JP2015190277A - Manufacturing method of large-sized artificial stone - Google Patents

Abstract

PROBLEM TO BE SOLVED: To efficiently manufacture a highly accurate artificial stone in large quantities, by preventing co-lifting of a hydraulic setting material installed when forming a notch groove.SOLUTION: A manufacturing method of an artificial stone having a thickness of 50 cm-100 cm manufactured by using a hydraulic setting material, and an outer frame block 2 is installed in a plane site with a height of a thickness or more of the artificial stone, and the hydraulic setting material C having a slump value of 5 cm-12 cm is filled-molded inside the outer frame block 2, and a notch index indicated by the product of surface hardness of the hydraulic setting material when filled in the outer frame block 2 or after completing filling and the ratio of an artificial stone thickness of the notch depth, is used as a management index, and a notch groove of the notch depth is formed on a partition plate so that the notch index falls within a constant range, and is crushed along the noth groove when a residual part strength index indicated by the product (σ×e) of uniaxial compressive strength σ of a hydration hardening body after curing and the ratio (e) of the artificial stone thickness of a residual thickness of reducing the notch depth from the artificial stone thickness is 0≤(σ×e)≤6.5.

Description

  The present invention relates to a method for producing a large artificial stone material having a thickness of more than 50 cm and not more than 100 cm used for, for example, covering stones for revetment in harbor construction, fishing reefs, algal reef mounds, and the like.

In recent years, from the viewpoint of protecting natural resources, stone collection regulations have been strengthened. Various materials are used.
The revetment block and covering block made of concrete are formed by filling and molding concrete into a mold with a predetermined shape, so it is necessary to maintain a stable dimensional shape and ensure wave resistance. There are advantages such as the ability to manufacture blocks of any weight, but in addition to the loss of molds, it requires much labor for the assembly and disassembly of molds and the curing management after placing concrete, so it is significantly more expensive than stone. However, there is a drawback that increases the construction cost of the facility. Therefore, application is limited in places and areas where waves are large and when the weight of stones available on the land is not enough. From the above, there is a demand for a method for producing artificial stone that can supply large stones at low cost.

Artificial stone manufactured using hydraulic materials such as concrete is generally cured for a certain period of time until the strength is developed by pouring the kneaded material into a flat or flat site where the thickness of the stone is dug. After that, it is manufactured by crushing using a crusher such as a giant breaker. As a standard of strength for crushing, it is generally recommended, for example, in Non-patent Document 1 that the compression strength reaches 5 N / mm ² . However, with such a method, it is difficult to control the size of the stone during crushing, so there is no problem in the production of stones with a wide range of specified particle sizes, but there are cases where stones with a narrow range of specified particle sizes are manufactured or heavy. When manufacturing a large stone of 800 kg / piece or more, there was a problem that there was a lot of loss during crushing and the yield was extremely inferior.

  Thus, as a method for solving the above-described problem, a technique for efficiently producing a large number of artificial stone materials having a fixed particle size range in a large amount in an artificial stone material made of a hydraulic material such as a steel slag hydrated solidified body is disclosed. For example, Patent Documents 1 to 3 disclose a method and a technique for more efficiently performing crushing and division performed on a flat ground level and before the curing.

  In Patent Document 1, a kneaded material such as concrete is placed on a flat surface, a mold is pressed from above, and then demolded, whereby the kneaded material is divided into 10 cm or more and 50 cm or less on one side to produce a block. The method is described.

  In Patent Document 2, a pit having a height equivalent to the thickness of a stone material such as earth and sand is provided on a site where a kneaded material is placed, and a steel slag hydrated solidified body is poured into the ridge and then a breaker or the like is cured. Is used to produce artificial stone by crushing.

  In Patent Document 3, a kneaded product of hydraulic material containing steel slag is spread on a flat ground and pressed, and then cut into notches for dividing into blocks of a predetermined size, and the kneaded product after curing. The manufacturing method of the steel slag roadbed material and the steel slag roadbed material which crush and manufacture a roadbed material after dividing the solidified body of this into a block shape are disclosed.

"Steel Slag Hydration Solid Technology Manual", February 2008, Coastal Technology Research Center

Japanese Patent No. 4502319 JP 2009-107908 A JP 2011-1234 A

However, the conventional method for manufacturing an artificial stone has the following problems.
In Patent Document 1, a stone block having a product thickness of 10 cm or more and 50 cm or less is targeted, and a form material having a top member and a side member is pressed using a kneaded material having a slump value of 0 to 5 cm. A block having a predetermined size is manufactured. That is, since the kneaded material having a slump value of 0 to 5 cm has low fluidity and cannot be sufficiently filled, compaction is performed by pressing a formwork material having an upper surface member and a side surface member. Using this technology, when trying to manufacture a large artificial stone material with a thickness of more than 50 cm and not more than 100 cm, the formwork material becomes large and the pressing depth becomes deep. There is a problem in that voids remain in the product, and the strength is weak and only brittle stones can be produced. In this respect, there is room for improvement. In addition, since it is essential to use a formwork material, the surface texture of the product can only be smooth, and a stone material that is required to have a rough surface that has been crushed in order to improve the adhesion of a bite or algae There is also a problem that it is not suitable for manufacturing.

