concrete materials to produce concrete products. Then, the base paper with the concrete hardening retarder layer formed on the surface is attached to the surface of the plate-shaped or film-shaped rigid base material via the adhesive layer, and a desired pattern is formed on the base paper with a cutter. After cutting, remove this pattern part or the part other than this pattern part. The washout design panel produced is the third gist, and it is a washout design panel that is used by attaching it to a concrete form when pouring a concrete material to produce a concrete product, and using a base paper with an adhesive layer. In the state of being attached to the surface of a plate-shaped or film-shaped rigid substrate through the above, after cutting a desired pattern on the base paper with a cutter, a concrete hardening retarder layer is applied to the surface of the base paper to form the above pattern. The wash-out design panel produced by removing the portion other than the above portion or the above-mentioned pattern portion is the fourth gist.

[0007] That is, the first method for producing a surface-exposed concrete product of the present invention is to use a base paper having a concrete hardening retarder layer formed on the surface thereof as a plate-like or film-like rigid base material via an adhesive layer. A desired pattern is cut on the above-mentioned base paper with a cutter in a state of being attached to the surface, and then this pattern portion or a portion other than this pattern portion is removed to produce a washout design panel. Then, the washout design panel is attached to a concrete formwork, and a concrete material is cast to produce a concrete product. As described above, according to the first method for producing a surface-exposed concrete product of the present invention, when the washout design panel is produced, the base paper (on which the concrete-hardening retarder layer is formed) is provided with the adhesive layer on the surface. A desired pattern is cut with a cutter on the above-mentioned base paper of a rigid base material that has been pasted through, and then this pattern portion or a portion other than this pattern portion is removed. Therefore, of the surface of the base paper attached to the surface of this washout design panel, the concrete hardening retarder layer is not formed in the above removed portion, and the concrete hardening retarder layer is formed in the portion not removed. ing. Therefore, when the washout design panel is attached to a concrete formwork and a concrete material is cast to produce a concrete product, a portion corresponding to the rigid base material of the washout design panel has a predetermined size on the surface of the concrete product. A portion that is formed in a recess having a depth (that is, a depth that approximately corresponds to the thickness of the rigid base material) and that corresponds to the portion that has not been removed (that is, the portion where the concrete hardening retarder layer is formed) Will be formed in a deeper recess. As a result, in the case of the washout design panel in which the pattern portion is removed, the desired pattern rises in the portion corresponding to the rigid base material (more specifically, only the difference between the depths of the both concave portions is described. , It will be expressed as makeup. On the other hand, in the case of a wash-out design panel in which a portion other than the pattern portion is removed, the portion corresponding to the rigid base material is in a state in which the desired pattern is recessed (more specifically, the depth of both recesses is Only the difference is dented)
You will be able to express yourself with makeup.

In such a method for producing a surface-patterned concrete product of the present invention, since the washout design panel is composed of a plate-shaped or film-shaped rigid base material,
Due to its rigidity, the washout design panel can be easily fixed to the fixed position of the mold by one or several people without bending. Also, the number of places to attach the washout design panel with nails or adhesive tape is reduced. From these things, work efficiency improves. Moreover, as described above, since the washout design panel is composed of a plate-shaped or film-like rigid base material, wrinkles do not occur on the washout design panel, the washout surface is uniform, and the washout pattern is uniform. Become. In addition, the wash-out design panel does not sag, and there are no wrinkles or other marks on the concrete product. From these things, the quality of the concrete product can be kept constant. If the panel is thick, the washout design panel itself can be used as a mold.

Further, the base paper having the concrete hardening retarder layer formed on the surface thereof is stuck to the surface of the plate-like or film-like rigid base material via the adhesive layer, and the base paper is desired to be cut by a cutter. After cutting the pattern, the design part is created by removing the part of this pattern or the part other than this part to create a washout design panel, so when using screen printing suitable for continuous production to form the desired pattern. On the other hand, in the washout design panel used in the method for producing the first surface-patterned concrete product of the present invention, the base paper is cut by a cutter and then the pattern part or a part other than the pattern part is removed to obtain a desired pattern. Since the pattern is formed, it is suitable for small lot production and does not require the printing mold that was necessary for screen printing. Less expensive, it becomes possible to shorten delivery times.

In the method for producing a first surface-textured concrete product of the present invention, when the washout design panel is attached to a part of a concrete formwork,
By selecting a place to be attached to the concrete form, it becomes possible to form a desired pattern at a desired place.

