JP2597253B2 - Method of manufacturing concrete member with decorative body and joint forming member - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to various types of concrete members having a large number of decorative bodies provided on the surface of a concrete base material, for example, architectural panels (curtain walls, relief panels, floor panels, etc.), Manufacturing method of soundproofing panel, wall panel, gate post, retaining wall block, seawall block, retaining block or panel, bridge main pole, gutter cover, community waterway, sidewalk board, walkway block, flowerbed block, etc. and The present invention relates to a joint forming member used in the method.

[0002]

2. Description of the Related Art Conventionally, a method of attaching decorative objects such as tiles one by one to a base mortar has been widely known. However, according to this on-site method, a scaffold is required and construction efficiency is extremely poor. Due to the problem, in recent years, a unit construction method has been adopted in which a concrete panel with a decorative body is manufactured in a factory, carried into a construction site, and assembled to an outer wall. According to this unit construction method, there is an advantage that the quality of the concrete panel with the decorative body can be stabilized, the durability is good, and the construction period can be shortened because of the factory production.

In a conventional method of manufacturing a concrete panel with a decorative body, a formwork is first assembled on a surface plate, and for example, a number of tiles are arranged inside the formwork as decorative bodies with their surfaces face down. A foamed resin tape as a joint forming member is packed between the side surfaces of the tiles so as to be in contact with each other. In the case where a unitized tile is used by attaching an adhesive film to the surface of a large number of tiles and packing the foamed resin tape between the side surfaces of each tile so as to be in contact with each other, the unitized tile is placed on a platen. Lie down on Subsequently, concrete is poured into the space on the back side of the tile and foam resin tape,
After the concrete is solidified, the tiled concrete panel is released, and the foamed resin tape is removed.

However, the side surface of the tile and the side surface of the foamed resin tape are not completely in contact with each other, and small gaps are formed in some places, so that the mortar and cement paste in the concrete seep out from the small gaps. Often adhere to the tile surface and become dirty. Since the dirt cannot be easily removed, it takes a lot of trouble to clean the dirt.

Therefore, a joint forming member as disclosed in Japanese Patent Application Laid-Open No. 58-98568 has been developed. As shown in FIG. 9, the joint forming member is made of a foamed resin layer 36 and water-swellable paper 37 having water swelling property. The water-soluble paper 37 is swelled as shown by a chain line in FIG. 9 by watering or the like before the concrete is poured, so that the water-soluble paper 37 is between the side surface 35 a of the joint forming member 35 and the side surface 1 a of the tile 1. To prevent the mortar and cement paste from seeping out. Note that, in FIG. 9, the small gap is shown as being enlarged more than usual. Here, in general, joints are often formed in columns and rows like so-called potato joints or slightly-blind joints. Therefore, as shown in FIG.
The joints described above are formed by dividing the joint forming member 35 into bar materials for columns and rows and arranging these and the tiles 1 alternately and sequentially. However, it is more advantageous to use a joint forming member formed in a frame shape in which the vertical and horizontal rows are integrated because labor saving in the cutting step and the arrangement step can be achieved. For this reason, as shown in FIG. 11, a separate water-swellable water-soluble paper 37 cut into strips is formed on the side surface of the foamed resin layer 36 in the shape of a girder frame punched by a press or the like.
Was considered to be attached.

[0006]

However, sticking the water-swellable water-soluble paper 37 to the side surface of the foamed resin layer 36 one by one is a very time-consuming operation, so that this type of joint forming member 38 is required. Was formed in a frame shape and was not manufactured for profit.

The water-soluble paper 37 formed on the side surface 35a of the joint forming member 35 also swells in the direction perpendicular to the joint surface as shown by a chain line in FIG. As a result, concrete is poured in this state, and as a result, corners 18
However, there is a risk that the joint shape will be lost and a beautiful joint shape will be lost.

[0008] It is an object of the present invention to prevent the mortar and cement paste in concrete from adhering to the surface of the decorative body, thereby simplifying the cleaning work at the time of finishing and reducing the corners of the joint. An object of the present invention is to provide a method of manufacturing a concrete member with a decorative body that is not cleaved and a joint forming member that can easily manufacture a frame-shaped joint forming member.

[0009]

In order to achieve the above object, a method for manufacturing a concrete member with a decorative body according to the present invention is characterized in that a plurality of decorative bodies are brought into close contact with a mold surface, and A joint forming member composed of a joint forming layer and a water swellable layer formed on the surface is arranged on the mold surface in a state in which the side surfaces are separated from each other. A step of disposing between the side surfaces of the decorative body in a state where the side surface of the joint forming member is in close contact with the side surface of the decorative body, and swelling the water swellable layer by spraying water on the joint forming member. Filling the small gap generated between the side surface of the decorative body and the joint forming member, casting concrete in the back side space of the decorative body and the joint forming layer, and after the concrete is solidified, The decorative body and concrete are integrated Was released decorative member with concrete member Tsu, it was configured to include a step of removing the joint member.

