JP2903379B2 - Manufacturing method of precast concrete slab with external finishing material - 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 manufacturing a precast concrete slab and a special filled clay for the method. In particular, for precast concrete slabs, exterior finishing materials such as irregular-shaped tiles or natural stones that are difficult to pre-attach are factory pre-adjusted by a face-down method, and exterior finishing materials pre-attached precast concrete plate manufacturing methods, and The present invention relates to a precast concrete slab manufacturing method capable of transferring a free-form surface or a pattern determined by design to a concrete surface of an exposed finished precast concrete slab, and a special filled clay for these manufacturing methods.

[0002]

2. Description of the Related Art The work of attaching various materials as exterior finishing materials for buildings or structures is increasing year by year. In recent years, precast concrete slabs (PC version) and wall slabs with precast exterior finishing materials on precast concrete foam slabs (PCF slabs) have been produced in factories as exterior materials for this type of building or building. To
The method of attaching to structural members on site has become common. PC
As a face-down method of driving an exterior finishing material into a plate or a PCF plate, a method of driving a pre-packed tile set in a foamed polyethylene foam or a stone formed in a predetermined plane shape is generally used.

[0003]

2. Description of the Related Art In recent years, as a design design of a PC plate or a PCF plate, the use of natural stones which are difficult to pack and exterior finishing materials having irregularities has been increasing. Conventionally, when a natural stone (cobble stone, iron flat stone, etc.) is used as an exterior finishing material, a so-called face-top method is often used in which a special mortar is laid on the concrete surface once cast and the natural stone is set later. ing. In the case of this method, the production becomes two steps, and at the same time, the work of laying the mortar and setting the natural stone are all in the formwork, and the work efficiency is reduced. Also,
In the two processes, there is a restriction of an open time caused by the setting of concrete or special mortar with the lapse of time after the construction, and it is difficult to manage the construction time. The special mortar surface has a drawback that it is difficult to be smoothed even with ironing, so that it is not in an aesthetically satisfactory situation. In terms of durability, bleeding water generated in the mortar may form a water film on the lower surface of the natural stone, which may lower the adhesion strength between the natural stone and the mortar. Due to the difference in shrinkage between mortar and concrete, delamination of the interface is also a concern.

[0004] As an example of the face-down method that is currently being carried out, a concrete hardening retardant is applied to the bottom of a formwork, and then an exterior finishing material is driven in and concrete is poured into the mold.
There is a so-called washing method in which the surface of the concrete is washed away after the mold is released to expose the exterior finishing material. The disadvantage of this method is that the washing depth is as small as 6 to 8 mm at the maximum, and the degree of freedom in design is limited. The washed-out concrete surface also causes a paste component to flow out due to a setting retarding effect, resulting in a grainy state and a decrease in durability. In the tile pre-installation method, the first premise is that the exterior finishing material is a fixed form in the sheet pack process. There is a drawback that it cannot be applied when the planar shape and the cross-sectional shape of the exterior finishing material are irregular or irregular, and when the posture at the time of setting is unstable. Second, there is a problem of adhesion due to the dimensions and surface accuracy of the exterior finishing material and the joint material made of foamed polyethylene foam for packs, and it is not possible to completely prevent the concrete paste from entering the finished surface side. There is. For this reason, it is necessary to remove the concrete leaked and solidified on the finished surface and the side surface of the exterior finishing material after the PC plate is released from the mold.

[0005]

SUMMARY OF THE INVENTION Therefore, a first object of the invention of the present application is to provide a specially filled clay for a precast concrete slab manufacturing method, and (1) the characteristics of the exterior finishing material and the design finishing method. By changing the mixing conditions, free viscosity and fluidity can be selected, and there is no deformation due to vibration compaction at the time of placing concrete or concrete's own weight pressure. (2) Stable against heat such as steam curing In addition, it is chemically stable to concrete and does not deform each other. (3) In the final step, it can be easily washed off with high-pressure washing water or the like, and is washed out. Concrete surface can avoid graining, P
An object of the present invention is to provide a specially filled clay for a C-plate manufacturing method. The second object of the invention of this application is as described in the above (1), (2),
(3) and (4) fixing between the exterior finishing material and the PC form surface and between the exterior finishing materials, and preventing movement and floating of the exterior finishing material; (6) chemically stable to exterior finishing materials, causing mutual deformation It is an object of the present invention to provide a specially filled clay for a PC plate manufacturing method in which an external finishing material is pre-installed. A third object of the invention of the present application is to provide a case that can be arranged without difficulty even when the planar shape of the PC plate exterior finishing material is irregular or irregular and the required posture during setting is unstable. An object of the present invention is to provide a PC plate manufacturing method for finishing materials. A fourth object of the invention of the present application is to provide a method for manufacturing a pre-packaged exterior finish material, which prepacks the exterior finish material, and greatly simplifies the finishing operation of the demolded PC plate. Is to be greatly reduced. A fifth object of the invention of the present application is to provide a method for manufacturing a precast concrete slab which can easily transfer a free-form surface or a pattern determined by design to a concrete surface of an exposed finish precast concrete slab. is there.