  On the other hand, Patent Document 2 has a problem that a large site area is required for installation of the fence, so that it is not suitable for mass production and the production efficiency is low. In addition, since the kite is required every time it is manufactured, installation takes time and cost. In addition, if the kneaded material is placed directly after forming the koji with soil or ballast, the soil or ballast will adhere to the surface of the product, and the appearance of the product will be significantly impaired. It is necessary to provide it between the bag and the bag, which further increases labor and cost.

  Furthermore, in Patent Document 3, after inserting a dedicated cutting tool, it is pulled out to form a cutting groove. At this time, if the kneaded product has a high viscosity, the kneaded product may rise together with the cutting device. There are problems that the surface cracking occurs and the block shape is deteriorated, or that a lot of material loss occurs and the yield is deteriorated. On the other hand, if the viscosity of the kneaded material is low, the above-described simultaneous climbing and surface cracking at the time of drawing can be prevented, but there has been a problem that the cut groove disappears and crushing to a desired size becomes impossible. In order to stably manufacture large artificial stones with a thickness of more than 50cm and less than 100cm used for revetment covering stones, fishing reefs and algal reef mounds in port construction, it is necessary to make the depth of the cut groove deeper. The above-mentioned problem at the time of pulling out becomes particularly significant, and there is a problem that the shape is deteriorated and the material loss is increased.

  The present invention has been made in view of the above-mentioned problems, and can prevent the hydraulic material placed at the time of forming the cut groove from rising together and surface cracks, and a large amount of high-precision large-sized artificial stone materials. An object of the present invention is to provide a method for producing a large artificial stone that can be produced efficiently.

  In order to achieve the above object, the method for producing a large artificial stone according to the present invention is a method for producing an artificial stone having a thickness of more than 50 cm and not more than 100 cm manufactured using a hydraulic material, wherein A step of installing an outer periphery mold having a height equal to or greater than the above and enclosing in a rectangular shape when viewed from above, and a step of filling and molding a hydraulic material having a slump value of more than 5 cm and not more than 12 cm in the outer periphery mold The product of the surface hardness a of the hydraulic material during filling into the outer peripheral formwork or after completion of filling and the ratio c (= D / H) of the artificial stone thickness H of the cutting depth D to be formed Using the cutting index indicated by (a × c) as a management index, a partition plate partitioned into a desired plane dimension of the artificial stone material so that the cutting index is within a certain range is placed using a heavy machine. Cut from the upper surface of the metal to the bottom with a cutting depth D Ratio e () between the step of forming the groove, the uniaxial compressive strength σ of the hydrated cured body after curing, and the artificial stone thickness H of the remaining thickness A obtained by subtracting the cutting depth D from the artificial stone thickness H = A / H), and when the remaining portion strength index indicated by the product (σ × e) reaches the strength satisfying the formula (1), the crusher is used to form the artificial stone. And crushing along the cut groove.

  In the present invention, when manufacturing an artificial stone material having a thickness of more than 50 cm and not more than 100 cm, a hydraulic material having a slump value of more than 5 cm and not more than 12 cm is placed, and the surface hardness a of the hydraulic material and the depth of cut D to be provided are provided. In order to maintain the ratio c of the artificial stone material thickness H within a certain range, a notch groove having a cutting depth D is formed, and then the residual thickness obtained by subtracting the cutting depth D from the uniaxial compressive strength σ and the artificial stone material thickness H. When the product of the ratio e to the thickness H of the artificial stone material of A is equal to or higher than the strength satisfying the above-described equation (1), the artificial stone material is efficiently produced in large quantities by crushing along the cutting line. Can be manufactured. In other words, when forming a cut groove to divide the hydraulic material being cured, crush the artificial stone of the desired shape and size along the cut line while forming a cut groove with no surface cracks or co-ups. It can be manufactured without loss, and work efficiency and yield can be improved.

  Various surface hardness a can be applied as long as the resistance value at that time can be measured by pressing a rod-shaped or cylindrical device against the hydraulic material, and the soil hardness after soil compaction is measured. A technique using a cone penetrometer is effective. That is, the cone index a1 is measured by a cone penetrometer, and the cut index indicated by the product (a1 × c) of the ratio c (= D / H) of the cut depth D and the artificial stone material thickness H is expressed by equation (2). By forming the cut groove at this time, it is possible to form the cut groove that does not cause any rise or surface crack.