According to a second aspect of the present invention, in the joint forming member, the joint forming member is disposed between the side surfaces of the plurality of decorative bodies, and the joint forming layer is disposed such that the side surfaces contact the side surfaces of the decorative body. And a water-swellable layer formed on the surface of the joint forming layer.

Here, the "decorative body" can be provided on the surface of the concrete member, and its material, dimensions and shape are not limited as long as at least the edge of the surface is flat. Examples of the material include tiles (rough tiles, smooth tiles, etc.), natural stones (rock, sandstone, marble, granite, etc.), artificial stones, ceramic plate reliefs, and the like. In addition, examples of the surface shape include a shape in which the entire surface is flat, and a shape in which the central portion of the surface is concave. The “mold surface” refers to a molding surface of a mold that varies depending on the type, size, shape, etc. of the concrete member to be manufactured. Further, "the surface is in close contact with the mold surface", the case where the surface of the decorative body or the water-swellable layer directly adheres to the mold surface,
This includes both the case of indirectly contacting through a sheet and the like.

As the "joint forming layer", for example, a foamed polyurethane, a foamed polyethylene, a foamed polystyrene or the like formed in a frame shape or a tape shape can be mentioned. Examples of the “water-swellable layer” include polyacrylate, polyacrylic acid-polyvinyl alcohol copolymer, starch-polyacrylic acid, isobutylene-maleic anhydride, polyvinyl alcohol, and polyacrylamide. Using a water-swellable resin such as, a liquid water-swellable resin impregnated in paper or nonwoven fabric, or a powdery water-swellable resin sandwiched between paper or nonwoven fabric or attached to the surface (The paper or nonwoven fabric is bonded to the joint forming layer with an adhesive), powdered water-swellable resin is directly bonded to the joint forming layer with an adhesive, liquid water-swellable resin Can be directly spray-bonded to the joint forming layer. Among water swellable resins, isobutylene-maleic anhydride-based product name “KI gel” (manufactured by Kuraray Co., Ltd.) is suitable for the present invention in terms of particle size, water absorption capacity, water absorption speed, and the like. In particular, the product name “KI Gel-201K-F2” is desirable.

The ratio of the water-swellable resin contained in the paper or nonwoven fabric is generally 5 to 120 g / m ² , preferably ^{2 to} 120 g / m ² .
It is 0 to 80 g / m ² , and is adjusted according to the roughness of the surface and side surfaces of the decorative body. If the amount of the water-swellable resin is too small, the swelling becomes small and the small gap generated on the side of the decorative body and the side of the joint forming member cannot be filled. Conversely, if the amount is too large, the joint forming layer is pushed up more than necessary. This is because it is not possible to form a regular eye ground. Examples of the adhesive for bonding the “joint forming layer” and the “water swellable layer” include an organic solvent type adhesive such as an acrylic type, ethylene vinyl acetate type, and rubber type containing no water, and a starch type adhesive. And a pressure-sensitive adhesive such as a polyvinyl alcohol-based adhesive or a commercially available double-sided tape.

[0014]

According to the method of manufacturing a concrete member with a decorative body according to the first aspect, in the step of watering the joint forming member,
The water-swellable layer mainly swells so as to increase its thickness on the surface side, but its edge swells so as to protrude to the side surface of the joint forming member, so that the edge between the decorative body and the joint forming member side surface. To fill the small gaps that occur. Further, in the next concrete placing step, the water-swellable layer swollen in the thickness direction is also pressed by the weight of the concrete and protrudes to the side surface of the joint forming member. Therefore, between the side surface of the decorative body and the side surface of the joint forming member, the protruding water-swellable layer reliably seals in the vicinity of those surfaces. Prevents oozing on the surface of the decoration. Further, since this water swellable layer is formed on the surface of the joint forming layer, the protruding water swellable layer does not reach the back surface of the joint forming layer, and the corner of the joint of the concrete member to be formed. Do not go around.

According to the joint forming member of the second aspect, it is extremely easy to form the joint in a frame shape. That is, a frame-shaped joint-forming member can be easily manufactured by punching a joint-formed layer and a water-swellable layer into an integrated plate-like body by pressing or the like.

[0016]

DESCRIPTION OF THE PREFERRED EMBODIMENTS An embodiment in which the present invention is embodied in a concrete panel for an outer wall provided with tiles as a decorative body will be described below with reference to FIGS. In this embodiment, the tile 1 is employed as a decorative body, and the tile 1 is used as a unit by being attached to the resin film 4 together with the joint forming member 5. Therefore, these members will be described first.