[0006]

[Means for achieving the object]
In addition, in order to achieve the above objects, a method for manufacturing a precast concrete slab in which an exterior finishing material is pre-attached according to the invention of the present application includes the following steps: (1) production of specially-filled clay; (2) a step of forming a state in which a number of exterior finishing materials are arranged on the inner bottom of the PC formwork, and a specially filled clay layer bonded thereto is densely interposed therebetween; 3) a step of setting a reinforcing bar in a PC form, (4) a step of placing concrete in a PC form in which a reinforcing bar is set, and (5) curing the placed concrete to form a PC plate. Process, (6) From PC formwork,
Demolding process of PC plate with special filling clay layer, (7)
It consists of the step of finishing and washing the surface of the PC plate. The above-mentioned special filled clay has plasticity, viscosity, and tackiness by adding and mixing a plasticizer (eg, bentonite) and a setting modifier (eg, water glass) to dry fine-grained sand as a base material and kneading with water. , And caking properties are appropriately adjusted.

The special filled clay can freely change its plasticity, viscosity, tackiness, and caking property by changing the mixing ratio of the plasticizer and water depending on the shape characteristics of the exterior finishing material. . In addition, since the special filled clay (when no setting modifier is used) does not have coagulation properties, the adjusted plasticity, viscosity, tackiness and caking properties hardly change. Therefore, there is no need to consider the time constraints associated with the set of exterior finishing materials. Therefore, a pre-packing method in which an exterior finishing material is packed in advance is also possible if certain moisturizing stock conditions are possible. If the special filling clay needs fluidity due to the characteristics of the exterior finishing material, adding water glass as a setting modifier to the mixing water can facilitate the work of spreading and filling the special filling clay. I can do it. The specially-filled clay according to the invention of this application has no reactivity with concrete, and the hardened concrete surface can be smoothed by smooth finishing the surface of the specially-filled clay. Further, it is also possible to apply a concrete setting retarder, an organic pack agent or the like to the surface of the specially filled clay.

[0008]

DESCRIPTION OF THE PREFERRED EMBODIMENTS The invention of this application is implemented in the following modes. In the first embodiment, bentonite as a plasticizer, water glass as a coagulation modifier, and a water-retaining agent / mixing water are added to dry fine-grained sand as a basic material, and the mixture is kneaded. This is a special filling clay for precast concrete slabs with pre-finished exterior finishing materials. In the second embodiment, the specially filled clay according to the first embodiment, which is adjusted to have a viscosity suitable for a form direct laying system, is layered and densely spread on the bottom surface of the PC form 8 in a layered manner.
A specially-filled clay layer 4 is formed, and an irregularly shaped exterior finishing material S is inserted and arranged in the specially-filled clay layer 4 to form a special space between the exterior finishing materials S and between the exterior finishing material S and the bottom surface of the PC form 8. A step of forming a state in which the filled clay layer 4 is densely interposed and the special filled clay layer 4 is firmly bonded thereto, a step of setting the reinforcing bar ib in the PC formwork, and setting the reinforcing bar ib. The step of casting concrete into the PC form 8, the step of hardening the cast concrete C to produce the PC plate, the step of forming the PC with the special clay layer from the PC form 8.
This is a method for manufacturing a precast concrete plate with an exterior finishing material pre-attached, comprising a series of steps of removing the plate and washing and finishing the surface of the PC plate.

A third embodiment, a special filling clay forming the first embodiment, special packing clay layer laid and densely in layers pallet 6 _three surfaces for packs in module allocation from the PC version Dimensions 4 and its special filling clay layer 4
Inserting and lining the irregular exterior finishing material S against
A state in which the specially filled clay layer 4 is densely interposed between the exterior finishing materials S and between the exterior finishing material S and the _three surfaces of the pack pallet 63, and the specially filled clay layer 4 is firmly bonded to them. Process, a step of laying out pre-packs composed of the above steps in a PC formwork,
b, setting concrete in a PC form on which reinforcing bars ib are set, hardening the cast concrete to produce a PC plate, and attaching a special filling clay layer 4 from the PC form. Demolding process of PC plate and PC
This is a method for manufacturing precast concrete slabs with pre-attached exterior finishing materials, consisting of a series of steps for washing and finishing the slab surface. In the fourth embodiment, the specially-filled clay layer 4 is formed by pouring the specially-filled clay according to claim 1 into the bottom surface of the PC form 8 so that it can be poured. while Plug and arranged irregularly shaped exterior finishing material S ₄ against the clay layer 4, forming a joint between Dogaiso finishing material S _4, the step of setting a reinforcing bar ib in PC-type frame 8, rebar a step of casting concrete into a PC form in which the ib is set, a step of hardening the poured concrete to produce a PC plate, a step of removing the PC plate with the special clay layer from the PC form, and This is a method for manufacturing precast concrete slabs with pre-attached exterior finishing materials, consisting of a series of steps for washing and finishing the PC slab surface.

