JP2007153651A - Method of producing resin coated concrete product - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To produce a low cost resin coated concrete product by improving productivity with simple and low cost production equipment. <P>SOLUTION: The resin coated concrete product 1 is produced by mounting a core forming body 4 formed by a core forming body forming form 7 in a resin layer forming form 9 in which a resin material 8 is filled and applying vibration and pressure load to the resin layer forming form 9 by a vibration mechanism 13 and a pressurizing mechanism 14 to form a resin layer 5 applied to the outer peripheral surface of the core forming flask 4. <P>COPYRIGHT: (C)2007,JPO&INPIT

Description

  The present invention relates to a method for producing a resin-coated concrete product in which an outer peripheral surface of a core molded body formed of cement concrete or mortar is coated with a resin concrete layer.

  Concrete products formed from cement concrete or mortar are used in various fields such as buildings and civil engineering structures. Concrete products generally have an unsatisfactory gray color, which is the color of limestone, which is a raw material for cement. For example, in order to improve the cityscape, not only buildings but also curbs, sidewalks, and gutter lids are used. For road facilities such as the above, colorization with an appropriate color tone is being attempted.

  Conventionally, colored concrete products have been formed by adding a colorant having an appropriate color tone to ready-mixed concrete, or by spraying with an air gun or the like after molding. Such colored concrete products have a smooth and finished surface as compared with resin products, and it is difficult to obtain properties such as gloss and hue, and there are also problems such as discoloration.

  As concrete products, those formed by so-called resin concrete using an epoxy resin, a urethane resin or a polyester resin as a binder instead of or in addition to cement are also provided. Resin concrete products have various characteristics such as durability, corrosion resistance, weather resistance, high strength, light weight, and easy coloration. However, such a resin concrete product is very expensive as a resin material used as a binder as compared with cement, and when a suitable coloring or pattern is applied, a coloring agent and a pattern aggregate are also expensive. It becomes cost.

  In concrete products, various types of resin-coated concrete products are provided in which a cement concrete core-molded body having a predetermined shape is formed from cement concrete, and the outer peripheral surface of the core-molded body is coated with a resin concrete layer (Patent Documents). 1 and Patent Document 2). Such a resin-coated concrete product is made of a cement concrete made of cement concrete, which reduces the amount of resin concrete used by maintaining mechanical strength, thereby reducing the cost. Thus, the characteristics of the resin concrete described above are exhibited.

JP 2002-248611 A.

JP2003-41897A.

  By the way, in the composite cement concrete product disclosed in Patent Document 1, the resin concrete layer constituting the shell is coated and integrated on the outside of the cement concrete molding constituting the core via a disappearing member that disappears after molding. . For composite cement concrete products, a primary mold for shell molding, a secondary metal mold, a core, and a guide mold are used. After the resin concrete layer is molded by the primary molding process, cement concrete molding is performed by the secondary molding process. Mold the object. Such composite cement concrete products require expensive equipment investment because of the use of an expensive mold with a complicated structure as described above. In addition, in the composite cement concrete product, a process of setting a disappearing member such as polystyrene foam in the molding die every time a molding process is required, and hardening of the resin concrete that deteriorates due to the presence of moisture is required. From the characteristics, there is a problem that the cement concrete must be molded at the timing when the resin concrete layer is hardened and the production molding efficiency is poor.

  The resin-coated segment disclosed in Patent Document 2 is composed of a reinforced concrete segment core body whose surface is roughened and a resin mortar that covers the entire six outer surfaces of the core body. The resin-coated segment is molded into a concrete segment core, and then attached to a centrifugal mold that is installed in a centrifugal molding drum. The centrifugal molding drum is driven to apply centrifugal force to the mold. A resin mortar layer is formed on the six outer surfaces of the core by injecting resin mortar and demolding the resin mortar after curing. In such a method for producing a resin-coated segment, the centrifugal molding drum requires a large installation space, and when a large resin-coated segment is molded, a large driving source is also required, so that the equipment burden is extremely large. Further, in such a method for producing a resin-coated segment, since the resin mortar is injected into the centrifugal mold in a high-speed rotation state, the mold structure is complicated and expensive.