The tile 1 is a smooth tile whose entire surface is formed in a flat rectangular plate shape and whose surface becomes smooth.
Moreover, a radius is formed on the surface edge. On the back surface of the tile 1, a concrete connecting groove 2 having three stripes and a groove shape is formed.

The joint forming member 5 includes a joint forming layer 6.
And a water-swellable layer 7 formed on the surface (the lower surface in FIG. 1) of the joint forming layer 6. In the present embodiment, as a joint forming member 5, a water swellable layer 7 made of a paper sheet impregnated with a water swellable resin at 60 g / m ^{2 is} used as an acrylic type joint. What was stuck with the adhesive of the above was used. This joint forming member 5
Are arranged between the two tiles 1 as shown in FIG.

In order to manufacture the joint forming member 5, first, as shown in FIG. 2, a paper sheet 9 containing a water-swellable resin is superimposed on a plate-like foamed polyurethane 8 and bonded with an adhesive. An integrated plate 10 is formed. Subsequently, as shown in FIG. 3, after the adhesive of the plate-like body 10 is dried, the adhesive is dried and punched out with a press or the like to form a joint frame-shaped joint forming member 5 including a joint forming layer 6 and a water-swellable layer 7. I do. By such a method, the girder frame-shaped joint forming member 5 can be easily manufactured.

In order to form the tile unit 12 in which the tile 1, the joint forming member 5 and the resin film 4 coated with the adhesive only on one side are unitized, a resin film having the adhesive coated side facing upward is formed. The surface of the water-swellable layer 7 of the joint forming member 5 is stuck on the joint 4. In this embodiment, a film made of vinyl chloride was used as the resin film 4. Subsequently, a plurality of the tiles 1 are arranged between the frames of the joint forming member 5 with their surfaces 1b facing down. At this time, as shown in FIG. 1, the surface 1b of each tile 1 adheres to the resin film 4 by the adhesive. Also,
The side surfaces 1a of the tiles 1 are separated from each other with the joint forming member 5 therebetween, and the side surface 1a of the tile 1 is in contact with the side surface 5a of the joint forming member 5. Note that, in FIG. 1, the small gap is shown in an enlarged manner than usual, and thus this contact state is not shown. By the unitization, the arrangement on the mold surface 3 in the next step can be facilitated.

Next, a method for manufacturing the concrete panel 11 for an outer wall with a tile using the tile unit 12 will be described. (1) The tile unit 12 is placed flat in the concrete panel forming apparatus 13. This molding device 13
As shown in FIG. 5, it is composed of a surface plate 14 and a mold 15. The platen 14 is formed with a larger area than the concrete panel 11 formed by a metal plate, and its upper surface as the mold surface 3 is horizontal. Formwork 15 is the surface plate 1
Four mold steel members are assembled on the base plate 4 so as to be disassembled by bolts (not shown), and constitute a molding space having the same shape as the concrete panel 11. Note that a seal member 20 made of rubber or the like is interposed between the surface plate 14 and the mold 15. On the other hand, since the tile units 12 are arranged flat on the mold surface 3, the surfaces 1 b of the plurality of tiles 1 are
Is closely adhered through the resin film 4. Those tiles 1
Are unitized, so that the side surfaces 1a of the tiles 1 are arranged on the mold surface 3 while being separated from each other. Since the joint forming member 5 is also unitized with the tile 1, the surface of the water-swellable layer 7 is in close contact with the mold surface 3 via the resin film 4, and the side surface 5a of the joint forming member 5 The tile 1 is disposed between the side surfaces 1a of the tile 1 in contact with the side surface 1a. Subsequently, the tile unit 12
After the arrangement, the reinforcing bars 19 are arranged in the molding device 13 by a support member (not shown).

(2) Next, water is sprayed on the joint forming member 5. The water-swellable layer 7 swells to increase its thickness mainly on the surface side due to the sprinkled water, but its edge swells to protrude to the side surface 5a side of the joint forming member 5;
As shown by a two-dot chain line in FIG.
a and a small gap generated between the joint forming member 5 and the side surface 5a.

(3) Next, concrete 16 is poured into the space on the back side of the tile 1 and the joint forming member 5. Then, the water swellable layer 7 swelled in the thickness direction is pressed by the weight of the concrete 16 and the side surface 5 of the joint forming member 5 is pressed.
Protrude to a side. Therefore, between the side surface 1a of the tile 1 and the side surface 5a of the joint forming member 5, the protruding water-swellable layer 7 is reliably sealed in the vicinity of those surfaces. The components and cement paste components are prevented from seeping out to the surface 1b of the tile 1. Further, since the water swellable layer 7 is formed on the surface of the joint forming layer 6, the protruding water swellable layer 7 does not reach the back surface of the joint forming layer 6, and the concrete panel 11 to be formed is formed. Eyes ground 17
Corner 18 is not excreted.