In the fifth embodiment, the special filling clay layer 4 of the first embodiment is spread on the bottom surface of the PC form 8 to form a special filling clay layer 4, and the surface portion thereof is designed by design. A step of transferring the determined pattern, a step of setting the reinforcing bar ib in the PC form, and a step of setting the reinforcing bar ib.
Casting concrete into C formwork, curing concrete to make PC plate, removing PC plate with special clay layer from PC formwork, washing PC plate surface・ This is an exposed precast concrete slab manufacturing method consisting of a series of finishing steps. In the sixth embodiment, the special filling clay according to the first embodiment is spread on the bottom surface of the PC form 8 to form the special filling clay layer 4, and the surface of the special filling clay layer 4 is made of concrete. applying a setting retarder D, atypical step of setting the exterior finishing material S _6, step of setting a reinforcing bar ib in PC formwork 8, concrete into the PC mold 8 set with rebar ib Setting step, hardening the cast concrete C to produce the PC plate 10, removing the PC plate 10 with the special clay layer from the PC form 8, washing and finishing the surface of the PC plate 10. This is a method of manufacturing and washing out precast concrete slabs with pre-attached exterior finishing materials, consisting of a series of steps. The seventh embodiment uses a special filling clay according to the first embodiment, and lays a split skin tile or the like 2 on the inner bottom wall of the split skin tile or the like pack form 1 to form a split skin tile or the like pack. A step of manufacturing P; a step of laying the pack P such as the split skin tile on the bottom surface of the PC form 8;
A step of setting a reinforcing bar ib therein, a step of placing concrete in a PC form 8 in which the reinforcing bar ib is set, a step of curing the placed concrete to produce a PC plate 10, This is a method of manufacturing a precast concrete slab with a split skin tile, comprising a series of steps of removing the PC slab 10 with a clay layer and washing and finishing the surface of the PC slab 10.

[0011]

【Example】

[First Embodiment] A description will be given of a specially filled clay (artificial clay) for a method of manufacturing a precast concrete slab in which an exterior finishing material is pre-attached according to the invention of this application, and a method of manufacturing the same. The special-filled clay according to the invention of this application is prepared based on dry fine-grained sand, bentonite and kneading water, and a setting modifier (water glass) and a water retention agent are added according to the application. The mixing ratio is as follows: dry fine-grained sand: bentonite: kneading water =
It is also possible to change the blending weight ratio based on about 3: 1: 1, taking into account the shape of the exterior finishing material and the ease of setting. If fluidity is required for laying specially filled clay, increase the amount of mixing water and add an appropriate amount of a setting regulator. This specially filled clay has a high water retention property and its plasticity, viscosity, tackiness, and caking properties do not change at all when stored in a closed container.

In parallel with the research and development of the specially filled clay having the above-described structure, the present inventors have developed a method of manufacturing a PC plate using an external finishing material and using the clay. Therefore, the method for manufacturing a PC plate with pre-attached exterior finishing material according to the invention of this application includes at least the following four basic steps. (1) A step of setting an exterior finishing material on the bottom of the form using the above-mentioned specially filled clay, and this step is to spread the above-mentioned specially filled clay in a layered and dense manner on the bottom of the form to form a specially filled clay layer. Forming and laying and laying an exterior finish on the special filled clay layer, or laying an exterior finish on the bottom of the formwork, and painting or pouring the special filled clay between them It is embodied as a process. In this step, a state is realized in which the above-mentioned specially filled clay is densely filled between the exterior finishing materials and between the exterior finishing material and the bottom of the formwork, and these and the specially filled clay layer are firmly bonded. . (2) a step of casting concrete on the specially filled clay layer and the exterior finishing material; (3) a step of releasing the PC plate with the specially filled clay layer; (4) a specially filled clay layer from the surface of the PC plate Washing away. In addition, as described above, the physical properties of the specially-filled clay mixed and kneaded are weakly alkaline (about pH 8). Therefore,
The washing water generated during the removal of the specially filled clay can be treated in the same neutralization tank as the sludge water generated in a concrete factory. Further, since it does not contain any chemical harmful substances, the used artificial clay can be reused for soil improvement.

[Second Embodiment] A second embodiment of a method for manufacturing a precast concrete slab in which an exterior finishing material is pre-attached according to the present invention will be described. The second embodiment is directed to a relatively small-scale precast concrete slab using an exterior finishing material pre-applied direct hitting method using cobblestone as an exterior finishing material. FIG. 1 is an explanatory diagram of the second embodiment. In FIG. 1, 4 is a specially filled clay layer, 8
Is a PC form, S is a boulder, C is concrete, and ib is a reinforcing bar. In the second embodiment, the PC form 8 is manufactured in advance, and additionally, specially filled clay, cobblestone S, concrete, iron (trowel), and reinforcing bar ib are prepared.