  In addition, for the measurement of the surface hardness a, a technique using a Yamanaka type soil hardness meter that measures the hardness of the soil is also effective. That is, the surface hardness a is measured by a hardness a2 by a Yamanaka type soil hardness meter, and the cutting index indicated by the product (a2 × c) of the cutting depth D and the ratio c (= D / H) of the artificial stone thickness H is obtained. By forming the cut groove at the time of the formula (3), it is possible to form a cut groove that does not cause both rising and surface cracking.

  According to this method, since the partition plate for inserting the cut groove does not need to be a dedicated one, it is possible to easily cope with an artificial stone material having a thickness of more than 50 cm and not more than 100 cm.

  Further, in the method for producing a large artificial stone according to the present invention, the volume ratio of the hydraulic material is such that the steelmaking slag is 64 to 71 vol%, the total amount of cement, blast furnace cement and blast furnace slag fine powder is 9 to 12 vol%, water Is characterized by being a mixture of 15-18 vol% and air volume 4-6 vol%.

  Furthermore, in the method for producing a large artificial stone according to the present invention, the volume ratio of the hydraulic material is such that the total amount of steelmaking slag and granulated blast furnace slag is 66 to 69 vol%, and the total of cement, blast furnace cement, and blast furnace slag fine powder. It is characterized by being a mixture of 10 to 12% by volume, 15 to 18% by volume of water, and 4 to 6% by volume of air.

  According to the method for producing a large artificial stone material according to the present invention, a large artificial stone material can be produced from a hydraulic material (such as a hydrated solid body) using steel slag, and a steelmaking slag or blast furnace produced as a by-product at a steelworks. An inexpensive artificial stone material that effectively utilizes granulated slag can be produced. Steelmaking slag contains mineral components such as iron, calcium, and silica in its components, so when used as a hydraulic material, it elutes in seawater and promotes the growth of organisms. In addition, since the crushing surface of the artificial stone material produced in the present invention has an uneven surface on which seaweeds tend to settle, it is suitable as an algal reef substrate and can be provided at a low cost as a large artificial stone material for algal reefs. .

  According to the method for producing a large artificial stone material of the present invention, in the process of forming the cut groove, the cut groove that is effective for crushing without side-up or surface cracking by selecting a cut depth suitable for the surface hardness of the hydraulic material By setting the remaining thickness obtained by subtracting the cutting depth from the thickness of the artificial stone and the strength of the hydraulic material during crushing to conditions suitable for crushing, the loss during crushing is reduced. Therefore, it is possible to produce an artificial stone material rich in shape stability, and to produce a high-precision artificial stone material in a large amount and efficiently. In addition, by applying this method to a hydrated hardened body using steel slag, it is possible to reduce the cost of large stones for algae beds that have surface properties rich in surface irregularities and mineral elution characteristics of steel slag. Can be manufactured.

It is a perspective view which shows the outline | summary of the manufacturing state of the large sized artificial stone material by embodiment of this invention. It is a perspective view which shows the structure of the cutting tool of the state with which the heavy machine was mounted | worn. (A) is the AA arrow view shown in FIG. 2, Comprising: The front view of a cutting tool, (b) is the BB arrow view shown in FIG. 2, Comprising: A cutting tool is seen from a lower surface. It is a figure. It is a perspective view which shows the hydraulic material in which the cutting groove was formed after the cutting. It is a perspective view which shows the cutting depth and residual thickness in an artificial stone material. It is a graph which shows the relationship between a cone index | exponent and Yamanaka type | mold hardness. It is a figure which shows the relationship between a cutting index and a cutting score (corn index). It is a figure which shows the relationship between a cutting index and a cutting score (Yamanaka hardness). It is a figure which shows the relationship between a residual part intensity | strength index and a crushing score. It is a top view of the manufacturing yard shown in FIG. (A)-(c) is a sectional side view which shows the manufacturing process of an artificial stone material.

  Hereinafter, the manufacturing method of the large sized artificial stone material by embodiment of this invention is demonstrated based on drawing.

  The method for producing a large artificial stone material according to the present embodiment is a method for producing an artificial stone material 1 having a thickness of more than 50 cm and not more than 100 cm manufactured using a hydraulic material C that hardens with time. As shown in FIG. 1, an outer frame block 2 (peripheral mold) that is movable so as to surround four sides is installed on a predetermined plane site, and the hydraulic material C is filled in the outer frame block 2.

The outer frame block 2 is a block made of a stone divided into a plurality of pieces, and an outer frame of an arbitrary size can be formed by appropriately combining these blocks. In the present embodiment, it is formed in a vertically long rectangular shape as viewed from above. In the present embodiment, a total of 32 artificial stone materials 1 manufactured by being placed inside the outer frame block 2 are manufactured in four rows in the short side direction and eight rows in the long side direction. It will be. In addition, the artificial stone material 1 is a dimension whose vertical and horizontal height is 1 m, for example.
The outer frame block 2 has a height equal to or greater than the thickness of the artificial stone material 1 in a plane site, and is enclosed in a rectangular shape in a top view.