  In conventional resin-coated concrete products, as described above, the amount of resin concrete used is reduced, and concrete products that exhibit the characteristics of cement concrete and resin concrete are formed. However, there is a problem that the cost cannot be reduced as much as a result because it requires a new and large-scale manufacturing facility and the productivity is lower than that of a general concrete product. In addition, in conventional resin-coated concrete products, the difference in shrinkage between cement concrete and resin concrete is large, so there is a risk that the resin concrete layer will be peeled off or cracked, and the resin concrete will be affected by moisture in the cement concrete. There is also a risk that the uncured material will be uncured.

  Therefore, the present invention solves the above-mentioned conventional problems, improves productivity by a simple and inexpensive manufacturing facility, and thus makes it possible to manufacture a low-cost resin-coated concrete product. It has been proposed for the purpose of providing a method for producing a concrete product.

  The method for producing a resin-coated concrete product according to the present invention that achieves the above-described object uses a core molded body molding mold and a resin layer molding mold, a core molded body molding process, a resin material filling process, and a core Resin coating formed by coating the outer peripheral surface of a core molded body formed of cement concrete or mortar with a resin layer through a molded body attaching process, a resin material compacting process, a resin-coated concrete product molding process, and a demolding process. Manufacture concrete products. In the method for producing a resin-coated concrete product, in the core molded body molding step, cement concrete or mortar is poured into the cavity of the core molded body mold, and the mold is removed from the cavity to mold the core molded body. In the method for producing a resin-coated concrete product, a predetermined amount of resin material is filled in the cavity of the resin layer forming mold in the resin material filling step. In the method of manufacturing the resin-coated concrete product, the core molded body is positioned and mounted in the cavity of the resin layer molding mold in the core molded body mounting step. In the resin material compaction process, the resin-coated concrete product is produced by tightening the resin layer molding mold and vibrating the cavity in a pressurized atmosphere, thereby allowing the resin material to become the outer peripheral surface of the core molded body. Wrap around. In the resin-coated concrete product manufacturing method, in the resin-coated concrete product forming step, a resin-coated concrete product in which a resin layer is formed of a resin material that covers and hardens the outer peripheral surface of a core molded body is formed. In the method for producing a resin-coated concrete product, in the mold releasing step, the resin layer forming mold is removed and the resin-coated concrete product is taken out from the cavity.

In the method of manufacturing a resin-coated concrete product, a small dimensional value or volume of, for example, about 0.5 mm to 5 mm in comparison with the dimensional value of the final form product is obtained by forming molds and operations equivalent to general cement concrete products. A core molded body having a size of about 85% to 99% is formed. In the method for producing a resin-coated concrete product, for example, a resin material such as an unsaturated polyester resin is 20 to 50% by weight, a curing agent is 0.5 to 2.0% by weight, and calcium carbonate is 20 to 50% by weight. A resin material having a basic composition of 20% by weight to 50% by weight of a fine aggregate of 1% by weight or less, and a decorative material, a coloring agent (pigment), a fiber and the like added as appropriate is used. A predetermined amount corresponding to the thickness of the resin layer is filled in the resin layer forming mold. In the method for producing a resin-coated concrete product, in the resin material compacting step, for example, the frequency is 20 Hz to 100 Hz, the acceleration is ² G to 10 G, and the applied pressure is 0.3 N / mm ^{2 to} 1.0 N / A vibration load and a pressure load are allowed to act alone or in combination under the condition of mm ² .

  In the method for producing a resin-coated concrete product, since the core molded body is mounted in the cavity of the resin layer molding mold, the finished accuracy of the resin layer on the mounting surface is slightly lowered. Therefore, in the method for producing a resin-coated concrete product, the resin-coated concrete product is installed as an installation surface where the mounting surface of the resin layer forming mold of the core molded body is not exposed to the outside. In the method for producing a resin-coated concrete product, when a resin layer having a good finish is formed on all outer peripheral surfaces, the resin material on the mounting surface is leveled with a trowel or the like in an uncured state.

  According to the method for producing a resin-coated concrete product according to the present invention, a core molded body is formed by a molding frame and work equivalent to a general cement concrete product, and a simple pressurization and vibration drive source is attached. The resin-coated concrete product in which the resin layer is formed on the outer peripheral surface of the core molded body is manufactured by the resin layer molding mold having a simple structure. According to the method for producing a resin-coated concrete product according to the present invention, the amount of expensive resin material used is reduced, a large-scale capital investment is not required, and productivity is improved, thereby reducing the cost of resin-coated concrete. It is possible to produce a product. According to the method for producing a resin-coated concrete product according to the present invention, application to various concrete products in all fields is possible, and the peeling of the resin layer from the integrated core molded body is suppressed, durability, It is possible to obtain an inexpensive resin-coated concrete product that has excellent corrosion resistance, weather resistance, etc., has a smooth and well-finished surface, and is excellent in properties such as gloss and color.