As shown in FIG. 1A, a specially filled clay 4 is spread to a predetermined thickness in a PC form 8 to form a specially filled clay layer 4 and its surface is smoothed. Special filled clay layer 4
After smoothing the surface of FIG.
As shown in (b), the boulders S are inserted so as to be at substantially equal intervals. The depth of the insertion is a depth at which the boulder S abuts against the bottom surface of the PC formwork 8. Since the special filling clay removed by the cobblestone S moves in the horizontal direction, the thickness of the special filling clay layer 4 increases substantially uniformly as a whole. Each boulder S is fixed in a desired direction as shown in the figure by the thickness of the special filling clay layer 4. (At the time of inserting the cobblestone S, if the special filling clay layer 4 is too hard (hard) due to insufficient water or the fine sand component is too small, only the surface of the special filling clay layer near the cobblestone S is locally Swells and creates irregularities. In such cases,
The unevenness must be eliminated by stroking the iron at the corresponding location. )

Next, a reinforcing bar ib is inserted into the PC form 8 as shown in FIG.
As shown in (c), it is set, and concrete C is poured into the PC form 8 and hardened. Thereby, the PC plate 10 with the clay layer is formed in the PC form 8. PC formwork 8
When the PC plate 10 with the specially filled clay layer is released from the PC form 8, the specially filled clay layer on the surface is removed. The removal operation can be easily performed by, for example, a known water jet washer. Thus, the PC version 10 using the cobblestone S is completed. (End of All Processes) The second embodiment can be easily applied to irregular application of an exterior finishing material and an irregular exterior finishing material in general.

The properties of the specially filled clay to be used in the second embodiment are determined by the above-mentioned steps and the properties of the dry fine-grained sand or bentonite used as a starting material. That is,
The properties of the specially filled clay to be used in this example are PC
The specially filled clay layer 4 can be formed on the inner bottom wall of the formwork, and the formed specially filled clay layer 4 is formed when the cobblestone S is inserted and the immediately below specially filled clay is removed to remove the cobblestone S. The surface of the specially filled clay layer 4 between the cobblestones S is evenly bulged without the local specially filled clay layer surface being locally bulged to form irregularities. When the concrete is cast, the shape of the concrete itself and the close contact between the stone and the cobble stone S are maintained against the casting pressure, thereby preventing the concrete paste from entering and leaking to the finished surface side of the PC plate 10. It is adjusted by moderate addition of water and sand so as to ensure complete and complete inhibition and to be easily washed off in the final step, for example by means of a water jet washer.

[Third Embodiment] A third embodiment of the PC plate manufacturing method with an external finishing material pre-attached according to the invention of this application will be described. The third embodiment is directed to a relatively large-scale and mass-produced precast concrete slab, and is a packing method using a natural stone having an unspecified shape, for example, a cobblestone as an exterior finishing material. FIG. 2 is an explanatory diagram of the first half of the third embodiment, and FIG. 3 is an explanatory diagram of the second half of the third embodiment. In Figure 2-3, the special packing clay layer 4, _{6 3}
Is a pallet for boulder packs, 9 is a pack split, 10 is a PC
Edition, _{1 3} formwork for boulder pack, S is the boulder (boulder),
8 is a PC form, S is a boulder, j is a seam between packs, and C is concrete. In this embodiment, in advance, to manufacture a PC-type frame 8, and formwork 1 ₃ for cobble packs. PC version 10
Is divided into packs as indicated by a broken line 9 in FIG. The pack split 9, the dimensions of the cobble packs P ₃ are determined, then the dimensions of a cobble-pack frame 1 ₃ is determined. For cobblestone-pack frame 1 ₃ does not have a bottom. In addition to these, special filling clay 4, pallet 63 ₃ for cobblestone, cobblestone S, and concrete are prepared.

[0018] First, a description will be given of a process of manufacturing cobblestone pack _{P 3.} Over the entire bottom of the boulders pack formwork 1 _3, as in FIG. 2 (b), pallet one boulder pack 6
₃ is laid. Inner cobblestone pack formwork 1 _3, the upper side of且玉stone pack pallet E6 _3, as shown in the figure, place the special filler clay layer 4 formed separately plate, attached to the pallet boulder pack by pressing from above Let it. Alternatively, the upper surface of the cobble packs pallet 6 _3, a special filling clay 4 smeared predetermined thickness to form a special filler clay layer 4, the surface is smooth. After the surface of the specially-filled clay layer 4 is smoothed, the cobblestones S are inserted into the specially-filled clay layer 4 at substantially equal intervals as shown in FIG. The depth of the insertion is a depth at which the boulder S abuts against the bottom surface of the PC formwork 8. However,
The frame-shaped peripheral portion of the specially-filled clay layer 4 is not inserted with the cobblestone S but is left as it is as shown in the figure. When you plug the work of boulders S is completed, for formwork boulder pack of non-bottom 1 ₃
Only vertically, that is, demold. The contents remain in their original position. Thus, as in FIG. 2 (d), is finished cobblestone pack _{P 3,} prepack work is completed. After completion of the pack operations, when temporarily stocking boulders pack P ₃ is for preventing drying of the special filler clay layer 4,
Placing appropriate sheet across boulders pack P ₃ by the Corporation.

