JP2730875B2 - Manufacturing method of glazed cement products - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for producing a glazed cement product, and more particularly, to a cement product such as a concrete panel used for an interior or exterior surface of a building, the surface of which is made of glass. The present invention relates to a method for producing a glazed cement product having a glaze surface.

[0002]

2. Description of the Related Art A glazed cement product is formed by forming a vitreous glaze such as a ceramic surface on the surface of a cement product such as a concrete panel, and is much more beautiful and smooth than a conventional cement product. It has a nice appearance. In addition, it has an advantage that it is hard to be stained and is hardly scratched, and is used as an interior finishing surface or an exterior finishing surface of various buildings.

In order to manufacture a glazed cement product, first,
Ordinary Portland cement is mixed with aggregates such as sand, water and other materials, formed into a predetermined shape by a mold, and then demolded to produce a semi-dry cement molding. A glaze as used in the manufacture of ceramics or the like is applied to the surface (bottom side of the mold) of the cement molding. This work is called glaze. As a specific operation of glazing, a glaze in a predetermined thickness is formed by applying a liquid glaze to the surface of the cement molding using a spray gun or a roll used for painting or the like. After firing the cement molded body on which the glaze layer is formed, the cement molded product is cured and cured, whereby the glazed cement product having the above-mentioned glassy glaze surface is obtained.

[0004]

The glazed cement product manufactured by such a method can transfer an arbitrary pattern to the glaze surface by forming various patterns on the bottom surface of the mold, thereby further improving the design. be able to. However, when curing is carried out with a mold, if the curing time is long, water will move to the bottom of the mold and hydrate and harden. It is taken in and the moisture on the surface layer of the cement molded body on the glaze application side becomes excessive. When a glaze is applied to the surface of the cement molded body in such a state and fired, excess water (bound water) on the surface layer evaporates, thereby deteriorating the adhesion between the glaze and the surface of the cement molded body. A malfunction occurs.

Accordingly, an object of the present invention is to provide a method for producing a glazed cement having excellent quality performance by suppressing the occurrence of glaze defects such as baldness in the above-mentioned method for producing a glazed cement product. is there.

[0006]

According to a first aspect of the present invention, there is provided a method of manufacturing a glazed cement product, comprising the steps of: mixing a cement material obtained by kneading cement, aggregate, and water; After molding and semi-curing with a mold having a mold surface, the cement molded product is removed from the mold, a glaze layer is formed on the mold surface side of the cement molded product, and a cement molded product having this glaze layer Baking to form a glaze layer into a glaze finish layer, and then curing and curing the cement molded product having the glaze finish layer to produce a glazed cement product having a glaze surface, at least in contact with the mold surface At least a part of the cement used for the cement material is made of a high-strength cement (including a super-high-strength cement).

[0007] The method for producing a glazed cement product according to claim 2 is characterized in that, in the production method according to claim 1, cement used for all cement materials is made of high-strength cement (including ultra-high-strength cement). I do. According to a third aspect of the present invention, there is provided the method for manufacturing a glazed cement product, wherein the cement used for the cement material in contact with the mold surface is made of a high-strength cement (including a super-high-strength cement). Features.

According to a fourth aspect of the present invention, there is provided a method for manufacturing a glazed cement product according to the first aspect, wherein the cement used for all cement materials is a mixture of an early-strength cement (including an ultra-high-strength cement) and an ordinary cement. It is characterized by comprising a mixed cement. The method for producing a glazed cement product according to claim 5 is the method according to claim 4,
Ordinary cement is characterized in that it is mixed to account for 5 to 95% by weight of the mixed cement.

A method of manufacturing a glazed cement product according to claim 6 is characterized in that a cement material obtained by kneading cement, aggregate and water is semi-cured in a mold having a bottom surface as a mold surface and then molded. After demolding the cement molded product from the mold, forming a glaze layer on the mold side of the cement molded product, firing the cement molded product having the glaze layer to form a glaze layer into a glaze finished layer, A method for producing a glazed cement product having a glaze surface by curing and curing a cement molded product having a glaze finish layer, wherein warm water is used as water.