  The hydraulic material C placed in the outer frame block 2 is blended to a slump value of 5 to 12 cm. Table 1 shows the results of a filling test using concrete and a hydrated solid body as the hydraulic material C. Here, in Table 1, 14 types of formulation examples are described. The slump value described in the table describes the range of the results of a plurality of tests conducted during the test. In addition, each No. in the table. The volume ratio (vol%) described in the lower row describes the volume ratio of each compounding material when the total volume including the air amount is 100. No. 1-4 is concrete, but if the slump is less than 5 cm (No. 1), the packing density is poor, and if the slump exceeds 13 cm (No. 2), the casting thickness cannot be maintained, and the material is fluidly collapsed, On top of that, it is difficult to overlay using a heavy machine, but in the range of slump 5-12 cm (No. 3, 4), it is possible to secure filling density and maintain the casting thickness without any problems. Yes. This situation is shown in No. The same applies to the results using 5 to 14 hydrated solidified products. That is, when the slump is less than 5 cm (No. 5), the packing density is poor, and when the slump exceeds 13 cm (No. 6), the casting thickness cannot be maintained, the material is fluidly collapsed, and a heavy machine is used thereon. While it is difficult to repeatedly cast, in the range of slump 5 to 12 cm (No. 7 to 14), the filling density can be secured and the casting thickness can be maintained without problems. Of the test formulations using hydrated solids, no. 7-10 is a hydraulic mixture in which the steelmaking slag is 64-71 vol%, the total amount of cement, blast furnace cement, and blast furnace slag fine powder is 12-9 vol%, and the water is 18-15 vol%. No. 11-14 is a hydraulic mixture in which the total amount of steelmaking slag and granulated blast furnace slag is 66 to 69 vol%, the total amount of cement, blast furnace cement and fine powder of blast furnace slag is 10 to 12 vol%, and water is 18 to 15 vol%. is there.

  Then, in the method for manufacturing a large artificial stone material according to the present embodiment, the hydraulic material C cast to a predetermined height in the outer frame block 2 is rolled using a bucket of a power shovel or the like to level the cast surface. The Next, when cured to a predetermined hardness, a predetermined depth from the upper surface of the hydraulic material C placed in the outer frame block 2 using the cutting tool 3 shown in FIG. The notch groove K is formed by cutting up to this point.

  As shown in FIG. 2 and FIGS. 3A and 3B, the cutting tool 3 includes a horizontal plate 31 (partition plate) and an artificial stone material 1 that is suspended and manufactured on one surface of the horizontal plate 31. And four vertical plates 32 (partition plates) arranged with a distance corresponding to a substantially width dimension. This cutting tool 3 is inserted into the hydraulic material C with the respective surfaces of the horizontal plate 31 and the vertical plate 32 facing in the vertical direction, whereby a predetermined depth D (see FIG. 4) is provided in the hydraulic material C. And the cut groove K of FIG. 5) is cut. Although the horizontal plate 31 and the vertical plate 32 are not shown, the thickness gradually decreases from top to bottom. That is, in the cutting tool 3 of the present embodiment, the three artificial stone materials 1 can be partitioned in one direction with a single cutting.

  The length L shown in FIG. 3A of the incision portion of the incision device 3 is desirably cut to a desired depth within the thickness of the artificial stone material, so that it is desirable to ensure the thickness of the artificial stone material.

  The timing of forming the cut groove K by cutting is such that the cut can be formed without applying dynamic force at the time of penetration, and the cutting tool can be pulled out while maintaining a hardness that does not disappear after the cut is made. At this time, it is necessary to set the depth and timing so that surface cracking due to the co-up of materials does not occur. Therefore, at this timing, by setting the relationship between the surface hardness of the hydraulic material after placement and the depth of the cut groove to an appropriate range, the surface caused by the disappearance of the cut groove and the rising up in a state where the penetration resistance is relatively small. Since it is possible to form a cut groove without cracks, this is defined by a cut index (formulas (2) and (3) described later).

  First, there are various methods for measuring the surface hardness of the hydraulic material in the setting / curing process, and a method suitable for the production site conditions may be selected. Examples thereof include a proctor penetration resistance measuring instrument shown in JIS A 1147 “Concrete setting time test method”, which is a method for measuring the setting time of concrete. Then, various measuring methods were verified, and a management method using a cone index with a cone penetrometer or a hardness with a Yamanaka soil hardness tester was adopted as a method for managing the formation of a cut groove in a large artificial stone.