The method for producing the second surface-patterned concrete product of the present invention also has the same effects as the first method for producing the surface-textured concrete product of the present invention. On the other hand, by using the washout design panel of the present invention, it is possible to realize the method for producing a surface-patterned concrete product of the present invention that exhibits the above-mentioned excellent effects.

Next, the present invention will be described in detail.

The present invention has a washout design sheet provided with a plate-like or film-like rigid base material, a base paper, and a concrete hardening retarder layer.

A plate material or a paper material is preferably used as the rigid base material. A plywood plate (thickness: 1 to 24 mm) is preferably used as the plate material, but a rigid plate material such as a styrene plate or a resin plate may be used. on the other hand,
Thick paper (thickness: 1 to 10 mm) is preferably used as the paper material, but any other paper material may be used as long as it has rigidity.

A film-like synthetic paper is preferably used as the base paper, but a PP sheet or the like may be used.

The concrete hardening retarder constituting the concrete hardening retarder layer is not particularly limited as long as it delays hardening of the surface of the concrete product. For example, an ultraviolet curable resin, a substance that is hydrolyzed by an alkali, a substance that adsorbs calcium ions, or the like can be used. These can be used alone or in combination. From the viewpoint of workability, it is preferable to use it as a liquid by dissolving or mixing and dispersing it in an appropriate solvent. Further, it may be mixed with an adhesive, an adhesive, a resin liquid, a viscosity adjusting liquid, a filler, a water-swelling agent and the like. Furthermore, because the properties of each concrete hardening retarder (solid, liquid, viscosity, particle size, PH, etc.) differ in the amount of concrete material removed by washing out, the hardening delay time, etc., the concentration, type, combination, The usage method and the like may be changed as appropriate to set the desired removal amount and curing delay time.

As a method of applying the concrete hardening retarder, brush application, spray spraying, roller application,
Various methods such as dipping are performed, and the method is not particularly limited. In addition, drying and curing can also be done by leaving it to stand naturally, drying with hot air,
Various methods such as infrared drying are performed, and the method is not particularly limited. The drying conditions are also various conditions depending on the type of the concrete retarder used, etc., but are generally at room temperature to 120 ° C. for several minutes to several hours.

[0018]

BEST MODE FOR CARRYING OUT THE INVENTION Next, embodiments of the present invention will be described in detail with reference to the drawings.

FIG. 1 shows one embodiment of the washout design panel of the present invention. 1 is a washout design panel, as shown in FIG. 2, 900 mm (length) x 1
Rectangular veneer plate (rigid base material) 2 formed to 800 mm (width) × 2.5 mm (thickness), and this veneer plate 2
A base paper 4 which is attached to the surface of the adhesive via an adhesive layer 3;
A concrete hardening retarder layer 5 formed on the entire surface of the base paper 4 is provided, and the base paper 4 is cut out into a desired pattern (in this embodiment, one bird). The part 6 is formed.

The concrete hardening retarder layer 5 is formed by applying a concrete hardening retarder to the entire surface of the base paper 4 and then drying and hardening it, and the thickness thereof is in the range of 10 to 500 μm. It is set.

The cutout portion 6 can be formed, for example, as follows. That is, first, CAD
Draw multiple design drawings with (Computer Aided Design), have the customer see these design drawings, and have the customer select the design drawing that they like. Then, the design drawing that the customer likes is adopted as the pattern of the cutout portion 6 as it is. Next, CA
Input the data of D into the cutter machine. Next,
With the base paper 4 attached to the entire surface of the veneer board 2 (see FIG. 3), CAD data is output from the cutter machine and the cutter 7 is moved. The cutter 7 is used to design the base paper 4 by the customer. After cutting the figure (see FIG. 4), the part of the design drawing is peeled off from the veneer plate 2. On the other hand, the customer decides where on the surface of the concrete product to place the design drawing that the customer likes, and the design drawing (FIG. 5) to be described later is arranged so that the design drawing is placed at that place. Position and fix the washout design panel 1 in (Ref.).

Using such a washout design panel 1, for example, a concrete product can be manufactured as follows. That is, first, the formwork 11 used when placing the concrete material 10 (see FIG. 5).
To prepare. Then, the washout design panel 1 is detachably fixed to the inner surface of the formwork 11 with nails or screws so that the concrete hardening retarder layer 5 on the surface becomes the contact surface with the concrete material 10 (see FIG. 5). . At this time,
As described above, the washout design panel 1 is positioned on the mold 11 so that the cutout portion 6 is arranged at the position desired by the customer. Next, the concrete material 10 is attached to the formwork 11 to which the washout design panel 1 is fixed.
After the concrete material 10 is cured and hardened,
The form 11 and washout design panel 1 are peeled off. After that, the uncured portion 1 due to the concrete hardening retarder remaining on the surface of the obtained concrete product 12
Rinse 2a (see FIG. 6) with water. As a result, the concrete product 12 having the washout pattern 12b formed on the surface thereof
Can be manufactured (see FIG. 7).