[0010] A method of manufacturing a glazed cement product according to claim 7 is characterized in that, in the manufacturing method of claim 6, at least one of the aggregate and the mold is heated.
The method for producing a glazed cement product according to claim 8, wherein the cement material obtained by kneading cement, aggregate, and water is semi-cured in a mold having a bottom surface as a mold surface, and then molded. From the cement molded product, form a glaze layer on the mold surface side of this cement molded product, bake the cement molded product with this glaze layer to form a glaze layer into a glaze finished layer, A method of manufacturing a glazed cement product with a glaze surface by curing and curing a cement molded product having a layer, characterized by forming a glaze layer on the mold surface by removing only the bottom side of the mold. And

[0011]

In the method for producing a glazed cement product according to the first aspect, at least one cement material in contact with a mold surface is obtained when kneading an aggregate and water with cement to obtain a cement material such as mortar or concrete. Use cement whose part is made of high strength cement (including ultra high strength cement).
After curing and molding the obtained cement material in a mold, the cement molded product is removed from the mold, a glaze layer is formed on the mold contact surface of the cement molded product, and the glaze layer is fired. After forming a glaze finish layer, the cement molded product is hydrated and cured to produce a glazed cement product having a glaze surface.
Here, at least a part of the cement used for the cement material in contact with the mold surface is an early-strength cement (including ultra-high-strength cement). The mold can be demolded before the water moves excessively to the mold surface. For this reason, it is possible to prevent the generation of excessive bound water on the mold surface (glaze-coated surface) side,
The occurrence of glaze defects such as glaze baldness can be suppressed, and a glazed cement excellent in quality performance can be obtained.

In the method for manufacturing a glazed cement product according to the second aspect, since the cement used for all cement materials is a high-strength cement (including an ultra-high-strength cement), the entire curing time is further reduced, and the glaze baldness is reduced. The occurrence of glaze defects can be suppressed, and a glazed cement with excellent quality performance can be obtained. In the method for producing a glazed cement product according to claim 3,
Since the cement used for the cement material in contact with the mold surface is a high-strength cement (including ultra-high-strength cement), the curing time on the mold surface is reduced, and the occurrence of glaze defects such as glaze baldness can be suppressed. A glazed cement with excellent performance can be obtained.

[0013] In the method for producing a glazed cement product according to claim 4, since the cement used for all cement materials is a mixed cement obtained by mixing an early-strength cement (including an ultra-high-strength cement) and an ordinary cement, it is inexpensive. Curing time can be shortened by using ordinary cement, and glazed cement with excellent quality performance can be obtained at low cost. In the method for producing a glazed cement product according to claim 5, the ordinary cement is made of mixed cement.
Since it is mixed so as to occupy about 95% by weight, it is possible to suppress the occurrence of glaze defects such as glaze baldness and the like under optimal conditions according to the atmosphere by adjusting the amount of ordinary cement.

In the method for producing a glazed cement product according to the sixth aspect, since hot water having a temperature higher than room temperature is used as the water, the curing time can be shortened, the generation of excessive combined water can be prevented, and glaze baldness and the like can be prevented. The occurrence of glaze defects can be suppressed.
In the method for manufacturing a glazed cement product according to claim 7, since at least one of the aggregate and the mold is heated, the curing time is further reduced, and the generation of excessive bound water can be prevented, and the glaze baldness and the like can be prevented. The occurrence of glaze defects can be suppressed.

In the method for manufacturing a glazed cement product according to claim 8, since only the bottom side of the mold is removed from the mold to form the glaze layer on the mold, the glaze can be removed before the entire mold can be removed. It can be applied and can prevent the generation of excessive bound water on the surface layer, and can suppress the occurrence of glaze defects such as glaze baldness.

[0016]

Embodiments of the present invention will be described below with reference to the drawings. Embodiment 1 FIG. 1 is a flowchart showing the manufacturing process of one embodiment of the method for manufacturing a glazed cement product according to the present invention.

In FIG. 1, a glazed cement panel, which is a glazed cement product, comprises a step of kneading cement, aggregate, and water to obtain a cement material, a step of pouring the cement material into a mold, and a step of Semi-curing, drying the cement molded body after demolding, glazing the surface of the cement molded body, firing the glazed cement molded body, and rehydrating and curing the cooled cement molded body. It consists of processes. In the kneading step, it is a feature of the first embodiment of the present invention that the curing time in the semi-curing step is shortened by using early-strength Portland cement or ultra-high-strength Portland cement as cement.