(4) Next, after the concrete 16 has solidified, as shown in FIG. 6, the concrete panel 11 for an outer wall with a tile, in which the tile 1, concrete 16 and reinforcing bar 19 are integrated, is released. Then, the joint forming member 5 is removed. Thereafter, the cleaning operation and removal of excess concrete 16 attached to the tiles 1 and joint surface 17. In this case, since the excess concrete 16 does not adhere to the surface 1b of the tile 1, the finishing cleaning work can be simplified.

The present invention is not limited to the configuration of the above-described embodiment, and may be embodied by arbitrarily changing it without departing from the spirit of the present invention as follows. (1) The decorative body is not limited to a square-plate-shaped tile, and for example, a disk-shaped natural stone or a triangular-plate-shaped artificial stone is also used. Therefore, the joint forming member is not limited to the cross-girder frame shape, and may be a frame-shaped joint forming member 28 formed by punching a circular hole 26, a triangular hole 27, and other various holes as shown in FIG. (2) As shown in FIG. 8, the joint forming member 25 may be formed by joining a plurality of bar members, L-shaped, T-shaped or cross-shaped joint forming members 25 in a cross-girder frame shape. (3) The resin film is not essential. In the case of a decorative body having a flat surface and a large weight, the mold surface of the surface plate and the surface of the decorative body are in close contact with each other, so that the resin film can be omitted. (4) The procedure of unitizing the tile, joint forming member and resin film and then arranging them on the mold surface is not essential, and each of the non-unitized units may be arranged on the mold surface.

[0026]

According to the method for manufacturing a concrete member with a decorative body according to the first aspect of the present invention, since the mortar component and the cement paste component of the concrete are prevented from adhering to the surface of the decorative component. not only simplifies the cleaning of the finish, an excellent effect that it is nor Egureru corners of joint surface.

Further, the joint forming member according to the second aspect has an excellent effect that a frame-shaped joint forming member can be easily manufactured.

[Brief description of the drawings]

FIG. 1 is a sectional view showing an embodiment in which the present invention is embodied in a method for manufacturing a concrete panel for an outer wall with a tile, and showing an enlarged main part of FIG. 5;

FIG. 2 is a perspective view showing a state before a joint forming member used in the manufacturing method is processed into a frame shape.

FIG. 3 is a perspective view showing a state where the joint forming member is processed into a frame shape.

FIG. 4 is a perspective view showing a tile unit in which a joint forming member and a tile are arranged on a resin film.

FIG. 5 is a cross-sectional view showing a process in which a tile unit is arranged in a concrete panel forming apparatus and concrete is cast in the same manufacturing method.

FIG. 6 is a perspective view of a concrete panel for an outer wall with a tile manufactured by the same manufacturing method.

FIG. 7 is a perspective view showing another example of the joint forming member.

FIG. 8 is a perspective view showing another example of the joint forming member.

FIG. 9 is a cross-sectional view showing a use state of a joint forming member of a conventional example.

FIG. 10 is a perspective view showing a joint forming member of a conventional example.

FIG. 11 is a perspective view showing another conventional joint forming member.

[Explanation of symbols]

Reference Signs List 1 tile 1a side surface 1b surface 3 mold surface 5 joint forming member 5a side surface 6 joint forming layer 7 water swellable layer 11 concrete panel for tiled outer wall 16 concrete 25 joint forming member 28 joint forming member

Claims (2)

(57) [Claims] 1. A method of manufacturing a plurality of decorative bodies in a state where their surfaces are in close contact with a mold surface and their side surfaces are separated from each other.
While being arranged on the mold surface, a joint forming member consisting of a joint forming layer and a water swellable layer formed on the surface thereof is formed by bringing the surface of the water swellable layer into close contact with the mold surface and the side surface of the joint forming member Disposing between the side surfaces of the decorative body in a state of being in contact with the side surfaces of the decorative body; and spraying water on the joint forming member to swell the water-swellable layer, thereby forming the side surface of the decorative body and the side surface of the joint forming member. Filling the small gap generated between the above and the step of casting concrete in the space on the back side of the decorative body and the joint forming layer; and after the concrete has solidified, the decorative body and the concrete have been integrated. Releasing the concrete member with a decorative body, and removing the joint forming member. 2. A joint forming member arranged between the side surfaces of a plurality of decorative bodies, wherein the joint forming layer is arranged such that the side surfaces are in contact with the side surfaces of the decorative body, and the joint forming member is formed on the surface of the joint forming layer. And a water-swellable layer formed thereon.