  When these methods are applied to hydraulic materials, both have a linear relationship as shown in FIG. And the conditions which can form a favorable cut groove | channel were calculated | required from the relationship between the surface hardness, penetration resistance, the loss | disappearance degree of a cut groove | channel, and the degree of the surface crack by co-up. As a specific example, the conditions under which a good cut groove can be formed will be described based on the cone index by a cone penetrometer and the hardness by a Yamanaka type soil hardness meter.

First, conditions for forming the cut groove based on the hardness based on the cone index will be described.
Table 2 shows the evaluation of the formation condition of the cut groove by the cone index. The cone index a1 after a certain time has elapsed after placement is measured for each time using a cone penetrometer, and at the same time as the cone index a1 is measured, the cutting groove is formed by using a cutting tool. This was done by changing D. The ratio of the depth D of the cut groove to the total thickness H of the artificial stone (cut depth ratio) is c = D / H, and a1 × c is defined as the cut index, and the relationship between this and the formation condition of the cut groove Examined.

  The evaluation of the formation condition of the cut groove is performed based on the penetration resistance size, the disappearance degree of the cut groove, and the presence or absence of surface cracks due to co-upping. The case where there is a problem is 0.5, and the case where the problem is larger than 0.5. The score was given as 0.25, 1.0 when there was no problem, and the state where no problem occurred in all (state where multiplication of all scores was 1.0) was arranged. These are summarized in Table 2, and FIG. 7 shows the relationship between the cut index and the score of the cut groove. Accordingly, when the cone index a1 is used, a good cut groove can be formed as long as the expression (2) is satisfied.

The basis for defining equation (2) based on Table 2 will be described more specifically.
Here, a good incision is formed by making it as deep as possible within the range where the notch groove inserted using the incision jig does not disappear as described above and surface cracks due to co-up and impact do not occur. The On the other hand, when the cutting depth ratio c of the cutting groove is about 0.2 and shallow, it has been confirmed that crushing along the cutting groove is difficult at the time of crushing, and that a stone material having a desired size cannot be formed.
Further, in order to prevent the cut groove from disappearing, the condensation hardening of the hydraulic material needs to proceed to some extent. In the region where the cone index a1 is less than about 500 kN / m ² , the hydraulic material becomes too soft and the cut groove disappears. Therefore, the region where the cone index a1 is less than about 500 kN / m ² is excluded.

The lower limit value of the cutting index (a1 × c) in equation (2) is based on Table 2. That is, Case No. In 1-7, the cone index a1 was 744 kN / m ² , the cutting index 483.6, the rating was 1, and there was no problem regarding the magnitude of penetration resistance, the disappearance of the cutting groove, and the presence or absence of surface cracks due to coup. Become. Case no. In 1-4, the cone index is 449 kN / m ² , the cutting index is 404.1, and the rating is 0.5, which is problematic. Therefore, the lower limit value of the cutting index in the equation (2) is set to 440, which is a substantially intermediate value between the two. That is, when the cutting index is smaller than 440, the hydraulic material is too soft and the cutting groove disappears.

Next, the basis of the upper limit value of the cutting index (a1 × c) will be described.
In order to form a deep groove (as a target, the cutting depth ratio c is 0.5 or more) without causing surface cracks, it is necessary that the setting hardness of the hydraulic material does not advance excessively. And it has been confirmed that surface cracking is likely to occur because the harder the resistance at the time of jig insertion and the higher the frictional resistance at the time of extraction.
For example, the condition for inserting a good slit at D / H = 0.8 to 0.9 which is substantially equal to the thickness of the stone is about 700 to 1700 kN / m ² in terms of cone index, and about 1700 kN / m ² ( 2) Set to the condition of the upper limit of the equation. In regions harder than this, surface cracks occur in the case of deep grooves, so the only way to form a crack-free groove is to make it shallow. If the cone index is 3000 kN / m ² , D / H = 0.5 to 0.6, and if 4000 kN / m ² , D / H = 0.3 to 0.4 is obtained, which is the upper limit of the formula (2). This is the basis for the value.

Specifically, in Table 2, when the cone index a1 is 1733 kN / m ² as the upper limit, In 1-10, the cutting depth ratio c is 0.8, the cutting index is 1386.4, the score is 1, and there is no problem. On the other hand, Case No. 1-11, the cutting depth ratio c is 0.95, the cutting index is 1646.4, and the score is 0.25, which is problematic. For this reason, the upper limit value of the cutting index in the equation (2) is set to 1520, which is a substantially intermediate value between the two. That is, when the cutting index a1 exceeds 1520, the cone index a1 increases and becomes hard, so that it becomes difficult to form a groove, and the frictional resistance at the time of drawing increases and surface cracking occurs.
As described above, the expression (2) indicating the evaluation of the cutting property (score of the cutting groove) is defined by using the cutting index indicating the relationship between the cone index a1 and the ratio c of the depth D of the cutting groove.