Hereinafter, a method for manufacturing the glazed cement panel of Example 1 will be described in the order of steps. First, a high-strength Portland cement or an ultra-high-strength Portland cement, an aggregate, water, and a high-performance water reducing agent are put into a mixer and kneaded well to produce a cement material such as mortar or concrete. As the aggregate, shale-based aggregates, magnetic chamotte, minestones and the like which are usually used may be used. In addition, an appropriate admixture or admixture may be used according to the properties such as strength and water resistance required for the glazed cement panel. When reinforcing the glazed cement panel, a reinforcing material such as a reinforcing bar or a net may be buried in the mold in advance.

Subsequently, the obtained cement material is cast into a mold. After casting in a mold, curing conditions are controlled and curing is carried out for a predetermined time and a half. The curing time is preferably 4 to 12 hours in the case of high-strength cement and 2 to 6 hours in the case of ultra-high-strength cement in consideration of the water transfer time and productivity. This curing can be performed by warm air curing, natural curing, infrared heating curing, high frequency heating curing, or the like.

After the curing, the mold is removed and the cement is taken out.
The molded body is pre-dried with a hot-air circulation dryer, etc.
State. The drying temperature and drying time depend on the cement
Although it varies depending on the thickness, etc.,
3-5 hours is a guide. After drying, the cement molding
Glaze such as raw glaze, boric acid frit glaze, leaded glaze on the surface
Apply. The amount of glaze applied is not particularly limited, but generally
0.3-2kg / m ^TwoBrush coating, spray coating
It is glazed by sink coating.

The cement molded body after the glaze is fired in a firing furnace such as a roller hearth kiln. The firing conditions vary depending on the type of glaze, etc.
Firing is performed for about an hour. The calcined cement molded body is immersed in water for about 30 to 60 minutes to rehydrate, then cured at 50 to 60 ° C. and 90 to 98% RH for about 3 days. The panel 10 is manufactured. The glazed cement panel 10 includes a cement molding 12 and a glaze surface 11 formed on the surface of the cement molding 12.
And

Next, a specific embodiment of the first embodiment of the present invention will be described. Table 1 shows the mixing ratio of the three types of cement materials. Here, 30.5% by weight of cement, 36.7% of foamed shale-based aggregate having a small particle diameter, and 32.8% of foamed shale-based aggregate having a large particle diameter were blended. As the cement, ordinary Portland cement was used as a comparative example, and early-strength Portland cement and ultra-high-strength Portland cement were used as examples. A high-performance water reducing agent was further added to these cement materials at 2% by weight based on the cement, and 50% by weight of water was added to the cement (W / C ratio: 50) and kneaded well with a mixer.

[0023]

[Table 1]

The thus obtained three types of cement materials of the comparative example and the two examples were mixed with 300 width × 300 length ×
The mixture was poured into a mold having a depth of 30 and semi-cured at a curing temperature and a curing time shown in Table 2, and was demolded to prepare a cement molded body.

[0025]

[Table 2]

The obtained cement molded body was dried at 300 ° C. for 5 hours, glazed with a boric acid frit glaze, and fired at 850 ° C. for about 1 hour. After baking, it was cooled, immersed in water for 30 minutes to perform rehydration treatment, and cured at 60 ° C. and 98% RH for 3 days to produce a glazed cement panel. As a result, as shown in Table 3, in the case of semi-curing at a normal temperature of 20 ° C., in the case of ordinary Portland cement as a comparative example,
Glazing baldness does not occur only when semi-cured for 8 hours to 12 hours, and when less than 8 hours is less than 6 hours, concrete (cement molded product) does not solidify and cannot be removed.
If the time is longer than 24 hours, the bound water is generated,
Glazing baldness was caused by the effect of the evaporation. On the other hand, in the case of the early-strength Portland cement as an example, it was possible to remove the mold after curing for at least 4 hours, and no glaze baldness occurred thereafter. Furthermore, in the case of Portland cement, which had been super-high-strength, after curing for at least 2 hours, it was possible to remove the mold, and thereafter, no glaze was generated.