[0019] Next, a description will be given of the PC version of the manufacturing process using a boulder pack _{P 3.} On the inner bottom wall of PC form 8,
As FIG. 3 (e), the respective boulder pack P _3, the allocation street, that is, set so as to adjacent to each other. At this time, a seam j between the packs occurs, but care should be taken so that no gap is formed at this seam. When you are finished setting work of boulders pack P ₃ is, and stroked iron the pack between the seam j (trowel), and the seams off. An arrow t in FIG. 3F indicates a state where the seams j are connected and integrated by a trowel.
As shown by the arrow ins in FIG. 3G, the cobblestone S is inserted into the frame-shaped portion left without inserting the cobblestone so far.

When the second insertion work of the cobblestone S is completed, the reinforcing bar ib is set in the PC form 8 (FIG. 1).
(C)). After the reinforcing bar ib is set, concrete C is poured into the PC form 8 and hardened. Thereby, the PC plate 1 with the special filling clay layer is placed in the PC form 8.
0 is formed. The PC plate 10 using the cobblestone S can be obtained only by removing the PC plate 10 with the special filling clay layer from the PC form 8 and washing away the special filling clay layer 4. (The entire process is completed.) The characteristics of the specially filled clay to be used in the third embodiment are defined by the above-described processes and the characteristics of the dry fine-grained sand or bentonite used as a starting material. You. Accordingly, the properties of the specially-filled clay to be used in this embodiment are the same as those of the specially-filled clay used in the second embodiment.

[Fourth Embodiment] A fourth embodiment of the PC plate exterior finishing material attaching method according to the invention of this application will be described. The fourth embodiment is a method of using a relatively large iron slab of an unspecified shape as an exterior finishing material. FIG. 4 is an explanatory diagram of the fourth embodiment. In FIG.
8 PC formwork, special packing clay layer 4, Teppei stone as S ₄ exterior finish, ib is rebar, C is a concrete. In this embodiment, the PC form 8 is manufactured in advance, and additionally, specially filled clay, iron slab S ₄ , concrete C, iron (trowel), and reinforcing steel ib are prepared.

As shown in FIG. 4A, a specially filled clay layer having a high fluidity and containing a setting agent is poured into the bottom surface of the PC form 8 to a predetermined thickness to form a specially filled clay layer 4. ,
The surface is smoothed with a trowel. After smoothing the surface of the special filler clay layer 4, contrast, as FIG. 4 (b), plug-arranged Teppei stone S _4. The depth of Teppei stone S ₄ of the plug is Teppei stone S ₄ are the depth impinging on the bottom of the PC type frame 8. Furthermore, pouring the thickness of the special filling clay, for example, about 1/2 of the thickness of Teppei stone S _4. Thus, between adjacent Teppei stone S _4, as shown in FIG. 4 (b), the joint is produced.

Next, a reinforcing bar ib is inserted into the PC form 8 as shown in FIG.
As shown in (c), it is set, and concrete C is poured into the PC form 8 and hardened. As a result, a PC plate with a special filling clay layer is formed in the PC formwork 8. After removing the PC plate with the special filling clay layer from the PC form 8,
Removal of specially filled clay on the surface. The removal operation can be easily performed with a water jet washer.
Thus, it rises can PC version using Teppei stone S _4.
(End the total process.)

Fifth Embodiment A fifth embodiment of the PC plate manufacturing method according to the present invention will be described. The fifth embodiment is a method of transferring a free-form surface or a pattern determined by design to a concrete surface, targeting an exterior exposed finish precast concrete slab. FIG.
Is an explanatory diagram of the first half of the fifth embodiment, and FIG. 6 is an explanatory diagram of the second half of the fifth embodiment. In FIGS.
Is a PC mold frame, 4 is a special filled clay layer, 11 is a pressing pattern (design pattern), 12 is a negative pattern, 13
Is a pattern pattern, ib is a reinforcing bar, and C is concrete. In this embodiment, a PC form 8 is manufactured in advance, and in addition, a special filling clay, a pressing pattern 11, a concrete C, a trowel (iron), and a reinforcing bar ib are prepared.

As shown in FIG. 5 (a), a specially filled clay having a high fluidity and a coagulant added thereto is poured into the bottom surface of the PC form 8 to a predetermined thickness to form a specially filled clay layer 4, and the specially filled clay layer 4 is formed. Smooth the surface. After the surface of the specially-filled clay layer 4 is smoothed with a trowel, the upper surface of
As shown in (b), a pressing pattern (design pattern) is pressed. Thereby, the negative pattern 12 is transferred to the surface of the special filling clay layer. The casting thickness of the special filling clay is about twice the depth of the negative pattern 12.