Next, the conditions for forming the cut groove based on the hardness by the Yamanaka type soil hardness meter will be described.
Similar to the above-mentioned cone index, the results of examining the case where the hardness a2 by the Yamanaka type soil hardness tester is used are shown in Table 3 and FIG. In this case, if the expression (3) is satisfied, a good cut groove can be formed.

  The lower limit value of the cutting index (a2 × c) in the equation (3) is based on Table 3. Case No. in Table 3 In 2-4, the Yamanaka soil hardness tester hardness a2 is 639, the cutting depth ratio c is 0.9, the cutting index is 574.7, and the rating is 0.5, which is problematic. Case no. In 2-7, the Yamanaka-type soil hardness meter hardness a2 is 1037, the depth of cut ratio c is 0.65, the depth of cut index is 674, the score is 1, and there is no problem. Therefore, the lower limit value of the cutting index in the equation (3) is set to 630, which is an approximately intermediate value between the two. That is, when the cutting index is smaller than 630, the hydraulic material is too soft and the cutting groove disappears.

Next, the basis of the upper limit value of the cutting index (a2 × c) will be described.
Case No. in Table 3 2-15, the Yamanaka soil hardness tester hardness a2 is 4158, the cutting depth ratio c is 0.4, the cutting index is 1663.1, the score is 1, and there is no problem. Case no. 2-12, the Yamanaka soil hardness tester hardness a2 is 2744, the cutting depth ratio c is 0.65, the cutting index is 1783.6, and the rating is 0.25. Therefore, the upper limit value of the cutting index in the equation (3) is set to 1720, which is an approximately intermediate value between the two. That is, when the cutting index exceeds 1720, the hardness is high and the resistance is increased, so that it is difficult to form a groove, and the frictional resistance at the time of drawing is increased, resulting in surface cracks.

  Here, after forming the cut groove, there is no deviation from the cut line, and in order to suppress the generation of crushed debris and perform high-yield crushing, the strength at the time of crushing should be appropriately set according to the condition of the cut groove. There must be. Therefore, since the crushing resistance at the time of crushing depends on the remaining thickness A obtained by subtracting the depth D of the cut groove from the thickness H of the artificial stone material and the expression strength of the hydraulic material at that time, it is an axis of the hydraulic material after curing. The product (σ × e, the remaining portion in the present invention) of the compressive strength σ and the ratio e (= A / H) of the thickness H of the artificial stone with the remaining thickness A obtained by subtracting the cutting depth D from the thickness H of the artificial stone. Using the strength index as a parameter, friability was evaluated at various strengths and depths of cut grooves. The evaluation of crushability is based on the idea that the crushing operation is efficient and that the crushing loss can be reduced with the desired dimensions, so that the efficiency of the crushing operation, the deviation from the cut line of the crushing surface, and the amount of crushing waste generated Evaluated from the viewpoint. And in each evaluation, when the crushing efficiency is poor, when the deviation degree of the crushing line is large and the desired size cannot be obtained, the score when the crushing waste is 10% or more is 0.5, and the other good condition is 1 0.0, all in good condition (state where the multiplication of the score is 1.0) was examined. The results are shown in Table 4, and the relationship between the remaining part strength index and the overall score is shown in FIG. As a result, since the remaining part strength index σ × e when the score is 1 is 0 to 6.5, good crushing is possible by performing crushing when the equation (1) is satisfied. .

In the formula (1), the lower limit value 0 is for performing good crushing in a state where the strength is small, and is a condition when a deep cut groove is formed. Further, the upper limit value 6.5 is set based on the fact that it has been confirmed that if the strength development progresses to some extent, it is not possible to perform good crushing in a shallow cut groove where the cut depth ratio c is 0.5 or less. ing.
As described above, the equation (1) is defined using the residual portion strength index indicating the relationship between the compressive strength σ and the ratio e between the residual thickness A and the artificial stone material thickness H.

  Specifically, the basis of the lower limit value of the remaining portion strength index σ × e will be described. Case No. 4 in Table 4 In 3-4, the remaining part strength index is 0.6 and the rating is 1, which is no problem. In this case, if it is smaller than 0.6, the depth of cut becomes large and the remaining portion becomes small, so that a crack occurs in the remaining portion. Here, the remaining portion strength index σ × e of 0 indicates a case where a cut groove penetrating the stone thickness is formed. That is, an artificial stone can be produced without any problem even when the lower limit value is smaller than 0.6. In addition, although the target is an artificial stone material having a thickness of 50 to 100 cm, when the thickness exceeds 60 cm, it is difficult to form a cut groove, but in the case of about 50 to 60 cm, a cut groove that penetrates the entire thickness is formed. Can be formed (e = 0 state). If the cut groove penetrates, an artificial stone divided into predetermined dimensions can be obtained with almost no crushing, and the stone can be produced without any problem. Therefore, even in the case of a stone having a thickness exceeding 60 cm, a state in which the cutting depth ratio c is 1.0 (e = 0) is realized even if the thickness is large by devising a jig for inserting a cutting groove. Therefore, the lower limit value of the equation (1) is set to 0.