[0027]

[Table 3]

In semi-curing at 60 ° C., as shown in Table 4, in the case of ordinary Portland cement as a comparative example, glaze baldness is not generated only when semi-cured for 3 to 8 hours, and If the time is shorter than 2 hours, the concrete (cement molded product) will not solidify and cannot be removed.
In the case of 9 hours or more, which is longer than the time, bound water was generated, and glaze baldness was generated due to the effect of evaporation. On the other hand, in the case of the early-strength Portland cement as an example, after curing for 3 hours or more, it was possible to remove the mold, and thereafter glaze baldness did not occur. Furthermore, in the case of Portland cement, which had been super-high-strength, after curing for at least one hour, it was possible to remove the mold, and no glaze was generated thereafter.

[0029]

[Table 4]

As described above, when the early-strength Portland cement or the ultra-high-strength Portland cement is used, the curing time can be shortened, so that glaze baldness is less likely to occur on the surface, and a glazed cement product having a good glaze surface and excellent quality performance. Can be manufactured. Example 2 In Example 1, as the cement mixed with the cement material, all the early-strength Portland cement or the ultra-high-strength Portland cement was used. However, as shown in FIG. Ultra-high strength Portland cement 15 may be used, and inexpensive ordinary Portland cement 16 may be used in other parts.

In the second embodiment, as in the first embodiment, the curing time on the mold surface side is shortened, excess water is not taken in as bound water, and glaze baldness is hardly generated on the surface. A glazed cement product having a glaze surface and excellent in quality performance can be manufactured at a lower cost than when all of the product is manufactured using early-strength Portland cement or ultra-high-strength Portland cement.

Embodiment 3 In the above two embodiments, ordinary Portland cement, early-strength Portland cement or ultra-high-strength Portland cement was used alone, but these may be used in combination. In this case, in the kneading step, the ordinary Portland cement and the early-strength Portland cement or the ultra-high-strength Portland cement are mixed at a predetermined ratio. In this case, too, the curing time can be shortened, so that glaze baldness is less likely to occur on the surface, and glazed cement products with good glaze and excellent quality performance are manufactured entirely with fast-strength Portland cement or ultra-fast-strength Portland cement. It can be manufactured at a lower cost than when it is done.

Specific examples will be described below. Table 5 is a table showing the mixing ratio of cement and the results of curing at a curing temperature of 60 ° C. and curing times of 2 hours and 9 hours.

[0034]

[Table 5]

Example 1 was applied to a cement having a mixing ratio shown in Table 5.
Water, aggregate, and high-performance water reducing agent are added to a mixer at the same ratio as described above and kneaded to obtain a cement material (concrete).
It was poured into a mold, semi-cured at a curing temperature and a curing time shown in Table 5, and demolded to prepare a cement molded body. Then, the obtained cement molded body was glazed and fired under the same conditions as in Example 1, immersed in water for 30 minutes for rehydration treatment, and cured for 3 days to produce a glazed cement panel.

As a result, it was found that even with ordinary Portland cement alone, concrete could not be solidified and the mold could be removed even with a curing time of 2 hours which could not be removed. Further, it was found that glaze surface defects such as glaze baldness do not occur even with ordinary Portland cement alone even with a curing time of 9 hours in which glaze baldness occurs due to excess bound water. In addition, as a result of further diligent experiments, it was found that when mixing ultra-high strength Portland cement and ordinary Portland cement, it is sufficient to mix 5% or more of ultra-high strength Portland cement. When mixing early strength Portland cement with ordinary Portland cement, 1
It was found that 0% or more should be mixed.

Embodiment 4 In the above embodiments, water at normal temperature was charged into the mixer in the kneading step, but hot water may be charged into the mixer. When warm water is used, the curing time can be reduced, and the same effect as described above can be obtained.
A specific embodiment will be described below.

No. 1 in Table 1. A cement material was obtained with the same composition as when the ordinary Portland cement No. 1 was used. However, the temperature of the water to be added was 20 ° C. as a comparative example, and 40 ° C. and 60 ° C. as an example. This was put into a mold and cured under the conditions shown in Table 6.