Next, a reinforcing bar ib is inserted into the PC form 8 as shown in FIG.
As shown in (c), it is set, and concrete C is poured into the PC form 8 and hardened. As a result, a PC plate with a special filling clay layer is formed in the PC formwork 8. After removing the PC plate with the special filling clay layer from the PC form 8,
Removal of specially filled clay on the surface. The removal operation can be easily performed with a jet washer. Thus,
A relief-released PC plate on which the pattern 13 designed on the concrete surface is transferred is completed. (End the total process.)

[Sixth Embodiment] A sixth embodiment of the PC plate manufacturing method with an exterior finishing material according to the invention of the present application will be described. The sixth embodiment relates to a method of applying a stone to a stone and washing and finishing the concrete. FIG. 7 is an explanatory diagram of the first half of the sixth embodiment, and FIG. 8 is an explanatory diagram of the latter half of the sixth embodiment. 7 and 8, reference numeral 8 denotes a PC formwork,
4 Special filling clay layer, S ₆ turbulent paste for Motoishi, D is the concrete retarder, ib is rebar, C is a washout concrete. In this embodiment, a PC form 8 is manufactured in advance, and in addition to this, specially filled clay, main stone S ₆ for random application, concrete setting retarder D, concrete, iron (trowel), and reinforcing steel ib Have prepared.

As shown in FIG. 7 (a), a special filled clay is spread on the bottom of the PC form 8, or a special filled clay having a high fluidity and a coagulant is added to a predetermined thickness. A specially filled clay layer 4 is formed and its surface is smoothed with a trowel. After smoothing the surface of the special filled clay layer 4, a concrete setting retarder D is applied. next,
As shown in FIG. 7B, the finishing stones are randomly stuck and arranged. The casting thickness of the special filling clay is, for example, about の of the main stone thickness.

Next, a reinforcing bar ib is inserted into the PC form 8 as shown in FIG.
As shown in (d), it is set, and concrete C 'for washing out is poured and hardened in the PC form 8. by this,
A PC plate with a special filling clay layer is formed in the PC formwork 8. When the PC plate with the special filling clay layer is released from the PC formwork 8, the surface of the special filling clay and the surface of the concrete C 'for washing out are washed out. The removal operation can be easily performed with a jet washer. In this way, a PC plate is randomly placed on the washed concrete surface. (End the total process.)

[Seventh Embodiment] A seventh embodiment of the PC plate manufacturing method with an exterior finishing material according to the invention of the present application will be described. The seventh embodiment is a construction method in which split tiles and rib tiles are used as exterior finishing materials. FIG. 9 is an explanatory diagram of the first half of the seventh embodiment, and FIG. 10 is an explanatory diagram of the second half. 9 to 10, reference numeral 1 denotes a split tile or a rib tile pack formwork (hereinafter referred to as a "split tile or the like pack form") and 2 denotes a split tile or a rib tile (hereinafter referred to as a "split tile or the like"). .), 3
Is a joint material, 4 is a special filled clay layer, 5 is a ruler, 6 is a pallet for packs such as split skin tiles, and P is a pack for split skin tiles and the like. In this embodiment, a pack form 1 such as a split skin tile and a PC form (not shown) are manufactured in advance. The vertical width and the horizontal width of each of the split skin tiles 2 used in the seventh embodiment are usually constant, but the heights are usually not constant and vary. The height of the frame is adjusted to the maximum height of the heights of the split skin tiles 2 and the like. In addition to these, a split skin tile or the like 2, a joint material 3, a special filling clay, a spatula, a ruler 5, a split skin tile or the like pack pallet 6, and a water jet washer are prepared.

First, the manufacturing process of the pack P such as a split skin tile will be described. As shown in FIG. 9A, split skin tiles 2 and the like are arranged on the inner bottom wall of the split skin tile pack formwork 1 according to the standard dimensions. At that time, each split skin tile 2 or the like 2 has the finished part facing upward. When the operation of arranging the split skin tiles 2 and the like is completed, the joint material 3 (for example, the joint material 3 made of expanded polyethylene foam) is put in the joint. The height of the joint material 3 is the same as the joint bottom when the PC plate is completed. Joint material 3
Make sure that is properly seated in the joint.
The special filling clay is applied on each joint part containing the joint material 3 and each split skin tile 2 by pressing with a spatula, and the special filling clay layer 4 is densely formed as shown in the figure. . In the specially filled clay layer 4, all the tiles 2 and all the joint members 3 are completely filled as shown in FIG. 9A. The special filling clay layer 4 and the split skin tile 2 are:
Combined by adhesive force.