  Hereinafter, embodiments of the present invention will be described in detail with reference to the drawings. Embodiment shows the application example of the ground concrete block body manufactured through each manufacturing process which mentions the detail shown in FIG. 1 as the resin covering concrete product 1 later. Therefore, in the following description, the resin-coated concrete product 1 is expressed as a ground concrete block body 1. The ground concrete block body 1 is formed in a horizontally-long rectangular block shape as shown in FIG. 2 and abuts the ground edges 2L and 2R facing each other in the length direction along the section area between the roadway and the sidewalk of the road. It is installed by arranging and joining the tips 2L, 2R with joints 3 using a resin adhesive. In addition, this invention is not limited to the manufacturing method of this ground concrete block body 1, For example, it applies when manufacturing concrete products of other fields such as other curb blocks or road auxiliary equipment, such as a ditch cover and a concrete plate. Is done.

  As shown in FIG. 3, the ground concrete block body 1 is composed of a cement concrete core molded body 4 and a resin layer 5 formed by covering the outer peripheral surface of the core molded body 4. In the present specification, the term “resin” is used for the sake of simplification of description, but includes resin concrete and resin mortar.

  The ground concrete block 1 is integrally formed with a substantially V-shaped fitting protrusion 6L on the ground 2L side and a substantially V-shaped fitting recess 6R on the ground 2R side, The fitting is performed by fitting the fitting convex portion 6L and the fitting concave portion 6R. The ground concrete block body 1 is formed with a resin layer 5 having an appropriate color tone or pattern, and constitutes a road that clearly distinguishes the roadway from the sidewalk and creates a unique atmosphere by colorization.

  In the ground concrete block body 1, as described above, the fitting convex portion 6L is formed on the ground tip 2L side, and the fitting concave portion 6R is formed on the ground tip 2R side, thereby facilitating the installation work and about It is possible to reduce the amount of resin adhesive used for the joint 3 having a thickness of 10 mm. In the ground concrete block 1, the core molded body 4 is covered with the resin layer 5 as described above, so that the fitting convex portion 6 </ b> L and the fitting are compared with the cement concrete integrated ground block. It is possible to form the combined recess 6R with high accuracy and without any chipping. Further, in the ground concrete block body 1, for example, an unsaturated polyester resin adhesive or an epoxy resin adhesive is used instead of the cement mortar easily cut at the edge used in the cement concrete integrated ground block body. These resin adhesives or silicon-based adhesives can be used in reduced amounts, and are firmly bonded to each other.

  The ground-end concrete block body 1 comprised as mentioned above is manufactured through the manufacturing process shown in FIG. In the manufacturing process of the ground concrete block body 1, the core molded body forming mold 7 for molding the core molded body 4 and the outer peripheral surface of the core molded body 4 which is filled with the resin material 8 and positioned and attached are covered. A resin layer forming mold 9 that integrally forms the resin layer 5 is used. The manufacturing process of the ground concrete block body 1 includes a core molded body molding step S-1, a resin material filling step S-2, a core molded body mounting step S-3, a resin material compacting step S-4, Resin-coated concrete product forming step S-5 and demolding step S-6.

  In the manufacturing process of the ground concrete block body 1, the core molded body molding form 7 formed in the core molded body molding process S-1 is formed in the same manner as the molding mold for molding a conventional general cement concrete product. Thus, the core molded body 4 is formed by an equivalent operation. In the core molded body forming step S-1, either concrete or mortar can be used according to product specifications, and reinforcing bars and the like are arranged as necessary. In the core molded body molding step S-1, the core molded body 4 having a slightly smaller outer dimension than the ground concrete block body 1 which is the final product is molded by the core molded body molding form 7. In the core molded body molding step S-1, the core molded body mold 7 forms the cavity 10 with, for example, a small dimension value of about 0.5 mm to 5 mm or a volume ratio of about 85% to 99% in comparison with the dimension value. The core molded body 4 having a thickness is configured to be molded.