[0039]

[Table 6]

Then, the obtained cement molded body was glazed and fired under the same conditions as in Example 1, immersed in water for 30 minutes to perform rehydration treatment, and cured for 3 days to produce a glazed cement panel. . As a result, as shown in Table 7, in the case of the comparative example in which the temperature of water was 20 ° C., a good glaze surface was obtained only with the curing time between 3.0 and 8.0 hours.
In the case of the embodiment at 60 ° C., a good glaze surface was obtained with a curing time between 2.5 and 8.0 hours, and in the case of the embodiment at 60 ° C., 2.0
A good glaze surface was obtained with a curing time between ~ 8.0 hours.

[0041]

[Table 7]

As described above, by using the warm water, the curing time can be shortened and the curing time can be widened. In this case, it was found that when the mold and / or the aggregate were heated to the same temperature, the curing time was further shortened. Embodiment 5 In the embodiments described above, the cement material was poured into a tray-shaped mold without a lid, cured, and removed from the mold. However, before the entire mold could be removed using a mold with a removable mold surface. Alternatively, only the mold surface may be removed. As shown in FIG. 4, the mold 20 includes a rectangular annular side frame 21, a bottom plate 22 serving as a mold surface, and a lid 23. The bottom plate 22 and the lid 23 are detachable from the side frame 21.

When such a mold 20 is used, the lid 23 is detached from the side frame 21 when the cement material is charged.
At the time of curing, the lid 23 is attached to the side frame 21, and after a predetermined curing time has elapsed, the mold 20 is turned over, the bottom plate 22 faces upward, and the bottom plate 22 is removed from the side frame 21. The glazing can be performed in this state in an exposed state.
As a result, the curing time until glazing can be shortened.

A specific embodiment will be described below. No. 1 in Table 1. A cement material was obtained with the same composition as when the ordinary Portland cement No. 1 was used. This was put into the mold 20 with the lid 23 removed, and then cured under the conditions shown in Table 8 with the lid 23 attached.

[0045]

[Table 8]

After the curing time is over, the form 20 is moved to 18
The bottom plate 22 is turned upside down by 0 degrees and the bottom plate 22 is arranged upward.
Was removed from the mold. Then, the partially demolded cement molded body is glazed under the same conditions as in Example 1, and after one hour, the entire mold is demolded, and the glazed cement molded body is baked and immersed in water for 30 minutes. After rehydration treatment, curing was performed for 3 days to produce a glazed cement panel.

As a result, when the entire mold was removed, the mold could not be removed until the curing time was 3 hours, and after 8 hours, the glaze was peeled off. In Example 5 where a mold is formed, if only the glazed surface is partially demolded for 2.5 to 8 hours, excess moisture does not move to the glazed surface,
It turned out that the whole demolding was always good.

[0048]

According to the method for producing a glazed cement product according to the first aspect, at least a part of the cement used for the cement material in contact with the mold surface is an early-strength cement (including an ultra-high-strength cement). The curing time until demolding on the mold surface side of the mold is shortened, and demolding can be performed before water excessively moves to the mold surface side. For this reason, it is possible to prevent the generation of excessive bound water on the mold surface (glaze-coated surface) side,
The occurrence of glaze defects such as glaze baldness can be suppressed, and a glazed cement excellent in quality performance can be obtained.

In the method for producing a glazed cement product according to the second aspect, since the cement used for all cement materials is an early-strength cement (including ultra-high-strength cement), the entire curing time is further reduced, and the glaze baldness is reduced. The occurrence of glaze defects can be suppressed, and a glazed cement with excellent quality performance can be obtained. In the method for producing a glazed cement product according to claim 3,
Since the cement used for the cement material in contact with the mold surface is a high-strength cement (including ultra-high-strength cement), the curing time on the mold surface is reduced, and the occurrence of glaze defects such as glaze baldness can be suppressed. A glazed cement with excellent performance can be obtained.