As described above, in this embodiment, the washout design panel 1 does not bend or the like due to its own rigidity, so that the washout design panel 1 can be placed at a predetermined position on the formwork 11 by one or several persons. Can be easily fixed. Then, for the fixing, a fixing tool such as a nail or a screw which is usually used for other work at the work site can be utilized. By these things, work efficiency improves. Furthermore, before the concrete material 10 is poured, the washout design panel 1 is hardly stretched even if it is heated by direct sunlight or the like. Further, even if rainwater or the water content of the concrete material 10 is absorbed, the dimensions thereof do not change. Therefore, the wash-out surface of the obtained concrete product 12 becomes uniform and the wash-out pattern 12b becomes uniform, so that a certain quality can be secured. Further, when the washout design panel 1 is formed, the base paper 4 is cut by the cutter 7, so that it is not necessary to make a printing mold which is necessary for screen printing.

FIG. 8 shows another embodiment of the washout design panel of the present invention. In this embodiment, the veneer plate 2 (see FIG. 2) that constitutes the washout design panel 1 is formed in a circular shape, and the outer peripheral portion thereof constitutes the outer peripheral portion of the pattern itself. In addition, the cutout portion 6
Is made up of an annular portion 6a and four straight line portions 6b extending from the annular portion 6a, and the entire surface of the base paper 4 (see FIG. 2) consisting of four fan-shaped portions and a central circular portion is covered with concrete. The curing retarder layer 5 is formed. Also,
FIG. 9 shows a concrete product 12 obtained by using the wash-out design panel 1 of this embodiment. The other parts are the same as those in the above embodiment, and the same parts are denoted by the same reference numerals. Also in this embodiment, the same actions and effects as those of the above-mentioned embodiment are exhibited.

FIG. 10 shows still another embodiment of the wash-out design panel of the present invention. In this embodiment, in the washout design panel 1 shown in FIG.
The base paper 4 attached to the surface of the veneer plate 2 via the adhesive layer 3 (see FIG. 2) is provided with the cutout portion 6 while leaving a desired pattern. That is, the base paper 4
Of these, a portion other than the desired pattern is formed in the cutout portion 6. In addition, a concrete product 12 obtained by using the washout design panel 1 of this embodiment,
It shows in FIG. The other parts are the same as those in the above embodiment, and the same parts are denoted by the same reference numerals. Also in this embodiment, the same actions and effects as those of the above-mentioned embodiment are exhibited.

FIG. 12 shows concrete products 13-15 obtained using yet another embodiment of the washout design panel of the present invention. In this embodiment, 3
Large washout patterns 13b to 15b are drawn on the concrete products 13 to 15, and each concrete product 1
At the connecting portions of 3 to 15, each washout pattern 13b to
15b is clean and continuous.

In each of the above-described embodiments, the base paper 4 on which the concrete hardening retarder layer 5 is formed is cut by the cutter 7.
Although the cutting is not limited to this, the base paper 4 on which the concrete hardening retarder layer 5 is not formed is cut by the cutter 7, and then the concrete hardening retarder layer 5 is applied to the base paper 4. You may form. In addition, in each of the above embodiments, the concrete product 1
Although the washout patterns 12b to 15b are formed on a part of the surfaces of 2 to 15, the washout patterns 12b to 15b may be formed on the entire surface of the concrete products 12 to 15.

[0028]

As described above, according to the method for producing a surface-exposed concrete product of the present invention, since the wash-out design panel is composed of a plate-like or film-like rigid base material, it is not bent due to its rigidity. Instead, the washout design panel can be easily fixed in place on the formwork by one or several people. Also, the number of places to attach the washout design panel with nails or adhesive tape is reduced. From these things, work efficiency improves. Moreover, as described above, since the washout design panel is composed of a plate-shaped or film-like rigid base material, wrinkles do not occur on the washout design panel, the washout surface is uniform, and the washout pattern is uniform. Become. In addition, the wash-out design panel does not sag, and there are no wrinkles or other marks on the concrete product. From these things, the quality of the concrete product can be kept constant. When the panel is thick, the design panel itself can be used as the formwork.