  In the core-molded body forming step S-1, it is preferable to use hard concrete, for example, immediately-removed concrete with a slump of 0 cm, rather than fresh concrete as the concrete material. As is well known, instant de-concrete has a low fluidity compared to ready-mixed concrete, and forms a molded article having a rough finished surface. In the core molded body molding step S-1, by using such immediate de-concrete, the immediate de-concrete is put into a mold and compacted, and then demolded immediately and the core molded body 4 is taken out. Is possible. In the core molded body molding step S-1, by using instant removal concrete, the core molded body 4 having a rough surface is realized by reducing the cost of the core molded body mold 7, realizing a multi-cycle by shortening the curing period. By forming, the degree of adhesion with the resin layer 5 to be formed in a later step is increased, and the occurrence of peeling or the like is suppressed.

  In the core molded body forming step S-1, since immediate concrete removal is used, the core molded body forming mold 7 is compacted by applying pressure vibration to the core molded body forming frame 7 as necessary, and the cavity 10 is formed by the mold releasing step. The core molded body 4 molded from is taken out. As shown in FIG. 1, a large number of convex portions 11 are integrally formed on the core molded body 4 on the bottom surface that becomes the mounting surface 4 </ b> A in a resin material compaction step S- 4 described later. The core molded body 4 is configured such that a gap for allowing the resin material 8 to wrap around the outer peripheral surface is formed between the bottom surface of the resin layer forming mold 9 and the mounting surface 4 </ b> A by these convex portions 11.

  In the manufacturing process of the ground concrete block body 1, the resin layer forming mold 9 having the cavity 12 corresponding to the final shape of the ground concrete block body 1 is used in the resin material filling process S- 2. A predetermined amount of the resin material 8 is filled in advance. As the resin material 8, it is possible to use a conventional material using an epoxy resin, a urethane resin, a polyester resin, or the like as a binder. Specifically, the resin material 8 includes 20% to 50% by weight of a resin material such as an unsaturated polyester resin, 0.5% to 2.0% by weight of a curing agent, and 20% to 50% by weight of calcium carbonate. %, 1 mm or less of fine aggregates having a basic composition of 20% by weight to 50% by weight, decorative aggregates, colorants (pigments), fibers, etc. that determine the appearance specifications of the ground concrete block body 1 are appropriately added. . In addition, the resin material 8 is not limited to this composition, The thing of a suitable composition according to the specification of the ground concrete block body 1 is used.

As will be described later, the entire resin layer forming mold 9 is vibrated by an attached vibration mechanism 13 in order to cause the resin material 8 to wrap around the outer periphery of the core molded body 4 and to be compacted. The vibration mechanism 13 applies a vibration load to the resin layer forming mold 9 under conditions of, for example, a frequency of 20 Hz to 100 Hz and an acceleration of 2G to 10G. In addition, the resin layer forming mold 9 is configured by forming the cavity 12 as a sealed space and applying a pneumatic pressure by the pressurizing mechanism 14. Pressurizing mechanism 14, for example, the cavity 12 and pressurized state of ^{0.3N / mm 2 ~1.0N / mm 2} . In the resin layer forming mold 9, the vibration load by the vibration mechanism 13 and the pressure load by the pressure mechanism 14 are applied alone or in combination.

  In the manufacturing process of the ground concrete block body 1, the core molded body 4 is positioned and mounted in the cavity 12 of the resin layer molding mold 9 in the core molded body mounting step S-3. In the core molded body attaching step S-3, as described above, the resin layer molding mold 9 is formed with the cavity 12 that is slightly larger than the outer shape of the core molded body 4, so that the core molded body is attached. A cavity for forming the resin layer 5 is formed over the entire outer periphery of the body 4. In the resin layer forming mold 9, as described above, a large number of convex portions 11 are integrally formed on the mounting surface 4 </ b> A of the core molded body 4, so that an appropriate gap is provided between the bottom surface of the cavity 12. Is configured.