  Next, the basis of the upper limit value of the remaining portion strength index σ × e will be described. Case No. 4 in Table 4 In 3-11, the remaining portion strength index that gives a problem with a score of 1 has a maximum value of 6.2. Case no. In 3-15, the residual strength index at which the evaluation is problematic is the minimum value of 6.9. Therefore, the upper limit value of the remaining part strength index in the formula (1) is set to 6.5, which is a substantially intermediate value between the two. That is, when the remaining portion strength index exceeds 6.5, the strength development proceeds to some extent, and when the depth of cut depth c becomes a shallow groove with a depth of c of 0.5 or less, the crushing resistance strength of the remaining portion becomes too large. Good crushing is not possible.

Next, the construction procedure and operation of the method for manufacturing the artificial stone material 1 described above will be described with reference to FIGS.
First, as shown in FIG. 10, an outer frame block 2 having a height equal to or greater than the thickness of the artificial stone material 1 and enclosed in a rectangular shape in a top view is installed in a flat site.

  Next, as shown in FIGS. 11 (a) and 11 (b), the outer frame block 2 is filled and molded with the hydraulic material C blended in the slump of 5 to 12 cm so as to have the thickness H of the artificial stone. To do. Then, as shown in FIG. 11 (c), the depth of cut set in consideration of crushing efficiency while measuring the surface hardness a of the hydraulic material C during filling into the outer frame block 2 or after completion of filling. When the cutting index a × c (c = D / H) considering D is reached, the cutting tool 3 (horizontal plate) partitioned into a desired plane dimension of the artificial stone material 1 downward from the upper surface of the placement surface 31, the vertical plate 32) is formed using the heavy machine 30 to form a cut groove K having a depth D.

  Thereafter, as shown in FIG. 5, the residual thickness index (e = σ × A / H) obtained from the residual thickness A obtained by subtracting the cutting depth D from the thickness H of the artificial stone 1 and the uniaxial compressive strength σ (e = σ × A / H) described above ( When the expression 1) is satisfied, the material is crushed along a cut line (cut groove K) formed in the artificial stone 1 using a crusher equipped with a hydraulic breaker (not shown). That is, by inserting the chisel of the hydraulic breaker into the cut groove K, the remaining thickness A portion where the artificial stone materials 1 are continuously provided can be broken and separated. In particular, it becomes easy to fix the tip position of the concrete breaker at the position where the cut grooves K intersect.

  Thus, when manufacturing the artificial stone material 1 having a thickness of more than 50 cm and not more than 100 cm, the hydraulic material C prepared in the slump of 5 to 12 cm is placed, and the depth D of the surface hardness of the hydraulic material C is desired. A notch groove K having a depth of cut D is formed when the surface hardness is within the range of the notch index, and then the notch line is reached when the uniaxial compressive strength is equal to or greater than the strength satisfying the above-described formula (1). The artificial stone material 1 can be manufactured in a large amount and efficiently by crushing along.

In this case, since the cutting tool 3 for inserting the cutting groove K does not need to be a dedicated one, it is possible to easily cope with the artificial stone material 1 having an arbitrary thickness of more than 50 cm and not more than 100 cm.
In addition, since the artificial stone material 1 produced has a crushing surface and a textured surface that is easy for seaweeds to settle, it is suitable as an algal reef substrate, and the artificial stone material 1 for alga reef is efficiently produced in large quantities. Can be manufactured.

  Moreover, in this Embodiment, the artificial stone material 1 which used the steel slag as a material can be manufactured, manufacturing efficiency can be improved using the steel slag which may arise in a steel mill, and manufacturing cost can be reduced. Reduction can be achieved.

  In the manufacturing method of the large-sized artificial stone material by this Embodiment mentioned above, the residual thickness A which deducted the cutting depth D from the thickness H of the artificial stone material 1, and the intensity | strength of the hydraulic material C at the time of crushing are suitable conditions for crushing By setting to, it is possible to prevent the hydraulic material C that has been cast when the cut groove K is formed from rising together, and it is possible to manufacture the high-precision artificial stone material 1 in a large amount and efficiently.

  Next, examples carried out to support the effects of the method for producing a large artificial stone material according to the above-described embodiment will be described below.

(Example)
In this example, as shown in Table 5, 30 cases of test production were performed for each production pattern. In the test, the surface hardness was measured by a cone index with a cone pertonometer, and the depth of cut was changed for each cone index, and the depth of cut was first evaluated. The depth of cut is the ratio of the depth of cut to the total thickness (D / H), 0.1-0.2, 0.3-0.5, 0.6-0.8, 0.9-1 It was performed at 4 levels of 0.0.