When the application of the special filling clay is completed, a ruler 4 having substantially the same dimension as the width of the tile pack is drawn along with the side frame of the tile pack formwork 1 as shown in FIG. Then, the excess specially filled clay is removed, and the required specially filled clay layer 4 is left on the same side (shift) as the side frame. The tile 2 is not exposed from the surface of the special filling clay layer 4. The surface of the special filled clay layer 4 is smoothed. After the surface of the specially-filled clay layer 4 is smoothed, the tile pack pallet 6 is precisely aligned with the specially-filled clay surface as shown in FIG. The mold 1 for the pack such as the split skin tile is turned upside down and removed. With this, pack P such as split skin tile
Is completed.

Next, a description will be given of a process of manufacturing a PC plate using a pack P such as a split skin tile. Each split skin tile pack P is set on the inner bottom wall of the PC form 8 so as to be adjacent to each other as shown in FIG. When the setting is completed, the joint material 3 made of foamed polyethylene foam is removed. Thereby, drying of the special filling clay layer 4 at the joint portion is prevented, and accuracy of the pack P such as the split skin tile is secured. PC formwork 8 on which packs P such as split skin tiles are set
Then, the reinforcing bar ib is set as shown in FIG.

A P on which a pack P such as each split skin tile is set
Concrete is poured and hardened in the C-form. As a result, a PC plate with a special filling clay layer is formed in the PC mold. From PC formwork to PC with special filling clay layer
Remove the plate. After removing the PC plate with the special filling clay layer, finish wash the surface. For the finish washing, it is only necessary to wash off the special filled clay layer 4 with a water jet washer. Thus, the PC version 10 using the split tile or the rib tile is completed. (Complete the entire process.) The characteristics of the specially-filled clay to be used in the seventh embodiment are defined by the above-described processes and the characteristics of dry fine-grained sand and bentonite used as a starting material. You. Therefore, the properties of the specially-filled clay to be used in this embodiment are the same as those of the specially-filled clay used in the first embodiment.

[0035]

As described above, the PC plate manufacturing method according to the invention of the present application has the following remarkable effects. (A) In the pre-attachment process for PC version exterior finishing materials, when the base material, plasticizer, and water are specially adjusted and specially filled clay is used, the planar shape of each exterior finishing material is irregular or irregular. However, between them, a dense specially filled clay layer in close contact with them can be easily formed. The formed special filling clay maintains its own shape and the adhesion between itself and the exterior finishing material, resisting the casting pressure and vibration during concrete casting, and completely prevents the penetration of concrete paste. Can be blocked. (B) In the step of pre-attaching an exterior finishing material such as a PC plate, by using the above-mentioned specially filled clay, even if the desired posture of the PC plate exterior finishing material is unstable, it is securely fixed in the desired posture. Can be (C) The finishing work was greatly simplified in the PC plate exterior finishing material pre-installation method. Finishing work is
It is only necessary to wash off the special filled clay remaining on the finished surface with a water jet washer, and no other work is required. (D) A free-form surface or a pattern determined by design can be easily transferred to the concrete surface of the exposed finish PC plate. (E) Therefore, the manufacturing cost of the PC plate was significantly reduced.

[Brief description of the drawings]

FIG. 1 is an explanatory diagram of a second embodiment of the present invention.

FIG. 2 is an explanatory diagram of a first half of a third embodiment of the present invention.

FIG. 3 is an explanatory diagram of a latter half of the third embodiment.

FIG. 4 is an explanatory diagram of a fourth embodiment of the present invention.

FIG. 5 is an explanatory diagram of a first half of a fifth embodiment of the present invention;

FIG. 6 is an explanatory diagram of a latter half of the fifth embodiment.

FIG. 7 is an explanatory diagram of a first half of a sixth embodiment of the present invention;

FIG. 8 is an explanatory diagram of the latter half of the sixth embodiment.

FIG. 9 is an explanatory diagram of a first half of a seventh embodiment of the present invention.

FIG. 10 is an explanatory diagram of the latter half of the seventh embodiment.

[Explanation of symbols]

DESCRIPTION OF SYMBOLS 1 Formwork for packs such as split skin tiles 1 ₃ Formwork for packs of cobble stones 2 Split skin tiles etc. 3 Jointing materials 4 Special filling clay 5 Ruler 6 Pallets for packs such as split skin tiles 6 ₃ Pallets for packs of cobblestones 8 PC formwork 9 packs 10 PC version 11 Pressing pattern (design pattern) 12 Negative pattern 13 Pattern pattern S Cobblestone S ₄ Iron flat stone C Concrete or concrete paste C ′ Washing concrete D Concrete setting retarder ib Reinforcing bar j Joint between packs P Packing tiles etc. P ₃ Cobblestone Pack

──────────────────────────────────────────────────続 き Continuing from the front page (72) Inventor Tsuyoshi Hanaya 2-11-20 Shinkoiwa, Katsushika-ku, Tokyo Esteopia Komori 103 (56) References JP-A-49-3916 (JP, A) (58) Fields investigated (Int.Cl. ⁶ , DB name) B28B 1/00-1/54