  In the manufacturing process of the ground concrete block body 1, in the resin material compacting step S-4, the vibration layer 13 and the pressurizing mechanism are pressed in a state where the resin layer forming mold 9 is clamped to make the cavity 12 a sealed space. By driving the mechanism 14 alone or simultaneously, a vibration load and a pressure load are applied to the resin layer forming mold 9. In the resin material compaction step S-4, the vibration material and the pressure load cause the resin material 8 filled in the cavity 12 to wrap around the outer peripheral surface of the core molded body 4 over the entire area. The resin material compaction step S-4 is basically a molding method in which pressure vibration is applied in the same manner as in the core molding body 4 using the above-described immediate demolding concrete, and a special resin layer molding die is used. No frame 9 or work is required.

  In the manufacturing process of the ground concrete block body 1, the vibration mechanism 13 and the pressurization mechanism 14 in a state where the resin material 8 is sufficiently wrapped around the outer peripheral surface of the core molded body 4 in the resin-coated concrete product forming step S-5. Until the resin material 8 is cured, the mold clamping state of the resin layer forming mold 9 is maintained. In the resin-coated concrete product forming step S-5, for example, the resin layer forming mold 9 is conveyed to a drying chamber, and a drying step is performed for about 1 hour in a heated atmosphere at 50 ° C to 70 ° C.

  In the resin-coated concrete product molding step S-5, the resin material 8 is hardened in the cavity 12, whereby the ground concrete block formed with the resin layer 5 that is integrated with the core molded body 4 and covers the outer peripheral surface thereof. The body 1 is molded. In the resin-coated concrete product molding step S-5, as described above, the core molded body 4 is molded using the quick-removing concrete with less moisture, so that the resin material 8 is reliably cured and formed on the rough surface. It hardens | cures in the state which bite into the outer peripheral surface of the core molded object 4. FIG.

  In the manufacturing process of the ground concrete block body 1, the ground concrete block body molded from the cavity 12 by removing the resin layer forming frame 9 after a predetermined curing time in the demolding step S-6. 1 is taken out.

  The ground concrete block bodies 1 manufactured through the above steps are arranged in the longitudinal direction along the section area between the roadway and the sidewalk of the road as described above with the mounting surface 4A of the core molded body 4 as the installation surface. The ground tips 2L and 2R are joined and installed by a joint 3 using a resin adhesive. In the ground concrete block body 1, the finishing accuracy of the resin layer 5 formed on the mounting surface 4 of the core molded body 4 attached in the cavity 12 of the resin layer forming mold 9 is slightly lowered. There is no particular problem with the usage pattern. In the manufacturing process of the ground concrete block body 1, when the finishing accuracy of the resin layer 5 on the mounting surface 4 is required as required, the resin material 9 is demolded in a semi-cured state, and the resin of the part The layer 5 is subjected to a leveling treatment with a trowel or the like.

  It is needless to say that the present invention is not limited to the side groove device shown as the embodiment described above. The present invention is also applied to various concrete products in which a lid is installed by closing an opening of a main body member having an internal space, such as a water collecting device or a water supply device.

It is a block diagram of the manufacturing process of the ground concrete block body shown as embodiment of this invention. It is explanatory drawing of the installation state of a ground concrete block body. It is a figure which shows a ground concrete block body, the figure (A) is a partially notched front view, the figure (B) is a side view, and the figure (C) is sectional drawing.

Explanation of symbols

  1 ground concrete block body (resin coated concrete product) 2 ground edge, 3 joints, 4 core molded body, 4A mounting surface, 5 resin layer, 6L fitting convex part, 6R fitting concave part, 7 core molded body molding Formwork, 8 resin material, 9 resin layer molding formwork, 10 cavity, 11 convex part, 12 cavity, 13 vibration mechanism, 14 pressure mechanism

Claims (1)

A core molded body mold for molding a core molded body and a resin layer mold for molding a resin layer covering the outer peripheral surface of the core molded body are used,
A core molded body molding step in which cement concrete or mortar is poured into the cavity of the core molded body mold to mold the core molded body;
A resin material filling step of filling the resin material into the cavity of the resin layer molding mold,
A core molded body mounting step for positioning and mounting the core molded body in the cavity of the resin layer molding mold;
A resin material compacting step for causing the resin material to wrap around the outer peripheral surface of the core molded body by vibrating the resin layer molding mold in a state where the inside of the cavity is in a pressurized atmosphere, and
A resin-coated concrete product molding step of molding a resin-coated concrete product in which a resin layer is formed of the resin material that coats and cures the outer peripheral surface of the core molded body;
And a demolding step of demolding the resin layer forming mold and taking out the resin coated concrete product from the cavity.

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