  And about the case where there was no problem in cutting operation, it crushed according to the expression degree of uniaxial compressive strength, and evaluated crushability.

  The evaluation method was “X” when there was any problem in the cutting operation, and “◯” when there was no problem. If good cutting grooves could not be formed, good crushing could not be performed, so crushing work was not performed. Also, in crushing operations, “×” indicates that the crushing efficiency is inferior, “○” indicates that there is no problem with efficiency, and crushing shapes and waste generation are reflected in the product yield as a result. From the above, the case where the yield was 80% or less was evaluated as “×”, the case where the yield was 80 to 90% was evaluated as “Δ”, and the yield was evaluated as “◯” when the yield was 90% or more.

As shown in Table 5, in the result of the cutting test, when the cutting index is within the range of the present invention (440 ≦ (a1 × c) ≦ 1520), a good cutting groove can be formed. In addition, even when the cutting index was outside the range of the present invention, no problem cutting work could be performed when the cutting depth was relatively shallow (test cases 5 to 10).
On the other hand, for the crushing work, if the residual strength index was within the range of the present invention (0 ≦ (σ × e) ≦ 6.5), a good crushing work with a yield of 90% or more could be performed. On the other hand, when the residual strength index is outside the range of the present invention, there are problems in terms of crushing efficiency, yield, etc., and good crushing work could not be performed.

  As mentioned above, although embodiment of the manufacturing method of the large sized artificial stone material by this invention was described, this invention is not limited to said embodiment, In the range which does not deviate from the meaning, it can change suitably.

  For example, in the above-described embodiment, a stone block is adopted as the outer frame block 2, but a plate-shaped mold may be used.

  Further, the hydraulic material forming the artificial stone 1 is not limited to the hydraulic material C using steel slag, and may be ordinary concrete using general aggregate. .

  In addition, it is possible to appropriately replace the components in the above-described embodiments with known components without departing from the spirit of the present invention.

1 Artificial stone 2 Outer frame block (peripheral formwork)
3 Cutting equipment 31 Horizontal plate (partition plate)
32 Vertical plate (partition plate)
A Remaining thickness C Hydraulic material D Depth of cut H Thickness of artificial stone K Cut groove

Claims (5)

A method for manufacturing an artificial stone material having a thickness of more than 50 cm and not more than 100 cm manufactured using a hydraulic material,
A step of installing an outer periphery formwork that has a height equal to or greater than the thickness of the artificial stone material in the plane site and surrounds in a rectangular shape in a top view;
Filling and molding a hydraulic material having a slump value of more than 5 cm and not more than 12 cm inside the outer periphery mold,
The product of the surface hardness a of the hydraulic material during filling into the outer periphery formwork or after completion of filling and the ratio c (= D / H) of the artificial stone thickness H of the cutting depth D to be formed ( Using the cutting index indicated by a × c) as a management index, a partition plate partitioned into a desired plane dimension of the artificial stone material is used to place the cutting surface of the artificial stone using a heavy machine so that the cutting index is within a certain range. Forming a cutting groove having a cutting depth D by penetrating downward from the upper surface;
A ratio e (= A / H) between the uniaxial compressive strength σ of the hydrated cured body after curing and the artificial stone thickness H of the remaining thickness A obtained by subtracting the cutting depth D from the artificial stone thickness H. Step of crushing along the cut groove formed in the artificial stone using a crusher when the remaining portion strength index indicated by the product (σ × e) reaches the strength satisfying the expression (1) When,
A method for producing a large artificial stone characterized by comprising:

The surface hardness a of the hydraulic material is measured by a cone index a1 using a cone penetrometer, and the depth of cut is represented by the product (a1 × c) of the ratio c of the depth of cut D and the artificial stone thickness H (= D / H). 2. The method for producing a large artificial stone material according to claim 1, wherein the index is expressed by equation (2).

The surface hardness a of the hydraulic material is measured with a hardness a2 by a Yamanaka soil hardness tester, and the depth of cut (D2) is expressed by the product (a2 × c) of the ratio c (= D / H) of the depth of the artificial stone. 2. The method for producing a large artificial stone material according to claim 1, wherein the index is represented by equation (3).

The volume ratio of the hydraulic material is
Steelmaking slag is a mixture of 64 to 71 vol%, cement, blast furnace cement, total amount of blast furnace slag fine powder is 9 to 12 vol%, water is 15 to 18 vol%, and air amount is 4 to 6 vol%. The manufacturing method of the large sized artificial stone material of any one of 1-3. The volume ratio of the hydraulic material is
The total amount of steelmaking slag and granulated blast furnace slag is 66 to 69 vol%, the total amount of cement, blast furnace cement and blast furnace slag fine powder is 10 to 12 vol%, water is 15 to 18 vol%, and the amount of air is 4 to 6 vol%. The method for producing a large artificial stone material according to any one of claims 1 to 3, wherein the method is provided.

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