In the method for manufacturing a glazed cement product according to claim 4, since the cement used for all cement materials is a mixed cement obtained by mixing an early-strength cement (including an ultra-high-strength cement) and an ordinary cement, it is inexpensive. Curing time can be shortened by using ordinary cement, and glazed cement with excellent quality performance can be obtained at low cost. In the method for producing a glazed cement product according to claim 5, the ordinary cement is made of mixed cement.
Since it is mixed so as to occupy about 95% by weight, it is possible to suppress the occurrence of glaze defects such as glaze baldness and the like under optimal conditions according to the atmosphere by adjusting the amount of ordinary cement.

In the method for manufacturing a glazed cement product according to the sixth aspect, since water heated to a predetermined temperature or more is used as the water, the curing time can be shortened, the generation of excessive bound water can be prevented, and the glaze baldness can be prevented. And other glaze defects can be suppressed. In the method for producing a glazed cement product according to claim 7,
Since at least one of the aggregate and the mold is heated to a predetermined temperature, the curing time is further reduced, the generation of excessive bound water can be prevented, and the occurrence of glaze defects such as glaze baldness can be suppressed. .

In the method for manufacturing a glazed cement product according to the eighth aspect, since only the mold contact surface side is demolded to form the glaze layer on the mold contact surface, the entire glaze layer can be demolded. Since the glaze can be applied to the surface, generation of excessive bound water on the surface layer can be prevented, and occurrence of glaze defects such as glaze baldness can be suppressed.

[Brief description of the drawings]

FIG. 1 is a flowchart showing a manufacturing process of one embodiment of a glazed cement product of the present invention.

FIG. 2 is a schematic sectional view of a manufactured glazed concrete panel.

FIG. 3 is a cross-sectional view showing the order in which cement materials are charged in Example 2.

FIG. 4 is a sectional view of a mold used in a fifth embodiment.

[Explanation of symbols]

 10 Glazed concrete panel 11 Glazed surface 12 Cement molded body 13,30 Formwork

Claims (8)

(57) [Claims] 1. A cement material obtained by kneading cement, aggregate and water, is semi-cured in a mold having a bottom surface as a mold surface, molded, and then a cement molded product is removed from the mold. Then, a glaze layer is formed on the mold surface side of the cement molded article, and the cement molded article having the glaze layer is fired to form the glaze layer into a glaze finished layer. Curing a cured product to produce a glazed cement product having a glaze surface, wherein at least a part of the cement used for the cement material in contact with the mold surface is formed from an early-strength cement (including an ultra-high-strength cement). A method for producing a glazed cement product, comprising: 2. The method for producing a glazed cement product according to claim 1, wherein the cement used for all cement materials is made of an early-strength cement (including an ultra-high-strength cement). 3. The method for producing a glazed cement product according to claim 1, wherein the cement used as the cement material in contact with the mold surface is made of an early-strength cement (including an ultra-high-strength cement). 4. The production of a glazed cement product according to claim 1, wherein the cement used for all cement materials is a mixed cement obtained by mixing a high-strength cement (including an ultra-high-strength cement) and a normal cement. Method. 5. The method for producing a glazed cement product according to claim 4, wherein the ordinary cement is mixed so as to account for 5 to 95% by weight of the mixed cement. 6. A cement material obtained by kneading cement, aggregate and water is semi-cured in a mold having a bottom surface as a mold surface and molded, and then a cement molded product is removed from the mold. Then, a glaze layer is formed on the mold surface side of the cement molded article, and the cement molded article having the glaze layer is fired to form the glaze layer into a glaze finished layer. A method for producing a glazed cement product having a glaze surface by curing and curing the product, wherein warm water of 40 to 60 ° C is used as the water. 7. The method for producing a glazed cement product according to claim 6, wherein at least one of the aggregate and the mold is heated. 8. A cement material obtained by kneading cement, aggregate, and water, is semi-cured in a mold having a bottom surface as a mold surface, molded, and then, a cement molded product is removed from the mold. Then, a glaze layer is formed on the mold surface side of the cement molded article, and the cement molded article having the glaze layer is fired to form the glaze layer into a glaze finished layer. Curing the product to produce a glazed cement product having a glaze surface on the surface, wherein only the bottom side of the mold is demolded to form the glaze layer on the mold surface. Method of manufacturing glazed cement products.