Claims (7)

(57) [Claims] 1. Dry fine-grained sand as a basic material,
A specially filled clay for the production method of a precast concrete slab with an external finishing material, which is formed by adding and kneading bentonite as a plasticizer, water glass as a setting modifier, and a water retention agent and mixing water. 2. The specially filled clay according to claim 1, which is adjusted to have a viscosity suitable for a method of directly laying and forming a form on a formwork, wherein the specially filled clay is layered and densely spread on the bottom surface of the PC formwork (8). A layer (4) is formed, and an irregular exterior finishing material (S) is inserted and arranged in the special filled clay layer (4) to form a space between the exterior finishing materials (S) and the exterior finishing material (S) and the PC form ( 8) forming a state in which the specially-filled clay layer (4) is densely interposed between the bottom surfaces and the state in which the specially-filled clay layer (4) is firmly bonded thereto; (I
Step of setting b), PC on which reinforcing bar (ib) is set
A step of casting concrete into the formwork (8), a step of hardening the poured concrete (C) to produce a PC plate, and removing the PC plate with the special clay layer from the PC formwork (8) And a series of steps to wash and finish the surface of the FC slab. 3. A specially filled clay layer (4) is formed by laying the specially filled clay according to claim 1 on a pack pallet (6 ₃ ) surface divided into modules from the dimensions of the PC plate in a layered and dense manner. , the special filler clay layer (4) Plug-lined irregular exterior finish (S), exterior finishes (S) and between the exterior finishing material (S) and packed pallet (6 ₃₎ special between the faces A step of forming a state in which the filled clay layer (4) is densely interposed and the special filled clay layer (4) is firmly bonded thereto; The process of laying in the P
A step of setting a reinforcing bar (ib) in a C-form (8), a step of setting concrete in a PC form (8) in which a reinforcing bar (ib) is set, and a step of hardening the set concrete to form a PC. From the steps of manufacturing the plate, removing the PC plate (10) with the specially filled clay layer (4) from the PC form (8), and washing and finishing the surface of the PC plate (10) A method of manufacturing precast concrete slabs with exterior finishing materials. 4. The specially-filled clay according to claim 1, wherein said specially-filled clay having sufficient fluidity is poured into a bottom surface of said PC formwork to form a specially-filled clay layer. irregular exterior finish of (S ₄₎ as well as plug and arranged with respect to the filling clay layer (4), forming a joint by special filler clay layer between Dogaiso finishing material (S _4), PC formwork (8) a step of setting a reinforcing bar (ib), a step of setting concrete in a PC form (8) in which a reinforcing bar (ib) is set, and a step of hardening the set concrete (C) to form a PC Step of manufacturing plate (10), P
PC form (10) with special filling clay layer from C form (8)
And a series of steps for washing and finishing the surface of the PC plate (10). 5. A specially filled clay layer according to claim 1 is spread on the bottom surface of a PC formwork to form a specially filled clay layer, and a pattern determined by design is transferred to the surface portion thereof. Steps to reinforce the steel bar (i) in the PC formwork (8).
Step of setting b), PC on which reinforcing bar (ib) is set
A step of casting concrete into a mold (8), a step of curing the cast concrete (C) to produce a PC plate (10), a step of forming a PC with a special clay layer from the PC form (8)
An exposed precast concrete slab manufacturing method comprising a series of steps of removing the plate (10) from the mold and washing and finishing the surface of the PC plate (10). 6. A step of forming a specially filled clay layer (4) by spreading the specially filled clay according to claim 1 on the bottom surface of the PC formwork (8), and forming a concrete on the surface of the specially filled clay layer (4). A step of applying a setting retarder, a step of setting an irregular exterior finishing material (S ₆ ), a step of setting a reinforcing bar (ib) in a PC formwork (8), a PC mold in which a reinforcing bar (ib) is set A step of casting concrete into a frame (8), a step of curing the cast concrete (C) to produce a PC plate (10), and a step of forming a PC plate (8) from a PC plate with a specially filled clay layer ( Step of demolding 10) and PC version (10)
A method of manufacturing and washing out precast concrete slabs with pre-attached exterior finishing materials, consisting of a series of steps for washing and finishing the surface. 7. A split skin tile or the like pack (P) using the special filled clay according to claim 1 and laying a split skin tile or the like (2) on the inner bottom wall of the split tile or the like pack formwork (1). ) Manufacturing process, the split skin tile etc. pack (P)
Laying on the bottom surface of the PC formwork (8), setting a reinforcing bar (ib) in the PC formwork (8),
b) Casting concrete into the PC formwork (8) on which is set, curing the cast concrete (C) to produce the PC plate (10), specializing from the PC formwork (8) A method for manufacturing a precast concrete slab with a split skin tile, comprising a series of steps of removing the PC slab (10) with a clay layer and washing and finishing the surface of the PC slab (10).