Further, the base paper having the concrete hardening retarder layer formed on the surface thereof is attached to the surface of the plate-like or film-like rigid base material via the adhesive layer, and the base paper is desired to be cut with a cutter. After cutting the pattern, the design part is created by removing the part of this pattern or the part other than this part to create a washout design panel, so when using screen printing suitable for continuous production to form the desired pattern. On the other hand, in the washout design panel used in the method for producing the first surface-patterned concrete product of the present invention, the base paper is cut by a cutter and then the pattern part or a part other than the pattern part is removed to obtain a desired pattern. Since the pattern is formed, it is suitable for small lot production and does not require the printing mold that was necessary for screen printing. Less expensive, it becomes possible to shorten delivery times.

In the method for producing a first surface-patterned concrete product of the present invention, when the washout design panel is attached to a part of a concrete formwork,
By selecting a place to be attached to the concrete form, it becomes possible to form a desired pattern at a desired place.

The method for producing the second surface-patterned concrete product of the present invention also exhibits the same effects as the first method for producing the surface-textured concrete product of the present invention. On the other hand, by using the washout design panel of the present invention, it is possible to realize the method for producing a surface-patterned concrete product of the present invention that exhibits the above-mentioned excellent effects.

[Brief description of drawings]

FIG. 1 is a perspective view showing an embodiment of a wash-out design panel of the present invention.

FIG. 2 is a sectional view showing the washout design panel.

FIG. 3 is a cross-sectional view showing a method of manufacturing the washout design panel.

FIG. 4 is a cross-sectional view showing a method for manufacturing the washout design panel.

FIG. 5 is a cross-sectional view showing a method of using the washout design panel.

FIG. 6 is a cross-sectional view showing a method of using the washout design panel.

FIG. 7 is a perspective view showing a concrete product.

FIG. 8 is a front view showing another embodiment of the wash-out design panel of the present invention.

FIG. 9 is a perspective view showing a concrete product.

FIG. 10 is a perspective view showing still another embodiment of the wash-out design panel of the present invention.

FIG. 11 is a perspective view showing a concrete product obtained by using the washout design panel.

FIG. 12 is a perspective view showing a concrete product obtained by using still another embodiment of the wash-out design panel of the present invention.

[Explanation of symbols]

2 veneer boards 3 Adhesive layer 4 base paper 5 Concrete hardening retarder layer

Claims (6)

[Claims] 1. A base paper having a concrete retarder layer formed on the surface thereof is attached to the surface of a plate-like or film-like rigid base material via an adhesive layer, and the base paper is desired to be cut by a cutter. After cutting the pattern of, the part of this pattern or the part other than this part is removed to make a washout design panel, and this washout design panel is attached to the concrete formwork, and the concrete material is cast to produce the concrete product. A method for producing a surface-exposed concrete product characterized by being produced. 2. The surface of the base paper after the base paper is attached to the surface of a plate-like or film-like rigid base material via an adhesive layer and a desired pattern is cut on the base paper with a cutter. A concrete hardening retarder layer is applied to the above, and the washout design panel is prepared by removing the above-mentioned pattern part or the part other than the above-mentioned pattern part, and this washout design panel is attached to the concrete formwork, and the concrete material is placed. A method for producing a surface-exposed concrete product, characterized in that a concrete product is manufactured by using the method. 3. The washout design panel is attached to a part of a concrete formwork.
Manufacturing method of the concrete product with the surface pattern described. 4. A washout design panel to be used by being attached to a concrete formwork when a concrete material is cast to produce a concrete product, wherein a base paper having a concrete hardening retarder layer formed on the surface thereof is used as an adhesive. After cutting a desired pattern on the above-mentioned base paper with a cutter in a state where it is attached to the surface of a plate-shaped or film-shaped rigid substrate through a layer, this pattern portion or a portion other than this pattern portion is removed. A washout design panel characterized by being produced by the above. 5. A washout design panel which is used by being attached to a concrete formwork when a concrete material is cast to produce a concrete product, wherein the base paper has a plate-like or film-like rigidity through an adhesive layer. In a state of being stuck on the surface of the base material, after cutting a desired pattern on the base paper with a cutter, a concrete hardening retarder layer is applied to the surface of the base paper to apply a part of the pattern or a part other than the part of the pattern. A washout design panel characterized by being produced by removing parts. 6. The washout design panel according to claim 4, which is used by being attached to a part of the concrete formwork.